Document BRGggkzO4zamJvEXeXMk5RZgo
TO: EDC/VOC EXPOSURE TEAM FROM: MARK WOODYEAR
DATE: FEBRUARY 19, 1991
RE: MEETING 2/18/91 MINUTES
The EDC/VOC Exposure team met in the Main Conference Room at 9:30 am Monday 2/18. In attendance were Nelson Perez (timekeeper), Craig LeJeune (scribe), Johnny Stephenson, Craig Davis, Mike Huber, Ernie Parsons, Max Hekmat, Francisco Ortiz, Art Reinhardt, Ron Williams, and Mark Woodyear (secretary).
Pancho began the meeting by introducing the members to the regulations facing PPG and the effects that this will have on our operations. He briefly described both the EDC IPEL and VOC laws.
Ron Williams then gave a brief history of the EDC IPEL regulation and some of our efforts to date. After January of 1993, respirators can only be used for emergencies, or other applications where engineering controls are not feasible. He mentioned that high costs could not be used as a reason for unfeasibility. Presently, we are in an interim period where respiratory protection can be used. After Jan. 1, 1993 we must comply with the new limits without using respiratory equipment. The new limits are 1 ppm TWA and 2 ppm STEL. He also mentioned that the Vinyl Institute has challenged the law in court. He estimated that our chances of winning the court action were about 50/50 and that any result" would not be known until late '91 or early '92.
There was then some discussion of the regulations. Several questions were raised as to what we were going, to consider as VOC's, will stabilizers be included, etc. Nelson will write a formal project scope for the project by the second meeting. Also, Ron will write an abstract of the EDC IPEL regulation. We will contact Plauche about the VOC regulations. These items should better define what needs to be done.
Johnny reviewed the work done so far. The project was divided into two phases. Phase I just had a pre-ACT meeting last Friday. This phase involves pump seals, tank vents, closed-loop sampling. It also includes money for purchase of some vacuum pumps and nitrogen heaters. Phase II is what we are working on. This involves clearing equipment, emissions from sumps, etc.
A team contract was then adopted. It is included in the attachments. Nelson then presented the project schedule to the group.
Next we reviewed and brainstormed a list of potential methods for clearing equipment. Assignments were made for members of the group to develop the procedures. It was further decided that each member would review the brainstorming list with operators and/or maintenance to get any ideas they may have on the subject. The final list of
SL 087861
clearing concepts and the person(s) assigned to develop the concepts are listed below:
Steaming Atntpping
Ho-1 nitnogen panging Vacuum PtggJng tinet (lAing deauy tiqutdA -to dJtptace Liquid ong. Sotuent waAding Redu.ce. # o4 ptuggad. neboJJten tubeA Canbon AbAonption FneezJng SotidA and JU.qai.dA Equtpment Re.daAJ.gn Hitnogen pangJug Waten-uioAding
MW CL
NP/EP CL FO/MW/EP MKH/CL HKH/UP/AP CD/PW/CL CD/FO
The development of each of these concepts involves several items. These items are listed under the concepts in the attached Activity List. The activity list will be updated after each meeting to reflect progress made. It should be used in addition to the assignments made at the meeting.
We then reviewed the activity list. Assignments were made to gather equipment lists and pressure/temp ratings for each piece of equipment in Derivatives that contains EDC or any VOC's.
The following assignments were made at the meeting:
f. Define VOC. - Andy P. 2. Exactty whan it VOC nepont dae. - Andy P. 3. Get openaton input 4 on cteaning conceptA titt. -
OpenationA PopA 4. Bning copy o4 VCM cJLeunJug SOP'-i. - Enoie 5. Mode P/T equipment tittfnotingA. - Huben/LeJeune 6. Hade. TE2 equtpment titt/notinga . - Retndandt/U. Penez 7. Hade. WTU equipment tiAt/natingA. ~ Z.Penez/Woodyean S. Hade. VCZ equipment tiAt/natingA. - PanAonA/Woodyeon 9. Hade. VDC equipment tiAt/natingA. - DaviA/U.Penez 10. Hade, EDC equipment tiAt/natingA. - DavJt/Le.Jeune, 11. Hade. EC-HCL equipment tiAt/natingA. - DawiA/U.Penez 11. Load at outage. AcdeduteA and tadJ.wJ.duat equipment outages
4 on tde next two montdA. WJtd an eye, tomandA testing cteaning conceptA. - ALL 13. ConAiden equipment betng cteaned 4 on TE-1 outage and poAAibte totting. - Ant PnoceAA EngnA 14. (Pond on developing cteaning concepts. - Att aAAigned
(see Agenda on next page) SI, OS'7S62
AGENDA
1. Review Assignments 2. TE-2 Test Schedule 3. Hake agenda for next meeting.
Distribution:
Attendees ~ Ismael Perez " Andy Plauche Vern Morgan --
Attachments:
Team Contract Updated Activity List Unit Notes for Reducing EDC Exposure Major Equipment Clearing with Potential
for
EDC Exposure
ACTIVITY LIST FOR P-3097 NEW EDC AND VOC EXPOSURE LIMITS
Revised 2/18/91
Abbreviations for the team members are:
Craig Davis Max Hekmat Mike Huber Craig LeJeune Vern Morgan
CD MJH MKH
CL VM
Francisco Ortiz FO
Ernie Parsons EP
Andy Plauche' AP
Ismael Perez
IP
Nelson Perez
NP
Art Reinhardt Johnny Stephenson Ron Williams Mark Woodyear
AR JS RW MW
Required
Responsible Completion
Individual(s)
Date
I. PROJECT LOGISTICS
1. Determine team meeting frequency. 2. Select and schedule meeting room. 3. Select and set-up file/drawing room.
ALL MW
CL
Done Done 2/25
II. REVISE SCOPE AND SCHEDULE
1. Issue Scope for Phase II. a) Establish a design basis. The guideline is to clear equipment as fast as or faster than is done currently. a) Review with Operations/Maintenance. b) Obtain approval from all Area Supervisors (including Maint.), Environmental, Industrial
Hygiene, and Dick Holliday. c) Send copy to White, Samelson, Graybill, and
possibly others in GO. 2. Prepare Project Schedule. 3. Develop abstract of the regulations. 4. Put this activity list in timeline.
III. DEVELOP CLEARING CONCEPTS
I. Brainstorm additional concepts
Some concepts are: a) Steam Stripping b) Hot Nitrogen Purging c) Vacuum d) Pigging
e) Water-Washing f) Nitrogen Purging
and SL
develop 087864
list.
NP By 2/27
Meeting
JS RW/AP
JS
ALL
MW CL NP/EP CL ALL ALL
Done 2/27 2/28
3/11
2/18
3/11 3/11 3/11 3/11 3/11 3/H
Page 1 of 5
g) Freezing solids and liquids h) Solvent Washing i) Displacing liquid orgs from tanks j) Equipment Redesign k) Reduce number of plugged reboiler tubes 1) Carbon Absorption
CD/FO MH/CL FO/MW/EP
ALL NP/MKH/AR
CD/RW/CL
For each concept: 1. Determine possible applications. 2. Draw Sketch and develop preliminary procedure to
illustrate the use of the concept. 3. Evaluate Feasibility.
a) Technical b) Economic c) Constructability 4. Discuss with Operators/Operations and Maintenance and obtain input. 5. Evaluate Results.
6. Determine limitations and potential problems
(Note - The responsible individual(s) for i t ems 1-6 is as listed for each concept above.)
3/11 3/4.1 3/11 3/11 3/11 3/11
3/11 3/11
3/11
3/11
3/11 3/11
IV. CATEGORIZE EQUIPMENT
1. Make a list of Equipment for each unit and determine Equipment Ratings (press/vacuum and t emp).
2. Brainstorm categories and develop an equipment list for each. Some categories are: a) Equipment rated for a full vacuum. b) Pressure Vessels. c) Atmospheric Vessels. d) Temperature Rating. e) Frequency of clearing or opening to the
atmosphere. f) others
g) ? h) ? 3. Verify Equipment integrity.
2/25 NP/CL/MW 3/4
Operations 3/4
V. PRELIMINARY SKETCHES AND FLOWSHEETS
4/1
1. Make generic sketches for each equipment type. 2. Develop Process Flow Diagrams (PFD). 3. Develop Preliminary P&ID's (new ones).
VI. MATCH CLEARING CONCEPTS TO CATEGORIES
3/13
1. Schedule and conduct meeting to discuss best alternatives.
2. Analyze clearing concepts and category for each piece of equipment.
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Page 2 of 5
3. Determine clearing parameters (temp/time/vac) for each piece of equipment.
4. Develop implementation strategy. a) How many clearing units? b) Where located? c) Mobile or permanent installation?
5. Determine owner/manager/maintainer of mobile type equipment.
VII. MATERIAL AND ENERGY BALANCES
1. Establish a design basis. 2. Determine where needed. 3. Utilize ChemCad when necessary. 4. Apply material and energy balances to clearing
concepts and include in FFD's.
VIII. DETERMINE METHOD OF TELLING WHEN EQUIPMENT IS. CLEARED
Given: Sampling is required to verify that a piece of equipment contains less than 1 PPM EDC or VOC.
1. Brainstorm methods. 2. Evaluate methods for VC and Chlorine. 3. Determine where to sample. 4. Determine how to sample. 5. Evaluate sampling techniques that can be done
by operations. 6. Develop or update SOPs for equipment clearing.
IX. ENVIRONMENTAL
1. Interact with Environmental Department. 2. Conduct testing of present water-washing. 3. Evaluate re-use of flush water. 4. Evaluate the affect in WTU and design
equipment or change concepts.
X. TEST CONCEPTS
1. Determine a specific piece of equipment to test in each category.
2. Obtain and Look at outage schedules. 3. Evaluate needed test equipment and procure. 4. Decide on procedure and develop
schedule. Design Experiments/Testing Methods, Locations, and Timing. 5. Make a sampling program and execute. 6. Collect data and evaluate results. 7. Determine charge number and fund resource.
VM
Page 3 of 5
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"*
3/18
4/15
4/29
4/15 3/4 2/27 3/11 3/18 4/15 2/21
XI. ECONOMICS
1. Compare current clearing time to new clearing time for each piece of equipment. May have a return if the new clearing time is shorter than the current clearing time.
2. Assess the positive economic impact in on-stream time by unit by product line.
3. Determine the operating cost increase of: a) utilities b) maintenance c) manpower.
4. Determine capital cost in matrix form as follows: a) Total cost for Derivatives. b) Cost by product line. c) Cost with and without solvents. d) Cost of EDC IPEL only. e) Cost of VOC regulation only.
XII. MARK-UP EXISTING P&ID'S
1. Develop a management procedure for drawings. 2. Determine needed drawings. 3. Get the prints. 4. Develop a logbook to keep track of drawings. 5. Engage project engineering and drafting.6. Learn the fileroom Drawing system. 7. Develop a new equipment numbering system. 8. Team to check final P&ID's for completeness.
XIII. DESIGN NEW EQUIPMENT AND COMPLETE EQUIPMENT SPEC SHEETS
1. Carbon beds. 2. Nitrogen heater(s). 3. Vacuum pump(s). 4. Steam Condensers. 5. Water vessels (portable). 6. Water Tanks. 7. Equipment for Pigging lines. 8. Pipe sizing. 9. Look at existing systems ability to handle
changes (vent headers/incin/wtu). 10. Blowers. 11. Mobile clearing units (self-contained). 12. Pumps. 13. Compressors. 14. Make new equipment list. 15. Team to check specification sheets for
completeness.
XIV. FINALIZE CLEARING PROCEDURES FOR CATEGORIES
1. Evaluate alternatives.
Page 4 of 5
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5/13 4/22 4/24 4/30
4/15 2/28 2/28 2/18 4/15
2/18 4/29
2. Develop and finalize written procedures. 3. Review with operations and maintenance.
XV. PREPARE PROCESS DESIGN PACKAGE
1. Finalize subheadings for the manual and
appendices.
Book I - Report (Articulated Text)
Tab-la. o4 Content*
Ab*trUCt
Justification
Project Overview
Ol*cu**lon of the EDC IPEL and VOC
Pao j ect
Energy and Material Balances
Vl*cu**lon
PFD' * and PS IV*
Equipment Design
Additional consideration*
Environmental Regulation*
Author*
Book II, III, etc. - Appendices
P-toce^i-i Floui*h.eet*
Design Ba*l*
Material and Energy Balance*
Proce** De*crlptlon(*)
Clearing Procedure*
Equipment Ll*t
Equipment De*lgn
Proce** Spec.
Pipeline Sizing
PStV*
PFD/PSID Revision Logbook.
Economic*
Correspondence
Meeting Minute*
2. Co-ordinate the secretarial duties. 3. Co-ordinate the manual development as
the project progresses.
XVI. PREPARE ACT
XVII. STUDY AND ESTIMATE PHASE
XVIII. CONTRACT ENGINEERING
1. Consider engaging Process Engineering Contractor. 2. Engage Project Engineering Contractor.
-- 5/13 2/28
5/13 5/13
7/1 7/1 FO 3/18
5/6
Page 5 of 5
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P-2097 EDC :Ej, .OS
MAJOR SOU I FMENT C_PjRI\G ^I~r POTENTIAL PERSONNEL EDC E/.POiuRE -IS"
01STI_LAT2ON COLUMNS IN EDC SERVICE: -tvCFO9LAST REBOILERS 2i_EAN CONDENSERS Clean packing , tra-tS papLACE MAJOR VALVES. ETC. v SS3E_ INTERNAL INSPECTIONS REPAIR INSTRUMENTATION
jTRER VESSEL REPAIRS
pp.'CESS 7 A NS : (WITHIN THE UNIT) PEFLACE vAlVES RE=AIF LEAKS DUE TC CORROSION OR
/ESSEl INTERNAL IMSPEC:IONS REPAIR INSTRUMENTATION
OTHER VESSEL REPAIRS
GASKET
'` FAILURE
EDC STORAGE TANKS: 'INCLUDING
REPLACE VALVES REPAIR LEAKS VESSEL INTERNAL INSPECTIONS REPAIR INSTRUMENTATION
REMOTE
LOCATION)
PROCESS PIPING: REPLACE VALVES RE=AIR LEAKS
REPAIR INSTRUMENTATION
EDC DRYERS: (INCLUDE REMOTE LOCATIONS) PREPARE FOR RECHARGING REFLACE VALVES, OTHER REPAIRS
EDC FILTERS: (INCLUDE REMOTE LOCATIONS) PREPARE FOR RECHARGING REPLACE VALVES, OTHER REPAIRS
PUMPS: PREPARE FOR SEAL REPAIRS REPLACE VALVES
HEAT EXCHANGERS / ECONOMIZERS PREPARE TO WASH / HYDROBLAST
REPLACE VALVES
VACUUM TRUCKS: LOADING / UNLOADING OPERATIONS WASHING
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29
30
PROCESS SUMPS / Llr" STATIONS; CLEAN ING SURFACE EVAPORATION lISSES MOVING WATERS TO AND FROM SUMC G . CERATIONS: AALSO I'iC^LCED IN E'_AMMA0_E LOADiNGi G. .f'iLOAuIfi'j 1 ANK LOADING UNLOADING TANK TRUCKS INSPECTING 'ANK CARS TANK TRUCKS LOADING/UNLOADING CRUMS "AR EUGGIES: wash InG LOADING / UNLOADING OTHER REAIRS WTU C_ASSIFIER: LOADING / UNLOADING MATERIAL CLEANING OPERATIONS
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31
PHIT PROPOSALS FOR THE RgDPCTION OF EDO EXPOSURE
PURPOSE THE PURPOSE OF THIS WRITE UP IS TO OUTLINE PROPOSED IDEAS FOR ENGINEERING REDUCTIONS IN EDC EXPOSURE AS REQUIRED BY CHANGE IN OSHA REGULATION. THIS CHANGE HAS LOWERED PERSONNEL EXPOSURE TO EDC TO 1 PPM FOR 8 HOURS TWA AND 2 PPM FOR A 15 MINUTE STEL WITHOUT THE USE OF RESPIRATORY PROTECTIVE EQUIPMENT. THESE ENGINEERING CONTROLS MUST BE IN PLACE BEFORE A DEADLINE OF DECEMBER 31, 1992 IN ORDER TO MAINTAIN COMPLIANCE.
WTU MODIFICATION OF THE FOLLOWING TASKS: 1. CLEARING OF THE BOTTOMS PLANT PRODUCT DRYERS. 2. DRAINING INCINERATOR KNOCK OUT POTS. A PROJECT CURRENTLY IN PROGRESS. 3. SAMPLING OF INCINERATOR FEED/BOTTOMS PLANT BOTTOMS. 4. REMOVAL OF ORGANICS FROM CSS AND BAT STRIPPER FEED SYSTEMS. 5. SAMPLING OF INCINERATOR FEED/BTMS PLANT BOTTOMS.
PER/TRI PROPOSALS BY N. PEREZ THAT WILL BE DISCUSSED WITH PER/TRI SUPERVISION REGARDING IDENTIFIED PROBLEM AREAS AS INDICATED BY PERSONNEL MONITORING: 1. BAT SUMP COVER THE BAT SUMP TO ELIMINATE WHILE DUMPING VACUUM TRUCKS. ADD A NOZZLE FOR VACUUM TRUCKS DISCHARGE. 2. BAT SUMP PRIMING ADD A BLEED LINE BACK TO THE COVERED BAT SUMP INSTEAD TO THE SUMP PAD. 3. CLEARING VAPORIZER FOR OUTAGE INSTALL A LOW POINT BLEED AT THE PUMP BOWLS TO INSURE COMPLETE DRAINAGE OF THE VAPORIZERS. UPON DRAINAGE. USE HEATED N2 TO PURGE THE VENT HEADER. KEEP STEAM GOING TO THE REBOILER TO HELP HEATING AND RID ORGANIC VAPORS. 4. VAPORIZER BLOWDOWN PIPING CLEARING N2 BLOW THE LINES EMPTY AND THEM USE HEATED N2 TO GET RID OF ORGANIC VAPORS. VENT TO VENT HEADER. 5. TRI STILL REFLUX DRYER DUMPING N2 PAD THE DRYER. WHEN EMPTY OF LIQUID. USE HEATED N2 TO RID ORGANIC VAPORS. VENT TO VENT HEADER. 6. TRI STILL REFLUX SYSTEM A. REFLUX PUMPS PUMP CLEARING LINE TO THE REFLUX TANK. USE DOUBLE SEAL ON THE PUMPS. B. REFLUX TANK EMPTY THE TANK INTO THE STILL AND USE HEATED N2 TO RID ORGANIC VAPORS. VENT TO THE VENT HEADER.
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7. LINE LEAK IN WHICH EDC IS A MAJOR COMPONENT BEGIN WORK ON INDIVIDUAL ITEMS FOR COST ESTIMATES.
TRI II
1. THE NEED FOR CLOSED LOOP SAMPLING IN THE FOLLOWING
LOCATIONS:
OHC ACID AT RX P/S
L.S. REFLUX BEFORE DRYERS
CHLORAL TREATMENT PRODUCT L.S. REFLUX AFTER DRYERS
DH BOTTOMS
LIGHTS TANKS
L.S. FEED
HEAVY STILL BOTTOMS
L.S. BOTTOMS
2. THE NEED FOR A CLOSED CLEARING METHOD FOR THE FOLLOWING
CLEARING PURPOSES:
OHC CRUDE TRANSFER PUMPS
LIGHT STILL FINAL FILTERS
OHC PRODUCT TRANSFER PUMPS
LIGHT STILL REFLUX FILTERS
CHLORAL TREATMENT FEED PUMPS
LIGHT STILL FINAL DRYERS
CHLORAL TREATMENT PRODUCT PUMPS LIGHT STILL REFLUX DRYERS
DH STILL FEED PUMPS
FURNACE FEED PUMPS
DH STILL BOTTOMS PUMPS
HEAVY STILL FEED PUMPS
LIGHT STILL FEED PUMPS
HEAVY STILL REFLUX PUMPS
LIGHT STILL BOTTOMS PUMPS
HEAVY STILL BOTTOMS PUMPS
LIGHT STILL REFLUX PUMPS
CHLORAL TREATMENT FILTERS
STEAM STRIPPER PHASE SEPARATOR ORGANICS PUMPS
3. THE POSSIBILITY OF INSTALLING DOUBLE TANDEM SEALS ON ALL
PUMPS LISTED IN NUMBER TWO ABOVE.
VCM II IMPLEMENTING CHANGES IN THE FOLLOWING JOBS THAT HAVE REOUIRED RESPIRATORY PROTECTION AS A PAST PRACTICE: 1. DRAINING AND CLEARING EDC PUMPS INSTALL PUMP CLEARING LINE. THE CLEARING LINE CAN DISCHARGE BACK TO THE VESSEL OR COMMON HEADER.
2. CATCHING OHC DEGASSER SAMPLES USE AN ACID RESISTANT SAMPLING RIG WITH A BOTTLE. SAMPLE TO BE CAUGHT BEFORE THE LCV AND DISCHARGE AFTER.
3. DISCARD EDC SAMPLES INTO THE PROCESS TANK USE 5 GAL JUG IN THE PLANT LAB UNDER THE HOOD TO EMPTY THE SAMPLE BOTTLES.
4. COLOR CHECK ON EDC REACTOR USE A SAMPLE RIG WITH A CLEAR BOTTLE CONTAINING A SMALL AMOUNT OF TESTING REGENT. TAKE THE SAMPLE FROM THE REACTOR PCV. A LIQUID SAMPLE CAN BE TESTED IN THE SAME FASHION EXCEPT IN THIS CASE THE LIQUID CAN GO FROM THE REACTOR LIQUOR TO A BOTTLE BOX OR SIMILAR ITEM.
5. SAMPLING EDC TRUCKS ROT""ST A TRUCK SAMPLE WITH EVERY SHIPMENT BY THE EDC SUP' :ER OR GET A CLOSED LOOP SAMPLE AT THE UNLOADING PUMi ,ND HAVE IT ANALYZED. IF OK. THEN FINISH THE
UNLC.OING PROCESS. 6. WORKING BY THE COVERED SEPARATOR
INSTALL A FLOATING COVER 7. CHARGING THE EDC REACTOR CATALYST POTS
EVALUATE THE INSTALLED CLEARING LINE PERFORMANCE. IF
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STILL HAVING POTENTIAL EDC EXPOSURE. CONSIDER USING HOT N2. 8. WASH DH STILL TO BE CONSIDERED AT A LATER TIME. 9. WASH DH STILL FEED ECONOMIZER N2 PAD OUT THE EDC TO A VESSEL, WHEN EMPTY. USE HOT N2 TO PURGE TO THE VENT HEADER TILL CLEAR. 10. CATCH EDC SAMPLES THAT ARE NOT CLOSED LOOP CONVERT TO CLOSED LOOP. 11. CLEARING INSTRUMENTS AND SIGHT GLASSED IN EDC SERVICE N2 PAD SIGHT GLASSES INTO THE VESSEL AND THEN PURGE TO THE VENT HEADER USING HOT N2. 12. DRAINING OR UNFLUGING LINES OR VESSELS CONTAINING EDC. GO TO A CLEARING VESSEL OR TAR BUGGY. AFTERWARDS. USE HOT N2 TO PURGE TO THE VENT HEADER IF OPENING IS NEEDED. 13. DUMPING EDC DOPP KETTLE INTO DRUMS NEEDING FURTHER STUDY. 14. FLUSHING PH PROBES IN EDC SERVICE BLOW BACK THE PROBES INTO THE VESSEL. 15. DRAINING LIQUIDS OUT OF VENT HEADERS INSTALL SMALL DIAPHRAM PUMPS TO PUMP LIQUIDS OUT OF THE HEADERS BACK INTO THE INTERMEDIATE CRUDE TANK IN OHC. 16. DRAIN ST-2 VENT TO KNOCKOUT POT USE DIAPHRAM PUMP TO PUMP BACK INTO THE TANK. 17. CLEARING CARBON/PELS BED AND FILTER N2 PAD OUT THE EDC IN THE VESSELS. USE HOT N2 TO PURGE TO A VENT HEADER OR RECOVERY SYSTEM: 18. CLEARING EDC STORAGE TANKS NEEDING FURTHER STUDY.
LP/EDC IMPLEMENTING CHANGES IN THE FOLLOWING ACTIVITIES THAT HAVE BEEN DETERMINED AS SOURCES OF EDC EXPOSURE: 1. ROUTINE SAMPLES IMPLEMENT CLOSED LOOP SAMPLING. 2. ORTHOTOLINE CHLORINE CHECK IN REACTOR CRUDE IN LINE CHLORINE ANALYZER AT REACTOR CONDENSER DRAIN. 3. ETHYLENE ANALYZER VENT SYSTEM TO PUT VENTS TO INCINERATOR HEADER. 4. RECHARGING OF DRYERS AND NEUTRALIZERS IN NEED OF FURTHER STUDY. 5. CLEARING OF PUMPS TO CLEAR PUMP SUCTION/BOWL FOR SEAL JOB, A PORTABLE N2 DRIVEN PUMP WILL BE CONNECTED TO LOW POINT DRAIN AND ALL LIQUID WILL BE PUMPED BACK TO SYSTEM. THEN PURGED TO VENT HEADER. 6. #2 AND #4 EDC TANKS USED AS AREA BTMS STORAGE TANKS. INSTALL BS&B VENT VALVES AND COMPRESS VENTS TO INCINERATOR. 7. CLEARING OF TANKS. VESSELS. AND COLUMNS A. PURGE TO INCINERATOR B. PURGE THROUGH CARBON BED. C. VACUUM PUMP EXHAUST TO INCINERATOR. D. VAPORIZE TO INCINERATOR USING N2 THROUGH PORTABLE
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/ *t-- Li- - ^ /
34
HEATER. 8. VERT HEADER LIQUID
INSTALL KNOCK OUT POTS WITH PUMPS TO TRANSFER LIQUID BACK TO THE SYSTEM. 9. SPENT SAMPLE ACCUMULATION BOX SYSTEM TO TRANSFER LIQUID BACK TO SYSTEM.
10. EDC REACTOR LIQUOR SAMPLES FORCED CIRCULATION CLOSED LOOP SAMPLING.
11. RUNNING ANALYSIS IN PLANT LAB A. NEW LAB VENT HOOD. B. EDC MONITOR FOR LAB.
12. PUMP SEAL LEAKS DOUBLE SEAL SYSTEM.
13. VALVE PACKING LEAKS CHANGE SPECS TO ORBIT VALVES.
14. FUGITIVE LEAKS A. AREA EDC MONITOR B. HAND HELD EDC MONITOR.
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AGENDA FOR FIRST EDC TPEL TEAM MEETING
J I. INTRODUCTION - F. ORTIZ/R.WILUAMS/APLAUCHE
Regulations Reason for team being formed ^II. STATUS OF WORK DONE TO DATE - N. PEREZ/J. STEPHENSON
J EL DEVELOP A TEAM CONTRACT
J IV. OVERALL PROJECT SCHEDULE
V. DISCUSSION/BRAINSTORM OF NEW CONCEPTS FOR PHASE II
Steaming - M. Woodyear ' Hot Nitrogen purging - C. LeJeune*"* Vacuum - N. Perez Pigging Water-washing Nitrogen purging
VL ACTIVITY LIST DISCUSSION
Main Categories:
**
Revise Scope & Schedule Develop Gearing Concepts Categorize Equipment Preliminary Sketches & Flowsheets Match Gearing Concepts to Categories Material & Energy Balances Determining When Equipment is Geared Disposal of Rinse or Flush Materials Test Concepts Mark-up Existing P&ID's Design New Equipment/Equip Spec Sheets Finalize Gearing Procedures for Categories Prepare Process Design Package
VIL MAKE ASSIGNMENTS
Vm. SCHEDULE NEXT MEETING AND MAKE AGENDA
10 min. 10 min. 10 min. 5 min. 15 min.
60 min.
5 min. 5 min.
SL 087875
PROPOSED TEAM CONTRACT FOR P-3097
1. Each meeting is to have an agenda with time limits. Agenda to be included in minutes
of previous meeting.
2. Each member to come prepared to the meetings.
3. Meetings to not exceed 1-1/2 hours.
4. Hold meeting as scheduled.
5. Start and end on time.
6. Meeting shall be held if proper members are present in lieu of quorum.
7. Rotate scribe, timekeeper, and secretary.
8. Timekeeper to be merciless.
9. Deal only with P-3097 issues.
10. One person speaks at a time.
11. Leader is to insure that each member has an opportunity to express their views.
12. No personal attacks or arguments.
13. Attempt to reach consensus. Vote only as a last resort
14. All ideas are good ones.
15. Pagers are to be turned down to lowest volume. - .
16. Use TQ methods on problem solving. 17. Distribute assignments equally to all members.
>*
18. Contract is amendable.
19. P&ID revisions based on majority. Those not present will initial revisions or may raise
objections to be discussed at the next meeting.
20. No update during the meeting for those who are late. (No rehash)
21. Minimize design in the meeting. If excessive time is being spent on a subject, it should
be tabled or an agreement reached to tum entire remainder of meeting to subject.
22. Meeting to start on time as soon as "quorum" is present
23. A person will be assigned to update P&ID's and maintain logbook. (Assignment will
rotate as with timekeeper, scribe, and secretary.) 24. Mgetin^s wijl be held on Wednesdays at lftOO A^fl.
25. Meetings will consi&^of'two"parts; a) Status report and^ b) Results of design work.
26. Minutes to be issued by Thursday morning.
^
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S'78'7'7
$ vfD^'
P-3097 EDC IPEL PROJECT SCHEDULE
2--91 4-91 ` 6-91 8-91 10-91 12-91 2-92 4-92 6-92 8-92 10-92 12-92 cfi
2/91 MEW
P-3097 PRE-ACT SCHEDULE
20 27 6 3 10
PROJECT LOGISTICS SCOPE Sc SCHEDULE DEVELOP CLEARING CONCEPTS CATEGORIZE EQUIPMENT SKETCHES Sc FLOWSHEETS MATCH CLEARING CONCEPTS TO CATEGORIES
MAT'L Sc ENERGY BALANCES DETERMINE METHOD TO TELL WHEN EQUIP IS CLEAR
ENVIRONMENTAL IMPACT
TEST CONCEPTS
ECONOMICS MARK-UP EXISTING PAID'S
DESIGN NEW EQUIPMENT FINAL CLEARING PROCEDURES
FINISH PROCESS PACKAGE PREPARE ACT PROJECT STUDY Sc EST. ENGAGE OUTSIDE ENGINEERING
2/91 MEW
III
Revised 2/15/91
ACTIVITY LIST FOR P-3097 NEW EDC AND VOC EXPOSURE LIMITS
------------------------------------------------------------------------------------------------------------------------------------------- --
Abbreviations for the team members are:
Craig Davis Max Hekmat Mike Huber Craig LeJeune Vern Morgan
CD MJH MKH
CL VM
Francisco Ortiz FO
Ernie Parsons EP
Andy Plauche' AP
Ismael Perez
IP
Nelson Perez
NP
Art Reinhardt Johnny Stephenson Ron Williams Mark Woodyear
AR JS RW MW
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I. PROJECT LOGISTICS
Required
Responsible Completion
Individual(s)
Date
1. Determine team meeting frequency. 2. Select and schedule meeting room. 3. Select and set-up file/drawing room.
II. REVISE SCOPE AND SCHEDULE
ALL MW CL
2/18*^* 2/19--' 2/25
1. Issue Scope for Phase II.
NP By
a) Establish a design basis. The guideline
Second
is to clear equipment as fast as or faster
Meeting
than is done currently.
a) Review with Operations/Maintenance.
b) Obtain approval from all Area Supervisors
(including Maint.), Environmental, Industrial
Hygiene, and Dick Holliday.
c) Send copy to White, Samelson, Graybill, and
possibly others in GO.
2. Prepare Project Schedule.
JS Done
3. Develop abstract of the regulations.
%***/It**h ^***---*
4. Put this activity list in timeline.
' Js'
2/28
11L., DEVELOP. CLEAR I Mg CONCEPTS
3/11
1. Brainstorm additional concepts and develop list. Some concepts are: a) Steam Stripping b) Hot Nitrogen Purging c) Vacuum d) Pigging e) Water-Washing f) Nitrogen Purging
ALL 2/18-
MW/?
3/11
CL/?
3/11
NP/i!** 3/11 3/11
?. ?
3/11 3/11
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087879 SL
g) Freezing solids and liquids h) others i) ? j) ?
For each concept:
1. Determine possible applications.
2. Drav Sketch and develop preliminary procedure to illustrate the use of the concept.
3. Evaluate Feasibility.
a) Technical b) Economic c) Constructability
4. Discuss with Operators/Operations and Maintenance and obtain input.
5. Evaluate Results.
^^
^i f
j*
(Note - The responsible individual(s) for items 1-5 is as listed for each concept above.)
3/11 --
3/11 3/11 3/11
3/11 3/11
IV. CATEGORIZE EQUIPMENT
1. Make a list of Equipment for each unit and
determine Equipment Ratings (press/vacuum and temp).
2. Brainstorm categories and develop an equipment
list for each. Some categories are:
a) Equipment rated for a full vacuum. b) Pressure Vessels.
M
c) Atmospheric Vessels.
d) Temperature Rating.
e) Frequency of clearing or opening to the atmosphere.
f) others
9) ? h) ?
3. Verify Equipment integrity.
V. PRELIMINARY SKETCHES ANJ2. FLOWSHEETS
1. Make generic sketches for each equipment type. 2. Develop Process Flow Diagrams (PFD). 3. Develop Preliminary P&ID's (new ones).
VI. MATCH CLEARING CQMCEPTS Ifl. CATEGORIES
1. Schedule and conduct meeting to discuss best alternatives.
2. Analyze clearing concepts and category for each piece of equipment.
3. Determine clearing parameters (temp/time/vac) for each piece of equipment.
4. Develop implementation strategy.
2/25 NP/CL/MW 3/4
Operations 3/4 4/1
3/13
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SL 087880
a) How many clearing units? b) Where located?
c) Mobile or permanent installation? 5. Determine owner/manager/maintainer of mobile
equipment.
type
VII. MATERIAL AND ENERGY BALANCES
1. Establish a design basis. 2. Determine where needed. 3. Utilize ChemCad when necessary. 4. Apply material and energy balances to clearing
concepts and include in PFD's.
VIII. DETERMINE METHOD OF TELLING WHEN EQUIPMENT
IS. CLEARED Given: sampling is required to verify that a
piece of equipment contains less than 1 PPM EDO or VOC.
..
1. Brainstorm methods.
2. Evaluate methods for VC and Chlorine. 3. Determine where to sample. 4. Determine how to sample. 5. Evaluate sampling techniques that can be done
by operations. 6. Develop or update SOPs for equipment cle'axing.
IX. ENVIRONMENTAL
1. Interact with Environmental Department. 2. Conduct testing of present water-washing. 3. Evaluate re-use of flush water. 4. Evaluate the affect in WTU and design
equipment or change concepts.
X. TEST CONCEPTS
1. Determine a specific piece of equipment to / test in each category. J2. Obtain and Look at outage schedules. 3. Evaluate needed test equipment and procure. 4. Decide on procedure anddevelop
schedule. Design Experiments/Testing Methods, Locations, and Timing. 5. Make a sampling program and execute. 6. Collect data andevaluate results. 7. Determine charge number and fund resource.
XI. ECONOMICS
1.Compare current clearing time to new clearing
VM
Page 3 of 5
Si *788i
3/18
4/15
4/29
4/15 3/4 2/27 3/11 3/18 4/15 2/21 5/13 4/22
time for each piece of equipment. May have a return if the new clearing time is shorter than the current clearing time. 2. Assess the positive economic impact in on-stream time by unit by product line. 3. Determine the operating cost increase of:
a) utilities b) maintenance c) manpower. 4. Determine capital cost in matrix form as follows: a) Total cost for Derivatives. b) Cost by product line. c) Cost with and without solvents. d) Cost of EDC IPEL only. e) Cost of VOC regulation only.
XII. MARK-UP EXISTING P&ID'S
1. Develop a management procedure for drawings. 2. Determine needed drawings. 3. Get the prints. 4. Develop a logbook to keep track of drawings. 5. Engage project engineering and drafting. 6. Learn the fileroom Drawing system. 7. Develop a new equipment numbering system. 8. Team to check final P&lD's for completeness.
XIII. DESIGN NEW EQUIPMENT AND COMPLETE EQUIPMENT SPEC SHEETS
1. carbon beds. 2. Nitrogen heater(s). 3. Vacuum pump(s). 4. Steam Condensers. 5. Water vessels (portable). 6. Water Tanks. 7. Equipment for Pigging lines. 8. Pipe sizing. 9. Look at existing systems ability to handle
changes (vent headers/incin/wtu). 10. Blowers. 11. Mobile clearing units (self-contained). 12. Pumps. 13. Compressors. 14. Make new equipment list. 15. Team to check specification sheets for
completeness.
XIV. FINALIZE CLEARING PROCEDURES FOR CATEGORIES
1. Evaluate alternatives. 2. Develop and finalize written procedures. 3. Review with operations and maintenance.
4/24 4/30
4/15 2/28 2/28 2/18 4/15
2/18 4/29
Page 4 of 5
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XV. PREPARE PROCESS DESIGN PACKAGE
1. Finalize subheadings for the manual and appendices. Book I - Report (Articulated Text) Table of Contents Abstract Justification Project Overview Discussion of the EDC IPEL and VOC Project Energy and Material Balances Discussion of PFD's and P&ID's Equipment Design Additional considerations Environmental Regulations Authors Book II, III, etc. - Appendices Process Flowsheets Design Basis Material and Energy Balances Process Descriptions) Clearing Procedures Equipment List Equipment Design Process Spec, sheets Pipeline Sizing P&ID's PFD/P&ID Revision Logbook Economics Correspondence Meeting Minutes
2. Co-ordinate the secretarial duties. 3. Co-ordinate the manual development as
the project progresses.
XVI. PREPARE ACT
XVII STUDY AND ESTIMATE PHASE
XVIII. CONTRACT ENGINEERING
1. Consider engaging Process Engineering Contractor. 2. Engage Project Engineering Contractor.
5/13 2/28
5/13 5/13
7/1 7/1 1 FO 3/18
5/6
Page 5 of 5
SL 087883
P-3097 MEET EDO EXPOSURE REGULATIONS MEETINGS RESPONSIBILITIES
MEETING # 1 2 3 4 5 6 7 8 9
10 11
SECRETARY MW CD
MJH MKH
CL PO EP AP
IP NP AR
SCRIBE CL FO EP AP IP NP AR MW CD
MJH MKH
TIMEKEi NP
AR MW CD MJH
MKH CL
FO EP AP IP
SL 87884