Document 6w0vEv92E3z6v0Rve48YY5av9

BLOCK #296 CRITICAL PROCEDURE NORMAL SHUTDOWN FRONT END - REACTORS TITLE: R-l/R-2 NORMAL OPERATING CONDITIONS REVISED: 5/13/96 PD REVISION: #0 APPROVED: CEJ HAZARDS TO BE AWARE OF: SAFETY/HEALTH CONCERNS: 1. POOR POSITION WHEN OPERATING FLASH STEAM B/V 2. CAREFUL NOT TO SUCK AIR IN HYDROLYZER 3. TRIPPING THE 71 SIDE. 4. DRY CL2 REACTS WITH TITANIUM 5. WET CL2 REACTS WITH TITANIUM ABOVE 150 DEG C ENVIRONMENTAL CONCERNS: 1. A CHLORINE OR PROPYLENE SPILL 2. BLOWING PSV'S 3. HIGH TOD OR PDC TO ENVIRONMENTAL OPERATIONS SAFETY EQUIPMENT: BLOCK SAFETY EQUIPMENT RESPONSIBILITY: 1. SOS'S AND OS'S TO IMPLEMENT AND MAINTAIN THIS PROCEDURE. 2. IT IS THE SOS'S RESPONSIBILITY TO MONITOR ALL ALARMS, FLOWS, LEVELS AND PRESSURES DURING AND AFTER SHUTDOWN. 3. IT IS THE OS'S RESPONSIBILITY TO MAKE SURE EVERYTHING IN THE FIELD IS SECURED IN A SAFE MANNER. PURPOSE: TO PROVIDE INSTRUCTIONS FOR NORMAL OPERATING CONDITIONS OF R-l/R2D. GLYCOL I PROCEDURE TRIP REACTOR PROP LOW DELTA P ACROSS C/V LIMIT 10.75# CONSEQUENCE WATER BACKING INTO PROPYLENE HEADER ACTIONS TO BE TAKEN BLOCK PROPYLENE C/L IN THE FIELD. PULL AND FOLLOW REACTOR TRIP PROCEDURE. CHECK SYSTEM FOR PROBLEM. IS IT A SYSTEM PROBLEM OR TRANSMITTER FAILURE? GET PROBLEM FIXED, PRESSURE UP AND RESTART THE REACTOR. DO A 045384 CONFIDENTIAL Reviewed 11/13/96 Page I of 11 TRIP REACTOR CHLORINE LOW DELTA P ACROSS c/v LIMIT 5# REACTOR LOW WATER FLOW 700 KLB/HR D-102 HIGH/HIGH LEVEL 90% CONSEQUENCE ACTIONS TO BE TAKEN WATER BACKING INTO BLOCK CHLORINE C/L IN CHLORINE HEADER THE FIELD. PULL AND FOLLOW REACTOR TRIP PROCEDURE. IS IT A SYSTEM PROBLEM OR TRANSMITTER FAILURE. GET PROBLEM FIXED. CHECK CL2 C/L FOR WATER BEFORE START UP. RESTART REACTOR USING THE REACTOR START UP PROCEDURE. EXOTHERM, IMPROPER NEED TO MAINTAIN A MIXING, TITANIUM AND MINIMUM FLOW OF 600 CHLORINE REACTION KLB/HR THROUGH E-70/E- 3C THROUGH REACTOR. IF FLOW CANNOT BE KEPT, STOP ALL FLOWS IN AND OUT OF R-2D/R102D ON THE SIDE WE LOST WATER. REFER TO EMERGENCY REACTOR TRIP PROCEDURE. RUPTURE DISC WILL BLOW CHECK THE PD-102AA/BB DUE TO HIGH PRESSURE AT PUMPS, PCH C/LOOP TO R- 15#'S. HIGH PRESSURE IS 102D AND MANUAL DUE TO HIGH LIQUID VALVES AT PUMP SUCTION LEVEL. LARGE PCH SPILL AND DISCHARGE ADD AT IF RUPTURE DISC BLOWS. PCH C/LOOP. SWITCH TO R-101 WILL SHUTDOWN ON OFF LINE PUMP TO HELP HIGH PRESSURE AT 12#. BRING LEVEL DOWN, R-101 MAY HAVE TO BE SHUTDOWN AND WATER CUT OFF REACTOR AND MANUALLY BLOCKED AT C/LOOP AND 1" BYPASS, ALSO MANUALLY BLOCK IN SEAL FLUSHES AT PD- 102AA/BB, S-71FF, E-101 LIQUID DROPOUT, RECOVERY, T-400 F/F BV'S. ALSO IF R-101 GOES DOWN, MANUALLY BLOCK IN ALL FLOWS IN AND OUT OF R- 102D AND D-102 ASAP. REFER TO EMERGENCY TRIP PROCEDURE. DO A 045385 CONFIDENTIAL Reviewed 11/13/96 Page 2 of 11 TRIP D-210 HIGH LEVEL D-2 HIGH/HIGH LEVEL D-2 HIGH PRESSURE LIMIT 50% ON BOTH TRANSMITTER OR 50% ON ONE TRANSMITTER AND HIGH DEW POINT ON THE OTHER 98/75% 7.0# CONSEQUENCE ACTIONS TO BE TAKEN LIQUID CHLORINE TO BLOCK CL2 REACTOR B/V'S REACTORS, BLOW PULL EMERGENCY RUPTURE DISC AND HAVE REACTOR TRIP A PCH SPILL PROCEDURE AND FOLLOW PROCEDURE STEPS. GET CL2 PLANT TO SUCK THE HEADER BACK. RUPTURE DISC WILL BLOW CHECK THE PD-2 AA/BB DUE TO HIGH PRESSURE AT PUMPS, PCH C/L TO R2D 10.07#. HIGH PRESSURE IS DUE TO HIGH LIQUID AND MANUAL VALVES AT PUMP SUCTION AND LEVEL. LARGE PCH SPILL DISCHARGE AND AT PCH IF RUPTURE DISC BLOWS. C/L. SWITCH TO OFF LINE R-l REACTOR WILL PUMP TO HELP BRING SHUTDOWN ON HIGH LEVEL DOWN. R-l MAY PRESSURE AT 7.0#. HAVE TO BE SHUTDOWN AND WATER CUT OFF REACTOR AND MANUALLY BLOCKED AT C/L AND 1" BYPASS. ALSO MANUALLY BLOCK IN SEAL FLUSHES AT PD-2 AA/BB, S-70 FF, E-l DROPOUT, RECOVERY AND T-400 FF B/V'S ALSO IF R-l GOES DOWN, MANUALLY BLOCK IN ALL FLOW IN AND OUT OF R-2D AND D-2 ASAP. REFER TO EMERGENCY TRIP PROCEDURE. RUPTURE DISC BLOWS AT IS THE PRESSURE COMMON 10.07#. WHEN RUPTURE TO BOTH DEGASSERS? IF DISC BLOWS A SPILL WILL YES, CHECK FOR OCCUR IMPURITIES IN THE INCOMING RAW MATERIALS(PROCESS WATER PROPYLENE, CHLORINE). CHECK THE LEVEL IN THE DEGASSER HIGH LEVEL WILL CAUSE HIGH PRESSURE. CHECK NITROGEN FLOW TO D-2, MAKE SURE THE C/V IS NOT STUCK OPEN. CHECK VENT SYSTEM OUT, COMPRESSOR AND VALVES. IS R-l IN BALANCE. REFER TO EMERGENCY TRIP PROCEDURE. 1 Reviewed 11/13/96 DO A 045386 CONFIDENTIAL rage JOi 11 TRIP D-102 HIGH PRESSURE LIMIT 12# CL2/PR0P RATIO SET POINT DEVIATION 20% D-102 HIGH TEMPERATU RE 130 DEG C CONSEQUENCE RUPTURE DISC BLOWS AT 50#. WHEN RUPTURE DISC BLOWS A SPILL WILL OCCUR. OUT OF BALANCE, PRESSURE PROBLEMS, CL2 INVENT POSSIBLE REACTION WITH WET CHLORINE AND TITANIUM AT 150 DEG C ACTIONS TO BE TAKEN IS THE PRESSURE COMMON TO BOTH DEGASSERS? IF YES, CHECK FOR IMPURITIES IN THE INCOMING RAW MATERIALS (PROCESS WATER, PROPYLENE, CHLORINE). CHECK THE LEVEL IN THE DEGASSERS, HIGH LEVEL WILL CAUSE HIGH PRESSURE. CHECK NITROGEN FLOW TO D-102. MAKE SURE THE C/V IS NOT STUCK OPEN. CHECK VENT SYSTEM OUT FOR ANY VALVES THAT ARE NOT WORKING. IS R-101 IN BALANCE? REFER TO EMERGENCY TRIP PROCEDURE. PULL UP REACTOR DIAGNOSTIC TROUBLESHOOTING CHECKLIST AND DETERMINE WHAT TRANSMITTER HAS DEVIATED. PULL EMERGENCY TRIP PROCEDURE. REPAIR AND START UP USING REACTOR START UP PROCEDURE. INCREASE WATER SPRAY FLOW. COMPARE D102 TEMP AGAINST R-101 OUTLET TEMP TO SEE IF THERE IS A POSSIBLE TRANSMITTER FAILURE OR IS THE REACTION TAKING PLACE IN THE REACTOR. PULL EMERGENCY TRIP PROCEDURE. INCREASE WATER RATIO TO R-101. AFTER PROBLEM IS FIXED, STARTUP R-101 USING THE R101 STARTUP PROCEDURE. Reviewed 11/13/96 046387 DO CONFIDE^ T At Page 4 of 11 TRIP D102 LOW/LOW WATER SPRAY LOW NITROGEN FLOW TO DEGASSER D-102 LOW/LOW LEVEL PD102 AA/BB TRIP THROX THROX LIMIT 5 GPM 100 SCFH 10% ON BOTH LEVEL TRANSMITTER SEQ 13 NOT IN RUN STEP SEQ 12 NOT IN RUN STEP CONSEQUENCE CL2 AND TITANIUM REACTION NO CL2 SWEEP EXPLOSIVE ATMOSPHERE, REACTION WITH TITANIUM, FIRE REACTOR VENT VAPORS COULD BE SUCKED INTO R102D CAUSING A REACTIVE CHEMICAL INCIDENT. NO VENTING CAPABILITIES, THROX IS DOWN NO VENTING CAPABILITIES, THROX IS DOWN ACTIONS TO BE TAKEN CHECK ALL WATER B/V'S IN THE FIELD TO VERIFY THEY ARE OPEN. CHECK THE CONTROL VALVE TO VERIFY IT IS WORKING PROPERLY. CHECK PROCESS WATER PRESSURE. CHECK FLOW TRANSMITTER. PULL R-101 EMERGENCY TRIP PROCEDURE. CORRECT PROBLEM AND RESTART R10I USING R-101 START UP PROCEDURE. CHECK NITROGEN CONTROL VALVE TO SEE IF IT WORKS PROPERLY. CALL UTILITIES TO SEE IF THERE IS A PROBLEM WITH THE NITROGEN HEADER PRESSURE. LOOK TO SEE IF THERE IS A TRANSMITTER PROBLEM. PULL UP REACTOR EMERGENCY TRIP PROCEDURE. CORRECT THE PROBLEM AND RESTART THE REACTOR USING THE REACTOR STARTUP PROCEDURE. CHECK THE PCH C/V INTO R-102 TO SEE IF IT STUCK OPEN ALSO SEE IF THE BYPASS IS OPEN. CLOSE BACK ON A PCH MANUAL B/V TO SEE IF THE LEVEL COMES UP. IF LEVEL COMES UP, THE C/V HAS PROBABLY BEEN EATEN AWAY. YOU WILL NEED TO RUN ON BYPASS UNTIL C/V CAN BE REPLACED. START THE 70 SIDE VENT COMPRESSOR SYSTEM, START UP THROX USING THE APPROPRIATE START UP PROCEDURES. START THE 71 SIDE VENT SYSTEM AND START UP THROX USING THE APPROPRIATE START UP Reviewed 11/13/96 D0 A 045388 CONFIDENTIAL TRIP D102 LOW TEMPERATU RE LIMIT 20 DEG C CL2 IN VENT 25% CL2 FOR 3 ANALYZERS MINUTES CONSEQUENCE CHLORINE AND TITANIUM REACTION CHLORINE REACTION IN VENT SYSTEM CAUSING FIRE OR EXPLOSION ACTION TO BE TAKEN INVESTIGATE POSSIBLE TRANSMITTER PROBLEM. IS D-102 WATER COOL? PULL R-101 EMERGENCY TRIP PROCEDURE. FIX PROBLEM AND RESTART R101 USING THE R-101 START UP PROCEDURE. PULL THE REACTOR DIAGNOSTIC TROUBLESHOOTING CHECKSHEET TO SEE IF THERE IS A TRANSMITTER PROBLEM. PULL REACTOR EMERGENCY TRIP PROCEDURE AND FOLLOW STEPS. ONCE PROBLEM IS IDENTIFIED AND CORRECTED, USE THE REACTOR STARTUP PROCEDURE TO BEGIN STARTING UP REACTOR. ALARMS PROP FLOW LOW DIFF ACROSS C/V LIMIT 17# CL2 FLOW LOW DIFF ACROSS C/V 8# REACTOR LOW WATER FLOW 1000 KLB/HR DEGASSER 50% HIGH LEVEL CONSEQUENCE POSSIBILITY OF WATER BACKING UP INTO THE PROPYLENE HEADER. TRIP IS 10.75# POSSIBILITY OF WATER BACKING INTO CL2 HEADER CAUSING A REACTION. TRIP IS 5# POSSIBILITY OF > EXOTHERM, IMPROPER MIXING, OR A TITANIUM AND CHLORINE REACTION. TRIP IS 700 KLB/HR POSSIBILITY OF PRESSURING UP DEGASSER AND BLOWING RUPTURE DISC CAUSING A SPILL D-2 TRIP IS 98.75% D-102 TRIP IS 90% ACTION TO BE TAKEN CHECK E-150C PRESSURE, RAISE PRESSURE IF LOW, CUT LOAD TO BRING PRESSURE UP. CUT LOAD TO BRING PRESSURE UP. CALL THE CHLORINE PLANT TO SEE IF THEY CAN RAISE THE HEADER PRESSURE. CHECK P-100 DISCHARGE PRESSURE PUT ON ANOTHER P-100 IF NEED. CHECK ON THE WATER C/V, MAKE SURE IT IS WORKING CORRECTLY. LOOK AT THE OH TRAIN AND CHECK THE VALVE POSITIONS. COULD IT BE AN INSTRUMENT PROBLEM? IF YES, GET FIXED. START DOWN PUMP AND OPEN DISCHARGE VALVE. OPEN PCH C/L BYPASS. CHECK PCH C/V TO SEE WHAT POSITION IT IS IN. TREND THE PCH FLOW TO Reviewed 11/13/96 A 0453fjo CONFIDENTIAL. Page 7 of 11 ALARMS D'2 HIGH PRESSURE LIMIT 4# D-102 HIGH PRESSURE 6# DEGASSER L0WN2 FLOW 800 SCFH Reviewed 11/13/96 CONSEQUENCE POSSIBILITY OF BLOWING RUPTURE DISC WHICH BLOWS AT 10.07# POSSIBILITY OF BLOWING RUPTURE DISC WHICH BLOWS AT 50# POSSIBILITY OF AN EXPLOSIVE ATMOSPHERE TAKING PLACE IN THE DEGASSER DUE TO A LOW CL2 SWEEP ACTION TO BE TAKEN CHECK LEVEL, IF HIGH LOWER THE LEVEL. CHECK THE VENT FLOW, IF LOW CHECK OUT ALL THE VENT SYSTEM VALVES, BYPASS FLOW TRANS. IF VENT FLOW IS HIGH, THERE IS A PROBLEM WITH EITHER THE REACTOR OR DEGASSER. CHECK THE N2 FLOW TO D2, MAKE SURE THE C/V IS NOT STUCK OPEN. IS R-l IN BALANCE? IS THE PRESSURE COMMON TO BOTH SIDES? IF YES, CHECK FOR IMPURITIES IN THE INCOMING RAW MATERIALS (PROCESS WATER, PROPYLENE, CHLORINE) CHECK LEVEL, IF HIGH LOWER THE LEVEL. CHECK THE VENT FLOW, IF LOW CHECK OUT ALL THE VENT SYSTEM VALVES, BYPASS FLOW TRANS. IF VENT FLOW IS HIGH, THERE IS A PROBLEM WITH EITHER THE REACTOR OR DEGASSER. CHECK THE N2 FLOW TO D2, MAKE SURE THE C/V IS NOT STUCK OPEN. IS R-101 IN BALANCE? IS THE PRESSURE COMMON TO BOTH SIDES? IF YES, CHECK FOR IMPURITIES IN THE INCOMING RAW MATERIALS (PROCESS WATER, PROPYLENE, CHLORINE) CHECK THE N2 HEADER PRESSURE IF LOW CALL UTILITIES TO SEE WHAT THE PROBLEM IS. CHECK N2 CONTROL VALVE TO SEE IF THERE IS A PROBLEM. IF THE PROBLEM IS NOT COMMON TO BOTH SIDES THERE COULD BE A TRANSMITTER PROBLEM . GET REPAIRED. 045390 DO A 00NFT05N*nAL Page 9 of 11 ALARMS D-102 LOW WATER SPRAY LIMIT D102 LOW TEMP 30 DEG C D-102 HIGH TEMP 120 DEG C CL2 IN VENT ANALYZERS HIGH 7.5% CL2 IN VENT 15% ANALYZER CONSEQUENCE POSSIBILITY OF A CL2 AND TITANIUM REACTION POSSIBILITY OF A CL2 AND TITANIUM REACTION POSSIBLE REACTION OF WET CL2 AND TITANIUM AT 150 DEG C POSSIBILITY OF A CL2 REACTION IN THE VENT SYSTEM POSSIBILITY OF A CL2 REACTION IN THE VENT SYSTEM. ACTION TO BE TAKEN CHECK TREND ON FLOW TO SEE WHAT HAPPENED TO THE FLOW. CHECK ALL VALVES TO VERIFY THAT THEY ARE OPEN INCLUDING THE CONTROL VALVE. CHECK PROCESS WATER HEADER PRESSURE. START ANOTHER P-100 IF NEEDED. CHECK FLOW TRANSMITTER. IS THE PROCESS WATER COOL? CHECK FOR POSSIBLE TRANSMITTER PROBLEM. COMPARE R-I01 OUTLET TEMP TO D-102 TEMP. SHOULD BE CLOSE. INCREASE WATER SPRAY FLOW. INCREASE WATER RATIO TO R-101. COMPARE R101 OUTLET TEMP TO D-102 TEMP TO SEE IF THE REACTION IS TAKING PLACE IN THE REACTOR OR D-102. POSSIBLE TEMP. TRANS. PROBLEM. CHECK THE CL2 AND PROPYLENE PRESSURES TO SEE IF THERE IS AN UPSET. PULL A REACTOR DIAGNOSTIC TROUBLESHOOTING CHECKSHEET TO SEE IF THERE IS A TRANSMITTER GOING BAD. CHECK THE CL2 AND PROPYLENE PRESSURES TO SEE IF THERE IS AN UPSET, PULL A REACTION DIAGNOSTIC TROUBLESHOOTING CHECKSHEET TO SEE IF THERE IS A TRANSMITTER GOING BAD. GLYCOL 1 PROCEDURE R-1B NORMAL OPERATING CONDITIONS C2 FLOW RATE CL2 FLOW RATE H20 FLOW RATE ORP VENT READING TEMP INLET H20 TEMP 17.000 TO 35,000 #/HOUR 28.000 TO 59,000 #/HOUR 12.000 TO 18,000 #/HOUR TRACKING 1.000 TO 4,000 SCFH 80 TO 100 DEG C 58 TO 65 DEG C DO A 045391 OONFTDFNTIAL Reviewed 11/13/96 Page 10 of 11 PCH YIELD PRESSURE R-2D NORMAL OPERATING CONDITIONS FEED STEAM RATE BOTTOMS TEMP. OH TEMP PRESSURE CAUSTIC RATE LEVEL >90% 4 TO 9 PSIG ON BOTTOM TO MAINTAIN LEVEL IN D-2 AS NEEDED TO CONTROL PO IN R-2D BTMS FLOW < 100 PPM 85- 100 DEG C 70 -95 DEG C -9 TO -4 # VACUUM TO HOLD .06 TO .12 EXCESS IN BOTTOMS 25% Reviewed 11/13/96 a OAb-^ DO CONF Page 11 of 11