Document 936N306pOYedpE2KzE10mQxq6
J. D. Olson
Interoffice Communication
From: Dote:
Subject:
d. E. Knittig and P. C. Tebo May 30, 1990
5305 RESIDUAL VCM REDUCTION - PHASE I
Based on the comments from the RVCM Reduction meeting on April 10, 1990, we want to implement Phase I of the RVCM Reduction Project. Phase I will be the installation of:
1. A silo air heater, 2. Additional spargers in T-407, 3. Flow indication on T-646 through T-652 and
T-407, 4. Sparger team cleanout design on T-407
and T-646 through T-653, 5. Repair of old module hot water charge to
rinse control valve, CV-497, 6. Test spargers on T-647.
Phase I
.1.
2
3. 4.
items will provide for: Heated silo air, Improved agitation. More reliable agitation. Hot rinse.
and
Phase II
.1.
2
3.
items will be: Low pressure air system. Recipe optimization, and Small blend tank sparger
improvements.
Phase II will be implemented after Phase I results are
evaluated.
Phase I items are to be 4th quarter
projects. The installation goal is November 1990.
&*~y '^a7
Doug Knittig Process Engineer
Rich Tebo
oeic
Process Engineer
cc:
Aberdeen - RWS, DCS, JDO, JMV, REP
Houston - EJM, PCS, RDM, MCM Saddlebrook - MAE Austin - HGC
DFJ,
RBN,
SCH,
JME,
VAB.0001104602
5305 RESIDUAL VCM REDUCTION - PHASE I CLASS A DESIGN
ABERDEEN CHEMICAL PLANT
MAY 14, 1990
Prepared by:
x.c. R. C. Tebo
and by:
D~. e\ Knittig ' Process Engineer
Approved by:
Jx<. `T/Uu*-- ^
S. C. Hillman Senior Process Engineer
VAB.0001104603
5305 RESIDUAL VCM REDUCTION - PHASE I ABERDEEN CHEMICAL PLANT
TABLE OF CONTENTS
Introduction Design Basis Process Description Impact Statements Equipment List Instrument List Tie-In List Line Schedule Work List Drawings
VAB.0001104604
5305 RESIDUAL VCM REDUCTION - PHASE I ABERDEEN CHEMICAL PLANT
INTRODUCTION
Project Description
This project will reduce residual VCM in 5305 resin during the winter months. This design is based on the recommendations of the RVCM Reduction Team (Doug Knittig and Rich Tebo). Recommendations by Bobby Hawkins* Natural Team (Vinyl Shift Supervisor) were used to address reducing blend tank sparger pluggage problems. The project will install:
1. An inline air heater to heat silo air. A temperature controller will regulate the heated air to the silos at 130F.
2. Four new spargers and relocate existing spargers in blend tank T-407 to eliminate dead spots.
3. Flow indication on spargers for small blend tanks T-646 through T-653 and T-407 to monitor aeration air volumes.
4. Cleanout ports on spargers for small blend tank T-646 through T-653 and T-407 to facilitate cleanout of plugged spargers.
5. Spargers in T-647 to test additional sparger cleaning improvements recommended by Bobby Hawkins' Natural Team.
Problem Description
American Mirrex is a major customer of 5305 and 5265 resins for rigid calendaring applications. A 250 ppb RVCM content in the resin they get is important to achieving 10 ppb RVCM in their manufacture of food wrapper film. American Mirrex has asked all suppliers to meet a 250 ppb specification on RVCM. American Mirrex currently must lot select acceptable RVCM level resin for this application.
A competitor has guaranteed American Mirrex that 80% of its resin will have less than 250 ppb residual VCM. Prior work has shown that Vista can produce 250 ppb or less RVCM resin all the time 9 months of the year during warm weather, but needs improvement to meet this specification during the three winter months. The goals of this project is to provide American Mirrex with 250 ppb residual VCM 5305 resin 80% of the all year round. The current winter average is 500 ppb. After this design the average will be 210 ppb and 55% of production will meet American Mirrex*s specifications during the winter months.
VAB.0001104605
A
5305 RESIDUAL VCM REDUCTION - FHASE ABERDEEN CHEMICAL PLANT
INTRODUCTION
Problem Description (Continued)
During the winter of 1989, several designs of experiments were used to determine significant effects on finished product RVCM levels for 5305 and 5265. Heated blend tank, heated silo air, particle size, and agitation were found to be significant. The following table is a list of the recommendations from the RVCM Team, percent reduction RVCM, and project item. It should be noted that these items are not additive.
Recommendation
Percent RVCM Reduction
Proiect Items
Particle Size-120 microns Heated Silo Air Hot Rinse Agitation Improvements
Cumulative Effect
30% 25% 20% 20%
40%
Winter Observation Silo Air Heater Work Order on Valve Spargers, Cleanout port, Flow Indication
By controlling particle size to approximately 130 microns, the acceptable customer specification, and installing the other project items, 5305 and 5265 production will meet the 250 ppb RVCM specification 55% of the time during the winter months. We will lot select to meet American Mirrex's needs.
An inline air heater will be installed to heat silo air.
A
temperature controller will regulate the heat to the silos at
130F. The RVCM Reduction Team evaluated resin quality at that
temperature and found no detrimental effects.
Blend tank heating requires the hot rinse of all 5305 reactors. Cold rinses to the small blend tanks significantly reduce VCM removal during aeration. Both the old and new modules can be rinsed manually through the hot water charge pumps. In the old module the hot water charge to rinse control valve, CV-497 is not operating properly. A work order will be written to repair it.
Blend tank agitation improvements are:
1. The relocation of existing spargers and installation of new spargers on T-407.
2. Flow indication on small blend tank T-646 through T-653 and T-407.
3. Cleanout ports on small blend tanks T-646 through T-653 and T-407.
4. Test spargers on T-647.
VAB.0001104606
5305 RESIDUAL VCM REDUCTION - PHASE I ABERDEEN CHEMICAL PLANT
INTRODUCTION
Problem Description (Continued)
The spargers in T-4 07 are spaced such that dead spots exist in the
blend tank. The new spargers will eliminate dead spots resulting
in better agitation and therefore improved RVCM removal. Other
benefits are rinse heel elimination and consistent centrifuge feed.
Flow indication on all the small blend tank and T-407 will indicate
sparger pluggage.
Currently, there exists no indication of
pluggage other than contamination or high residual VCM.
The
Sparger Team Cleanout Design will be incorporated into the T-407
sparger improvements, both new, relocated and existing, for a total
of eight. The Cleanout design will be added to T-646 through T-
653, with three spargers on each tank, for a total of 24 on the
small blend tanks. When operations find a plugged sparger, the new
cleanout will help place the sparger back into service without
sparger removal.
Test spargers in T-646 and T-647 will be
evaluated by the Sparger Team.
This is a 4th quarter project. To meet the goal of 250 ppb RVCM 53 05 resin for winter 1990, the project must be installed by November 1990.
Additional work is being done to further reduce low mole RVCM for 1991 because the business area believes that eventually RVCM levels will be targeted down to 10 ppb in 5265 and 5305, and 100 ppb in 5385 and 5415. Any future projects should not conflict with this project.
Alternatives
1. Stockpiling of resin from summer months (low residuals) for the winter months (high residuals) was considered. The business area determined this to be too costly based on summer sales. Being soldout in the summer leaves no production for inventory.
2. Various air heaters were considered for silo air heating including air duct heaters, radiant heaters, and circulation heaters. The immersion heater chosen met the process requirements and was the most cost effective.
3. An option to hot rinse was steam heating the blend tanks. Steam heating was costly, approximately $300,000, and presented some quality concerns.
5305 RESIDUAL VCM REDUCTION - PHASE I ABERDEEN CHEMICAL PLANT
INTRODUCTION
Alternatives (Continued)
4. A number of blend tank improvements were considered- The
Sparger Team recommended flow indication and a cleanout
port design based on their investigation.
A new
compressor for a low pressure air system was considered
but would not meet the time constraints.
Flow
distribution will be improved but total flow will be
improved by the use of existing compressors.
Economic Analysis
rhis project is a customer driven quality improvement. Justification is based on an improved position at American Mirrex.
\
\
VAB.0001104608
Projected Mirrex Shipments
Jan
Mar
May
July
Sept
Nov
Annual
VAB.0001104609
A 5305 RESIDUAL VCM REDUCTION
PHASE I ABERDEEN PVC PLANT
DESIGN BASIS
The basis of this project is resin quality improvements. RVCM reduction to 2 50 ppb for 53 05 will assure continued success at American Mirrex. Though RVCM reduction is the primary purpose of this design, an added quality benefit is contamination reduction. This design will allow Vista to meet 250 ppb RVCM in low mole production at 55% of shipments based on an average particle size of 130 microns.
VAB.0001104610
5305 RESIDUAL VCM REDUCTION PHASE I
ABERDEEN PVC PLANT
PROCESS DESCRIPTION
Silo air heater, H-101, will heat silo air to a set point of 130F. TIC-101 will control the temperature. TIC-101 will be located in substation #10 for weather projection. (See Drawings 1 and 2.)
Flow indication on blend tanks T-646 through T-653 and T-407 will
be provided by orifice meters,FI-646 through FI-653 and FI-407:
The air flow will be balanced on the small blend tanks.
(See
Drawings 3 and 4.)
Four new air spargers will be added to T-407.
The existing
spargers SP-407 B and D will be relocated and the new spargers SP-
407 E, F, G, and H added (see drawing 5, 6, and 7). All spargers
on T-4 07 will be modified with the Sparger Team cleanout port. All
spargers, SP-407 A through H, will need new restriction orifices,
RO--407 A through D for the existing spargers and RO-407 E through
H for the new spargers. These orifices will balance flow to each
individual sparger. (See Drawings 5, 6, and 7.)
The Sparger team cleanout ports will be added to T-646 through T-653. A new set of test spargers, SP-647 A,B,C, will be added to T--647.
Work on CV-497, old module hot water charge to rinse control valve, will be completed on a work order.
VAB.0001104611
5305 RESIDUAL VCM REDUCTION PHASE I
ABERDEEN PVC PLANT
IMPACT STATEMENTS
The Residual VCM Project will lower 53 05 residual VCM to 250 ppb to meet American Mirrex's needs. Vista is working toward a 100% supplier status at American Mirren. Reducing residual VCM will improve our position at American Mirrex.
VAB.0001104612
5305 RESIDUAL VCM REDUCTION PHASE I
ABERDEEN PVC PLANT
EQUIPMENT LIST
Item Number H--101
Service 600 Series Silo Air
SP--407 E, F, G, and H SP--647 A, B, C
T--407 Short Spargers T-647 Test Spargers
VAB.0001104613
4*441-S
2-84
Chromaiox*
* 'm~w
- -- -- - --*7> ^ ^ -4 Tfif^xv* : r3K^.''>* **+.
'iiu#
P, 0. BOX 19*23 BATON ROUGE, LOUISIANA 70898
h
i W ' * 't
.#
*" (*. P,. 1 "** | I I
I
PHONE3*
(904) 293-Ot
PAX
(804) 293-09
ff
1
May 4, 1990
Vista Chemical AberdQ9nr MS
Attention: Doug Knittig
Reference: CHROMALOX HEATER & CONTROL PANEL
Dear Doug,
We are pleased to quote the following chromaiox heater and controls par your request.
We quote as follows-
r
ITEM #1:
CIRCULATION HEATER
CATALOG#: DESCRIPTION:
TMI-1850R1E4C37 8" 150 LB STEEL FLANGE WITH 18 INCOLOY ELEMENTS, 52" IMMERSED LENGTH, LIQUID TIGHT TERMINAL COVER, TYPE K THERMOCOUPLE WELDED TO SHEATH WITH SEPARATE LIQUID TIGHT JUNCTION BOX, RATED 50 KW, 480 VOLT, 3 PHASE
PRICE: DELIVERY:
$4,034.00 4-6 WEEKS ARO
NEL
BALES REPRESENTATIVES FOR CHROMALOX - EDWIN L. WICGANO DIVISION, EMERSON ELECTRIC CO.. PITTSBURGH, PA. 19208
VAB.0001104615
J.
i v.'ht
Immerskmheatora/ffaogedB
TV** ii ?n jtwt; -
- - iT
A **
11
' O'*1
J ,u
For corrosive solutions
3 to 14 inch, 150 lb. steel flange 3 to 125 kW 240 & 480V, 1 & 3 phase Incoloy sheath, 23 W/in2
Type TMI
Applications
For more severe corrosive solutions than can normally be used with stain less steel elements. For solutions of medium concentra tion in the 10 to 25% range, generally based on the more corrosive the chemi cal, the lower the concentration must be
kept. For higher temperature air and selected gases where velocity and heat transfer properties will keep sheath tem perature below 1600F.
Refer to dimensional page lor flange terminal housing dimensions.
6-1 Gen, purpose endow_______ 6-3 Expiostos-resistanl enciosurs
E-4 Moisture resistant endow
Ph- Dim. In. Wt. Catalog
KW Volts Circ. aso B*
lbs. No.
Sta tus PCN
Dim. Catalog In. N Na.
Sta tus PCN
Dim. Catalog In. N No.
Sta tus PCN
Dim.
la. N
6 Inch 150 lb. Steel Flange, 12 Incoloy Sheath Elements - 23 W/ln*
18 240 2 18 480 2
3 25% 3 25%
67 TMI-1218 67 TMI-1218
AS 197069 1 AS 197085 1
TMI-1218E3 TMM218E3
24 240 2 24 480 2
3 33 3 33
76 76
TMM224
TMI-1224
t" AS AS
197093 1 197114 1
TMI-1224E3 TMI-1224E3
30 240 2 30 480 2
3 40% 3 40%
84 TM1-1230 84 TMI-1230
AS 197122 1 AS 197149 1
TMI-1230E3 TMI-1230E3
36 240 2 36 480 2
3 48 3 48
111 TMM236 111 TMI-1236
AS 291952 1 AS 197173 1
TMI-1236E3 TMI-1236E3
42-1S0 kW and above available -- consult sales office. 'Add 7 lbs. to wgt. for E3 & E4 HSQ.
AS AS
AS AS
AS AS
AS AS
186360 186343
186386 186407
186423 186440
186466 186462
1% 1%
1% 1%
1% 1%
1% 1%
TMH218E4 TMH218E4
TMI-1224E4 TMI-1224E4
TMM230E4 TMI-1230E4
TMM236E4 TMI-1236E4
AS AS
AS AS
AS AS
AS AS
186351 186378
186394 186415
186431 186458
186474 186490
1% 1%
1% 1%
1% 1%
1% 1%
8 Inch 150 lb. Steel Flange, 18 Incoloy Sheeth Elements 23 W/in*
30 240 3 30 480 3
3 32% 3 32%
112 TMI-1830R1 AS 112 TMI-1830R1 AS
197270 1 197296 1
Consult sales office.
40 240 3
40 480 3
3 43'Vi s 125 TMI-1840R1 AS 197309 1 3 43"/, e 125 TMI-1840R1 AS 197325 1
50 , 240 3 150 480 3
3 51% 3 51%
130 TMH860R1 AS ^I3?3.... 1--, /_
3
l5O TMl-l850ftl AS 197350
__________ ______________~
*"B" Length inside tank
To order Specify quantity, catalog number, voltage, number phases, kW, product code number (PCN)
4 ABovcT 3
Availability
S -- Stocked in finished form for immediate shipment.
AS -- Assembly stock -- shipment (1) week Also available with stainless steel sheath. NS -- Non stock (made to order). Consult Sales Office for delivery.
s
5s"r 2-1% 05-2.0
217 VAB.0001104616
Vista Chemical Company
PROCESS ENGINEERING DEPARTMENT HOUSTON TEXAS
Date: Mays, 1990 By: RCT
Appd:
Class "A" Design Specification Sheet
Air Spargers
Plant: Aberdeen PVC Plant
Project: Blend Tank Agitation Improvement
1 :Item Number
SP-407 E,F,G,H (2)
2 Service
Blend Tank Agitation
3 Location
T-407
4
5 Operating Conditions
6
-
7
I
8
Slurry Temperature
Tank Pressure Air Temperature
--
.
140 F
_ . . Atmos 100 F
..
.
-- --
1 9| 10
Air Pressure Air Flow
8 psig 25.7 SCFM per sparger
11
12 Mechanical Details
13 Length
60 inches (3)
14 Diameter
2.067 inches
15 Sparger Hole Diameter
1/4 inch
16 Sparger Hole Spacing
6 inches between holes, 3 inches from each end
17 Direction of Holes
Holes pointed down
18 Maximum Hole Diameter
0.452 inches
19 Material of Construction
304 SS
20 Elevation
10 inches off bottom (1)
21 Nozzle size
4 inches
22
23
24
__ _____ ________
_________________ __________________
25
_____
26
27
" -- - 28 29
30
31 32 Notes
......
.............
33 1. Spargers to be installed parallel to tank floor. Tank floor is sloped five degrees
34 2. Four spargers required
35 3. Sparger supports are to be added on tank floor as required
36
37 38
39
40 . . .
.
Issue 1
Page:
j
VAB.0001104617
Vista Chemical Company
PROCESS ENGINEERING DEPARTMENT HOUSTON TEXAS
Date: May 5, 1990 By: RCT
Appd:
Class "A" Design Specification Sheet
Air Spargers
Plant: Aberdeen PVC Plant
1 Item Number 2 Service 3 Location
4 5 Operating Conditions 6 Slurry Temperature 7 Tank Pressure 8 Air Temperature 9 Air Pressure 10 1 Ai' r Flow 11 12 Mechanical Details 13 Length 14 Diameter 15 Sparger Hole Diameter 16 Sparger Hole Spacing 17 Direction of Holes 18 Maximum Hole Diameter 19 Material of Construction 20 Elevation 21 Nozzle size 22 23 24 25 26 27 28 29 30 31 32 Notes 33 1. Existing Spargers 34 35 36 37 38 39 40
Issue 1
Project: Blend Tank Agitation Improvement SP-407 A,B,C,D (1) Blend Tank Agitation T-407
140 F Atmos 100 F 8 psig 55 SCFM per sparger
approx 8.5 ft 2.067 inches
Holes pointed down
304 SS 10 inches off bottom 4 inches
l 1
|1l
.
__
.
Page:
VAB.0001104618
Vista Chemical Company
PROCESS ENGINEERING DEPARTMENT HOUSTON TEXAS
Date: By:
Appd:
Class "A" Design Specification Sheet
Air Spargers
Plant: Aberdeen PVC Plant
r l Item Number S P - 6AZ__
2 1 Service 3 (Location 4
5 Operating Conditions
6 Slurry 7 Tank Pressure 3 Air Temperature 9 Air Pressure 10 Air Flow 11 12 1 Mechanical Details
Project: Blend Tank Agitation Improvement
Blend Tank Agitation
140 F Atmos 100 F
ptr sparopr
A
VAB.0001104619
A
5305 RESIDUAL VCM REDUCTION PHASE I
ABERDEEN PVC PLANT
INSTRUMENT LIST
Item Number FI-407 FI-646-653 PG-407 A r B / C f D,E,F,G,H PG--646 A, B, C PG-647 A, B, C PG-648 A, B, C PG-649 A,B,C PG--650 A, B, C PG-651 A, B, C PG-652 A, B, C PG-653 A, B, C RO-646 A, B, C RO--647 A, B, C RO--648 A, B,C RO-649 A,B,C RO-650 A, B, C RO--651 A, B, C RO--652 A, B, C RO-653 A,B,C RO--407 A, B, C, D
RO--407 E, F, G, H
TIC-101
Service Air Flow Indication T-407 Air Flow Indication T-646-653 Pressure T-407 spargers Pressure T-646 spargers Pressure T-647 spargers Pressure T-648 spargers Pressure T-649 spargers Pressure T-650 spargers Pressure T-651 spargers Pressure T-652 spargers Pressure T-653 spargers Orifices for T-646 spargers Orifices for T-647 spargers Orifices for T-648 spargers Orifices for T-649 spargers Orifices for T-650 spargers Orifices for T-651 spargers Orifices for T-652 spargers Orifices for T-653 spargers Orifices for T-407 existing
long spargers. Orifices for T-407 new short spargers Temperature controller on H-101.
VAB.0001104620
16 A
2 | TO <ftU8Ml STANOARO 3 | PLAT* MATERIAL: 3183.3. 4 RTJ RMQ MATT. A TYPC 5 BORE MAXIMUM MTV 6 t STAMP TO ISA STANOARO 7 | TAG NO. 'rH - 4-0
------------ 1 OTHER
otw
2^4 S S
cT)
nearest t/r OTHM
| RATING A PACING | TVPE:
| mattj
tap size
I RANGES AY TAG NO.
WVLO NECX STEEL UT NRT
| OTHea 1 OTHER ) OTHER
VAB.0001104621
PLANT
ITEM NO. SERVICE
VIS1A
ArBEiLvegjd
Vista Chemical Company
GENERAL ENGINEERING HOUSTON, TEXAS
Specification Sheet
PROJECT
L&JQ T7WC
SPECIFICATION DATA SHEET
PROJECT NO
A.F.c. NO.
P.O. NO
MADE BY
DATE
M IYI*>6
APP'O BY .
i m PeovGrt&srs
4r01
A
DWVE.g
4 00 CAPS4gt;c
model no, 4too
O too /Nome s
MtNQ#-
fS>io*J S
*2. O
DiFFEA&iJTiAL
i> WYE& ! mjj H Et/TL
3>ox foonzLS' Ucusrz>,Aj TX nines'
-4-46 -//`H*
it 1 f I I
J
2-84
4-441-S
ORTFICE - VERSION 82.01 T-407 S3T Air Flow Measurement Orifice 10 Jul 86
ORIFICE BORE CALCULATION FOR GASES OR VAPORS SQUARESHARP-EDGED ORIFICE PLATE - RADIUS TAPS TYPE 304 STAINLESS STEEL ELEMENT STATIC PRESSURE MEASURED UPSTREAM OF ORIFICE
BAROMETRIC PRESSURE
PS IA
14.7
FLOW CONDITIONS:
TEMPERATURE PRESSURE
DEGREES F PSIG
100.0 60.0
FLUID PROPERTIES:
DENSITY AT TEMP. MOLECULAR WEIGHT COMPRESSIBILITY FACTOR HEAT CAPACITY RATIO VISCOSITY AT TEMP.
L3./CU.FT. LB./MOLE
CENTIPOISE
0.3598 28.90
0.999 1.42 0.019
MAXIMUM FLOW RATE
LB./HR. SCFH MSCFD
2285. 30000.
720.
PIPE REYNOLDS NO.(0.63 MAX FLOW)
240943.
FLOW INSTRUMENT DATA:
MAXIMUM DIFFERENTIAL PRESSURE INCHES WATER
100.0
INSIDE PIPE DIAMETER ORIFICE BORE DIAMETER
INCHES INCHES
1.987 1.265
DIAMETER RATIO(BETA)
0.63639
PERMANENT PRESSURE DROP AT MAXIMUM FLOW RATE
PSI
2.2
FA * i.0007 KO * 0.66225 FR - 1.0075 S 0.273162 FC = 0.9893 FOR PIPE REYNOLDS NO. Y = 0.9937
*
240943.
**** DIFFERENTIAL PRESSURE (INCHES WATER) IS GREATER THAN FLOWING PRESSURE (PSIA)
VAB.0001104623
ORIFICE - VERSION 82.01
' 3'-w-1
METER FACTOR CHART
T-407 SBT Air Flow Measurement Orifice
LINE ID 1.987
ORIFICE ID 1.265
MAXIMUM FLOW 30000. SCFH METER DIFF. 0- 100.0
0.0 0. 1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
1 3000 3300 3600 3900 4200 4500 4800 3100 5400 5700 2 6000 6300 6600 6900 7200 7500 7800 8100 3400 8700
9
3 9000 9300 9600 9900 10200 10500 10800 11100 11400 11700 4 12000 12300 12600 12900 13200 13500 13800 14100 14400 14700
5 15000 15300 15600 15900 16200 16300 16800 17100 17400 17700 6 18000 13300 18600 18900 19200 19500 19800 20100 20400 20700
7 21000 21300 21600 21900 22200 22500 22800 23100 23400 23700 8 24000 24300 24600 24900 25200 25300 25800 26100 26400 26700
9 27000 27300 27600 27900 28200 28500 28800 29100 29400 29700
4
VAB.0001104624
MAKS
V1S1A Vista Chemical Company GNCRAi ENONffWNO HOUSTON. texas
Orifice Plates & Flanges
Including Data for Bore
Calculations
fJ ________________ PflCLECT SLU/L/tV e^
orifice plates
STANOAAO
OTHER
PATINO 4 FACING
speotcatton
PROJECT NO. -- A.F.E. NO______ REQ. NO______
OATE __ MAOE BY _i
T?Q N < M l V i
APP O BY
'A P/? J V t *
ORtPfCC FLANGES
:V T
31 j UNE RANGE LO, INS. 32 seals. OLewrp
1*500_________________ _____________ ________________________
33 | manometer type 34 ) OtPE. RANGE INS M|0 ORT 3si STATIC RANQS. P3U
6 - Sd
1
() !1
36 | CHART OR SCMJi RANGE 37 I CHART MULRPUER
1 1 a*
|
v1 .1
38 | 39) 40 |
| j|
1
41 ) 42 |
|
|
43 ) ________________________
w\n\ IAS& ^ynsTi/O &
ottiftce
FMa)66J
___________________________________________________________________
-
i
......................... ! 1
.......
<?HT MoQIPY ptriAJG Fo
I 1
VAB.0001104625
VISIA
Visfa Chemical Company
GENERAL ENGINEERING HOUSTON, TEXAS
Specification Sheet
PLANT
ITEM NO. SERVICE
ABBA
PROJECT
GS1
SPECIFICATION OATA SHEET
PROJECT NO. _
A.F.c. NO
P O. NO.
MADE BY .
DEK.
DATE ///e/m APP O BY
PVJY&e.
4-000
MODEL I/O. 4-0 BO
&aa/6e :
MIA/tiZ Di<Ji!>ioa/S :
CAPS
DI Ff=&e.EAS77AL
/- 0
'AATttt
p*EU*e
A&E
72.. Oo BA
Dv/YEit t*JmuM&srs
Soy
4>f)72A>
AOUBTDM TX 772 OS'
ll*H,
f-441-S
ORIFICE * VERSION 82.01 Small SBT Air Flow Measurement Orifice
10 Jui 86
ORIFICE 30RE CALCULATION FOR GASES OR VAPORS SQUARE.SHARP-EDGED ORIFICE PLATE - RADIUS TAPS TYPE 304 STAINLESS STEEL ELEMENT STATIC PRESSURE MEASURED UPSTREAM OF ORIFICE
3AR0METRIC PRESSURE
PSIA
X4 4 . ^/
FLOW CONDITIONS:
TEMPERATURE PRESSURE
DEGREES F PSIG
100.0 60.0
FLUID PROPERTIES:
DENSITY AT TEMP. MOLECULAR WEIGHT COMPRESSIBILITY FACTOR HEAT CAPACITY RATIO VISCOSITY AT TEMP.
*.D ./Lu.r i . LB./MOLE
CENTIPOISE
0.3598 28.90
0.999 1.42 0.019
MAXIMUM FLOW RATE
LB./HR. SCFH MSCFD
762. 10000.
240 .
PIPE REYNOLDS NO.(0.63 MAX FLOW)
106390.
FLOW INSTRUMENT DATA:
MAXIMUM DIFFERENTIAL PRESSURE INCHES WATER
50.0
INSIDE PIPE DIAMETER ORIFICE BORE DIAMETER
INCHES INCHES
1.500 0.879
DIAMETER RATIO(BETA)
0.58603
PERMANENT PRESSURE DROP AT MAXIMUM FLOW RATE
PSI
1.2
FA = 1.0007
KO * 0.64154
FR - 1.0112
S = 0.224109
FC = 0.9942 FOR PIPE REYNOLDS NO. = 106390.
Y = 0.9970
*
**** ORIFICES LOSE ACCURACY IN LINES SMALLER THAN 2 INCHES.
IF POSSIBLE, USE A 2 INCH LINE.
20 A
VAB.0001104627
i
ORIFICE - VERSION 82.01
!<
21
METER FACTOR CHART
Small SBT Air Flow Measurement Orifice
LINE ID 1.500
ORIFI CE ID 0.879
MAXIMUM FLOW 10000. SCFH METER D IFF. 0- 50.0
0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9
1000 1100 1200 1300 1400 1300 1600 1700 1800 1900 2 2000 2100 2200 2300 2100 2500 2600 2700 2800 2900
3 3000 3100 3200 3300 3400 3500 3600 3700 3800 3900 4 4000 4100 4200 4300 4400 4500 4600 4700 4800 4900
5 3000 5100 5200 3300 3400 5300 5600 5700 5800 5900 6 6000 6100 6200 6300 6400 6500 6600 6700 6800 6900
7 7000 7100 7200 7300 7400 7500 7600 7700 7800 7900 8 8000 8100 8200 8300 8400 8500 8600 3700 8800 8900
9 9000 9100 9200 9300 9400 9500 9600 9700 9800 9900
VAB.0001104628
i
pi ant
Page IP
A
PRESSURE GAUGES
CH>^\cAl
project
&\/cm #D\Aor\w - pww.se. r
10
11
12
13
14
15
28 29
30 +
31 i 32
J4 !
35 i 36
fi
PS "&5J A
| t
pe- c*Sl c
i \\
PS- t5"LA/! /
A P C' &.53JS. =>s - ** sic.
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-----------------------
........................................................
___
.____ J_____ ----- rk\ 1 1 _J11
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vt
Vc SP-65-1 A
V1 &C sp-feS^W
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--
VAB.0001104629
31 | LINE FLANGE I.O.. INS. 32 j SEAL S. G. <a GOTF 33 | manometer type i 34 I OlFF. RANGE INS H,0 DRY 35 j STATIC RANGE. PSIA 1 36 CHART OR SCALE RANGE 1 37 ! CHART MULTIPLIER ! 38 | 39 | 40 I t 41 | I 42 i 1 43 1
|
1
|
1 1i
! 1
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__________________________
1 '1
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11-85
VAB.0001104630
i
ORIFICE - VERSION 82.01 T-407 RO ABCD 5/5/90 RESTRICTION ORIFICE BORE CALCULATION FOR GASES OR VAPORS TYPE 304 STAINLESS STEFL ELEMENT
BAROMETRIC PRESSURE
PS IA
14.7
FLOW CONDITIONS
TEMPERATURE PRESSURE(UPSTREAM)
PRESSURE DROP
DEGREES F PSIG
PSI
100.0 60.0
52.0
FLUID PROPERTIES
DENSITY AT TEMP. MOLECULAR WEIGHT COMPRESSIBILITY FACTOR HEAT CAPACITY RATIO VISCOSITY AT TEMP.
MAXIMUM FLOW RATE
LB./CU.FT. LB./MOLE
CENTIPOISE
LB./HR. SCFH MSCFD
0.3598 28.90
0.999 1.42 0.019
251. 3300.
79.
RESTRICTION ORIFICE DATA
INSIDE PIPE DIAMETER ORIFICE BORE DIAMETER
DIAMETER RATIO(BETA)
INCHES INCHES
2.067 0.262
0.127
VAB.0001104631
1 t*j
9 t FLUID 10 i flow units 1 1 1i MAXIMUM FLOW 12 | normal flow 13 | FLOW. PRESSURE-PSIG 14 1 FLOW. TEMPERATURE *F
15 i S. G. >a 60*F &
T5 i S. G. i.a F. 7 & 1 7 ) SUPERCOMP. FACTOR ria O. P 1 8 | VAPOR GAS MOL WT 19 | VISCOSITY. CP (a F_ T 20 | steam ouauty. % 21 t STEAM SUPERHEAT *F 22 j
23 j 24 1
\
25 1
26 27 ji28 I
29 1
30 | ACTUAL ORIFICE L CL. INS
31 I line FLANGE I.D.. INS. 32 j SEAL S. G. (a 60*F
j33 MANOMETER TYPE
34 | DIFF. RANGE INS H,0 DRY
35 [ STATIC RANGE. PSIA
36 | CHART OR SCALE RANGE
| 37 ! CHART MULTIPLIER
38
i 39
i 40 I
' 41 !
| 42 1
' 43
44
I 45 i
(u/>i
46 1 47 I
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49 I
50
51
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O. I 85" P.otT
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SPEC NO
REV OF _
VAB.0001104632
t
ORIFICE - VERSION 82.01 T-407 Agitation 5/5/90 RESTRICTION ORIFICE BORE CALCULATION FOR GASES OR VAPORS TYPE 304 STAINLESS STEEL ELEMENT
BAROMETRIC PRESSURE
PSIA
14.7
FLOW CONDITIONS
TEMPERATURE PRESSURE(UPSTREAM)
PRESSURE DROP
DEGREES F PSIG
PSI
100.0 60.0
52.0
FLUID PROPERTIES
DENSITY AT TEMP. MOLECULAR WEIGHT COMPRESSIBILITY FACTOR HEAT CAPACITY RATIO VISCOSITY AT TEMP.
MAXIMUM FLOW RATE
LB./CU.FT. LB./MOLE
CENTIPOISE
LB./HR. SCFH MSCFD
0.3598 28.90
0.999 1.42 0.019
126. 1650.
40.
RESTRICTION ORIFICE DATA
INSIDE PIPE DIAMETER ORIFICE BORE DIAMETER
DIAMETER RATIO(BETA)
INCHES INCHES
2.067 0.185
0.090
r
VAB.0001104633
VISIA Vista Chemical Company
SPECIFICATION OATA SHEET
11-85
SPEC NO.
REV OF
VAB.0001104634
quotation will not be considered if supplier does not complete right hano
COLUMN.
9/12/an VAB.0001104635
*
4-44I S
2-84
I
ROSS* &' PETHTEL, INC.
P.O. BOX 15223 BATCH ROUGE, LA 70895
jV 14(
i *
"l
TO:
*** 4
ATTENTION:
yMUje^-
. NUMBER OF PAGEH* v
0
DATE:
QUOTED 3Y
/__________________________
nz1 i M i
t.Cl\rtLUX
PHONE NUMBER: 504-293-C520
FAX NUMBER:
504-293-0524
REFERENCE:
WE QUOTE AS FOLLOWS:
ITEM n QUANTITY
-^-237
MODEL NUMBER AND DESCRIPTION
LIST PRICE
Hit/) v*rr
3auHcbwi
rV
mwm
PRICES GOOD FOR: DELIVERY: FOB: FREICHT:
TERMS: PtX.
LX-.... .
Leid ~Jzicsm
VAB.0001104637
BATON ROUGE LA
ITEM #2:
SCR
CONTROL PANEL
------------------------------------------------------------------- ---------
(Continued)
--------------------------------------------- . _
PRICE: DELIVERY: FOB:
$2,950.00 1 WEEK NOLENSVILLE
TN
ITEM #3:
CATALOG#: DESCRIPTION:
PRICE: DELIVERY: FOB:
4233-60110 NEMA 3R ENCLOSURE, 36"x24"x12 " WITH ONE MODEL #2001 MICROPROCESSOR BASED TEMPERATURE CONTROLLER, ONE MODEL #3901 OVERTEMPERATURE CONTROLLER, TWO MODEL #4115 SCR POWER CONTROLLERS, LOAD FUSING, POWER DISCONNECT, TRANSFORMER, SHUTDOWN CONTACTOR, "POWER ON" LIGHT , WINDOW OVER CONTROLLERS, EXTERNAL RESET PUSHBUTTON.
$3,715.00 6-8 WEEKS LAVERGNE, TN
ITEM # 4:
THERMOCOUPLES
CATALOG#: DESCRIPTION:
PRICE: DELIVERY: FOB :
1J1DKG2"W2QL
TYPE J THERMOCOUPLE 2" LONG 316 STAINLESS STEEL SHEATH, HINGED ALUMINUM HEAD.
BY 1/8" DIAMETER, 1/2" NPT FITTING
$72.00 EACH 2-3 WEEKS BATON ROUGE LA
(ROSS 6 PETHTEL WILL INVOICE)
*
THE #4532 SERIES QUOTED AS ITEM #2 IS NOT AVAILABLE IN NEMA 4 OR 3R WITH A 50 KW RATING, IF AN OUTDOOR RATING IS NECESSARY WE MUST USE THE #4233 SERIES.
If you need any assistance please call.
Regards
Craig P Arceneaux ROSS & PETHTEL INCORPORATED
VAB.0001104638
H/18 Controls/Electronic
4
i
Temperature controllers 2000 series
One or two (heat/cool) control outputs
Auto-tuning or manual tuning (2001)
Separate heat/cool control parameters
Auto/manual operation with bumpless transfer
All control parameters field selectable
4 Coded security levels
Models 2001 and 2002
if*-*
Features ON/OFF. proportional or PID
Ramp/soak function
Dual display -- process and set point
Relay, triac. 4-20mA and solid state re lay drive output modules
Analog process inputs with field calibra tion of engineering units
Alarm(s) field programmable as high, low, + deviation, -deviation or deviation
Front panel calibration
Non-volatile memory, no battery back-up required
r
iI
TTf
3.7a
(96)
3.7a
(96)
MEASURMENTS ARE SHOWN tN INCHES MILLIMETERS ARE SHOWN IN PARENTHESIS
FRONT PANEL FUNCTIONS
I
Yellow LEO indicates Heat Control IOijIquI * \) ON
Digital Display lor Process Temperature
j Red LED's indicate Alarm 1 ON"
Green LED's indicate
Menu No or Value
^dsisppilaayyed in lower
i
Pushbutton to select
Menu No or Value lor lower display
iD
i/_"i/
n
ii
n
i,
_ D 6 i?
V - *4
i ^L
vfcilow LED indicates Cool Control (Output #2) 'ON'
Green LED'S mdcate temperature scale selected
i
Green LED indicate Set Point displayed n lower display
Lower Digital Display lor Set Points. Menu Nos Values
Pushbutton increases Menu Nos ano values
Pushbutton decreases Menu Nos and Values including Control and Alarm Set Points
488 VAB.0001104639
Controls/Electronic
Chromakstf
Tv
^Temperature controllers 2000 senes
2001/2002 Remote S1 Point and Procoas Signal Output
*
/
REMOTE SET POINT GENERATOR
HEAT OUTPUT
'fI
l1
OO
C"
Jac<'wrai|I
Alt* o o c
j
Chromalox
COOL OUTPUT
#2
PROCESS SIGNAL OUTPUT
. 2002 Heat/Cool Ratio Feature
SCR POWER CONTROLLER
COOLING WATER RETURN
SOLENOID VALVE
proportional proportional
I BAND
BAND j
PROPORTIONAL BAND
Proportional Band = 20F Effective Heat Proportional Band = 10F Effective Cool Proportional Band = 10F Heat/Cool Ratio = i .0 Heat Output Limit = 100% Cool Output Limit = 100%
PROPORTIONAL PROPORTIONAL
BAND
BAND I
20* PROPORTIONAL BAND
Proportional Band = 20F Effective Heat Proportional Band = 10F
Effective Cool Proportional Band = 10F Heat/Cool Ratio = 2.0 Heat Output Limit = 100% Cool Output Limit = 100%
The Heat/Cool Ratio (Gain Ratio) feature is applied when the Cool Output (#2) control mode is PID. It balances the heating and cooling capacities of the system, yielding stable process control. Note that the Heat/Cool Ratio creates an "Effective Cool Output Limit" of 50% in the second illustration.
Options RS-232C or RS-422A Digital Communi- cations
Process Signal Output
Remote Set Point
r
CONTROL OUTPUT MODULES
Control output modules
Changing the output of the 2001/2002 is accomplished by simple replacement of the plug-in output module. Each controller is supplied with the control output type speci fied when ordering (see ordering informa tion on following pages). Additional control output modules are available to change the control output as application demands.
2002 pictured
489
Solid state relay drive
Current/voltage (selectable)
Relay
Triac
Controls
VAB.0001104640
H/20 Controls/Electronic
unromaicxxr
Temperature controllers 2001
Specifications -- 2001
Control Mod* (Field Selectable): ON/OFF hroportional (P) Proportional with automatic reset/integral (PI) F'roportional with automatic r bset/integral and rate/derivative (PID)
Control Adjustments (Field Selectable): Control Set Point: 0 to 100% of span (3F or C) Deadband: 0 to 100F F'roportional Band (Gain): 0.1 to 999.9% of span Manual Reset: Adjustable to any output lovel requirement. Automatic Reset: 0.00 to 99.99 repeats per minute Fate: 0 to 500 seconds
Control Outputs Relay: Normally open (N.O.) 5.0 Amps at 120V AC, 2.5 Amps at 230V AC. Triac. Rated at 1 Amp, 10 Amp inrush current, 120V AC or 230V AC. Current: 4 to 20 mA DC into a 0 to 800 ohm load. SSR Drive: Transistor output of + 20V DC at 40mA DC.
Alarm Outputs Alarm Modes High, range 100% of span, non-latching Low, range 100% of span, non-latching + Deviation, 0-250F above control set point -Deviation, 0-250F below control set point Deviation, 0-250F above/below con trol set point
Input Specifications Type J Thermocouple f'ron/Constantan): -100 to 1400F (-73 to 760C) Type K Thermocouple (Chromel/Alumel): -100 to 2100F (-73 to 1149C) Type T Thermocouple (Copper/Constantan): -350 to 750F (-212 to 399C) 100 Ohm Platinum RID: -200 to 1000F (-128 to 537C) 4-20 mA (1-5V DC) Field Selectable Range
Analog Remote Set Point (option) Input Range: 4-20 mA (1 to 5V DC)
Analog Process Output (option) Output Signal: 1 to 5V DC referenced to instrument common
Instrument Power Requirements 120 or 230V AC, + 10%, -15%, 50 to 60 Hz
Operating Environment 30 to 130F (0 to 55C)
Ordering Information 2001
ModelMicroprocessor-Based 1/4 DIN Temperature Controller
_________________________________________________________________
2001
P. PI. PD, PID and ON/OFF Control Modes -- Oual Display (Process and Set Point) -- Auto or Manual Tuning -- Auto Manual -- Alphanumencs -- Reverse or Direct Acting -- Two Alarm Relays with Programmable Mode Selection
CodeControl Output
________________________________________________________________
1 Relay -- 1 N O. Form A Contact. 5 A at 120V AC. 2.5 A at 230V AC 2 Triac. 1 Amp at 120 or 230V AC 4 4-20 mA into 0-800 ohm load
7Solid State Relay Drive 20V DC at 40 mA DC
CodeNot Used
__________________________________________________________ __
0Add to Complete Model Number
CodeAlarm Output
2 2 Relay Outputs Form A Contact Per Relay. 5 A at 120V AC 2.5 A at 230V AC
CodeAuxiliary Input/Output Option
0 None 1 Analog Remote Set Point, 4-20 mA or 1-5V DC 2 Analog Remote Set Point and AnalogProcess Readout Signal tor "J"
Thermocouple input (1-5V DC) 3 Analog Remote Set Point and Analog Process Readout '' mat for "K"
Thermocouple input (1-5V DC) 4 Analog Remote Set Point and Analog Process Readout S > for 100
ohm RTD input (1-5V DC)
5 Analog Remote Set Point and Analog Process Readout Sigi. >r "T" Thermocouple input (1-5V DC)
8 IMon-lsolated Digital Communications 9Non-lsolated Digital Communications & Analog Remote Set Point
CodeSensor Type Range
1 Thermocouple (field selectable): Select "J" -100 to 1400F (-73 to 760C) or "K" -100 to 2100F (-73 to 1149C) or T" -350 to 750F (-212 to 399C)
or 4-20 mA DC (1-5V DC) 0-100.0% (selectable range) '2 Thermocouple R" 50 to 3000F "S" 50 to 3000F
4-20 mA <1-5 Vdc) 0-100.0% (selectable range) 4 RTD 100 Ohm Pt -200 to 1000F (-128 to 537C)
or 4-20 mA DC (1-5V 0C) 0-100.0% (selectable range)_______________________________________________________
2001-20211Typical Model Number
490
'Contact factorv for avanabilitv
VAB.0001104641
Controls/power
Chromakntr
Selecting power control: SCR or contactor?
SCR vs. contactor power control
Mechanical contactors switch power in :ull ON and OFF cycles. For this rea son, they should be used at cycle times p|:15 seconds or longer for reasonable
ice life. Because of the full ON and switching, and the limited cycle
time, contactor controlled processes must have a higher tolerance for process temperature overshoot and un dershoot (as illustrated at right).
pn SCR (Silicon Controlled Rectifier) power switch differs from other switches |wits fast action. For example, while a contactor may cycle three times per
minute, a Chromalox SCR cycles ap
proximately once per second. This fast SCR cycle time results in process tem perature maintenance much closer to the desired set point. The SCR con troller modulates small increments of power to the load, unlike traditional mechanical control, and eliminates the overshoot and undershoot associated with contactor control.
Other factors such as ambient tempera ture, electrical noise and air con taminants should be considered when selecting a power controller.4
r
Q) *
aO.
*
o *
Contactor
Contactor Control
EQ> Time
SCR Control
&4>
Time
4
*
SCR power control system
A typical power control system consists of: RTD or Thermocouple u Temper ature Controller u Firing Package Q SCR Power Controller
I
Often trie Firing Package is part of the temperature controller and is not a separate component.
These components work together to control the heating of the process:
;1. The temperature sensor provides a ! signal to the temperature controller.
.2. The temperature controller compares t the sensor signal to the predeter{ mined set point and generates an
output signal that represents the difference between the actual process temperature and the set point.
3. The firing package uses this control output to generate a time proportion al signal for the SCR power con troller, switching the SCR on and off, thus regulating the power to the heater.
L
547
*
A.C. Power
T
LL
VAB.0001104642
H/78 Controls/power
Chrorrralox* -4
SCR power control: the basics
Zro-crossover firing
Chromaiox SCR Power Controllers are zero-crossover fired, also referred to as burst firing. Zero-crossover fired power controllers are ideal for control of pure resistive leads that can accommodate rapid, full power, ON/OFF cycling. Zerocrossover firing does not create RFI (Radio Frequency Interference) and will not adversely affect sensitive electronic equipment (computers, other SCR pow er controllers, logic controllers) located in the same area. Additionally, Chroma lox SCR's are protected from line volt age transients, making them more reliable in a wide variety of applications.
Zero-crossover fired SCR's. when couoled with a time proportioning con trol (firing package) such as the VariWatt, operate in a series of full ON and OFF cycles known as time proportional burst firir.g. The time proportioning con trol accepts the control output signal and converts it into a time proportional signal, determining the amount of ON time and OFF time per duty cycle. The continuous, highly repetitious rate of full ON and full OFF cycles produces a smooth power output to the load (heat er) and a stable process temperature.
1 second
i second
-- CYCLE TIME
CYCtE IfcC ---
lOO*|\AA/\AAA/WVAAhAA/WWAAAAA
Load connection diagrams
These suggested connection diagrams illustrate common load connections for resistive heaters.
Input From J*L Controller
Typical Input Hook Up with Single Phase Load
II
S i
cmi
cm
i
\ cm
Delta Load Configuration Three Phase, Three-Leg
. ! !
III
HAC
Time Proportional Burst Firing
:icm
4115
cm
4115
cm
Delta Load Configuration Three Phase, Two-Leg
<
Wye Load Configuration Three Phase, Three-Leg*
* Wye connected loads are not recommended for appltca* tions with more than one element per leg per circuit. An element failure m any leg increases the probability of further element failure tn that leg.
VAB.0001104643
Rpr Controls/power
unromates*
electing an SCR power controller
R component selection table
[15, 150. 200. 275 480. 600
Volts
240/480 240/480
240/480
240/480
240/480 240/480 240/480
r-fcsKs 1 1
3 3 3 3
Legs
1 1
2
2
3 3 3
Dimensions--Inches
2.6 x 4.8 x 5.0 2.6 x 4.8 x 5.0
8.6 x 8.0 x 8.0
7.5 x 15.0 x 9.9
14.0 x 19.0 x 6.0 21.0 x 19.0 x 8.3 27.0 x 27.0 x 10.5
Model
4115 4115
4117
4120
4130 4130 4130
Pegs J/32
J/33
SCR power panel selection table
V,
1 ,4 ^Control Panel Requirements (power (kW)
0-33
0-38
21-458
Voltage
120
AJ w 208
If
T
240
277
if iLt oad r t-
480 Single Phase Three Phase. 2-Leg
ij Three Phase. 3-Leg
Enclosure
NEMA 12
NEMA 3R L 4 NEMA 4
NEMA 7
r Dimensions (Inches) r
-
21 x 20 x 11 25 x 20 x 11 28.5 x 21 x 13
PP |Wt" 36 x 24 x 12 I'M 42 x 30 x 12
48 x 36 x 12
60 x 36 x 12 Br,L 72 x 36 x 12
| Control Input
Current 4-20 mA
j -
Solid State Relay Drive
Potentiometer L (Remote or Local)
F"i 3-20 Vdc
Model 4532
4534
S' S' S' S'
V*
V*
S' S'
s'
S' s' s'
4537 S'
s' s' s' s' s'
S'
s'
s' s' s' s'
4212
s' S' S' s' s' s' s'
S'
s'
4213 S' y y s' s' S'
s'
s'
S'
4232
s'
s* s' S' s' s'
S' S' s' s' s' y s'
4233
s' s' S' S' s'
y s' s' s* s' s' s'
Power
549
VAB.0001104644
H/80 Controls/power
ChfDmalooc?
SCR control panel: Illustration
Overtemperature Controller
Driver Controller
Power "ON" Lamp
Control Power Transformer
Fusing for Control Power T ransformer
Louvered NEMA 12 Enclosure
Disconnect Switch
Shutdown Contactor
installation Instructions
complete with spare parts lists
Firing Card
Firing Card Fusing
550
SCR Power Controller Model 4130
VAB.0001104645
/81 Controls/power
Chromaiox?
'ower controller Vari-Watt
lows manual control of waters using 4115 solid ate power controllers
:>wer limit adjustment and ie compensation features
jeepts three input types
matures
e Chromaiox Vari-Watt controller ac-
pts a control signal input and educes a time proportional output sigl to drive solid state power conllers, such as the Chromaiox 4115 ;R power controller. The Vari-Watt a 4115(s), when used together, prole an affordable total power control stem that results in continued cost vings through reduced power usage.
iri-Watt accepts 4-20 mA, external ntact closure or remote 10K potenmeter control signal inputs.
>war limit adjustment is field seiecta3, allowing the maximum load power be set from 0% to 100%, and is parularly useful for load protection.
ne voltage compensation feature is so field selectable, and is designed for >e when the Vari-Watt is operated anually. When implemented, this feare minimizes the effects of line volge fluctuations and load changes.
ad LED located on the controller indittes load power "ON".
Red LED Indicates Lo id Power ON
Power Limit Adjustment Potentiometer
Line Compensation Feature
Specifications Control Signal Input
4-20 mA Input Specs Input Impedance Turn ON Signal Full ON Signal
Output Cycle Time Line Voltage Compensation
indications Power Limit Adjustment
Ordering Information Description Vari-Watt Power Controller Remote 10K Potentiometer Kit Isolation Transformer (required for
remote 4-20 mA input signal applications)
Loop and Remote Poten with Auto-Manual Switch
MANn. AUTO
Positive -- Negative----------
>------------------*-
>
4-20mA Current Input Positive -----Negative-----Not Used-----Not Used------
4-20 mA DC External Contact Closure (ON-OFF) External 10K Potentiometer (manual ad justment)
200 ohms 4-6 mA DC 18-20 mA DC 15V DC at 15 mA, nominal 1 second, nominal Automatic, over range of 40 to 100% of power (can be disabled). Red LED indicates load power "ON" 0 to 100%, internal potentiometer, for testing or limit protection.
Part Number 0135-20051 0135-27000
0005-12017
Output Connections
4115
4115
Solid State Relay ?
Solid State Relay " + _2___ 2-
Negative ________
}fT20~ VAC Input
Isolation Transformer (see note)
551 VAB.0001104646
H/82 Controis/power
Chromatoc*
Solid state power controller 4115
Zero-crossover fired
Dual SCR design
Solid state power control, No contacts to pit or wear
Features
The Chromalox 4115 Power Controller is a single-pole, normally open switch ing device that accepts any 3-32V DC control input signal and provides ON/OFF zero-crossover switching of 120 to 480V AC loads from 40 to 90 amperes. The inverse-parallel SCR out put devices and built-in snubber of the 4115 provides highly reliable, noiseimmune drive circuitry for longer life and higher load capacity than triacs. Control input can be provided by Chro malox controller models 2000. 3900. 3910. 3290 and 3800, or any other con trol device providing a 3-32V DC control output signal. One controller can drive several 4115's with their inputs connect-
ed in parallel or series.
i j ; I
j i
j
i
i
i
FIGURE 1
T
2.3
y
(57.2)
1.9
(47)
t - fS)
j q
FIGURE 2
(22.2)
Measurements are shown in inches Millimeters are shown in parenthesis.
Output Specifications
Nominal
Power Controller AC Line
Model No.
Voltage Range
4115-20400 4115-20750 4115-40400 4115-40900
120 to 240V AC 120 to 240V AC 208 to 480V AC 208 to 480V AC
Maximum Switch Orop
1.6V 1.6V 1 6V 1.6V
Max. Oft Leakage
240V AC 480V AC
10 mA 10 mA
--
--
--
--
12 mA 12 mA
Max. Pwr. Une Voltage At Turn On Peak Repetitive
15V AC 15V AC 35V AC 35V AC
Max. One (1) Cycle Surge Current
500A 1000A 500A 1000A
PIV Rating
500V 500V 800V 1000V
VAB.0001104647
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Solid state power controller 4115
/Derating Curve*
Model 4115 controller mounted on: A. Chromalox Heatsink. P/N 0029-00628.
fins mounted in vertical olane, operating
in still air. 8. 12' x 12" x V8'' aluminum plate mounted
in vertical plane, operating in still air. tiC. Chromalox Heatsink P/N 0029-00628. 1 fins mounted in horizontal plane, operat-
I inci in still air. D. 6" x 6" x V8" aluminum plate mounted in
vedicat plane, operating in still air. E. No heatsink used. Mounted in still air. ? ) Aoditional heat dissipation possible by
positioning power controller on heatsink
ffri in cool air stream.
0 ---------1----1-------------*----1
2025303540465055
Air Temp. (*C)
Models 4115-20400 and 4115-40400
Amps RMS
20 23 30 35 40 45 50 55
Air Temp. (*C)
Models 4115-20750 and 4115-40900
Ordering Mode 4115
Solid State Power Controller
Sinole Phase. ON/OFF Output. Zero Crossover Fired. 3-32V DC Control Signal Input. Open Style
Code
Voltage
Maximum Current*
PIV
2040
2075 4040 4090
120 to 240V AC 120 to 240V AC 240 to 480V AC 240 to 480V AC
40 Amps 75 Amps 40 Amps 90 Amps
500 500 800 1000
Code
Configuration
0 No Heatsink 1 With Heatsink (Dimensions 4 8 x 5.0 x 2.6 inches)
4115-
____________
Resistive loaas omy. Consult derating curves lor specific application ratings
Information
Dimensions Figure 2 Figure 1 Figure 2 Figure 1
553 VAB.0001104648
5305 RESIDUAL VCM REDUCTION PHASE I
ABERDEEN PVC PLANT
TIE-IN LIST
Heated Silo Air 1. No tie-ins required.
Flow Indication 1. No tie-ins required.
Sparger Additions 1. Tie-in to Existing 2" Air Ring on T-646 through T647 and T-407. 2. Add six new 4" nozzles on T-407.
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VAB.0001104650
5305 RESIDUAL VCM REDUCTION PHASE I
ABERDEEN PVC PLANT
WORK LIST
Heated Silo Air 1. Remove existing 15 KW heater. 2 . Install new 50 KW heater, H-101. 3 . Reuse existing conduit, if possible. 4 . Use substation 10 spare breaker for power. 5 . Install TIC-101 in substation 10. 6. Install temperature gage downstream of heater.
Flow Indication 1. Install flanges and orifices as needed for FI -646 through
653 and FI-407. 2 . Use existing flanges when possible, adding radius taps
for FIs. 3 . Install FIs.
Scarcer Additions 1. Add flanges to T-407 for new spargei: configuration. 2. Install new spargers SP-407 E, F, G, and H, SP-646 A,B,C
and T-647 A,B,C. 3 . Relocate SP-407 B and D. 4. Add Sparger Team blend tank cleanout with 2" plug valve,
211 fullport ball, 2" check valve, restriction orifices, and pressure gages. 5 Blank spare nozzles.
VAB.0001104651
DRAWING LIST
5305 RESIDUAL VCM REDUCTION PHASE I
ABERDEEN PVC PLANT
1. RVCM Reduction Heated Silo Air - Plot Plan/P and ID 2. RVCM Reduction Heated Silo Air - H-101 3. Flow Indication and Cleanout ports- Small Blend Tanks 4. Flow Indication Cleanout ports and Spargers - Large Blend Tank 5. T-407 Existing Conditions 6. T-407 Proposed Sparger Layout 7. T-407 Sparger Detail 8. T-646/T-647 Sparger Layout and Detail
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15 KV. LENGTH! .42'
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HEATED SILO AIR-H-20J
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4' FLANGE
AIR FROM KNOCKOUT POT AND SILO MANIFOLD
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IR TO FILTER AND SILOS
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BASE SETUP (BO
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t. Restriction Or IfIce 2. Check Valve
3. Isolation Valve
A, Full Port Ball Valve
Bleeder
5. Pressure Gauqe
BLEND
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0 AIR SUPPLY
BLEND TANK
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MODIFICATION 1 CMD
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2. Tube Inside Pipe to Allow Flushing
FLUSH t
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HOOKUP
MODIFICATION 2 (M2>
2. 1 inch U-tutoe Sparger
3. 1 Inch Bleeder
MDDIFICATIQN 3 (M3)
1. Base case 2. Flange w/ Packing
to insert lance for flushing at ball valve.
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VISTA CHEMICAL pq
SPARGER TEAM RECOMMENDATIONS
DRA.WIMC Ayo.
Douglas E. Knittig
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From: Date:
5415 Decontamination Team - D.L. Toll Ison, D.E. Knittig
VEIASeptember 25, 1989
RESULTS AND RECOMMENDATIONS
The 5415 Decontamination Team was formed in response to Southwire' s contamination complaints. To satisfy the customer's needs, the team worked to identify and quantify 5415 contamination sources and reduce the contamination level. The new specification was set for 13 total average count or 16 highest for any one compartment.
The team recommends:
1. Dryer #5 be modified similar to Dryers 6, 7, and 8 2. Investigate lab test versus tester variability 3. Screwfeeder improvement on Dryers #4 and #5 4. Improve test variability 5. Search for mere accurate/reliable test method 6. Railcar cleaning improvements 7. Railcar sampling improvements 8. Cleaning railcar sampling containers before obtaining
test sample and before being reused 9. Reactor rinse improvements 10. Changing reactor condenser drilling and hydroblasting
frequency
Items 9 and 10 are still under investigation to determine their viability. The recommendations are based on an investigation of the process and a design of experiments. These improvements cover the process, sampling, and testing because the Nested Design Study (see Appendix B) showed that each area contributed equally to product variability.
Any additional recommendations or comments should be directed to the team by Monday, October 2, 1989.
The 5415 Decontamination Team cc: RWS, DCS, RfiN, HGC, CJMc, KB, DFJ, SCH Houston: EJM, RRS Austin: RBQ Saddlebrook: MAE
VAB.0001104666
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The 5415 Contamination Team was formed August 16, 1989 to search for a way to reduce 5415 black/brown contamination. The team was formed as a result of Southwire's contamination complaints and commitment of Vista to a new specification of an average total contamination of 13 and highest count of 16 for any one railcar compartment. Based on Vista's quality effort to satisfy our customer's needs, the 5415 Contamination Team will search for a cause of contamination and focus on achieving our specification goal through suggestions and recommendations to vinyl operations for improvements to the process.
BACKGROUND
During the week of 8/21/89-8/25/89, the team evaluated the process performance and collected baseline data. To determine contamination sources and their quantities, samples were taken along process at: reactor dump, blendtank discharge, dryer outlet, and railcars. The contamination contributed by each is as follows:
Reactors Blendtank Dryers Railcars
59% (constant) 0%
37% (variable) 4%
In addition to the samples, equipment was visually inspected for cleanliness.
a. Reactors The reactors (741-744) appeared relatively clean with minimal buildup, including the condensers. The condensers were drilled in late July, but over one month of monitoring, they began to show signs of buildup. The process water was also analyzed and found satisfactory.
b. Dryers Dryers #4 and #5 appeared to have the worst buildup after three days. The cleaning procedures were modified on these dryers. For one week, they were cleaned every other day. This showed a 1-2 contaminant decrease. Comparing the dryer temperature spikes to the contamination counts yielded no correlation. The calcium stearate used was also analyzed and found acceptable.
c. Chemwash Tank The tank is cleaned every day. The visual check showed no obvious problems, but it is very important that the strength be maintained above 5.
d. Railcars The railcar cleaning and sampling techniques were found to be satisfactory. Visual inspection after cleaning showed that small amounts of residue say on the sides of the compartments.
VAB.0001104667
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From the in-house study, most of the contaminants were resin particles that had been burned and some were chiggers (resin that has been through chemwash) . R&D has some samples that they are identifying for us. There was a question raised about heat degradation in the railcar. A relatively good sample of resin was placed in a 150 degree oven for 5 days and no significant change was noted. This theory is also being tested by our R&D.
The Nested Design Study is detailed in Appendix B. The major results are:
Variance distribution
1/3 process 1/3 sampling 1/3 testing
i
Control data
c-9.43 UCI^18.6
Top versus bottom
Tavg-10.1 Bavg-8.75
Probability of out of spec material (without assignable causes)
2%
These results lead the team to make the following recommendations.
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DRYER #5
The recommended changes on Dryer #5 include: install full cone pull distribution plate away from wall 1/2" install cooling bar increase airflow (if possible)
These improvements should decrease the contaminant count by 4-5 particles. The pre- and post- modification data for Dryer #8 support this fact (see Appendix A, Figure 1), as well as the visual inspections.
The temperature in Dryer #5 is typically unstable, more so than in any of the other dryers. These modifications will keep resin from sticking to the walls and burning when the temperature spikes upward. It will also put Dryer #5 in a more competitive range with the other dryers, after Dryer #4 modifications in November (see Appendix A, Figure 2).
LAB TEST VS.
The nested design showed that approximately 33% of product variability is due to testing, but it did not distinguish between test and tester. After these variances are determined, efforts may be focused on the worst of the two areas. It will also give operations a more specific confidence range when deciding whether or not to ship a particular railcar/truck.
The team recommends that the cooling water flow through the screwfeeder jac on #4 and #5 be increased. Visual inspections showed that resin accumulates burns on top of the,^ j ackets. The cooling water increase should remedy problem. of Co\-crv\r . /
or Cjk co / fo]
There are several ways to improve test variability. The importance of this recommendation depends on the results of the test vs. analyst results. The recommended changes include:
testing 100 gm (200 ml) samples to see if that yields a more representative count (this is what Southwire tests).
testing multiple samples for each compartment will reduce variability by a definite amount, depending on the number of samples.
The test variability can be improved by at least one of these methods, regardless of the test vs. analyst results.
Improvements of the existing test may or may not prove satisfactory. Since testing accounts for over 30% of the product variability, the option of using a more accurate and reliable test should not be overlooked. Talking with other resin manufacturers about their test methods, as well as exploring the modification of existing technology to fit our purpose are two approaches this team recommends.
The visual inspections of the railcars showed that a relatively small amount of residue stays on the sides of the railcar compartments after normal cleaning. As a result of this, operations has modified its procedures to include:
hitting the sides of hopper with rubber mallets
using air hoses
to get residue off of the walls. This will be an added precaution against cars that are returned to the plant with open hatches.
The procedure used to sample railcars was studied and found to be satisfactory. The only suggested improvement would be to use bare hands when getting the samples instead of wearing gloves.
CLEANING RAILCAR SAMPLE CONTAINERS
The team recommends that the outside of each sample container be vacuumed by the lab technician before opening it. This is because the containers are frequently on the ground the lose dirt sticks to them easily. In addition, they should be vacuumed Inside before being used again because resin stays on the sides after it has been emptied.
REACTOR
Since the reactors contribute almost 60% of the contamination in the process, it if logical to investigate improved rinsing. This topic has not been looked into in detail, but will in the near future. Some of the options to consider
different nozzles additional nozzles
higher pressure water
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Visual inspection supports this recommendation.
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This topic has been considered, but not in detail. The team has followed the condenser buildup of one <failcai5 but only for one month. More time will be
needed to investigate the benefits of this suggested improvement. Visual Inspections are scheduled during new Module turnaround in October.
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Figure 1. Figure 2.
Dryer #8 Performance Dryer Contamination
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AVGERAGE CONTAMINATION COUNT
DRYER #8 PERFORMANCE
modification results
15
14
13
12
11
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DRYER CONTAMINATION
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DRYER 5
DRYER 7
DRYER 8
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