Document 5bov6NgRkdE2ajKxE1Qqg8XmJ

OPERATING MANUAL AMS EMERGENCY KILL SYSTEM ABERDEEN PVC PLANT September 1, 1981 FINAL ISSUE Work by: Senior Process Engineer Chemicals Division Phocess Engineering Department conoco 1-3 Interoffice Communication To C. L. Miller, Aberdeen, Mississippi From R.D. Melling, Ponca City, Oklahoma Date September 1 , 1981 Subject Emergency Kill System Operating Manual The final issue of the Emergency Kill System Operating Manual is attached. This issue incorporates comments and suggest ions from the August 18 plant review meeting. I Richard 0. Melling Senior Process Engineer Chemicals Division Process Engineering Department ms Enc CC: RAF:SJV:PEM:JAD:MPB CRM:JAB:J LW:JHM File: A-20.3 f VAB.0001132701 i TABLE OF CONTENTS OPERATING MANUAL AMS EMERGENCY KILL SYSTEM ABERDEEN PVC PLANT I. INTRODUCTION........................................ A. PURPOSE .................................... B. OPERATOR RESPONSIBILITIES C. PROCESS INFORMATION . . . II. GENERAL PROCESS DESCRIPTION . III. SAFETY ............................................. IV. OPERATING PROCEDURES.................. A. INJECTION PROCEDURES. . . B. ROUTINE OPERATION . . . . C. TESTING PROCEDURES. . . . V. APPENDIX............................................. VI. Pl DIAGRAMS...................................... 1-3 Page N Aom . 1 1 1 1 3 5 8 8 12 15 17 26 VAB.OOOl132702 Page 1 1-3 INTRODUCTION A. Purpose The purpose of the Emergency Kill System is to increase the re liability and effectiveness of equipment and procedures used to safely and quickly stop the polymerization reaction in the reactors. Stopping the reaction prevents excessive pressure buildup which can cause emergency releases through the reactor relief valves. This system allows any or all reactors to be shut down in an orderly and safe manner. This manual describes the system and the operator's responsibilities for operating and maintaining the system. * B. Operator Responsibilities The operator is responsible for producing quality products in a safe and efficient manner. He fulfills his responsibilities by knowing the following and passing a written exam: 1. Understanding how his equipment functions. 2. Understanding what role each piece of equipment plays in the process. 3. Keeping a close and regular check on equipment. 1*. Knowing how to spot malfunctions and correct them. 5. Keeping his area of responsibility safe and clean. 6. Keeping complete and accurate records. C. Process Information The polymerization reaction of VCM to form PVC gives off heat and accelerates as temperature increases. As the temperature increases, the reactor pressure also increases. It is there fore necessary to remove the heat of reaction with cooling VAB.0001132703 Page 2 1-3 I. INTRODUCTION (CONTINUED) C. Process Information (Continued) water in the reactor jacket and condenser. Reactor agitation is also required to maintain uniform reactor mixing and efficient heat removal. If reactor cooling and/or agitation is lost, the reaction must be stopped. Failure to do so would result in a runaway reaction with increasing temperature and pressure. The reac tor pressure could increase until the rupture disk/safety valve assemblies would vent the reactor contents to the atmosphere. The new Emergency Kill System provides the capability of in jecting up to 25 gallons of killing agent into each reactor I either remotely from the control room or manually at the re actor top head platform. Killing agent can be injected into a reactor as soon as agitation is lost to take advantage of mixing caused by residual swirling motion. Maintaining cool ing water flow after loss of agitation will also help mixing by refluxing in addition to removing heat of reaction. \ VAB.0001132704 Page 3 GENERAL PROCESS DESCRIPTION Refer to the attached P&l diagrams for the complete system layout for each reactor area. Emergency kill injection pots are provided at grade level for each reactor. All injection pots are to be maintained at 300 psig pressure using high pressure nitrogen cylinders. A separate nitro gen cylinder and spare are provided for each injection pot. Level gauges and pressure gauges are provided on each pot in addition to board-mounted low pressure alarms and low level indicators. The A operator should check the appropriate injection pot level and pressure before starting each reactor charge sequence. Killing agent can be injected into the reactor either remotely by the lead operator or locally by the A operator. Normally, the emergency kill system will be activated from the board to minimize time and maximize mixing. One switch for each reactor operates automatic double block valves at the reactor top head * level. Placing the switch in automatic mode opens the valves and allows a low level switch in the injection pot to close the valves. Placing the switch in the momentary-contact manual mode also opens the valves but the valves close when the switch is released. Each injection pot low level switch also activates a local light at the * manual injection point at the reactor top head level. The auto matic closure of the remote injection valves and the local low level indicator light are provided to prevent nitrogen from being injected into the reactor, blanketing the condenser and reducing cooling efficiency. VAB. I I. GENERAL PROCESS DESCRIPTION (CONTINUED) Page A Emergency injection headers are provided at the reactor top head level in each reactor area. These headers will allow any injec tion pot to be used to kill any reactor in each area or to inject additional killing agent if needed. The procedure requires two hoses, one to connect an injection pot to the header, and one to connect the header to the reactor. Killing agent can then be in jected locally by the A operator or remotely by the lead operator. It should be noted that when the emergency injection header is used, the injection pot low level switch will neither automatically close the remote injection valves nor light the appropriate local indicator light. Caution should be taken to prevent charging nitro gen into the reactor. The remote injection automatic valves will be operated by nitrogen supplied by a high pressure nitrogen cylinder and spare. A boardmounted low pressure alarm is provided for each area to alert the d board operator when the cylinder in use has dropped below 600 psig. A cylinder with less than 600 psig pressure does not contain enough nitrogen to operate the control valves and should be immediately changed out with a full cylinder. 1-3 VAB.0001132706 Page 5 1-3 * Nl. SAFETY The operation of the emergency kill system does not present any extremely hazardous situations. In fact, it's main purpose is to reduce the potential for having hazardous situations in the reactor area. However, some potential hazards are present and precautions should be taken to prevent serious incidents. A. The killing agent AMS has been in use for some time in the plant and the operators should already be familiar with the corresponding safety hazards and proper handling procedures. The attached vendor literature describes chemical properties and safe handling procedures. It should be emphasized that AMS is highly reactive in the presence of the peroxide ini tiators used in the plant. AMS AND INITIATOR SHOULD NEVER BE MIXED UNDER ANY CIRCUMSTANCES. B. The new AMS injection pots will be maintained at 300 psig by high pressure nitrogen cylinders. Due caution should be exer cised in the handling of nitrogen cylinders. Operators should avoid damaging the outlet valves on these cylinders. The AMS injection pots will contain AMS under 300 psig pressure, so t proper safety precautions should be taken while working with or near these vessels. The injection pots must be depressurized before the block valves on the pot funnel or AMS fill line are opened. The nitrogen supply to a pot should be turned off at the pot prior to vent ing the pot. The pots should only be vented through the bleed valve on the pressure gauge/pressure switch piping on the top of the pots. POTS SHOULD NEVER BE VENTED THROUGH THE FUNNELS ON THE SIDE OF THE POTS. VAB.0001132707 1-3 Page 6 III. SAFETY (CONTINUED) C. The rupture disk and relief valve assemblies for each injec k tion pot are set to relieve at 1*00 psig, the vessel design pressure. Since nitrogen bottle regulators occasionally leak through, a potential exists for overpressuring the injection pots and causing the rupture disk to burst. Even if the killing agent didn't spray out when the relief devices opened, it is i probable the relief valve would not completely reseat and the nitrogen bottle would slowly depressure through the pot and relief valve to atmosphere. The outside operator should routinely check injection pot pressures to insure it is neither too low nor too high. D. The AMS killing agent is a volatile hydrocarbon, and thus fire and explosions are theoretically possible. Precautions should be taken to prevent spills and excessive accumulation of flam mable vapors. E. Since the injection pots are connected to the reactors, a poten tial exists for backing VCM into the pots. This poses no serious immediate problem since the AMS would kill any reaction that was occurring. However, it could present an exposure problem later when the injection pot is opened. The injection pots should be maintained at 300 psig pressure except when re- fi1 Iing. F. Finally, operators should keep in mind that this system will be used when the plant is in an upset condition, i.e., power failure, loss of cooling water, reactor runaway, etc. It is VAB.0001132708 1-3 Page 7 IIl. SAFETY (CONTINUED) critical that this system must operate properly in such an emergency. System maintenance and operator familiarity with this system are equally important factors ensuring the dependability of this system. VAB.0001132709 1-3 Page 8 IV. OPERATING procedures A. Injection Procedures 1. The emergency kill system should be activated under the following circumstances: a. Extended loss of cooling water to a reactor in poly merization mode. * b. Extended loss of agitation to a reactor in polymeriza tion mode. When agitation is lost, it is Important to kill the reaction as soon as possible. The reactor contents will continue to swirl for about four minutes after agitator shutdown, and AMS injection during this period is much more effective. c. A runaway reaction with increasing temperature and pres sure which is not responding to small AMS Injections (short stop) from the initiator charge pot. d. Any other circumstance considered by the operator to represent a significant chance of over pressuring the reactor or affecting safe operation of the plant. 2. The emergency kill system must be activated If the reactor reaches the following pressures for the following products: a. 5305 with CTA b. 5305 without CTA c. All other products 3. Lead Operator Duties 155 psig 165 psfg P* 1A5 pslg a. The lead operator should remotely Inject AMS into the i polymerizing reactors which require killing by placing the appropriate hand switches in the AUTO mode. VAB.0001132710 Page 9 1-3 operating PROCEDURES (CONTINUED) A. Injection Procedures (Continued) 2. Lead Operator Outies (Continued) b. The lead operator should then check for confirmation of AMS injection from the board-mounted low level indicating lights, and from the A operator via radio. Injection time should be about 30 seconds. The boardmounted injection pot low pressure alarms will normally be tripped during AMS injection. If the pressure and level alarms are not tripped, the automatic AMS injection line may be plugged requiring manual injection. c. After AMS injection, the lead operator should closely monitor the reactor temperature and pressure. If cool ing water has been lost, he should take steps to restore cooling as soon as possible. d. If additional killing is required, the momentary-contact manual switch can be used. Caution should be exercised to prevent nitrogen from entering the reactor and blanket- L t- ing the condenser. e. If excess nitrogen does enter the reactor, the condenser should be vented to the recovery system. 3* A Operator Duties a. The A operator is responsible for field-checking AMS injection to each of the reactors to be killed. He should confirm that the injection pot level is at the low level mark on the level gauge. Too high a level VAB.0001132711 Page 10 1-3 OPERATING PROCEDURES (CONTINUED) A. Injection Procedures (Continued) 3 A Operator Duties (Continued) means not enough AMS was injected. No level may mean nitrogen has entered the reactor. b. The A operator should also check the pressures of the nitrogen cylinders used for AMS injection. Any cylinder with a pressure lower than 750 psig should be changed out to allow for a second AMS in ject ion. c. After checking the injection pot and nitrogen cylinders, the A operator should proceed to the reactor top level to confirm that the automatic injection valves are closed. If the valves are open, he should man ually block in the line and inform the lead operator that nitrogen has entered the reactor. It may be necessary to vent nitrogen to the recovery system to maintain reactor cooling. d. If the automatic injection system failed to work, the A operator should manually inject AMS to the re actor. He should open the manual double block injection valves, wait for the injection pot low level indicator light to light, then immediately close the double block valves. The valves should also be immediately closed if the line begins to vibrate from flowing nitrogen. VAB.0001132712 Page 11 1-3 +* IV. OPERATING PROCEDURES (CONTINUED) A. Injection Procedures (Continued) 3* A Operator Duties (Continued) e. If additional injection is required, the A operator should prepare the emergency injection header for use. This header is supplied to allow any injection pot to be used for any reactor. This is accomplished by connect- r ing one hose from a full and pressurized pot to the header and connecting a second hose from the header to the appropriate reactor. Injection can then proceed either locally or from the board. Caution should be exercized when using this header since the injection i pot low level switches will not work correctly and nitrogen may enter the reactor. f. As soon as possible after injection, the A opera tor should refill the empty AMS pots and prepare for a second injection if needed. 1. Close the block valve on the nitrogen supply line at the pot. ( 2. Depressure the pot through the pressure gauge vent valve. 3- Refill the pot with AMS from a 55"gallon drum using the air operated drum pump supplied with the system. An alternate filling procedure is to manually pour AMS into the funnel on the side of the injection pot. VAB.0001132713 t Page 12 1-3 ft IV. OPERATING PROCEDURES (CONTINUED) A. Injection Procedures (Continued) i 3 A Operator. Putles (Continued) f. (Continued) A. Block in the pot and repressure with nitrogen from the nitrogen bottles. i i n g. Radio communication between the lead operator and the A operator should be maintained. The A operator should inform the lead operator how the system Is operating p and what is being done in the field. The lead operator should keep the A operator Informed of reactor pres T i< P j sures and any apparent need for additional AHS injec n tion. B. Routine Operation \ 1. A reactor should not be charged unless its AMS injection \ system is in proper operating condition. it is the respon sibility of the A operator to check this in the field and notify the lead operator, prior to each reactor charge. The following items should be checked immediately before each charge: a. The AMS level in the injection pot should be at the full mark on the level glass. b. The pressure in the injection pot should be 300 psig. This should be checked both on the injection pot pressure guage and on the nitrogen cylinder regulator outlet pressure guage. VAB.0001132714 1-3 Page 13 IV. OPERATING PROCEDURES (CONTINUED) B. Routine Operation (Continued) c. The block valve in the AMS line near the injection pot should be fully open. d. The block valve in the AMS line at the reactor top * * head level near the hose connection should be fully open. e. Both block valves on the manual AMS injection line should be fully closed. If any of the above conditions are not met, they should be corrected before the reactor is charged. 2. To insure proper operation of the system, the following items should be checked by the A operator at the beginning of each shift: a. The pressure of the nitrogen cylinders being used for AMS injection should be at least 1200 psig. Cylinders with lower pressures should be changed out with full cylinders. EMPTY BOTTLES ARE NOT TO BE LEFT IN THE BOTTLE RACKS. b. The pressure of the nitrogen cylinder being used to actuate the automatic AMS injection valves should be at least 600 psig. Cylinders with lower pressures should be changed out with full cylinders. The pres- r"' ,* sure on the outlet of the regulator for this cylinder should be 100 psig. VAB.0001132715 Page 14 IV. OPERATING PROCEDURES (CONTINUED) B. Routine Operation (Continued) ,* c. The pressure gauges between the double block valves on both the automatic and the manual injection lines should routinely be bled to 0 psig. If pressure sub sequently builds up on these guages, it indicates that one or both of the double block valves are leaking. Note: These gauges will have pressure on them after AMS injection. d. All spare nitrogen cylinders in the racks should be full, i.e., cylinder seals are Intact. The above items are vital to the proper operation of the emergency kill system. If any of these conditions are not met, they should be immediately corrected. 3. Other Items which should be checked on a routine basis are: a. The automatic AMS injection line reactor nozzles should be checked for plugging. This can be done while the reactor is being rinsed. Full port ball valves have been provided on this line so that a rod or long wire brush can be run through the line to knock out plugging. This line should be checked once a week when the system Is being tested. b. The manual AMS injection line reactor nozzles should also be checked for plugging on a weekly basis. This should be done in a manner similar to that used for i checking the automatic injection line. 1-3 VAB.0001132716 Page 15 1-3 IV. OPERATING PROCEDURES (CONTINUED) C. Testing Procedures 1. The AMS injection system for each reactor will be tested weekly on a schedule set up by the process superintendent. Each system will be checked for line pluggage and valve operation. The testing procedure is outlined below: a. The A operator should perform a complete visual check of the system to be tested both at grade level and at the reactor top head level. b. He should then contact the lead operator on the radio and confirm that the reactor and Emergency Kill System are ready to be tested. c. He may then manually inject approximately one gallon q of AMS to the reactor by opening the manual injection valves for approximately two seconds. d. After AMS has been injected manually, the A operator should close the block valve near the hose connec tion and notify the lead operator that the automatic system is ready for testing. The lead operator may then remotely cycle the injection valves using the momentary-contact MANUAL mode of the control valve hand switch. e. During automatic AMS injection testing, the A operator should be checking for proper operation of the system, i.e., control valves, actuators, and solenoids. VAB.0001132717 Page 16 1-3 IV. OPERATING PROCEDURES (CONTINUED) C. Testing Procedures (Continued) f. After automatic injection testing, the A operator should rod out the vertical sections of line at both reactor injection nozzles to confirm the nozzles are not plugged. 3. The following must be done following a test prior to charging the reactor: a. The pot should be refilled with AMS. b. The pot should be pressurized to 300 psig. c. The AMS injection nitrogen cylinder pressure should be checked (above 1200 psig). d. The pressure of the nitrogen cylinder used to supply instrument air to the automatic AMS injection control valves should be checked (above 600 psig). e. The manual block valve at the reactor top head level near the hose connection should be reopened. VAB.0001132718 1-3 Page I 7 V. APPENDIX i VAB.0001132719 STORAGE AND HANDLING OF TM ^----TM-- * ALPHA-METHYL S'PYRENE Page 18 1-3 Alpha-Methyl styrene Is usually stored and handled in steel equipment, It is also compatible with stainless steel, aluminum, and galvanized iron. Copper and coppci alloys arc not recoin mended for this service. This product has a fairly low freezing point (about -10F) and low viscosity. Underground storage tanks and lines should be considered, as their use will prevent freezing in winter and keep the product cool in summer. Storage temperature should not exceed 100 F. Storage under a nitrogen blanket Is preferred; exclusion of air (oxygen) will reduce the ch; ances of polymerization, peroxide formation, and fire. Piping can be of the materials listed above. A centrifugal pump is suggested for transfer service. Teflon" is suitable for gaskets and packing. An inhibitor, para-tertiary butyl catechol (10-20 ppm), is used in alpha-methyl styrene to inhibit polymerization. If storage time is prolonged, the inhibitor concentration should be checked occasionally ami more inhibitor added, if needed. Alpha-Methyl styrene is a toxic chemical; contact with liquid or vapors should be avoided. * VAB.0001132720 a- n E T I! Y I. S T Y f> E N E Page 19 1-3 *. *" ** i V* v*Vf /? ;. i + CHEMICAL NAME: SYNONYMS: CHEMICAL FORMULA: CX-Methy 1 s tyrene I sop rope nyl benzene, a 1 pha-me thy 1 s tyrene, 2-phenylpropene, 1-me thy1-1-phenyl ethylene C9oll 10 CHEMICAL STRUCTURE: Vc=CH2 mmi Appearance.................................................................. '..................... Water-white liquid Mo 1 ecu 1 a r we i gh ............................................................................... 113.18 Flanunabil i ty limits, vol X, upper............................................ lower................................................ Flash point, open cup, C (Tag)................................................... closed cup, C (Tag)............................................. Autoignition temperature in air, C............................................ 6.1 1.9 52 (126F) 44 (112F) 575 (1066F) Boiling point at 760 mm Hg, C..................................................... 165.4 at 10 mm Hg, C....................................................... 48.5 Freezing point, C.......................................................................... -23.2 Vapor pressure, mm Hg at 20C....................................................... 1.9 Solubility, wt % in water............................................................. <0.1 (20C) water in............................................................... <0.1 Specific gravity at 20/4C..................................................... . 0.9106 Heat of vaporization at 1 atm, Btu/lb......................................... Heat of combustion at 25C, Btu/lb.............................................. % Coefficient of expansion at 20C, vol/C................................... 140 17,748 0.00096 Viscosity at 2UC, cps.................................................................... -94 Revised 3/15/76 VAB.0001132721 C'C-Ml.TIlYl SiYRtMt V* Page Son-.c si tin i f icunt reactions with the more common chemicals arc D r i e f 1 v cl i scussed ucI'jw: id^Lion forms aldehydes and peroxides if exposed to air (oxygen) . Can bo opoxidized and is attacked by strong oxidizing agents. 1-3 1 C*:n be hydrogenated caLalytically in the presence of metals. The unsaturnted vinyl group and the aromatic ring can both be hydrogenated under selec tive conditions. r.aloqenation Characteristic addition to the vinyl group and --------subs ti tut ion on the aromatic ring can occur with halogens such as chlorine or bromine. These exothermic addition reactions generally require catalysts and/or elevated temperatures and are not considered hazardous if properly controlled. However, reaction with chlorine which occurs at ambient tem peratures can be violent in the presence of light. Accidental contact of CX-methy1 styrene with halogens or halogen-containing compounds must be prevented. Acids - Under special conditions, the aromatic ring may be attacked by concentrated nitric or sulfuric acids. These reactions must be carefully controlled to avoid hazardous consequences. Also, hazardous oxidation may occur by contact with concentrated nitric acid. Hethoxylation - rX~ Methyl styrene can be reacted under special condi tions with formaldehyde or CO-H^ in the presence of a catalyst to yield an aldehyde or alcohol. This reac tion is considered to be nonhazardous as it is un likely to occur accidentally. The above discussed reactions other than oxidation* halogenation, aru polvmeri zatior; arc generally considered to be nonhazardous. However, when conducted*in the plant or laboratory, all of the reactions of f>methy 1 styrene should be properly controlled to avoid hazardous consequences. Rrvised 3/15/75 If the UCC customer wants to use rubber hoses for unloading tank trucks the recommended materials are Vit.on A or polyethylene lining, and steel or 304 SS fittings. Both Uniroyal and Goodyear manufacture rubber hose-, with a Vi ton A or polyethylene liner, .--CTaa.r..s.--it ........ ................... ....... _ Other elastomers such as n03reiie. butyl. buna-N, etc., are not recommended for handling Af.S because they will be chemically attacked by the AMS. Another type of hose tnat can be used is 304 SS flexible metal hose. ,,/- c/. VAB.0001132722 A-METHYL SIT RENE Thii it vj iunimciry of single exposure studies on cinimolt. The dote indicote the relative dug * M * oi liaKord in bumllnu) ;he product. Incrcniiruj degrees of hruord ore rxpressetl bv l! terms: slight, moderate, definite. serious. It must be remembered that results of t tiKpcr hi lonis on animals sonnot bo numerically translated to probable human response. Ihc Rcicorch Council define* *o*'Oiy ai iho capacity of <1 *ub*!ancir to pioducc injury. Hurord i* iKo protuibiiiiy lbc:i injury will mult from ihc handling or uic of ihc jubilance in the quantity, frequency and manner pf OiK`U,fJ . Toc*?y is only uue foclor important iq determining the di-grei* of hazard in handling a chemical or in a proposed us-.*. Fit vvm nl 11op*rtie\ of the chrmicol together w*ih t`K`nt and frvqurncy of enpaiurc ore equally important. Single tltin penetration refer* Jo a covered 24-hour kin contact with the liquid chemical* Single inhalation refer* to coniinuoudy breathing a certain coneenirofion of chemical vapor* for a specified period of lime. Primary irritation refer* lt> the sldn icipomc following uncovered ilun conloti A covered contact Can be expected lo hove o more icverc effect. Ihe term 10*$ hen been adopted civ a uniform expre* i4,m of single dose tonicity for comparing one chemical with another. It refer* to that quantity of chemical which UtU SO per cent of exposed animal*. For further uniformity, <iur:niitei orr cxpreviccl in gram* or milliliter* of chemical per ilogram of ortimal body weight. Cye injury refer* lo *urfoce damage produced by con tact of iho eye with ihc chemical, lego! rc*t>on*ib*hiy i* osiumcd only for the fact that oil *tud'm* reported here, and all opinions, oro ihoto of quohfied expert*. Single oral close in rats: moderate hazard. LDcq 6.50 ml per kilogram of body weight. For comparison, tsopropnnol has on LD^q of 5.84 grams/kg. Single skin penetration in rabbits: slight hazard. 16.0 ml/kg body weight killed 3 of 7 animals from a 24 hour covered exposure. This result suggests that ckin penetration in harmful amounts Is not apt to occur. Single inhalation by rats: slight hazard. Breathing vapors in a state approaching saturation in room ai.r for 8 hours killed 2 of 6 animals. Skin irritation, rabbit belly: moderate hazard. The undiluted chemical caused redness of short duration on the tender skin of the rabbit belly, Kyc injury, rabbits: slight hazard. The undiluted chemical caused no Irritation when an excess was instilled in the rabbit eyes. TYPED 5/24/77 For Further Information Write To: industrial Medicine and Toxicology Department VAB.0001132723 Ip . -^11 * .**^* r ;:-id Ail11 4*-+ *<( 4 ................. ^ yt.;-Mi* "l .... ant Voiiioiociucr _____ tv.),| . 1 . 4 4 . . sjrtiviy. rouble r.vis .ii'SPJ ^ ' 4 I- - +- * * !'icvdo:i:*\*:.:f y:o*J :v,t....... 4 b > * k i ' iS'ru'jSc). 30 AO . :en: ::t?.vdc ...................................................... **ti*;l*YA *- .* -* H****.--*4-tanc.............................. ti:!oxy*ntr."r.c! (Duty! Ceiiuscivci-Skin.......... ^ J ^ 4 | 1*1% + j * * * ^ + Satyr C'V'-KJ'/1 Clt-iCf ^**u ........... i 4 t * * * + ' <t-*C BylyfptKnol s>kW................. f :ft P# *1 rr,c f\ < .Jv/ \7i j STCL ppm"' mg/fn3' i 000 2275 10 A1 h 5 30 All -- -- 2 10 5 23 2 . A2 0.2 -.A? C.i L 4vrr\,' I #wV 25 120 75 100 205 IS1' 25 135 0.3 350 <55 pfvdion ................ sftpn cisutl.de.............. srocfi icimchioridc -- K^YA*-iiif,. t . ;*!hvMVl fiuoswlc............. !'iPi..`'.C?yt chloride...... m-Uiv' n*t,!!iyl . .. . . -- U':U:ru* 1 m'.reprjp.rnc. !`.:o:c?cn'r.'*'J0fCL`1hanc. Dtflorcpu'/ie -- Skin... !i:omium rr.cLd............. h.'orrncm (If) cc.r.pocnos (as Cr).... ihusnr.no (!HJ * f.rs Ci)---ih'irmnnn (VI) villi'rjuritie (;ie Di) r/.iii.'L'tv Cr V! COii:[iJJUiuI^................. -- 10 5. A2 2 C-.C5 Alls 2 1000 10 -- -- -- -- CJ 0 --. A2 30 30. A2 5 Alb iO G320 45 0.5 0.5 n.5 0.05 20 5 125 15 Certain venter insoluble Cr Vi compouncJ!:....... Chfvsenc......................... Cctali meial. dust 3 fume (2C Co) ............. Cyanogen rhioridc......... Cy ICihCXlf1 One .............. Cyciopentane................. Datapon........................ 1. 2-Oibromocthane -- P y"^ t+l p I 4 4 * # * * * ***** + * 0.05. A12 A2 A2 0.05 0.3 O.G 25 100 600 1.723 1 A4lb+% Alb 4n 0.1 ICO 400 SCO 2.580 Art a Iti o O' i i O 1 Li i i t I 3 i l V ii 1 . * fc 9 Substance SHI - hi in"' m 5/.ri*t: ; r. i-Dichkuo-1niwcelhanc................... 0*c I'ic* o?r cpenc............. DicUiaP.2laiv.im:................ t D:clliyl2!nips.................... t Dir.iiy! kclone................. > Dijiycidyl dhei (DGE)... t Dioxanc. tech. grade -- Skin.............................. t DipfCpyl ketone.............. Divtnyl bcn/cn;:.............. Eprchfothydrin -- Skin... t 2-C;'iOxyt*Uiani)i --Skin. *1 1 3 1C 200 0.1 25 50 1C 2 r.o 10 5 15 30 705 0.5 90 235 50 10 1S5 r 2-EUioxycUiyJ ricclalc (Ccliosalvc acelaic) -- Skin.............................. t Ethyl acrylate -- Skin.... Elhylcr.c rtibromidc. see l. 2-Oibron'.oci!'.2nc... 50 5 Alb 270 20 Alb Eilfylenc dientoride, see 1. 2-0c'iOkOctis3na ... tC Ethylene glycol. vapor. .. t Ethylene glycol Crnilroie.. t Elhytene oxide................. t Furtural -- Skin.............. + G lye idol (2. 3*Epoxy1-propanol)................. Hcxadiiorobutsdicnc...... t Hexane (ii-!tcx:*nc).......... (other Iscmers].......... t h>xonc (Wciiiyi isotuiyl ketone) -- Sk:n .......... 10 50 0.02 10 2 25 A2 25 500 50 10 125 0.2 20 S 75 A2 00 1 .EGO 2C5 C Hydrogen cyanide -- SK^Pi ^ ^ 2-Hydro>7propyl acrylate -- Skin........................ t Iscpropoxyethanoi.......... G.5 eh .v!scprcpyl3nilin5 -- SKiH ********** + **** t Mesityl oxide................... t Mcihac/ylic acid.............. 1 15 C wt t Methyl n*amvl ketone (2*Heplanonc)....... 50 1 Methyl bromide -- Skin . t Methyl n-buryi ketone -- t Mcliiyl chloride................ Methylene chloride (dichioromcthane)...... 5 5 50 * too 4. 4 Methylene dianiiinc . 0.1 t Methyl iodide --Skin.... 2. A2 Methyl isopropyl ketone . ? .hA 1 Methyl silica!i............1V___ 11 vJG^Mclftyl styrene. *-- 50 - * Nitrogen dioxide............. 3 1 oqlyccfjn.........*.......* * o.o? *- l-Nitroprcpar.e................ 15 * iQ5 1 nu GC /0 20 20 1C5 3G0 03 10. A2 i Q \> C -;-240 5 0.2 5 10 10. -- 25 -- -- 100 rr 5 ICO ICO 25 15 -- 0.0-1 -- -- 103 -- 100 -- 7 -- 7= c 25 100 15 100 500 0.5 0** GO r.a -- 75 -- _ 3G0 -- -- 20 370 540 ICO GO -- 0.4 -- 300 j^jri/* -- 300 -- 320 flH fJt too ' 4D5 50 -- 2C5 1.700 4 30 (lor 1970) Sut-sl cnee 1 *I 4* P *f\ m' * .* t t Phenyl cllicr -- Diphenyl mixture (vapcf) .......... 0. Phosphorous pcniachtoride.............. t P!**:linuni nirloi........... .. t fj-picpioijclonc.............. Pjcpicnic iC><J................ t Propylene glycul Cinitrale t Propylene oxide.............. Silver, metal.................... o.i -- -ifJ * ^ * > SJ 0 no 20 -- t Silver, soluble compounds (as Ag) ... -- Sodium bisulfite.............. Sodrum nictabisuifiie...... -- -- t Styrene, monomer (phcnyicihy!f.:ic)........ 50 Sulfur dioxide................. C Terphenyfs....................... <_ 0.5 5 A2 +4* 1Ai o.-; 50 0.1 C.01 5 0 2:5 Tetrasedrum pyrophosphate t Toluene-2. 4-dirsocyanjle (TDi).. t Triburyl phospale......... Trichtoroacctic ac.d....... f TricWcrcet.hylcne.......... Tiimeliiuc anhydride...... ` Vanadium (V? CH). '- V rt'.c'.l A 1:nvc............ Vinyl 'urumr.lc ....... -- Vinyl chloride............... . * Vinvi \zhir.? ' .. ........... 1 Weed dust. iMrrt word {as in lurnifurc r.akinn).................. 0.C05 0.2 -- 50 C.C05 -- 5. A2 S. Ala 50 0.04 2 51 270 C. C-` 0.05 20. A? 10. Ala t 1 *5 f 0.0! *f *. -- ^ 0.02 04 -- 150 -- -- -- CC t * * 11 0.1 Lv / ** O NOTICE OF INTENDED CHANGES MINERAL DUSTS Subslancc Asbestos Am r.site.............. Chrysolite........... Crccidofitfl.......... Trcmolile........... Olher forms.................. Diatomaceous earth, nali/ra!.............................. Silica, amorphous.............. Tele (fibrous)....................... TLV 0.5 fibcr/cc. Ala 2 Titers/cc AV 0.2 fiber/cc. Ain 0.5 fiber/cc. Ala 2 1.5 fmibge/rms/3c,c.EMcs.ar'aMfcuOaj dust n 6 mg/m3. Total dust (r.ll sampled S12CS) 3 mg/m3. Respirable dusl (< 5 Aim) y 0.5 ?iber/cc w VAB.0001132724 n * 1 * ; 1;: |I mV /i / f 1 : i ' * 1 ' '. * 4 J1 MAIEfUAL SAFETY DATA SHEET (A |j|if nvt-il iiy U S Hcl>.v uncm nf L .ibor * * fssmmi oil y Sumlin" to futm LiiO-OOS 4) PRODUCT NAME: a/p/ja-METHVISTYRENfc + * * * fc * <mrn 4 P.ag.e 23,,1-3 4 A CHEMICAL NAME CHEMICAL FAMILY: Aryls FORMULA: C.H C|CH ):CH ou -J MOLECULAR WEIGHT 118.18 SYNONYMS: tsopropenylbonzenc; a -methylstyrene; 2-phcnylpropene; 1 -methyl- 1-phcnylethylcne * * s^.. * . * I. : PHYSICAL I >' i \ * .. to * - . BOILING POINT, 760 mm. Hy 165.4 C.(329.7 'J F.) FREEZING POINT * J * 4*1 % -**- t * F S I * T l -23,2 C. )<* ** <t 4 I- a SPECIFIC GRAVITY <H?0 = 1) -J VAPOR OENSITY (air = 1) PER CENT VOLATILES BY VOLUME APPEARANCE AND ODOR 0.9116 at 20/20C. VAPOR PRESSURE AT 20C. 1.9 mm. Hg 4.1 SOLUBILITY IN WATER, % by vvt. 0.06 100 EVAPORATION RATE (Butyl Acetate = 1 j .................................. ...... #* 1) # *# .|> . , ' 0.22 Colorless liquid; characteristic odor. " * ' 'I 4 HAZARDOUS INGREDIENTS ^* 4 *(""<i* 4 "I r * N a * < MATERIAL Methylstyrene * -P IV- (See Sections III through VIII) +* FLASH POINT i test mt-lhod(s) FIRE AND EXPLOSION HAZARD DATA 112F.. Tag closed cup ASTM D 56 I 126F.. Tag open cup ASTM 0 1310 FLAMMABLE LIMITS in AIR. % by voluini. LOWER EXTINGUISHING MEDIA Use carbon dioxide or dry chemical (or small fires. Use foam (alcohol, polymer, or ordinary) for latgc fires. c SPECIAL FTHE FIGHTING PROCEDURES Self-contained breathing apparatus should be available to firemen. UNUSUAL FIRE AND EXPLOSION HAZARDS N o nc EMERGENCY PHONE NUMBER 304/744-3487 Hus numh.'f is av.iiijUic days, nigh is, weekends, and holiday! + 4- * ** wi.-1- Ujkoh C.ubnlc CorpOfJiiun beiHAcs run Hv- oai * ront.uncii he****n are (actual and IN* opinion* cpressed juc ihoso Ol Qualified 0*pcrU myaiding me results ol the Jests tiie tUM not 10 be UMrn as .1 mr* nt lm wtch Umon Carbnle Corporation assumes loyal responsibility They are oHef\dffiftjffijj&frtiQrv ,iiv.i viMiiiCatKKi Any use oi n n.t amt miomtaiian must be determined by tU* usei to he in accordance wim applicable Federal. State. and local laws and regulations 1-4 *- hr * i *- M 4t i - ' I ` I ' m4 t+ */ 1 I # * * -* * itii -it THRESHOLD LIMIT VALUE i IV: . HEALTH HAZARD DATA 100 ppm. -- not to he exceeded. Value from ACGIH (1976) Page 21* 1-3 ,-FECTS OF OVEREXPOSURE Vapors cause irritation of eyes, nose, and throat. Headache, nausea, and vomiting may occur. Eyes are irritated by the liquid. EMERGENCY AND FIRST AID PROCEDURES Remove to fresh air and call a physician. In case of contact, flush skin or eyes with plenty of water for at least 15 minutes. Call a physician for eyes. * * .i 1 +m* 4%Ll .*^ * : '** 1 * , I 4ta 1 f / - - . * * I x* 4 + ** + * m rn 4* w STABILITY 1.1 f * I 4 *< 1 I 44 * + * + ^ -1 1 *# - %* * 1.* * * * * * ' V: .REACTIVITY DATA 4* t I # ** * UNSTABLE STABLE y/ CONDITIONS TO AVOID Avoid heat and open flame. 4- INCOMPATIBILITY 'materials to avoid) Avoid contamination with oxygen, strong acids, chlorine. IAZARDOUS DECOMPOSITION PRODUCTS Burning can produce carbon monoxide and/or carbon dioxide. IAZARDOUS POLYMERIZATION May Occur J V Will not Occur * " CONDITIONS TO AVOID Avoid contamination with peroxides, strong mineral acids, metal halides, and similar polymerization catalysts. Para-tertiary butyl catechol is used as inhibitor; maintain its concentration at 10-20 ppm. w .* * % 4 4 4% 1. ,. ;TEPS TO BE TAKEN F MATERIAL IS RELEASED )R SPILLEO spiLl or leak procedures Wear suitable protective equipment. Collect for disposal. Toxic to fish; avoid discharge to natural waters. Sec Section VHI. vASTE DISPOSAL METHOO Incinerate in a furnace where permitted under appropriate Federal. Stale, and local regulations. Absorb on paper, evaporate on glass dish, then burn paper. VAB.000113272 4 * * VII. + RESPIRATORY PROTECTION (itjci.ily type) j SPECIAL PROTECTION INFORMATION Air-suppliecJ mask in confined areas VENT IL A riON j LOCAL EXHAUST f" MECHANICAL 1I (general) I- -*F PROTECTIVE GLOVES May bo needed \/ R u bbe r OTHER PROTECTIVE EQUIPMENT Eye bath and safety shower 4 SPECIAL h -k.a OTHER I Iiii EYE PROTECTION ...... j I Page 25 1-3 1 *' '31 `1 ^ 1 -I ^'H *Tvrr*rirJ * \ . * h .V: J ^ J * Monogoggles fe* I * PHICAUTIONARY LABELING a/p/ta-METHYLSTYRENE DANGER! CAUSES BURNS COMBUSTIBLE Do not get in eyes, on skin, on clothing. Keep away from heat and open flame. Avoid breathing vapor. Keep container closed. Use with adequate ventilation. Wash thoroughly after handling. FIRST AID: In ease of contact, immediately flush eyes or skin with plenty of water for at least 15 minutes while removing contaminated clothing and shoes. Call a physician. Wash clothing before reuse. FOR INDUSTRY USE ONLY OTHER HANDLING AND STORAGE CONDITIONS Store under a nitrogen atmosphere; forms acetophenone, aldehydes, and peroxides if stored under air. Dangerous concentrations of perqxidcs arc not expected to form in normal storage and handling, but storage under a nitrogen atmosphere is recommended. This chemical floats on water, is resistant to rapid biodegradation, and is highly toxic to aquatic life. Spills should not be flushed to sewers or waterways. The preferred mc.thod of disposal is to dilute with a non-reactive solvent or fuel stream and inejnerate. Ground areas can be covered with sand or sawdust after most of the spilled material has been removed. Absorbing materials, after use on small spills, should be disposed of in an approved chemical landfill or by burning. CAUTION: Do not use clays, micas, or acidic materials which might catalyze polymerization, as absorbents. Personnel engaged in disposal work should avoid contact of wastes by wearing proper protective clothing. 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Y.vore <p ) I f v*r w * .* I , I 4 * ...tifwinirt.ffir.f.i4iffljfft i jii1 p--b pP I jA fur **+ # r **' J * R 4 4.1H ^ #M iftllB* pif4'M|i *-** *** ' Bi|l i' I, f +4V4 ' * -tBP0 4 *i> +- 4-4*i)t"l`it-tttl4*4if<*4*'f li' 1 *r 1lTju> - * B*"*m* till' ' ||^ iiilH* ' *T* *- >14 If f4 - - n P+N I*.. - lint* 1 -r f1I 4*1 | * *lMf tllfl*' >ntn M 4 u_ ' TVUTltoOR I 1* <3>:^ '- *' f C'lONM.'S FOflA ESXISTII*S > i- - + . * * * 4 i 4 4 .REPRiSGRAliT COWPRBSS<?R. \ AMO .COMDCKI&eP. .cot I+4- 1 I-"1 - T 4** -* tAJfK*0AA notes; - ^ * * o BY IWlTlATTOC* STORAfX- POeGZHO. VCMOOR'-WTH Jlt^TRUMfMi rO c/:tjrco*TO j:cf.ct a c:ct4cc:ave- gout'.**-* pou i*:n-iec-jiCM *t,v rw;it;CT it Tws* <*- ttC\-ATE. IT (W CAv.fi O* nufe fi- *r X-OSirLH. *\ *._>*:,MiHt-O '.o TO uCLO.to tc; r^rrccr ths CiScue'wtSi^r prcm T^ti we*vrHCti, ,-- octcrcb ~^ - - f4) EXISTING dNUNtLI^-. ISA. LCCAU CEO ftEACOH U**T <S*AlQ, WOttM. a. t>nr c* 1* -ro hfr ncccTGD nr> pcotgct tmc cerRi(eCATioM lmit^ Pt^M TM6 wt-ATKeiC. jr DELCTCD J 4f, #* t VO : K to Ttt XX TAH o > 1 . is IM" d `' 14 --*- #t 4 * - t- 4+*l k ]- * .' OYrU DCt>4 ^AL0TCV4 *rrMp. Switch ILKAP5 ^pJKLKTfi T'iKAP C.UCOOD5R. O M (XX.AR AsUKC.vA ^ TUMP ALM1M CI.UCTUOM1C Kt-W exiSTiK^^ * * * / *p LOCAL IW^TCtMENT T CV*M H.- # , fi In-K ; , RE. VIS'lOn* 'i 1 a Tsiri ^ATOcif'.M 1.1 *'^1 C L ACT- 7V* * I i r * *i 1 ISU DAul D(SCf:lPllOl| e75[ /FL l" 14,^ f/ ^ I * ' BV CAD i t ru CONTIUENTAt oil COMPANY IIJPGC I-NCACfOftllYM. C0*1 ACHtONUrA1" >xi.:-r'rrir:fjau h ktiatoq, Ar?S'_-f^c~rr.siA!L.fssei cFi*Cx'f.ev'xJvj^itsR;om d*vvf.cL.r;:Ew r-vc. AArl> '**11: */,-'*/?* I* *'*;* ^,, . ,* V - C- *1 * 1 1-3 VAB.0001132737 I !i i i i ij :I I VAB.0001132738 14 VAB.0001132739 CONTINENTAL OIL COMPANY CONOCO CHEMICALS Aberdeen, Mississippi MAN U FAC TURING PROCEDURE Department:_______ __________________________ Process 'Title' Large Reactor Operations Procedure Section Title:Inerts Venting System Issue Number: Issue Date: 8-1-76 Reason For Issue:_____ Original Originated By:Gil Morgan__ _ This procedure describes the operation of the refrigeration system which supplies the coolant to the two knock-back condensors on the north and south recovery receivers. It does not include the process involved in collecting the inerts in the recovery receivers. Included is a system description, operating parameters, trouble shooting and corrective measures and operating log to be completed by the shift-.supervisor and turned in weekly to the vinyl supervisor. APPROVALS: Department Operations Supervisor: ___ ______ _.Date Department Operations Superintendent: Date Plant Superintendent:Date GAM/lpb 1/27/7$ VAB.0001132740 ALLMOND 211 * 1-4 A T NF.RTS VENTING SYSTEM OPERATING PROCEDURES * i SYSTEM DESCRIPTION': The Inerts Venting System is designed to provide a refrigeration capacity of 100,000 BTU/Hr. at -10 E to two knock-back condcnsors located on top of the north and south recovery receivers. The purpose of the system is to facilitate removal of inert materials accumulated during reaction and recovery. The coolant for the system is Freon 12. This refrigerant enters the suction of the Frick compressor as a gas where it is compressed to approximately 125 psig. It moves then to the discharge line oil separator which scrubs the oil picked up by the gas at the compressor and returns it to the compressor crankcase. The oil separator is equipped with a 250 watt heater to prevent any accumulation of condensed freon. From the oil separator the gas enters the condcnsor or, depending on the inert load, may be diverted into the hot-gas by-pass circuit. If it enters the condenser it is cooled and liquified by the cooling water flowing around the tubes of the condensor. The amount of cooling water is regulated by the discharge pressure. The liquified gas then falls into the receiver at approximately 105F and 125 psig. From the receiver it passes thru a filter-drier whicl removes any foreign matter and entrained moisture. At the discharge of the filterdrier is a small sight-glass which indicates the Freon 12 level and moisture entrainment. The liquid then passes thru the small heat exchanger where it is sub-cooled by gas returning from the knock-back condcnsors. The coolant then passes thiu the selected solenoid valve (or both solenoid valves if both receivers are in service) to the inlet of the float valve which meters it into the knock-back condcnsor maintaining a constant.level. A smaller float switch is located near the head of the condensor to detect an abnormally high level which will stop the compressor and shut the solenoid valves. As the coolant absorbs the heat from the VCM vapors and inerts in the condensor tubes, it is vaporized and exits thru the return line. It then passes thru the return trap which removes any entrained liquid. The return trap also icccivcs Eicon 12 and oi1 which is removed from the con densor by the skimmers. Ihe return traps arc also equipped with heaters which vaporise any leirigerant. Ihe oil which returns to the trap must be drained periodically by the utility mechanic in his daily unit check The bulls eye on the side of the trap indicates the oil level. The gas then pas ses thru the heat exchangers where i t is heated by the warm liquid and moves back into the compressor inlet an d starts the cycle over again. VAB.0001132741 A 4 1-4 0 PI; RAT ING 1N ST RU CTIONS: Following a lengthy shutdown, the following items must be checked: V 1 S u c 11 on J!Z Open Outlet Valves 2. Compressor a. Open Discharge Valve b. Check Oil Level - Site Glass should be 1/2 full c. Open Inlet Valve 2-3 Turns 3. Condensor Open Outlet Valve Open Cooling Water Valve Close Cooling Water By-Pass (in freezing weather leave this valve cracked open at all times) 4. Receiver a. Open valves before and after filter-dryer 5. Knock-Back Condensors a. Open Liquid Valves in Liquid Supply Line b. Clo.se By-Pass Valve c. Open Valves to Float Switches (2) d. Open Float Switch Equalizing Valves (2) e. Liquid Valve Between Moat Switch and Condenser - Open f. Open (2) Oil Drain Valves on each Condensor 6. Oil Drain Pot a. Close Oi) Drain Valves 7. Turn "north" switch to on position Turn "south" switch to on position' (Depending on recovery receiver being used) This switch opens: a. Liquid Line Solenoid b. Hot Gas Solenoid c. Oil Drain Solenoid activated for use .8 Check Condensor for cooling water flow. 9. Turn Hand-Off-Auto switch to Auto. Tf all controls are ok, system will start. T I 'Cl. - 'It: *:4 i,, ,,, VAB.0001132742 OPRRATING Continued Immediately open suction valve while watching pressure. Suction pressure should be between 0-25 psig and discharge pressure should not exceed 160 psig. 11. After system has warmed up for about 3-5 minutes, open the oil drain line from the separator to the compressor crankcase. 12. The system should now control automatically. Safety Controls 1. High-level cut-out float .switch located at top of condensor will shut down '..'hen liquid level gets too high. 2. High pressure cut-out will .shut, unit down when compressor discharge pressure gets too high. 175 psig is the cut-out point. 3. Low suction pressure cut-out will shut unit down when suction pressure gets too lew. 5 psig is the low pressure cut-out point. 4. Oil pressure cut-out will shut unit down when oil pressure gets too low. 20 psig is the low oil pressure cut-out point. Trouble Shooting 1 Moisture in System - Flenient in liquid line sight glass at discharge side of filter-dryer turns yellow Hlement will stay green when no moisture is present. Corrective Action: Have Maintenance change out filter element 2. Low Coolant (Freon 12) a. Bubbles can be seen in sight glass at discharge of filter-dryer b. Compressor will run continuously c. Suction pressure will be low Corrective Action: Have Maintenance check freon level and recharge as necessary. 3 Filter Dryer Outlet icing over - filter is plugged and must be replaced Corrective Action: Have Maintenancechange out filter element. 4 Low' Oil Level a. Return line from separator plugged. VAB.0001132743 i i f|. T-HIXK.J-: Trouble Shooting Continued 5. High Discharge Pressure 4 a. Insufficient cooling water supply b. Coolant overcharge c. Air in system d. Condensor tubes fouled Corrective Action: Check water supply line for closed valve Have Maintenance check freon level Have Maintenance bleed off inerts Have Maintenance check condensor 6. Constant Cycling a. Not enough load - hot gas by-pass valves open b. Insufficient water supply c. Air in system Corrective Action: a. Shut unit down between recoveries b. Check cooling water supply c. Have Maintenance bleed inerts and check freon ; level General 1. The refrigeration system is normally functioning properly when the float valves at the knock-back condenser liquid inlet are iced over. 2. To determine the true compressor oil pressure subtract the return pressure from the oil pressure. 3. The following table shows Preon 12 pressure at corresponding temperatures 4. Do not run the unit if the compressor overheats and kicks out until Maintenance has completely checked out the system. Temperature Fahrenheit Freon 12 Pressure 102 104 105 106 108 110 112 114 116 118 120 122 124 Note: Attached is the suggested operating log. 121 PS1G 125 PSIG 127 PSIG 128 PSIG 132 PSIG 136 PSIG M0 PSIG 144 PS 1G 149 PSIG 153 PSIG 157 PSIG 162 PSIG 167 PSIG VAB.0001132744 ; 4.: x i T * * 1 'H- * \d i_ * I- * 4 ^Xl A s >r /.\',~.?7? Jft'riOYJt kj> \' - r^* ^ / ff .^ . r _ 'J # / `art *077 U'-'T JV/TH 1' '' ' " ^'t, c/v' -S/ t ^ ' * '-r* >*. * -.'' V * // / A~V'r**/ /t , ? .riwt:it Li T + :4:...,^ <'uT<l i- -, v+ ....., . - : ^ 'I H 'Pillar*- -. -ipk_ - _ r_(. ..*-. . . .. . ] INLRTS REMOVAL OPPRATINC LOf I STARTING * Normal 105 - 155 Mon. Tues. Wed. Tluir. Fri. Sat. 1 Sun. 00 Compressor Discharge Temp. 00 00 ! r^ .| , 1 i1 * : Normal 100-125 PS1G 00 Compressor Discharge Press 00 5 PSIG-Low Cut-Off 00 175 PSIG Hi Cut-Off Normal 4 5 PSIG 4 5 ASK, l I! if 00 Compressor Oil Pressure r * 00 00 Nori:ia 1 1/2 Site G1 a s s 00 Crankcase Oil Level 00 00 Unit Shut-Down/Reason * j 1 !_j __ _______________ ___________________ !j_________ 1i_i ______________ i|;;1!?! :ii!'_11 ____ :!* ij iJ f ii* ____ '1i. 00 !i_ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _ _1 _ _ _ _ _ _ _ _ _ _i _ Lf KJ i 0 'J T( i\1 ^ i t * >1 JTL JV1 f ^ i w tj ^i >00 Corder.sor hater Temperature '00 (Out) [ ; | ________________ ; jJ iQO \' .1 * /A ^^ j 1s 1 1i l+ 1 it t! --- j \ _ ... `1 1_. .... l . Jl ___ ,,___ r ................. ; Y ! Ll--------------------------------------------------------------------------------------- r1 >00 Recovered V'Cl Receiver iOO Pressure ;oo aw-luir INIf. 4 r 1 I !, iJ 1 i ; ii ` i J ,t i t <i\i %\ I' t 4 iI jj|... j.lT4(l(1<llWWIpri VAB.0001132746 4 r r 1-5 T i i i * VAB.0001132747 conoco Interoffice Communication To D. E. Michels, Aberdeen, Mississippi From W. R. Finch, Ponca City, Oklahoma Date June 21, 1978 Subject Incinerator Training Manual--Aberdeen PVC Plant Attached are twenty copies of the Training Manual for your incinerator. The following changes have been made based on comments by Trane Thermal: 1. Trane state that normal water flow to the quench tank should be 40 gpm and minimum flow should be 30 gpm. This is to protect the downcomer tube. 2. Change fuel gas high pressure alarm and high pressure shutdown to 4.0 and 5.0 psig, respectively. 3. Trane also state that the radiation pyrometers indicate around 200F low; and based on field experience, the incinerator temperature control, alarms, and shutdown off the pyrometers should be adjusted downward. Walter R. Finch Senior Process Engineer Chemicals Division Process Engineering Department lkm Enc CC: DEM(20) File P-47.2 J-re., vh l t . r. <.T,L* t -r. ^ 1 IT.-I yAB.0001132748 KM** *++ b-f UV.i | P'J CONOCO CHEMICALS ABERDEEN, MISSISSIPPI TRAINING MANUAL/INCINERATION SYSTEM TABLE OF CONTENTS I. EPA Standard........................ 1 II, Safety Guidelines ........... ....................................... 2 III, General Description ................................. ........... 4 Process Flow Diagram ............................................................. 7 IV, Instrumentation and Process EquipmentDescription . . , , 8 Schematic Diagram ............................................... ...,,14 V.Operating Procedures A. General Information ........................................................................... 15 B. Local Panel Alarms and Switches.................................................. 17 C. Control Room Panel Alarms and Switches ........................... ..19 D. Malfunctions ....... ............................................................. 20 E. Shutdown Mode .............................................. .24 F. Start-up Procedures .................25 G. Venting Operation ........................................................ ..... 30 I -^j. jvi t.'*- QFf an ,.w< < i-- - *-Wr.v VAB.0001132749 - 1^3 r. ,t ,, r..,. 1-5 Training Manual Incineration System Aberdeen, Mississippi Page 1 I. EPA Standard The Environmental Protection Agency (EPA) promulgated a vinyl chloride emission standard in October of 1976 which covers plants which manu facture ethylene dichloride, vinyl chloride and/or polyvinyl chloride. The EPA decided to regulate vinyl chloride because it had been impli- r cated as a carcinogenic agent. The purpose of the standard was to minimize vinyl chloride emissions. This would have the effect of furthering the protection of the workers' and public's health by decreasing any risks associated with vinyl chloride exposure. To be in compliance with the standard the plant has to meet the following regulation: "The concentration of vinyl chloride in all exhaust gases discharged to the atmosphere from each... holding container in vinyl chloride service...is not to exceed 10 ppm..." Inerts that collect in the VCM recovered monomer receivers have been manually vented to the atmosphere in the past. This is not permitted in the EPA standard. All of the equipment that is being installed to meet the EPA compliance requirements will eventually route the inerts in the reactor and recovery system to the receivers. The build-up of inerts will be eliminated by venting to the incineration system. The incinerator will reduce the concentration of VCM in the vent stream via combustion to be in compliance with EPA's standard. VAB.0001132750 Training Manual Incineration 3ys tem Aberdeen, Mis lissippi Page 2 II. Safety Guidelines The operations and maintenance personnel will be responsible in adhering to all of the safety rules that have been previously set in the plant. They shall be familiar with the safe work procedur Engineering Work Practice Control Program." Items which are of particular concern for working safely around the incineration system are as follows: Hydrochloric Acid One of the byproducts from the combustion of vinyl chloride is hydr chloride. The hydrogen chloride is absorbed in the quench water forming Hydrochloric acid and hydrogen chloride are poisonous and very corrosive. Contact with either one causes burns and ulceration of the skin. A safety shower and eyewash basin are provided at the incinerator site. The eyes or skin should be flushed immediately with water for five minutes or more following contact with this acid. When work is required around the quench chamber ot scrubber during venting operations and where there is any possibility of coming in contact with the process streams, full face mask, protective rubber glove (not cloth or leather) and clothing are required to avoid skin contact. The quench chamber and scrubber water shall be drained to the sewer and or inspection Hot Mfetal Temperature opening The shell of the combustion chamber is not insulated (If it was insulated, excessive high temperatures would be generated at the carbon VAB.0001132751 Training Manual Incineration System Aberdeen, Mississippi Page 3 II. Safety Guidelines (Continued) Hot Metal Temperature (Continued) steel surface.) When the incinerator is operating, the outside surface temperature of the combustion chamber will exceed 300F. Avoid con tacting the combustion chamber with bare skin and clothing. Explosive Mixtures Whenever the fuel gas and combustion air control valves are being adjusted for proper firing rates, an oxygen analyzer should be used to determine the quantity of oxygen in the stack gases. To avoid producing explosive gaseous mixtures, there should always be oxygen present in the stack gases. Under all firing conditions the amount of oxygen in the stack gases should range from three to seven percent on a dry gas basis. The unit should never be run during oxygen deficient conditions (that is, no oxygen detected in the stack gases). If this were to happen, the unit should be shutdown and placed in the purge cycle to remove the flammable gases. . .i . :k, .1. i- -it'- J"i 4 VAB.0001132152 IX.fl, Si -I 1-5 Training Manual Incineration . ystem Aberdeen, Mississippi Page 4 III. General Description The incineration system is designed to reduce the concentration of VCM in the inert vent stream by means of combustion to be in compliance with EPA*s standard. The concentration of vinyl chloride in the exhaust gases is not to exceed 10 ppm with less than ten percent oxygen in the r stack gases at all design flow conditions. The incinerator is to burn the inert vent stream from the existing recovered monomer receivers. The major pieces of equipment in the incineration system are the com bustion air blower, combustion chamber, quench chamber, and packed scrubber. The destruction of the VCM will occur in the combustion chamber. The quench chamber is used to cool the combustion gases exiting the combustion chamber. The oxidation of VCM produces hydrogen chloride. Approximately ninety percent of the hydrogen chloride formed is absorbed in the quench water spray. The remain ing hydrogen chloride is removed in the packed scrubber. The hydro chloric acid solution drains into a sewer line going to the holding ponds. The pH of the No. 1 pond effluent is presently basic because of the caustic in the chem wash solution and plasticiser production. The caustic will neutralize the hydrochloric acid. If there is more hydrochloric acid produced than what was projected for the normal vent rate, the pH of the pond effluent will decrease, yielding an acidic condition. If this occure, caustic must be added to the No. 1 pond. ........................ ...... --l#v .i. . .if,..,. a*,.- VAB.0001132753 (i - T- , iv. f 1 .i 1-5 Training Manual Incineration System Aberdeen, Mississippi Page 5 HI. General Description (Continued) The incinerator will receive a single plant vapor vent stream, the recovered monomer receiver inert purge. This stream will have been cooled to 20F to recover the majority of contained VCM. Normal VCM concentration will be less than 40 volume percent, although during upset conditions, the VCM concentration can approach 100 volume percent. Due to process conditions, the inerts will not be vented continuously but on an as "required11 basis. However, the incinerator must remain in a "ready" condition at all times. During periods where no venting is required, the incinerator will maintain a preset firebox temperature to prevent damage to the refractory due to cyclic cooling. The incinerator will operate at an automatic "low-fire" position. The "low-fire" position is the lowest possible firing rate required to maintain a stable flame and keep the incinerator in a "ready" state. The inert vent stream will be sent to the incinerator on an intermittent basis by activating a manual switch. The vent will be on burner inlet pressure control to prevent excess flow to the incinerator. When the inert vent flow switch is activated, the combustion air control valve will open to a preset "high-fire" position. After the design air flow rate has been established, a control valve will open to start the vent flow to the incinerator. The incinerator will operate with temperature control of the firebox (combustion chamber). Normally there is insufficient VCM present to maintain firebox temperature and supplemental fuel gas will be added. VAB.0001132754 1-5 Training Manual Incineration i ystem Aberdeen, Mississippi Page 6 III. General Description (Continued) When there is excessive amounts of VCM and high firebox temperature, steam will be added to decrease the temperature in the combustion chamber. There must be sufficient dead band between the temperature set points for steam or fuel gas additions to minimize system cycling. Quench water to be used in the quench chamber, X-l, and the packed scrubber, W-l, will be the blowdown from the cooling towers. The expected blowdown rate is 60 gpm which is adequate for the cooling requirements for all of the firing positions. In case of a power outage or low water flow, city water will be used as the emergency source for the quench water. The process flow diagram shows the process conditions that are expected for the normal vent case. VAB.0001132755 1-5 3 2-J5 TAAIMIMG MANUAL E33ES3E3 ? i rtm #or "a1 dbsi&u Bwick3f=t rsn^Arre 7* lSO DAT! DESCRIPTION >Y OCo| ATO VAB.OOOl132756 i A 1-5 Training Manual Incineration System Aberdeen, Mississippi Page 8 The major pieces of equipment to be described in detail are the combustion chamber, quench chamber, and packed tower. How the feed streams are controlled and the rationale for the particular instrumenta tion scheme used will be outlined below. The combustion chamber shell is built out of carbon steel. The chamber is cylindrical in shape and has an approximate diameter of three and one half feet and is ten feet in length. The combustion chamber is lined with seven and one half inches of firebrick. The firebrick is designed to withstand operating temperature up to 3000F. If the firebrick is exposed to temperatures in excess of 2800F for long periods of time, the firebrick will begin to decompose. For this reason the incinerator unit will shutdown if the operating temperature is higher than 2800F. The shutdown can be initiated automatically by the dual thermocouple or the radiation pyrometers sensing the excessive temperature. During all modes of operation rapid changes in the operating temperature (more than a hundred degree change in several minutes) should be avoided. Any sudden fluctuations in temperature will generate thermal stresses in the firebrick and result in spalling of the firebrick. The combustion chamber's temperature is indicated both in the control room and out in the field on the local control panel. There is a warning alarm that will go off before the high temperature shutdown set point is reached. .. i. r hIHj . . r-r-| it :r rH'jtic'f rl rBu4-n.i1 h'j. | ii v i, i Hi VAB.0001132757 1-5 Training Manual Incineration System Aberdeen, Mississippi Page 9 IV, Instrumentation and Process Equipment Description (Continued) The combustion chamber is a holding container for the reactants (oxygen, methane and VCM). The combustion chamber is designed with a minimum residence time of 1,5 seconds. The combustion of VCM is almost an instantaneous reaction at high temperatures though the added residence time is further assurance in allowing the oxygen time to oxidize the VCM to water, carbon dioxide, and hydrogen chloride. The burner is located on top of the combustion chamber. The com bustion air, fuel gas, and the inert vent streams are fired downward into the combustion chamber. The inert vent stream is regulated by two pressure controllers in series. The flow rate is governed by the burner inlet pressure. The normal burner pressure should be around 3 psig. There is a flow indicator in the control room for observing the inert vent flow during venting operations. When the incinerator is in the "low-fire" position, the two safety shut off valves are closed and the bleed vent is open to the atmosphere. The double block and bleed arrangement was installed as a safety item to isolate the VCM feed stream from the burner during the "low-fire" or shutdown mode of operation. When the manual "high-fire" switch is activated in the control room, the linked combustion air and fuel gas valves open to their "high-fire" postion and then the bleed closes and the two safety shut-off valves open. There is a control valve that slowly ramps open to Initiate flow. The speed at which the valve opens will be slow enough for the fuel gas temperature controller to respond '13 -FI' "4c .II- -I-. r. 14,. VAB.0001132758 1-5 Training Manual Incineration System Aberdeen, Mississippi Page 10 IV. Instrumentation and Process Equipment Description (Continued) and thus minimize upsetting the incinerator operation. If the burner inlet pressure for the Inert vent exceeds 5 psig, the unit will automatically shutdown. Oxygen has been detected in the RVCM receivers in the past and during winter a propane/air mixture is used as fuel gas. A flame arrestor has been installed on both the inert vent line and fuel gas line at the burner to prevent a flame front from propagating back in the lines. The fuel gas flow is regulated by a temperature controller. The controller receives a signal from one of two radiation pyrometers. There is a switch in the control room for selecting which pyrometer to use. The signals from each of the pyrometers are recorded in the control room for detecting any drift or malfunction in the controlling pyrometer. An alarm will indicate when the combustion chamber temperature is too low or high. Upstream of the temperature control valve are the linked combustion air and fuel gas valves. These valves are linked to provide the approximate fuel gas to air ratio required for the "low-fire" and "high-fire" positions. The temperature controller's fuel gas valve is used to trim the fuel gas flow in maintaining the proper operating temperature. The double block and bleed arrangement is also provided on the pilot and mam fuel gas line. If the fuel gas regulator is malfunctioning or burner becomes plugged, the unit will shut down automatically on either low or high fuel gas pressure. There is A * ' -r *!**-'%inT-*:+**'!I I*!-*+ l~ "rfr- V#--. + -r- h r-^n -ii i ,|. r .1 . 4:1. - 4 rMH-L,.-. VAB.0001132759 --(W+l "- Training Manual Incineration lystem Aberdeen, Mississippi Page 11 1-5 A a wanning alarm before the high fuel gas pressure shutdown setpoint is reached. The combustion air is supplied by the air blower. If the motor fails or the blower discharge pressure is less than 1 psig, the incinerator will shut down automatically. There will be only two positions for the air control valve, "low-fire" and "high-fire". The "low-fire" is the lowest turndown position achievable for this particular burner. When the incinerator is in "low-fire", the incinerator is idling and there is no inert vent flow. At "high-fire" there is gyff^cifint amount of air to burn 1000 SCFH of VCM. Hence, if all of the inerts were bled from the receiver, the incinerator would be able to handle the inert vent stream even if it were 100 percent VCM. There is a burner selector switch at either the local or control room panel which will activate the linked valves to shift from "low-fire" to "high-fire" or vice versa. However, only the burner selector switch in the control room can activate the on-off control valve in the inert vent line to open. There are several lines which branch off of the main air supply header. There is a line used for the pilot air and another one which is used to supply the cooling air for the radiation pyrometers1 sight tubes* Instrument air is used to keep the lend on the pyrometers clean. Whenever the temperature in the combustion chamber rises, the fuel gas trim control valve should close. If the fuel gas valve is closed, and the temperature continues to rise, steam will be Injected to cool VAB.0001132760 1-5 A Training Manual Incineration System Aberdeen, Mississippi Page 12 XV. Instrumentation and Process Equipment Description (Continued) the flame on temperature control. At no time should the steam valve be open when the trim fuel gas control valve is also open. Flow indication is provided locally at the incinerator for the steam and fuel gas flows. The combustion gases exit the combustion chamber thru a Hastelloy downcomer tube. The lower end of the tube is submerged in water and is sprayed on the outside of the tube to cool the gases. The down comer tube is constructed from Hastelloy because it has a better resistance to corrosion attack by hydrogen chloride than other metals. The combustion gases should be cooled to less than 140F by the time they leave the quench chamber. The quench chamber is constructed from carbon steel and has a Kynar liner. The Kynar lining is resistant to the acidic environment (hydrochloric acid) up to a temperature of 275F. The spray nozzles are made from PVC and are accessible from the eight inch inspection ports on the quench tank. The quench water used in the quench tank and packed scrubber is the cooling tower blowdown. The expected blowdown rate is 60 gpm. A globe valve is used as the means of setting the blowdown rate to the incineration system. Strainers are provided at the incinerator site to remove any debris which might clog the spray nozzles. There is a warning alarm indicating low water flow to the scrubber and the unit will shut down if the total water flow is too low. Prior to a shutdown due to low water flow, a three-way valve will switch to city water as a back-up source. If the temperature of the effluent gases from the VAB.0001132761 - : ................................................ * t=j| b- *pi T hH a i- A 1-5 Training Manual Incineration System Aberdeen, Mississippi Pace 13 iy# Instrumentation end Process Equipment Description (Continued) quench tank, exceeds 180K, the unit will automatically shut down* The packed scrubber is made of fiberglass reinforced plastic (FRP). The FRP is good up to 190F for continuous operating temperatures. The scrubber is packed with one-inch ceramic Intalox saddles. The water flow to the scrubber is adjusted manually with a globe valve. A wash connection is provided to rinse the demister section of the scrubber if it is deemed necessary. There is an equilization line between the scrubber and quench tank to drain the scrubber to the quench tank. An alarm will indicate when the water level is rising in the quench tank. EPA requires that the stack gases be monitored continuously for VCM emissions. A heater and dryer sampling system is attached to the sample line off the scrubber stack. This sampling system contains a permeation tube which will remove the water vapor from the slip stream when dry instrument air is passed on the outside shell of the tube. If the water was not removed, the sample flow could become restricted due to the condensed water vapor plugging the line. The sample is withdrawn from the stack with the vacuum pump for the fixed point monitor system. VAB.0001132762 1 A 1-5 VAB.OOOl 132763 i I in ` + 1-5 A Training Manual Incineration System Aberdeen, Mississippi Page .15 V. Operating Procedures A. General Information The incinerator, H-l, removes VCM from the recovered monomer (RVCM) receivers vent stream via combustion with air. The vinyl chloride emission standard limits the maximum concentration of vinyl chloride in atmospheric vents to 10 ppm. To achieve this low concentration the RVCM receiver vent stream is first cooled to 20F to recover the majority of contained VCM and is then burned in a high efficiency burner at a high operating temperature (2400F) Since one of the products of the combustion of vinyl chloride is hydrogen chloride, the combustion gases from the incinerator are scrubbed with water in the quench tank, X-l, and the packed scrubber, W-l. The incinerator*s effluent gases are cooled and the hydrogen chloride is absorbed in the water, forming hydrochloric acid. The major operating parameters of incinerator operation are as follows: 1. The incinerator will operate continuously. a. A "high-fire", or vent position is provided when venting the RVCM stream to the incinerator. This provides maximum combustion air flow to the incinerator*s combustion chamber to insure that sufficient air is available. b. A "low-fire" position is provided when venting is not required. This reduces combustion air flow to the incinera tor and thus reduces natural gas usage (energy conservation) VAB.0001132764 A 1-5 Training Manuil Incineration System Aberdeen, Mississippi Page 16 V. Operating Procedures (Continued) A. General Information (Continued) 2. When the pressure has built up in the RVCM receivers, this is an indication that it may be time to vent the inerts from the receivers. However, the panel operator can use his discretion in determining when the receivers should be vented. 3. The incinerator's combustion chamber will operate at approxi mately 2400F at all times via temperature controllers, TIC-1 and TIC-2. When there is insufficient amounts of VCM present to sustain the combustion chamber temperature, supplemental natural gas will be added. When there is excessive VCM present in the vent stream and a high combustion chamber temperature, steam will be added to decrease the temperature. Sudden changes in temperature can damage the combustion chamber fire brick and refractory. 4. The hot combustion gases flow out of the combustion chamber through a Hastelloy tube into the quench chamber. Water sprays on the outside of the Hastelloy tube, thus cooling both tube and combustion gases. This cooling is required to prevent "melting" of the quench chamber liner and the scrubber. 5. Hydrogen chloride is removed from the combustion gases by the quench chamber and scrubber water sprays. This produces a hydrochloric acid solution which overflows from the quench tank into the sewer. Hydrochloric acid can cause severe burns. In case of contact, wash the exposed area thoroughly with water and contact the shift supervisor immediately. VAB.0001132765 fi 4 -"V**. -JU.: si-.- -r :rv*4ni n u- 1-5 A Training. Manual Incineration System Aberdeen, Mississippi Page 17 V. Operating Procedures (Continued) A. General Information (Continued) 6* Special operating procedures must be followed during initial start-up of the incinerator to dry and cure the firebrick (Trane Thermal will assist in training the operators for this phase of operation and outline the proper guidelines to use). This procedure should also be followed if the incinerator has been shutdown for an extended period of time which re sulted in the combustion chamber temperature dropping to less than 1000F. Modified procedures can be used for short shutdowns. 7. Since the incinerator site is remote from any major process area, an outside operator should check the incinerator several times per shift. Attention should be given to flow, pressure, and temperature indications that are provided at the incinerator site. 8. A constant amount of quench/scrubber water is supplied to X-l and W-l from the cooling water blowdown. City water will be used as the emergency source for the quench water in case of a power outage or low water flow. B. Local Panel Alarms and Switches * The panel and outside operators should be familiar with all of the alarms and switches at the local panel and control room panel. Care must be taken to assure that all switches are in their proper positions for safe incinerator operation. The following alarms and switches are located on the local panel at the incinerator: VAB.0001132766 A 1-5 Training Manu il Incineration System Aberdeen, Mississippi Page 18 V. Operating Procedures (Continued) B. Local Panel Alarms and Switches (Continued) 1. Switches or Pushbuttons a. Air Blower Start Button b. Air Blower Stop Button c. On-Off Switch (On, Off) (Can be used as emergency shutdown switch) d. Purge Start Pushbutton e. Burner Start Pushbutton f. Burner Selector Switch (Low-Fire, High-Fire, Remote) g. Operation Mode Switch (Warm-Up, Run) h. Horn Silence Button i. Annunciator Lamp Test Button 2. Indicating Lights a.. "Air Blower 0nM b. "Purging" c. "Purge Complete" d. "Pilot On" e. "Flame On" 3. Malfunction Alarms Set Point a. Scrubber Water Low Flow, FSL-7 b. Quench Tank High Level, LS-1 c. Fuel Gas High Pressure, PSH-2 d. Steam Low Pressure, PSL-5 (3.5 GPM ) ( 10" W.C. ) ( 4.0 psig ) ( 60.0 psig ) VAB.0001132767 ..r< r*--1 i- H. if il- S-kM.-H ... ,P|- I] ih 11 v *h kHv . I-b* .JU-1' i inj rtkST 1) & Wjf Comrtls 3 * *> o * UglvT r Oper+XC ^(#A O-^fer p*,l '< T, a(l SfaTCi** LO' X^-Acrr j ^stIo* loi*fc 1TTiAi^s Out- CL-fcrQ- Its C*e. -Cla O i* X-5 VAB.0001132768 Jfc 2itOQS lucmenAi&R HI FIRE.&OX HULFUUCTIOW LPT ROM6TU?SHUT OOWM JT EM PtR ATURt tHMPrVUFR.TQaOM, OTEETWMEPPHO* V.O FIREBOX CTPEVMRPOERMTEOTtRRE) STEAM VALVE OPEN ' H*c.rp *5WVt-*-k a ^TCu-fc. VI* TIC- I TR- lA/lft FI- I FILLET PAMEL -A" LAYOUT D8.TAM.S tli sw, u cua amraoaw OFF HICK Fin LOW FIRS MEMFlAl RftADY LOW FM V LOW TtW luKM OuM To TO TTFTi I'lU1141 HU 'UTIif 'IB1 lAi1 111r r3T Uj11 <g) (> i MtlStHHHUH I 4 2 fX-/V2F CM** FOR MtCROFILMCD MUUnttOt T T I t I V I T 1 T I T I ?- j T l^^tniiliinlnnliiiiMmliiiitimlMiiliiiiliintimluntinil i i i ._ ocscwmoM\ i-TWS TRAtJJUJe MANUAL. APR wP w OtD tfft CONTINENTAL OIL COMPANY INOtNSIftIMO CIMTIft POHCA CUT, OKLAHOMA COKATRBOftfLtbEROEOHMjPVPCA,MSYPESLATMLEEAMLYOUT AffD: OATS: 3/4/74 No. 1-5 VAB.0001132769 1-5 A Training Manual Incineration System Aberdeen, Mississippi P age 19 V Operating Procedures (Continued) B. Local Panel Alarms and Switches (Continued) 3. Malfunction Alarms (Continued) Set Point e. Refractory Thermocouple Failure, TISH-3A/B f. Scrubber High Temperature, TSH-4 g. Switch to City Water, FSL-2 ( 160F ) ( 35.0 GPM ) 4. Shutdown Alarms Set Point a. Waste Gas High Pressure, PSH-1 ( 5.0 psig ) b* Fuel Gas Low Pressure, PSL-3 ( 0.3 psig ) c. Combustion Air Low Pressure, PSL-4 ( 1.0 psig ) d. Fuel Gas High Pressure, PSH-6 ( 5.0 psig ) e. Air Blower Failure, MSD-1 f. Refractory High Temperature, TISH-3A/B ( 2800F ) g. Flame Failure, XY-1 h. Low Water Flow, FSL-6 ( 30.0 GPM ) Temperature ( 180F ) C. Control Room Panel Alarms and Switches The following alarms and switches are located on the control room panel: 1. Switches or Pushbuttons a. Burner Selector Switch (Low-Fire, High-Fire) b. Pyrometer Selector Switch (No. 1, No. 2) c. Emergency Shutdown Pushbutton d. Annuciator Acknowledge and Test Button + %.'! u:-1 VAB.0001132770 - I1** Tniil I III 'K'HlWU J Training Manual Incineration System Aberdeen, Mississippi 1-5 4 Page 20 V. Operation Procedures (Continued) C. Control Room Panel Alarms and 2. Indicating Lights a. ''High-Fire" b. "Low-Fire" c. "Low Temperature" d. "Low Temperature" e. "Ready" f. "Shutdown" 3. Malfunction Alarms Set Point a. Low Firebox Temperature, TAL-1 ( 2000F ) b. High Firebox Temperature, TAH-1 c. Steam Valve Open ( 2600F ) - d. Incinerator Alarm at Local Panel - 4. Shutdown Alarms a. High Firebox Temperature, TAH-2 Set Point ( 2800F ) b. Incinerator Shutdown at Local Panel D. Malfunctions The following alarms will indicate that there is a malfunction in the incineration system. Source of the problem should be located immediately to prevent an automatic or fnanual shutdown of the unit. 1 TAL-1 - Low Firebox Temperature (2000F) a. Check recorder, TR-1, to see if controlling pyrometer signal is in error. If it appears to be drifting, switch to other pyrometer for control. b. Check steam temperature controller, TIC-1, for steam addition. Valve should be closed. VAB.0001132771 ii m- -i; . Si t a I Sl ' ' ' : + - u T- 1-5 A Training Manual Incineration System Aberdeen, Mississippi Page 21 V. Operation Procedures (Continued) D. Malfunctions (Continued) 1. TAL-1 - Low Firebox Temperature (2000F) (Continued) c. The set point for TIC-1 shall alway be greater than the one for TIC-2. Check fuel gas temperature controller, TIC-2, to see if fuel gas valve is fully open. If temperature continues to drop while venting, switch to "low-fire". d. If temperature is decreasing in the "low-fire*1 mode, have outside operator check fuel gas flow and burner pressure. e. If burner pressure is not normal, this may indicate a plugged burner or gas regulator malfunction. Shut the unit down. f. Check combustion air pressure and line for sufficient air supply to burner. 2. TAH-1 - High Firebox Temperature (2600F) a. Check the pyrometer signals for error. Switch to other pyrometer if this is the source of the problem b. Check TIC-2 to see if fuel gas valve is closing. c. The set point for TIC-2 shall always be less than the one for TIC-1. If fuel gas valve Is closed, steam valve should be opening. Switch to "low-fire" if venting. d. In "low-fire" mode have outside operator check steam flow and pressure. If the temperature continues to rise, the unit will automatically shut down. -J . n-< irf- *:r> fe VAB.0001132772 Training Manual Incineration System Aberdeen, Mississippi Page 22' V. Operation Procedures (Continued) D. Malfunctions (Continued) 2. TAH-1 - High Firebox Temperature (2600F) (Continued) e. Check combustion air pressure and line for sufficient air supply to burner, 3, PAL-5 - Low Steam Pressure (60 psig) a. If venting, switch to "low-fire'*. Keep in "low-firett mode until normal steam pressure is established, 4, PAH-2 - High Fuel Gas Pressure (3 psig) a. Pressure regulator, PCi-3, may be sticking or hung-up. b. Decrease set point for TIC-2. Observe burner pressure at the pressure gauge located downstream of the fuel gas trim control valve, PG-10. If pressure does not decrease, the burner is plugged. Shut the unit down. 5. TISH-3A or 3B - High Refractory Temperature (2800F) a temperature pyrometers alarm indicates burnt thermocouple. Maintenance should replace the burnt out thermocouple at the earliest convenient time since the unit will shutdown if the other thermocouple bums out. 6. GPM) Immediately gauge located downstream of the total flow Indicating shutdown If low, switch to spare strainer. I * H*.~ ,............................. -!h : -|lr-fr.l >'l:. . s;. ^'**** i-1;** a* VAB.0001132773 '*-****-.--,, 4.w.. w 1-5 Training Manual Incineration System Aberdeen, Mississippi Page 23 V. Operation Procedures (Continued) D. Malfunctions (Continued) 6. FISL-7 - Low Scrubber Water Flow (3.5 GPM) (Continued) b. After switching strainers and water flow hasn*t increased, open the globe valve further. 7. TAH-4 - High Quench Effluent Temperature (160F) a. Check TR-1 for normal firebox temperature. b. If water flow is low, try switching to spare strainer. c. If temperature does not drop, put unit into "low-fire1* mode. 8. LAH-1 - High Quench Tank Water Level a. Check total water flow at the total flow indicating shut down switch, FI-6. If flow is above 50 GPM, close globe valve at the quench tank until flow is less than 50 GPM (100% on the scale). b. Open drain valve on quench drain seal leg. Close valve after level drops below the high level set point. c. If in "high-fire11 mode of operation, put incinerator in "low-fire". If level does not decrease immediately, close the globe valve for the quench tank feed. Do not decrease the flow below the set point for FISL-6 (30 GPM) (60% on the scale) T-I-" ii -MirV--. IV.-V.I9 ft*1-' "r llh: d*j irfi h11-::: p. . ijiip ft. , >ia -n . VAB.0001132774 n, rn-i?-IT* ni -r -t.~. r >1 >k i *i: .. v 4* A 1-5 Training Manual Incineration System Aberdeen, Mississippi rage 24 V, Operation Procedures (Continued) D. Malfunctions (Continued) 8. LAH-1 - High Quench Tank Water Level (Continued) d. If high level continues and burner operation becomes erratic (increase gas and air pressure at burner, poor temperature control, etc*), shut the unit down before water level reaches the firebox. After unit is shut down, block in water flow to unit. 9. FSL-2 - Switch to City Water ( 35 GPM) a. Check to see if the cooling water blowdown line is blocked in or plugged. b. If the switch was due to a power outage, do not reset valve until the power has been completely restored in the plant* E. Shutdown Mode The incinerator can "be manually shut down by a switch on the plant and local control panel* Shutdown will also be automatically initiated under the following emergency conditions: 1. High fuel gas pressure 2* Low fuel gas pressure 3* Flame failure Set Point (5.0 psig ) ( 0.3 psig ) 4* High firebox temperature 5* Low water flow 6* Low combustion air pressure 7 High quench effluent temperature ( 2800F ) ( 30.0 GPM ) ( 1.0 psig ) ( 180F ) VAB.0001132775 I-4-P*. . v ** e- * -u<*, *('" |P -t'-P* <r1i 1-5 A Training Manual Incineration System Aberdeen, Mississippi P age 2 5 V. Operation Procedures (Continued) E. Shutdown Mode (Continued) 8. High inert vent pressure Set Point (5.0 psig ) 9. Air blower motor failure The double block and bleed setup for the fuel gas and inert vent line shall close automatically during all emergency shutdown con ditions. When the incinerator is in a shutdown mode, the unit will be purged with air. The air blower will remain on unless the shutdown was caused by the air blower motor failing. Steam will be used to purge the unit for two minutes only on air blower shutdown. If the problems which created the shutdown condition, cannot be eliminated in a short period of time, shut the blower off to avoid cooling the refractory excessively (less than 1000F). However, do not shut the blower off until the steam line is blocked in. The steam purge comes on automatically whenever the air blower motor stops. Therefore, the steam line should be blocked in to avoid cooling the refractory unnecessarily. F. Start-up Procedures 1. Check all circuit and safety limit switches for normal conditions: a, Total water flow (flow indicating switch downstream of strainers, FI-6) should be 46 GPM (read 807 on the scale). .IHir- '1 If -Vp rfJT>- i'4-1 M l- N\U* : VAB.0001132776 -------------------"-nnriNjii m+.l . Training Manual Incineration System Aberdeen, Mississippi Page 2 6 V. Operation Procedures (Continued) F. Start-up Procedures (Continued) 1-5 b. The "City Water" alarm on the local panel should be off, c* Scrubber water flow (flow indicating switch downstream of globe valve, FI-7) should be 6 GPM (read 67% on the scale), d, Fuel gas pressure (pressure gauge downstream of pressure regulator, PG-6) at the incinerator should be 3 psig, e, Steam pressure (pressure gauge upstream of steam control valve, PG-5) at the incinerator should be greater than 100 psig, 2. In the control room the burner selector switch should be in "low-fire" position. 3. At the local panel, the operation mode switch should be in the "warm-up" position. 4. The on-off switch should be in the "off" position and the burner selector switch should be on "low-fire" at the local panel. The automatic block valves in the fuel gas line must be closed. 5. Start air blower, F-l, by pressing the pushbutton for the blower. The "blower-on" light should come on. Turn the local burner selector "switch to "high-fire". 6. Have panel operator put fuel gas temperature controller (TIC-1) on manual. Make sure trim fuel control valve is wide open, so as not to restrict fuel gas flow for main burner light off. VAB.0001132777 1-5 A Training Manual Incineration System Aberdeen, Mississippi Page 27 V. Operation Procedures (Continued) F. Start-up Procedures (Continued) 7. Check combustion air pressure (1.5 psig) and purge air flow (FI-5) to pyrometers. A flow rate of 7.0 CFM is required for each pyrometer. 8. To start purge cycle, turn on-off switch to the "on" position. Press the purge pushbutton. "Purging" light should come on. This light will remain on until the three minute purge cycle is complete. The "purge-complete" light should then come on. 9. The pilot is ready to be ignited. Turn burner selector switch to "low-fire". 10. Depress and hold the burner start pushbutton. The solenoid valves in the pilot line should open and the "pilot-on" light will come on indicating the flow of fuel gas to the pilot. 11. If the pilot is ignited and the flame is proven within ten seconds, the "flame-on" light will come on. The start button can be released. 12. If the pilot flame has not been established within ten seconds after depressing the burner start button, the solenoid valves will close and the "pilot-on" and "purge complete" lights will go off. Turn burner selector switch back to "high-fire". The unit must be repurged starting from step 8. 13. After the pilot flame has been proven, the pilot will remain on until the operation mode switch is turned to the "run" position. In the "run position the solenoid valves in the main fuel gas line will open, thus igniting the main flame. VAB.0001132778 1-5 Training Manual Incineration System Aberdeen, Mississippi Page 28 V. Operation Procedures (Continued) F. Start-up Procedures (Continued) After ten seconds the pilot solenoid valves close. As long as the main burner flame is proven, the ,,flame-on,, light will remain on. The proper heat-up schedule (step 16). 14. burner does not ignite and the pilot flame the main fuel gas solenoid valves will close. Turn burner selector switch back to "high-fire11. The incinerator has to be restarted from step 8. 15. Providing the refractory does not require curing or the incin- down the unit can be brought on line without proceeding through the heating schedule out lined below (step 16). Turn the burner selector switch to t "remote" position at the local panel. In the control room. the board operator controls the temperature rise by manually regulating the fuel gas control valve. The temperature should raise approximately 125F per hour. This can be observed by checking the refractory temperature indicators on the local panel at the incinerator. When the firebox temperature is above 2000F the "low temperature" light should go off and the "ready" light should come on. Put the temperature controller for the fuel gas (TIC-2) on automatic. At the local panel turn the burner selector switch to the "low-fire" position. The incinerator is now ready to follow the operation sequence for inert venting. A -j .* v, , , VAB.0001132779 1-5 A Training Manual Incineration System Aberdeen. Mississippi Page 29 V. Operation Procedures (Continued) F. Start-up Procedures (Continued) 16. For curing the combustion air and fuel gas valve will have to be unlinked temporarily. The air valve will be throttle as a means of temperature regulation during the first phase of the cure. Note: During the initial cure Trane*s Service Engineer will train the operators on the appropriate procedures to follow for this phase of operation. A. Raise temperature to 250F during a three-hour period. Hold the temperature at this level for a minimum of sixteen hours. The continuous pilot will be used for this phase. The operation mode switch should be on Mwarm-upM. Raise temperature to 1100 F over a seventeen-hour period at a rate of approximately 50F per hour. This will require turning the operation mode switch to the "run" position. The change over from pilot to "low-fire" main flame would occur during this time. C. Increase the temperature at a rate of 100F per hour to 1500F over a four-hour period. D temperature period, at a rate of approximately 175F per hour. Relink the combustion air and fuel gas control. Place the fuel gas controller on automatic. VAB.0001132780 L" ` H nil-)-sfjspi 4 ... , .p.. 1-5 A l> Training Manual Incineration System Aberdeen, Mississippi Page 30 V. Operation Procedures (Continued) F. Start-up Procedures (Continued) 17. After the incinerator is on-line and has stablized, the unit should be checked periodically each shift for any deviations from established operating norms. G. Venting Operation 1. Prior to starting vent flow, all alarm lights should be off at the local panel. The burner selector switch at the local panel and in the control room should be in the `'low-fire" position. 2. A run light in the control room should indicate that the unit is ''ready". Check TR-1 to see if the temperature has stabilized within the last ten minutes. TIC-1 and TIC-2 should be on automatic. 3. At the local panel turn the burner selector switch to "remote" position. 4. When the pressure in the RVCM receivers reach 70 psig, this is an indication that it may be time to vent the inerts from the RVCM receivers. The board operator will use his discretion in determining when the receivers should be vented. 5. Check to see that the refrigeration unit is operating. 6. Press the burner selector switch in the control room to "high- fire". The linked combustion air and fuel gas valves at the incinerator will shift to their "high-fire" position. After their position is proven, the vent line safety shut-off valves VAB.0001132781 A 1-5 Training Manual Incineration System Aberdeen, Mississippi Page 31 V. Operation Procedures (Continued) G. Venting Operation (Continued) open and the bleed valve closes automatically. CV-1 will then slowly ramp open. Flow indication should register on FI-1. The inert vent flow will stablize between 500 to 1000 SCFH. The flow rate is controlled by setting the burner pressure inlet with PC-2. 7. Check the temperature controllers frequently for stable incinerator operation. 8. The venting is terminated at the operator*s discretion. Indications of the depletion of inerts from the receiver will occur when the pressure decreases and levels out in the receiver or when the fuel gas valve begins to close. If the fuel gas valve is closed, and the steam valve is open, this will probably indicate that all of the inerts have been vented and the vent flow to the incinerator is all VCM. 9. To terminate vent flow press the burner selector switch to "low-fire". The incinerator will automatically shift to the "low-fire" position. Prior to the linked valves, shifting, CV-1 will ramp close and the double block valves will close. 10. Check the temperature controllers periodically for stable incinerator operation when it is in the "low-fire" mode. VAB.0001132782 * * I- VAB.0001132783 conoco Interoffice Communication To From S. J. Vincent v. E. Messick Date March 17, 1980 Subject OPERATING PROCEDURES - DELTECH AIR DRYER Attached are the operating procedures for the Deltech air dryer. A daily log sheet with explanation has been provided to assist the operator in checking the dryer and understanding what the normal conditions should be. More information on maintenance as well as detailed drawings of air flow, refrigeration, and electrical are included in the Deltech manuals. These manuals have already been distributed to the maintenance and operating heads involved. Maintenance and operating people were instructed about this manual bv the Deltech service representative. If you have anv questions, please call me. Veldon E. Messick Senior Process Engineer Attachments c: CLM, JLH, FWF(5), MCJ, RAF, MSR, AHS , ---r VAB`0001132784 fr+clrf' Jit*.!-* >rt i r^rf Jfc -`Ian.* *4 ir -t --i i. n x ih-w-r J pi 1 4-u. I . .. ai . OPERATING PROCEDURES DELTECH AIR DRYER TABLE OF CONTENTS I. THEORY OF OPERATION II. GENERAL PROCESS DESCRIPTION III. STARTUP / IV. RUN PROCEDURE Xy. DESIGN FEATURES A. DESICCANT SYSTEM B. ELECTRICAL SYSTEM C. REFRIGERATION SYSTEM , VI. DAILY OPERATOR CHECK /VII. S t^VIII. TROUBLESHOOTING DELTECH AIR DRYER FAILURE ih.ii :A. VAB.0001132785 -I - -tj t I- THEORY OF OPERATION l The heat pump dryer functions to provide a continuous supply of dry air bv automatically cycling the operation of two desiccant beds: one adsorb ing moisture from the air, the other being reactivated. Desiccant is used to store the water removed from the inlet air until the cycle reverses and the water is carried out to the atmosphere by the low pressure reactivation purge air. Reactivation of the offstream bed is accomplished by reducing the pressure of a portion of the dried air, thus expanding its volume, and then passing this purge air through the bed of desiccant that is being re activated. At the same time, this bed is being heated by hot refrigerant. The basic principle which makes this type of reactivation possible is that, at a given temperature, the quantity of water vapor carried in a saturated air stream depends only on the volume of the air. A volume portion of air at atmospheric pressure can contain as much water as a similar volume at an elevated pressure at the same temperature. The amount of water vapor removed from the system druing reactivation is determined by the temperature and flow of reactivation air. The dryness of the exit air can therefore be maintained at a very low level by controlling the temperature and flow of reactivation air (purge air). P The Deltech heat pump dryer utilizes a chiller to remove approximately 75% of the moisture contained in the inlet air before the air contacts the * desiccant. The amount of desiccant needed to adsorb the remaining 25% moisture is much less than that required to adsorb the entire moisture load as is the case with ordinary desiccant dryers. The energy removed from the inlet compressed air in the chiller is used for regeneration of the off stream desiccant bed. The inlet energy, increased via the ''Heat Pump" action of the refrigerant compressor, increases the temperature of the purge air, and thereby decreases the flow of the purge air required. The capacity of a desiccant to adsorb moisture at ultra low vapor pressures (ultra low dew points) is increased as the temperature is reduced. In the Deltech heat pump dryer, the chiller (refrigeration system) is also used to maintain the desiccant bed at low temperature throughout the drying cycle regardless of the heat of adsorption. The refrigeration system quickly cools the desiccant when the vessel cycle shifts from regeneration to drying. Fluctuations in the dew point of the exit air are much less than those experienced in drying systems that do not include refrigeration. Since the desiccant is not exposed to the very high temperatures needed for regeneration of systems without refrigeration, desiccant life can be expected to be substantiallv longer. VAB.0001132786 (MW... 1-6 II. GENERAL PROCESS DESCRIPTION The Deltech heat pump dryer takes advantage of the operating economics of refrigerated air dryers and the low dew point capability of desiccant. Refer to the schematic air flow diagram in Figure 1. In the heat pump process, the warm, wet compressed air enters a chiller where the temperature of the air is reduced to approximately 50F. Condensed moisture is separated and drained awav from the chiller. The air leaves the chiller and flows into * the desiccant vessel that is on the drying cycle, where additional moisture by adsorption down to the desired dew point. Inside the desiccant bed is a heat exchanger through which cold refrigerant is passed to keep the desiccant bed cool. Simultaneously, the alternate desiccant bed is being regenerated by heat from its exchanger which is now in series with the reheater. Hot refriger ant from the compressor is passed through coils in the desiccant bed to elevate the temperature of the desiccant. A small portion of the dry air from the reheater (purge air) is let down through an orifice and a pressure regulator. This air is used to sweep awav moisture desorbed from the regenerating desiccant. It is the rate of this purge air flow that controls the dew point of the outlet air. The unit is equipped with repressurization valves so that as the unit approaches its switchover point, the offstream bed is repressurized. This avoids pressure changes on cycle change. m A key factor affecting the dew point of the outlet compressed air is the amount of air used for purge. The purge valve and the purge timer is set at the time of startup to supply the specified dew point. Any re adjustment of this valve should be done only after consultation with the factory Figure I '(V VAB.0001132787 J-Ib. - r* SITH--IXS ...I . -I 1-6 K * III. STARTUP CHECKLIST mpleted After the installatior> has --='be decked: for startup, the A. Check main electrical supp y are provided. B. _ . charge from condenser. Release refrigerant charge (Th is done onlv for initial startup.) * and support of compressed air lines to the Check proper connection and support C. dry6T' ctions to the condenser (inlet to the water Check water supplyaConnections to ^ D. shollld be oP-n. II I f H-BMT"- *r- VAB.0001132788 T-'. iikiW I'P^' IV H- wH^4tU- i IV. RUN PROCEDURE % A. Turn on main electrical power to the dryer, first making sure the dryer ON/OFF switch is in the OFF position. The dryer must be left in this mode for at least four hours to allow the refrigeration com pressor crankcase heaters to complete their function. This procedure should be carried out if the main power supply to the dryer has been off for more than four hours. B. Crank open the valve on the inlet line sufficiently to pressurize the dryer. When the dryer is up to pressure, check all pipework connections for leaks. C. When the dryer is pressurized, check that the air supply to the valving cylinder is set at 60 psig and there is oil in the lubricator. D. When all checks are comnlete and the four hours has exnired, turn the dryer ON/OF^ swtich to the ON position. E. Let the dryer run for approximately five minutes to allow stabilization of the refrigeration system before slowly opening the outlet valve and closing valve to existing GDI dryer (see Section VIII). H r h: *--tp- *# f- . ' s "1 ''f L'IHf. i i . irfi ' vjp rfiiri VAB.0001132789 I J DESIGN FEACTURES A. Desiccant System Deltech heat pump dryers utilize desiccants such as silica gel, activated alumina, or both to adsorb moisture. Life expectancy for the desiccant in Deltech heat pump dryers is three to five years, depending upon inlet air quality and flow uniformity. Since there are no internal electrical heaters to cause large temperature differ entials as in other types of compressed air dryers, the deleterious effect on the desiccant of excessive temperature has been virtually eliminated. The heat exchangers within the desiccant vessels act as a support for the drying media while also ensuring uniform heating/cooling distribution during the drying and regeneration cycles. B. Electrical System The electrical system of the drver is designed around a cam timer that provides all the control function for changing the air flow and cooling/heating flow through the desiccant beds. Indicating lights and all the other controls to provide starting and protection for the compressor are also included. The electrical schematic included with the Deltech operating manual details all the equipment provided for the dryer. The circuit describes the function of each control provided. C. Refrigeration System Refrigerant flow to the chillers is automatically regulated by a thermostatic expansion valve (TEV). As shown in Figure 2, a system of solenoid valves (cam timer controlled) and check valves has been added to the basic refrigeration circuit of expansion valves, etc., to direct the flow of refrigerant from one bed to another. The dotted line indicates the flow of refrigerant for the cooling cycle. Refrigerant flow for the instance shown is through the left bed, as solenoid valves SB and SC are open, allowing flow through check valves CA and CD. Under these circumstances, the left bed is on the drying cycle and the right bed is being regenerated. The flow pattern through the desiccant beds is reversed when the right tower is drying. A second control valve (hot gas bypass, HGBV) is used in conjunction with the TEV to prevent freeze-up within the chiller, and to provide capacity control for the compressor when little or no compressed air is being used. VAB.0001132790 V. DESIGN FEATURES C. Refrigeration System (Cont.) A second TEV is used to control the flow of refrigerant through the desiccant vessels. These valves are preset at the factorv and may be readjusted on site by the startup engineer depending upon the applica tion. Adjustments should be made only by a trained refrigeration engineer. See the maintenance section of this manual for adjustment procedure and temperatures. 11 ; 4,, -j * ' r Figure 2 * c:w, i i * - > s? iWV - pi i- 1 hi >r> ^ VAB.0001132791 I-H.II rn-rr* + m- ,t-pi |H nfi-HK 1-6 VI. DAILY OPERATOR CHECK \ Automatic drain on prefilter should be checked to insure proper '-S functioning. A discharge in excess of one pint indicates a possible malfunction of the drain trap. Remove trap and clean all internal moving parts. B. Afterfilter should be blown down by operating manual valve on filter. This will prevent the buildup of excess dust particles, etc. NOTE Just after startup, settling down of the desiccant within the towers will cause more dusting than can be expected during normal running periods. The amount of dusting will dimish with operation. Chiller drain trap located at bottom of chiller should be checked to / insure it is working. The trap on the air to air exchanger should also be checked. ifc Check for a positive discharge from the purge air line. / E. Complete the "Dailv Log Sheet for the Deltech Air Dryer" as described below: 1. Check to make sure the ON/OFF switch is on. If it is, place a checkmark in the "POWER/ON" space on the logsheet. If it is off, turn power ON. 2. Check that the compressor running light in on. If it is on, place a checkmark in the "COMP. ON" space on the logsheet. 3. Place a checkmark in the space on the logsheet for the appropriate bed that is drying and regenerating. 4. Check the high head pressure, switch failure, and high humidity lights. If none are lit, place a checkmark in the appropriate spaces on the logsheet. If the switch failure light is on, check the pressure regulator to the switching cylinders. It should be set at 60 psig. If the high head pressure light or the high humidity light is lit, consult the troubleshooting portion of these precedures. 5. Record the refrigeration suction pressure on the logsheet. It should be between 50 and 65 psig with 54 psig being normal. 6. Record the refrigeration head pressure on the logsheet. It should be between 180 and 220 psig with 200 psig being normal. VAB.0001132792 VI. DAILY OPERATOR CHECK 7. Record the temperatures of the towers on the logsheet. 8. Record the tower pressures on the logsheets. The tower that is regenerating should be at atmospheric pressure except for 5 minutes before switch to 5 minutes after switch. During this time, it should be line pressure. The tower that is drying should be at line pressure. 9. Record air cylinder pressure on logsheet. The pressure regulator should be set at 60 psig. 10. Check purge air pressure. It should be set at 40 psig. The purge timer should be set at 6 seconds on and 12 seconds off. Any change from this purge setting should be done only after consulting Deltech engineering. 11. Inspect refrigeration sightglass. It should be clear with no bubbles and the indicating area should be green. A continuous stream of bubbles indicates loss of refrigerant charge. A color change from green to yellow indicates contamination. 12. Check refrigeration compressor oil level. 13. Record date and time readings taken. VAB.0001132793 The f,,ol,l,owi.ng c,ha^rts aarree pnrroovviiduecdu to he__l_n determine the mriQt O c fmiithat mav occur- and remedy + I- - i-. i- c.-h L'l- . .-4j< i VAB.0001132794 .. 'e- -m DAILY LOGSHEET FOR THE DELTECH AIR DRYER i p- \4\B.0001132795 I ( 1. ......................i t- h-\ \ ON VAB.0001132796 tr 0. PROBLEM P ROE ABLE CA'SE COMF1RMING CHECK CORRECTIVE ACTION Water downstrean of rv* er or excessively* iah dew point 1. Dryer turned off 4 2. Dryer on; bypass valves open Check if dryer light is on . Turn on after com pleting startup proced -.ire. Note location of valve actuator. Check why open. Jlose providing bed is pres surized . 3. Drain trap on chiller not work ing See if water is dis charging from drain pipe. Dismantle valve; clean or replace. This should be a routine daily maintenance program. 4. Refrigeration systen completely shut down Compressor on, light of f . t Compressor on, light on. Check main supply fuses and control circuit fuse. Check compressor con trol fuses at com pressor electrical box. 5. Air flow valve system does not shift Manually rotate cam timer to next change location. Insure that air supply to actuator is above 60 psig. Insure that there is oil in air line lubricator. Check proper opera tion of solenoid control valve. 6, Insufficient or no purge air Check exhaust from purge air muffler. Increase pressure of purge air to factory preset reading. 7. Refrigeration system malfunc tion resulting in hiah suction pressure Check comparative temperatures of refrigerant solenoid and check valves using manual as guide. Replace or repair faulty component. , 8. High suction pressure Check refrigerant charge for leaks. Check for leaks and recharge. Check adjustment of hot gas bypass valve Readjust to correct reading (54 psig) or replace if faulty. 9, Inlet air temper ature too high Check temperature of inlet air and com pare with specifi cation sheet. Check temperature of air from aftercooler and adjust if required. 10. Chiller iced up Check refrigerant suction pressure. Adjust hot gas bypass valve to give suction pressure of 54-65 psig . If too low, increase head pressure to 210 psig. 11. Excessive flow 12. Air pressure too low 1 3 . Elect nca 1 control failure Check specification for design limits. Chock specification for design limits. Chock circuit func tions using electri cal scheratic. Replace malfunctioning hot q-- as bvnass 4- -4 valve. Add another dryer. Consult factory. # Bring up to pressure. Consult factory . Repair as required. 1-6 A - . VH- -ml.-. , l^-l- * .. VAB.0001132797 PROBLEM Refrigeration cortpressor cut out on internal protection High current draw on refrigeration com pressor (s) PROBABLE CAUSE CONFIRMING CHECK 1, High current drawn * Unit should restart automatically when cooled down. 2. Leak in refrigoration system i j j i ......_.._.._.._._.._..________-_-_--_-_--_--_-__________1 J 1. Short in windings j Use "mega" across 1t 2, Leak m refrig windings to check t to ground short. eration system CORRECTIVE ACTION I When unit res4 rts, chock current irawn. Unit should run at rated amps shown on motor plate. t { \1t\ i fi This should be checked - onlv* bv a trained refrigeration engineer. j1 . Re*nlace com* oressor. f 1 *yi i This should be checked j only by a trained refrigeration engineer. l j Continuous bubbles in sight port Sight port indicator change to yellow No purge air curing normal cycle 3. Low on compressor 1 Check level through oil sight glass. Loss of refrigerant charge u4 --------------- ---------- --------- --| Check if exit dew j point is too high, 4 Add oil. If no im- prevement, replace * it----c---o--m--*- -n--rerrssor. -......... r 1< Check for leaks in j system and repair. r- i r i This should be done (i only by a trained re frigeration engineer. i Moisture in system j High head pressure Find leak in suction 4r : should not exceed side of refrigeration i 1 300 psig. i ; \ i ______________ ___________________ ii____________- i ____ __ system and repair. i This should be done i i only by a trained refrioeration engineer. ttjl ____^ . _____'___ ___________________ | i 1. Puree air j Check for air Clean strainer. strainer blocked | exiting puree and i f ] o *-c 2. Puree air sole- 1 noid ,falve closed Clean solenoid valve. or plugged t 3, Puree air control Note handle position Reset to pressure valve closed ! and gaoe pressure. 1 noted in s*o* ecifica1 tion sheet. 4. Puree air exhaust valve closed Purge air gage reads higher than normal. Replace valve or valve coil. 5 * Puree airvand letdown mufflers plugged Tower pressure on regeneration cycle should read 0. Remove muffler and note dryer performance Clean and reolace. * Hich pressure air in bed being purged 1. Butterfly valve leaking Shut down all other sources of hich pressure air and note results. Readjust or replace valves, Lubricate. 2* Valving motion not complete Check all valve attach points and note location of direction of flow indicator. Check and replace worn links or pins. * F^eadiust air cvlmder ** 4 r.o t ion . Lubricate. 3, Process air check valve leaking Reverse cycle to see if other valves hold. ---------------------------------------------------------i problem probable cal:'! CONFIRMING CHECK CORRECTIVE ACTION Compressor cut out on hich read pressure s v.- itch 1. Water suwplv k^ * turned off Check manual valves. Ocen valves. 2. liiah inlet water i Water supply should tercerat ure t not exceed 90F. Reduce temperature of water supply. 3. Water supply Pressure should not pressure too low te below 30 psia. + 4 . Hiah ln let air tenpe ra t ure Inlet air tempera ture should not ex ceed desicn specifi cation bv more than 2npt Provide boost pumps. Increase aftercooler ef f iciencv. 1 Ref rice ration conpressor cut out on lew oressure 5. Condenser fouled and dirt/ Temperature rise across condenser should not be more than 5F . Dismantle and clean* 6. Air in refr10erant system Check color indicator Check for leak in re through sight glass. frigerant system. Head pressure stays high when compressor is turned off. This should be cor rected only by a trained refrigeration engineer. 7. Solenoid valve m refrigerant sys tem fails to ooen Feel temperature of vavle using guide in manual. Coen valve * manually and note e f fcct. Replace val';e coils Check cam timer con trols. Check electrical system. 8. Check valve in refrice rant svs j tern jammed shut Feel temperature of valve using guide in manual. Lightly tap suspected valve and note re sults . If valve cannot be freed, pump down refricerant ar.d reolace -** a valve poppet. This should be done or.lv bv a trained refricerat:or, engineer. 9. Water valve failure Wait until switch resets. Restart drver and no to v/atu flow conditions. Replace valve or valve equipment. 1. Low inlet load 2 . Loss of ant charge Check flow and tem perature of inlet air . Compressor should re start after suction pressure rises and timer runs out. Turn off unit for 5 minutes. Restart, watching sight port. Bubbles should ap pear at first, then clear if system is full. If no bubbles appear, system has lost charge. Check for leaks in svstem, reoair and recharge with R22 until bubbles dis appear. See specifi cation sheet. Hot gas bypass valve out of adjustment Hot gas should be present after valve if load is below rated conditions. Adjust valve so that suction pressure is 54 psig. Failure in sole noid control sys tem for refnger ant changeover Check temperature of valves usmo quide in manual. Use manual lift stem to open valve and note conditions. Check electrical con trol system and re place or correct faulty component. 5. Refriaerant sole no id valve stuck closed Check operatina con dition while unit is running to note temperature of vaIves. Tap liuhtly and note any chancre. If valve does net release, re place poppet arter pump inn down system. TJiis should be done onlv bv a trained re- A& frigeration engineer. 1-6 A VAB.0001132799 'IN >* * -I'.H A ts J- z . . iw'i r --fc'p 1-6 A VIII. DELTECH AIR DRYER FAILURE * In the event that the Deltech air drver fails to perform, the procedure below should be followed. To take the Deltech off stream and put the GDI drver on stream: A. Turn on the power to the GDI dryer. B. Onen the valves to the inlet and outlet of the GDI dryer so that air can flow through the drver. C. Open the valve connecting compressor number 8 (72-708) to the surge drum near the Kemp drvers so that air from this compressor can flow through the Kemp drvers. (See Note 1.) D. Close valve connecting compressor number 8 (72-708) to the Deltech drv* er. E. Close inlet and outlet valves to the Deltech. F. Depressurize Deltech dryer using afterfilter bleed valve. NOTE: (1) The GDI drvw er is onlv rated for the air from one compressor. The * air from one compressor, (72-708), must be routed through the Kemp dryers. The following procedure should be used in switching from the GDI drver to the Deltech dryer, after the Deltech dryer is running (see startup proce dure for Deltech Sec. III). A. Crack the valve on the inlet of the Deltech prefilter and slowlv let the Deltech drver pressurize. When it is pressurized, open valve fullv. 4 B. Open the valve on the outlet of the Deltech dryer. C. Close the inlet and outlet valves on the GDI drver. D. Turn power off to the GDI dryer. E. Open valve connecting compressor number 8 (72-708) to the Deltech dryer. F. Close valve connecting compressor number 8 (72-708) to the surge drum near the Kemp dryers. 4 VAB.0001132800 i- 4 VAB.OOOl132801