Document 71gaO6L6JNzR7b8vavVLLYzDg

REACTOR SAFETY QUESTIONNAIRE Dear V'CSA Member, Reactor safety and prevention of vinyl chloride releases to the atmosphere from polymerization vessels are topics of utmost concern to us In the PVC Industry. Environmental agencies, particularly In the U.S., have adopted harsh stances and levied stiff fines on relatively small vinyl chloride releases 1n- recent years. The purpose of this questionnaire Is to provide an update to procedures, equipment, and precautions taken to prevent VCM releases from reactors. Results will be presented and discussed at the October general meeting later this year. NOTE: Multi-plant companies may wish to copy the survey and list separate answers from each plant If procedures/equipment vary greatly, or you may give a "composite/majority" response on one questionnaire. Please send replies by 31 August 1986 to: Harold G. Coleman Plastics Technology - R & D Lab #3 Air Products and Chemicals, Inc. P. 0. Box 538 Allentown, PA 18105 i4ai CTL020038 REACTOR SAFETY QUESTIONNAIRE I. HYOROSTAT PREVENTION OURING BATCH CHARGE - please complete the following table and answer the questions. Batch Inqredlent PRIMARY MEASUREMENT__________ Measuring Calibration Device Frequency Reliability ____________ BACK-UP MEASUREMENT Measuring Calibration Device Frequency Rel1 a b1111v Water VCM Others: We have no process water MA E Meter A E Example: Water Key: M (turbine) Device M = meter (type) L = level transmitter (type) W = weight VI = visual Inspection In reactor 0 * other (type) NOTES: L (DP), VI Calibration Frequency W a weekly M = monthly 0 = quarterly S = semi-annually A * annually N = as needed (maintenance) Reliability E excellent G good A average F fair P poor QUESTIONS la. Is a visual Inspection made after charging Is complete, before heat-up? YES NO lb. After heating to reaction temperature? YES NO X X >4ai CTL020039 REACTOR SAFETY QUESTIONNAIRE Are high level alarms employed on reactors? YES _____ NO __x Type of Device ______________________ Reliability Problems or Comments: ___________________________________________________________ Are reactor charge valve(s) MANUAL _____ or AUTOMATIC X Computer controlled? YES X Problems or Comments: _______ ________________ ___________ (check one)? no _____ How do you ensure that reactor Is empty prior to charging? The reactor is checked that it be empty before charging. What Is your typical batch tillage (batch charge volume/actual reactor volume)? 40 X CONTROLLING RUNAWAY REACTIONS 1. What process measurements are used to Indicate a "problem" batch, a "first alert" as opposed to an uncontrollable situation? (Check where appropriate.) a. Pressure b. . Temperature c. Other _____ How many PSI above reaction pressure? _____ _____ How many F above reaction temperature? _____ Water flow to the main cooling devices is monitored and an alarm is set to preact to a problem batch occurinq. CTL020040 REACTOR SAFETY QUESTIONNAIRE What Is don/e at this time? (Check where appropriate.) a. Rate of reaction moderated with retardant/shortstop _____ b. Batch partially dropped to another vessel _____ c. Batch killed with shortstop _____ d. Other Extra cooling is started and emergency degassing is begun. What process measurements are used to Indicate an emergency situation leading to an eminent release? (Check where appropriate.) a. Pressure 25 How p$i above reaction pressure? b. Temperature _____ How many F above reaction temperature? c. Agitation low amps _____ low RPM _____ high amps _____ d. Power Failure x e. Other _______________ ___ ___ g. Combinations (e.g., T & P) Please Indicate the actions taken at this point to prevent an uncontrolled release to the atmosphere. Number them sequentially In the order In which they are performed. t add shortstop (manually or automatically) _____ drop part of batch to another vessel 1 extra cooling (e.g., water on dome) 2_______ vent to recovery system _____ controlled vent to atmosphere CTL02004i REACTOR SAFETY QUESTIONNAIRE 5. For each type/size reac.tor you have, please provide the following data: Reactor Volume (U.S. Gal) Reactor Pressure Rating (PSIG) Rupture Disc Rating (PSIG1 Safety Relief Valve Set-pressure (PSIG) Maximum Normal Reaction Pressure (PSIG1 14,000 gal. 72 5 p<5ig ? 1 7 Psi9 None 135 .6 Please describe your shortstop addition system: (Check where appropriate.) _____ a. FULLY AUTOMATIC - when certain conditions are reached, shortstop Is mechanically Injected; no action needed by operator. b. SEMI-AUTOMATIC - when certain conditions are reached, shortstop Is mechanically Injected, but operator must somehow activate the system (as by pushing a button). X c. MANUAL - addition Is totally manual by operator. (For example, shortstop Is added to a pot, a valve Is opened and shortstop drains Into reactor.) d. No shortstop system exists or none Is used. e. Other (please describe) _______ _ 7. >421 If system Is fully automatic, can operator activate system manually before It Is activated by the process? YES NO _____ N/A _X___ CTL020042 REACTOR SAFETY QUESTIONNAIRE Shortstop Is added by (check where appropriate): a. Pump b. Nitrogen Pressure c. Gravity d. Rupture Oise e. Other (please describe _____ _____ X _____ _____________________ Is your shortstop system Independent for each reactor or a common system for several reactors? (Check appropriate response.) a. Independent b. Common c. Both X _____ _____ Please offer any general comments about your shortstop system concerning reliability, effectiveness, non-emergency batch kills, etc. CTL020043 REACTOR SAFETY QUESTIONNAIRE III. MISCELLANEOUS 1. How often do you Inspect reactor nozzles for PVC build-up or pluggage? (Check one.) Safety Valve Nozzle!s) Pressure Transmitter Nozzle(s) a. Never b. Every cleaning c. Every ___ batches _____ _____ _____ _____ _____ _____ d. Every batch e. Every reactor opening _____ _____ _____ _____ f. Other (describe) Saffitly--va 1 vt?--nn77lgs ago--checked--each batch- pressure transmitter nozzles are checked annually. 2. Do you have dual (redundant) pressure transmitters on your reactors? a. Yes x b. No _____ 3. Please Indicate what form(s) of back-up electrical power you have. (Check where appropriate.) a. Emergency generator _____ b. Second source X c. Other___________________________________________________ Please send replies by 31 August 1986 to: Harold G. Coleman Plastics Technology - R & D Lab #3 Air Products and Chemicals, Inc. P. 0. Box 538 Allentown, PA 18105 >421 CTL020044