Document 82Jwxym4n1VMyvdgDM8Z54K4B
To: J. D. Olson
InlmlRct
COHMNUfliCfltfOfl
From: Dale:
Subi*ch
W. B. Genetti JANUARY 09. 1992
VCM TANK FARM COMPRESSOR UPQRADE CLASS A11 DESIGN FINAL ISSUE
Attached is the final issue of the VCM Tank Farm Compressor Upgrade Class NAn Design. This project will install instrumentation at the VCM tank farm compressor shed for safer operation of the Corken compressors during VCM unloading.
All new and some existing instrumentation will be tied into the DCS. The necessary software can be easily developed to provide the interlocks and other functions required for operating the compressors within their design constraints. Performing the compressor shut down logic in the DCS will allow the operator to easily identify the problem in the event of a shutdown.
A drain line on the compressor header will be installed. This drain will be used to eliminate liquid in the compressor header before the compressors are started each time. The liquid from the drain will go to the Emissions Recovery System (ERS) knock-out pot near the shed.
*
Berlin Genetti Coop Process Engineer
CC: RWS, DCS, DFJ, DEK, JEN, TRM, DAM, RHS, MLC (2), JBA, BLT, LDH,
VAB.0001107958
h
VGM TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
CLASS "A" DESIGN JANUARY 09, 1992
WORK BY: H. T. Karris Coop Proosss Engineer
WORK BY:
W. B. Gsastti coop Proosss Enginser
R. H. Sneed Lead Process Engineer
VAB.0001107959
VGM TANK FARM C0MFRR880R UPGRADE
frPERl>FNff PLAN* JAMUART Of, Iff2
*
I. II. III. VI. V. VI. VII. VIII. IX. X. XI. XII. XII.
PROBLEM DEFINITION PROJECT DESCRIPTION JUSTIFICATION PROCESS DESCRIPTION ECONOMIC EVALUATION SAFETY AND ENVIRONMENTAL EVALUATION EQUIPMENT AND INSTRUMENTATION LIST SPECIFICATION SHEETS PIPING SCHEDULE WORK LIST DCS TIE-IN LIST DCS INTERLOCKS LIST DIAGRAMS
VAB.0001107960
VCM TANK FARM COKFRK88OR UPGRADE flanMn PLANT
JANUARY 09, 1992
On several occasions the rail car unloading system has shut down. There has been a catastrophic failure of the compressors causing damage to compressor housing and internals. Most failures have caused some emission of VCM. These failures have been caused by liquid entering the compression chamber or the compressor running above its design conditions.
h
VAB.0001107961
VGII TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
JANUARY 09, 1992
This project will install instrumentation for safer operation of the Corken compressors in the VCM tank farm. The instrumentation installed will shut down the rail car unloading system should one of the switches be triggered.
The tank farm instrumentation will include the following:
1. INDIVIDUAL COMPRESSOR SHUT DOWN
A. Low oil pressure switch on each compressor crank case.
B. Low pressure switch on the compressor inlet.
C. High temperature switch on each compressor discharge line.
D. High liquid level switch on each compressor knock-out pot discharge line.
2. ALL COMPRESSOR SHUTDOWN
A. High pressure switch on each compressor discharge line.
B. High high level switch on VCM storage sphere knock out pot.
C. Interlocks with existing instrumentation: 1. Sphere isolation valve. 2. Sphere deluge system. 3. Rail car deluge.
Each of the above switches will provide an input to the DCS. The DCS will also be responsible for providing the output for energizing the compressors. Software can be easily implemented for interlocking the above compressor shut downs.
CM TAME TARN COMPRESSOR UPGRADE ABBRDBBV PUIt
JAHUART Of, If92
Installing supplementary instrumentation and alarms in the tank farm will decrease the hazards associated with the unloading of liquid VCM rail cars. The end result of every malfunction of the unloading system is a VCM leak. It is necessary to know where the source of the malfunction came from and that the system will be shut down once a malfunction has occurred.
This safety and health project will reduce the possibility of a compressor shutting down and the system continuing to run and cause a VCM leak.
*
VAB.0001107963
CM TANK nu COMFKS8SOB UPQBADI
AB1RDIKM 'BUMS JANUARY 09, 1992
The existing high temperature switches, TSH-(105-110),
will be tied into the DCS (see P&I diagram!)
The
individual compressors will be shut down at 340 degrees
F.
Compressors CP-(102-105) have existing low pressure switches on their discharge line. These switches, PSL(107-110), will be moved to the inlet line of the compressor. A low pressure switch, PSL-106, will be installed on CP-101. The switches will be tied into the DCS. The DCS will shut down the individual compressor at 8 pisg.
The existing high pressure switch, PSH-106, on the emissions recovery system (ERS) knock-out pot, will be tied into the DCS. All compressors will shut down when the ERS pressure reaches 75 psig.
High temperature switches, TSH-(101 and 105), will be installed on the discharge of compressors, CP-101 and CP105. The other compressors have existing switches, TSH(102-104). These switches will be tied into the DCS. The individual compressors will be shut down at 230
High liquid level switches, LSH-(101-105), will be installed on the discharge line of the compressor knock out pots. These switches will be tied into the DCS. The DCS will shut down the individual compressor when a high level of liquid VCM is detected (see DCS interlocks list).
Low pressure switches, PSL-(101-105), will be installed
on each compressor crank case. These switches will be
tied into the DCS. The individual compressors will be
shut down at 12 psxg. io
^rrAasr-u/.
VAB.0001107964
VGM TANK FASK COMPRESSOR UPGRADE
aurdw plait
jamuary ot, 1992
LUt
High pressure switches, PSH-(101-105), will be installed
on the discharge line of each compressor. These switches
will be tied into the DCS. All compressors will be shut
down if any of the discharge lines reach
psig. A
HAZOP of the VGM tank farm determined the flex hoses the
weak link in the unloading system. All compressors will
be shut down before the flex hoses reach a hazardous
A high-high level switch, LSHH-101, will be installed on an existing nozzle on the sphere knock-out pot. This switch will be tied into the DCS. All compressors will be shut down if high liquid VGM level is detected. This will keep the sphere knock-out pot from overflowing into the compressor inlet.
All switches, both new and existing will be tied into DCS (see DCS tie-in list). A DCS controller card and three additional TRIO blocks will be purchased, as part of this project, to handle the 32 additional discreet inputs and 5 additional decreet outputs that must be tied into the DCS. A VCM unloading graphic will be created. The switches will generate alarms on the DCS when engaged. These alarms will be included in the ladder logic for energizing the compressors. This will provide compressor shut downs when the given alarm condition occurs (see DCS interlocks list)
Interlocks with other equipment will be created to shut down the compressors in the following instances:
1. The sphere isolation valve is closed (DCS NUMBER: 00X120).
2. The sphere deluge system is activated (DCS NUMBER: OOHAOOl).
3. The rail car deluge system is activated (DCS NUMBER: 00HA105).
VAB.0001107965
CM TANK mat COMPRESSOR UPGRADE ABERDEEN HUT
JANUARY 0, 1**2
PBOCBBS DESCRIPTION
The vinyl operator will use two-way radios to communicate with the yard operator. Although the compressors will be energized from the DCS, the yard operator will be required to start the compressors from a local hand switch. The compressors' hand switches will be located at the shed.
A drain line, 1-HX-101-N-A2-1, will be run from the vapor
header of the sphere to the ERS knock-out pot. This line
will be used to drain any liquid out of the vapor line
before the compressors are started. This line will be
tied into the vapor header at the existing bleeder valve
west of compressor CP-103.
A check valve will be
installed in this line.
All lines down stream of the new drain line, 1-HX-101-NA2-1, including the compressor knock-out pots and inlets to the compressors, will be heat traced and insulated.
This design will keep the compressors operating within there designed parameters. The compressors will be shut down before serious problems occur.
*
VAB.0001107966
VCM TANK TARN COMPRESSOR UPGRADE
AMADSa* PLANT
JANUARY Of, 1992
This project has a projected cost of $50M - $100M.
SAPBTY
This project will provide a safer operation of the compressors during the rail car unloading procedure. The ultimate result of the project will be a reduced chance for a VCM emission. This provides an added security to plant workers and the community.
*
VAB.0001107967
EQUIPMENT AND INSTRUMENTATION LIST
LEVEL SWITCHES
LSH-161 C5FP1
LSH-1 LSHH-101 [NEW
TEMPERATURE SWITCHES
1 CAPACITANCE PROBE LEVS. SWITCH LOCATED IN SPHERE KNOCK-OUT POT
b
PRESSURE SWITCHES
DCS HARDWARE
WILL BE PURCHASED FOR THIS PROJECT.
THREE ADDITIONAL TRIO BLOCKS MUST BE PURCHASED FOR THIS PROJECT.
VAB.0001107968
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*
CM TANK FARM COMPRESSOR UPGRADE ARRMBBM PLAMT
JANUARY Of, 1992
MO VGM UNLOADING SHUT DOWN REQUIRED:
1. Install the controller card and TRIO blocks on the DCS.
2. Create a DCS graphic for VCM unloading. A. Create Alarms for all switches (see DCS tie-in list). B. Create ladder logic for energizing the compressors (see DCS interlocks list).
3. Install wiring between the DCS (vinyl control room) and the compressors and switches.
CM UNLOADING SHUT DOWN REQUIRED:
1. Install LSH-(101-105) on compressor knock-out pot. A. Connect to the DCS (00LAXX1-5)
2. Install PSL-(106-110) to compressor knock-out pot discharge line. A. Connect to the DCS (00PAX17-21).
3. Connect TSH-(106-110) to the DCS (00TAXX7-11).
4. Install PSL-(101-105) to compressor crankcase. A. Connect to the DCS (00PAX22-26).
5. Install TSH-101 and TSH-105 to CP-101 and CP-105 discharge lines. A. Connect TSH-(101-105) to the DCS (00TAX12-16).
6. Install PSH-(101-105) to the compressor discharge line. A. Connect to the DCS (00PAX27-31).
7. Connect PSH-106 to the DCS (00PAX32).
8. Install LSHH-101 to the sphere knock-out pot (in existing nozzle). A. Connect to the DCS (00LAXX6).
VAB.0001107973
VOC TANK TARN COMPRESSOR UPGRADE ABNEDEW PUNT
JANUARY Of, 1992 WORK LIST (Continued. 9. Install 1-HX-101-N-A2-1 from the bleeder valve west
of CP--103 to the ERS knock-out pot. 14. Heat trace and Insulate all lines from the drain
line 1-HX-101-N-A2-1 to the compressor inlet.
VAB.0001107974
DCS TIE - IN LIST
INPUT
DSC NUMBER
00LAXX1 00LAXX2 00LAXX3 00LAXX4 00LAXX5 00LAXX6 00TAXX7 00TAXX8 00TAXX9 OOTAXIO 00TAX11 00TAX12 00TAX13 00TAX14 00TAX15 00TAX16 [OOPAXI7 loOPAXI 8 loo PAX 19 |oOPAX20 |oOPAX21 |oOPAX22 |oOPAX23 |oOPAX24 |00PAX25 |oOPAX26 |oOPAX27 |oOPAX28 |00PAX29 |oOPAX30 |00PAX31
00PAX32
1 |
|
SOURCE LSH-101
LSH-102 LSH-103
LSH-104 LSH-105 LSHH-101
TSH-106 TSH-107 TSH-108 TSH-109 TSH-110 TSH-101 TSH-102 TSH-103 TSH-104 TSH-105 PSL-106 PSL-107 PSL-108 PSL-109 PSL-110 PSL-101 PSL-102 P9L-103 PSL-104 PSL-105 PSH-101 PSH-102 PSH-103 PSH-104 PSH-105 PSH-106
DSC |00HMX33 |oOHMX34 00HMX35 00HMX36 00HMX37
OUTPUT
CP-101 CP-102 CP-103 CP-104 CP-105
VAB.0001107975
DCS INTERLOCKS LIST
ALL COMPRESSOR SHUT DOWN INTERLOCK
DESCRIPTION
00PAX27 OOPAX20 00PAX29 00PAX30 00PAX31
HIGH
HARQE
ON CP-101
DISCHARGE PRESSURE ON CP-102
DISCHARGE PRESSURE ON CP-103
DISCHARGE PRESSURE ON CP-104
HIGH DISCHARGE
105
OOUMX6 HIGH
-OUT POT
OOPAX32 HIGH
POT
OOX120 ISPHEREI8QLATIO
00HA001 IsPHERE DELUGE
ACTIVATED
0OHA105I RAIL
DELUGE
ACTIVATED
O0RI [
SOURCE PSH-101 PSH-102
PSH-104 PSH-105 LSHH-101 PSH-106
CP-101 SHUT DOWN
ALARM
description
OOUOOCI HK3HC
SSOR KNOCK
LIQUID LEVEL
00PAX17 OW
KNOCK-OUT POT
OOTAXX7 HIGH COMPRESSOR HEAD TEMPERATURE
00TAX12 HIGH COMPRESSOR DISCHARGE TEMPERATURE
00PAX22 ILOW C
SSOR OIL PRESSURE
ALL COMPRESSOR SHUT DOWN ACTIVATED
PRESSURE
SOURCE
SH-101 PSL-106
SH-106 lTSH-101 PSL-101
WHEN ALL ALARMS ARE OFF. DCS WILL ENERGIZE 00HMX33 AN OPERATOR WILL BE REQUIRED TO START CP-101 THROUGH A LOCAL HAND SWITCH.
CP-102 SHUT DOWN
DESCRIPTION
COMPRESSOR
K-OUT
LEVEL
00PAX18
COMPRESSOR KNOCK-OUT POT DISCHARGE PRESSURE
00TAXX8
COMPRESSOR HEAD TEMPERATURE
00TAX13
COMPRESSOR DISCHARGE TEMPERATURE
00PAX23
COMPRESSOR OIL PRESSURE
ALL COMPRESSOR SHUT DOWN ACTIVATED
SOURCE
LSH-102 PSL-107 TSH-107
SH-102 PSL-102
ALL ALARMS ARE OFF, DCS WILL ENERGIZE 00HMX34 M OPERATOR WILL BE REQUIRED TO START CP-102 THRC LOCAL HAND SWITCH.
VAB.0001107976
DCS INTERLOCKS LIST
(CONTINUED...)
CP-103 SHUT DOWN
DESCRIPTION
IOOLAXX3 IHIGH COMPRESSOR KNOCK-OUT LIQUID LEVEL 00PAX19 ILOW COMPRESSOR KNOCK-OUT POT DISCHARGE PRESSURE 00TAXX9 |HIGH COMPRESSOR HEAD TEMPERATURE I00TAX14 IHK3H COMPRESSOR DISCHARGE TEMPERATURE (00PAX24 ILOW COMPRESSOR OIL PRESSURE |ALL COMPRESSOR SHUT DOWN ACTIVATED
SOURCE
LSH-103 PSL-108 rrsH-i 08 fTSH-103 |PSL-103
WHEN ALL ALARMS ARE OFF, DCS WILL ENERGIZE 00HMX35. AN OPERATOR WILL BE REQUIRED TO START CP-103 THROUGH A LOCAL HAND SWITCH.
CP-104 SHUT DOWN
| DESCRIPTION
|Source!
|OOUOO(4 Mshcompressorknock^u^quid^ve^^^^^^^HLSH-104
00PAX20 |LOW COMPRESSOR KNOCK-OUT POT DISCHARGE PRESSURE PSL-109
lOOTAXIO |HIG H COMPRESSOR HEAD TEMPERATURE
TSH-109
00TAX15 HIGH COMPRESSOR DISCHARGE TEMPERATURE I00PAX25 ILOW COMPRESSOR OIL PRESSURE
rrsH-i 04 | PSL-104
|ALL COMPRESSOR SHUT DOWN ACTIVATED
WHEN ALL ALARMS ARE OFF, DCS WILL ENERGIZE 00HMX36. AN OPERATOR WILL BE REQUIRED TO START CP-104 THROUGH A LOCAL HAND SWITCH.
CP-105 SHUT DOWN
DESCRIPTION
OOLAXX5 HIGH C
KNOCK-OUT LIQUID LEVEL
00PAX21
COMPRESSOR KNOCK-OUT POT DISCHARGE PRESSURE
00TAX1
HIGH COMPRESSOR HEAD TEMPERATURE
OOTAX16
COMPRESSOR DISCHARGE TEMPERATURE
00PAX26
COMPRESSOR Oft. PRESSURE
COMPRESSOR SHUT DOWN ACTIVATED
SOURCE
SH-106 PSL-110
SH-110 SH-105 PSL-105
ALL ALARMS ARE OFF, DCS WILL ENERGIZE 00HMX37 M OPERATOR WILL BE REQUIRED TO START CP-105 THROUGH LOCAL HAND SWITCH.
VAB.0001107977
VCM TANK TABM COMPRESSOR UPGRADE uiMMiy yuan
JANUARY OR, 1002
XI
X
C=-3
A CP HM HS L LSH LSHH PG P PSH LSH T TSH
NEW EXISTING 4 WAY VALVE VALVE CHECK VALVE DCS INPUT/OUTPUT ALARM COMPRESSOR OUTPUT TO MOTOR LOCAL HAND SWITCH LEVEL DCS SIGNAL HIGH LEVEL SWITCH HIGH-HIGH LEVEL SWITCH PRESSURE GAUGE PRESSURE DCS SIGNAL HIGH PRESSURE SWITCH LOW PRESSURE SWITCH TEMPERATURE DCS SIGNAL HIGH TEMPERATURE SWITCH
VAB.0001107978
*
VCM TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
JANUARY Of, 1992
Nl PSL-(107-110) are existing pressure switches.
The
switches will be relocated from the compressor discharge
line to the compressor knock-out pot discharge line of
compressors CP-(102-105). A pressure switch, PSL-101,
will be installed on the compressor knock-out pot
discharge line for CP-101. 00PAX17-21 will indicate a
pressure of 8 psig or below. When the alarm activated,
the individual compressor will be shut down.
N2 LSH-(101-110) (00LAXX5--10) will shut down the individual compressors when liquid is detected in the discharge line from the knock-out pot.
N3 TSH-(106-110) (00TAXX7-11) are existing temperature switches located on top of the compressor head. All lines are connected to a control box with a set point of 340 degrees F. The control box will be tied into DCS. This will shut down the individual compressor.
N4 TSH-(101 and 105) (00TAX12-16) are new temperature
switches.
TSH-(102-104) are existing temperature
switches located on the discharge line of the
compressors. An individual compressor shut down will
occur at 230 degrees F.
N5 PSL-(101-105) (00PAX22-26) are low pressure switches
located on the compressor crankcase.
An individual
compressor shut down will occur at 12 psig.
N6 PSH-(101-105) (00PAX27--31) are high pressure switches
located on the discharge of the compressor.
All
compressors will be shut down at 125 psig.
N7 PSH-106 (00PAX32) will shut down all compressors when the
Emission Recovery System knock-out pot builds up pressure to 75 psig.
N8 LSHH-101 (00PAXX6) will shut down all compressors before the sphere knock-out pot overflows.
VAB.0001107979
VCK TXMX nutl COMPSB88OK UPGRADE MWBIM lUR
JANUARY 0, 1**2
tM
N9 The liquid VCM drain line will hie into a bleeder valve
on the VCM vapor line. This bleeder valve is located
west of compressor CP-103.
A check valve will be
installed in this line.
N10
All lines will be heat traced and insulated from the drain line to the compressor inlet. This includes the compressor knock-out pots.
VAB.0001107980
VAB.0001107981
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VAB.0001107982