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ABD00211503 COMPLIANCE PLAN CAPITAL ITEMS REACTOR VALVE LIMIT SWITCH REPLACEMENT ABERDEEN CHEMICAL PLANT August 6, 1985 WORK BY: Frank G. Jeanson Process Engineer REVIEWED AND APPROVED BY: Veldon E. Messick Chief Process Engineer ABD00211504 COMPLIANCE PLAN CAPITAL ITEMS REACTOR VALVE LIMIT SWITCH REPLACEMENT ABERDEEN CHEMICAL PLANT TABLE OF CONTENTS I. PURPOSE AND PROCESS DESCRIPTION II. INSTRUMENT SPECIFICATIONS III. DRAWINGS ABD00211505 COMPLIANCE PLAN CAPITAL ITEMS REACTOR VALVE LIMIT SWITCH REPLACEMENT ABERDEEN CHEMICAL PLANT I. Purpose and Process Description The purpose of this design is to provide the valves on the reactors and charge systems with accurate indication in the control room of the valve position. The existing limit switches do not provide this accuracy, since they are -operated by the position of the actuator and not the actual valve stem. This type of operation does not take into account the possibility of shearing between the valve stem and actuator, which has occurred here in the plant. This poses a potentially hazardous situation for a VCM release. This design will provide each of the designated valves on the reactors and charge systems with a new limit switch that operates on the position of the valve stem. These new limit switches will provide accurate indication in the control room and eliminate the hazard of a valve being open when it's actuator position is showing closed. A total of 107 valves will be equipped with this new type of limit switch. These limit switches will be mounted on the bracket between the valve and the actuator. Drawings of several different types of valves with the new limit switches are attached. Table I lists the valve location and manufacturer. Table II lists the different types of valves, quantity of each and actuator type. ABD00211506 TABLE I Reactor 745 + 700 600 + 500 600 500 400 Valve Location Size VCM Charge VCM Charge Chem Wash Rtm. Hot H2O Charge Sewer Dump 6" 6" 6" 6" 6" 6" Evacuation Recovery Evac./Rec. Vent 8" 6" 8" 4" VCM Charge VCM Charge Chem Wash Return Hot H2O Charge Sewer Dump 6" 6" 6" 6" 6" 6" Evacuation Recovery Evac./Rec. Vent 6" 6" 6" 3" Vent 3" VCM Charge 6" VCM Charge 6" Chem Wash Rtrn, 6" Hot H2O Charge Sewer Dump 6" 6" 6" Evacuation Recovery Evac./Rec. Vent 6" 6" 6" 3" 300 VCM Charge 6" VCM Charge 6" Chem Wash Return 6" Hot H2O Charge 6" Sewer 6" Dump 6" Manufacturer TuFline (Plug) 300 TuFline (Plug) 300 Jamesbury (Ball) TuFline (Plug) 150 Jamesbury (Ball) Jamesbury (Ball) TuFline (Plug) 150 TuFline (Plug) 150 TuFline (Plug) 300 TuFline (Plug) 300 TuFline (Plug) 300 TuFline (Plug) 300 KTM E0106 (Ball) TuFline (Plug) 150 TuFline (Plug) 150 WKM 6FBI12 (Ball) TuFline (Plug) 150 TuFline (Plug) 150 TuFline (Plug) 300 WKM (Ball) 3RB100 TuFline (Plug) 300 TuFline (Plug) 150 TuFline (Plug) 150 WKM (Ball) 6FB123 Module 310C TuFline (Plug) 150 Durco (Plug) 6411 WKM (Ball) 310 TuFline (Plug) 150 TuFline (Plug) 150 Jamesbury (Ball) WKM (Ball) 3RB100 310C TuFline (Plug) 150 TuFline (Plug) 150 KTM (Ball) E0106 TuFline (Plug) 150 TuFline (Plug) 150 WKM (Ball) 6FBI12 310 B ABD00211507 Reactor Valve Location Size Evacuation Recovery Evac./Rec. Vent 6" 6" 6" 3" 744 743 742 +741 VCM Charge 6" VCM Charge 6" Chem Wash Rtm. 6" Hot H^O Charge 6" Sewer 6" Dump 6" Evacuation Recovery Evac./Rec. Vent Charge System 6" 6" 6" 3" New Module Charge Pumps Suction 8" Discharge 6" Old Module Charge Pumps Suction 8" 8" Discharge 6" 6" Manufacturer TuFline (Plug) 150 TuFline (Plug) 150 TuFline (Plug) 300 TuFline (Plug) 300 Durco (Plug) 6411 TuFline (Plug) 150 WKM (Ball) 6F-B130 310B WKM (Ball) 6X4-B102 WKM (Ball) 6X4-B102 WKM (Ball) 6F-B112 310B TuFilne (Plug) 150 TuFline (Plug) 150 WKM (Ball) 6RB122 WKM (Ball) 3KB150 WKM (Ball) 8RB10 310 WKM (Ball) 6RB102 TuFline (Plug) 150 TuFline (Plug) 150 Durco (Plug) Fig 0431 TuFline (Plug) 150 ABD00211508 ABD00211509 COMPLIANCE PLAN CAPITAL ITEMS REACTOR VALVE LIMIT SWITCH REPLACEMENT ABERDEEN CHEMICAL PLANT III. Instrument Specification Item PLS-101 through 207 Description Promimity Limit Switches ABD00211510 Pi AMT ITEMNO SERVICE _ p\-- Conoco Inc. Engineering Center Ponca City. Oklahoma SPECIFICATION SHEET ^VNTAUrM I PROJECT , -- \Q\ -r^t~A 3.Q~7 V^- specif ica t ion smcct project no a r i (40 -- - !>Air -- no mi Aur mid mi \w u Y vffc^ P 0 NO __ L. i /v-. *-- ` X r- s\ _ rrc/r ' T /- J gr / - t : /^ / o _ /- ^ . c > Cr\ Lpcar'c).. : 0^ 0r^-oc CT~ a3^v^e^' v^we ^ v o~ ( KoAA Arer ! (oQ <3 r~ Cor^pg`-'-y A' ^ r ; - c lA 7/377V pAvCris-'' i-'<\ 1 /j-MPT oor^A 3. ' a-m r e --~r------------------------------; * c 'r^e1 no^:.i*o y, --' conJ^A i t- Ci (Or'` *S.T" :.mi vk 1? ^ `"3^ , v /,>,e )/\ -- IF aJ F -S'rc^.i- '-'.jxa y 3,3/3 ^ ^ ki 4 44I S L SHEET__________ of REV "T . ./I Series 70 Switch A Rugged and Dependable Line of Totally Enclosed Proximity Limit Switches from General Equipment & Manufacturing Company, Inc. i ;*i'.i i-` ' (; 2#:v.'-, I -M fr* \4r>-- . , If End Cap: .050" Stainless Steel (304) End Cap, available with thicker End Caps for higher pressure. Pressure Options: Normally the standard 5/8" diameter will withstand 2000 PSI. Larger cases with thicker walls and front End Caps will allow the switch to function at much higher pressures (up to 10,000 PSI). Certification available as factory option. Case: 300 Series Stainless Steel case, plain or threaded body (5/8-18 NF). Different body lengths available, SEE options on MODELS AVAILABLE. Magnets: Made with a high energy product magnet. An excellent coercive force which converts into grams of Contact Pressure for reliable operation. Meets MMPA Specifications. External Threads: Machines to meet SAE 5/8-18 UNF Specifications. Units available with or without threads. Contacts: Type Silver, Cadmium Oxide, resists welding and is some of the most widely used Contact Material in the industry. Sized to withstand approved ratings. Hermetically Sealed Contact Chamber. Bearing: Consists of a finely around Stainless Steel Pin and durable plastic housing. Sized to withstand a wide temperature range. Resists seizing and gives millions of free operations. Potting: Terminal cavity filled with epoxy resin com pound for sealing and mechanical support of wire/ cable connections. Body Tube: Made of Free Mechanical Stainless Steel. Resists most all harsh environments and withstands high working pressures. Impervious to water, oils and gases. Internal Threads:1/2-14 NPT. complies with CSA requirements for Explosion Proof Applications. Wire or cable leads available to meet Customer's Specifications. ABD00211513 >. When time, accuracy, and dependability count... you can count on the 70 Series GO Switch. ' Maintenance free; engineered for precision, performance and reliability. --\ The standard 70 Series GO Proximity Limit Switch has been designed and built to rugged specifications for use in most industrial and environmental applica tions. Each switch is totally enclosed, hermetically sealed and capable of operating in hostile environments. The standard stainless steel housing is impervious to oils, caustic acids, water laden areas and most Standard Models atmospheric conditions, with a broad operating temperature range. (See specification) Many different models of the switch are available for your design needs. (See ordering information for specifications, detail and options.) Hazardous Location approved models for Class I, Division 1, All Groups Model 713360 No conduit connection, 18" 3 conductor cable with water resistant squeeze connection, type 300 stainless steel housing with 56-18 NF x 1.5" threads with 2 lock nuts. Model 713570 A NPT conduit outlet, 18!' 3 conductor cable, type 300 stainless steel housing with 56-18 NF x 2.813" threads with 2 lock nuts. Model 713524 Yt NPT conduit outlet with 18" potted, 3 conductor cable, type 300 stainless steel housing, no threads. UHMMiliMUtin Model 713420 No conduit outlet, 18" potted, 3 conductor cable, type 300 stainless steel housing; no threads. Model 713660 No conduit outlet, 18" potted. 3 wire leads, type 300 stainless steel housing with 56-18 NF x 1.5" threads with 2 lock nuts. Model 713564 Yt NPT conduit outlet with 18" potted, 3 conductor cable, type 300 stainless steel housing with 56-18 NF x 1.5" threads with 2 lock nuts. iMnMtMUitllilUltilliMUtUUiiMlinw Model 713460 No conduit outlet, 18" potted. 3 conductor cable, type 300 stainless steel housing with 56-18 NF x 1.5" threads with 2 lock nuts. Model 713720 A NPT conduit outlet with 18" potted, 3 wire leads, type 300 stainless steel housing, no threads. Model 713574 A NPT conduit outlet with 18" potted. 3 conductor cable, type 300 stainless steel housing with 56-18 NF x 2.813" threads with 2 lock nuts. Model 713520 A NPT conduit outlet, 18" 3 conductor cable, type 300 stainless steel housing, no threads. Model 713760 A NPT conduit outlet with 18" potted, 3 wire leads, type 300 stainless steel housing with 56-18 NF x 1.5" threads with 2 lock nuts. Model 713724 A NPT conduit outlet with 18" potted, 3 wire leads, type 300 stainless steel housing, no threads. WIIOIIlMlWMiltMIfa Model 713560 Vj NPT conduit outlet with 18" 3 conductor cable, type 300 stainless steel housing with 56-18 NF x 1.5" threads with 2 lock nuts. Model 713770 'A NPT conduit outlet, 18" potted 3 wire leads, type 300 stainless steel housing with 56-18 NF x 2.813" threads with 2 lock nuts. Model 713764 A NPT conduit outlet with 18" potted, 3 wire leads, type 300 stainless steel housing with 56-18 NF x 1.5" threads with 2 lock nuts. Approved switches are in compliance with current bulletins 1243.1273 and 1308. Model 713774 A NPT conduit outlet with 18" potted. 3 wire leads, type 300 stainless steel housing with 54-18 NF X 2.813" threads. These switches are U/L and CSA approved for industrial control, general purpose use. See hazardous location approved models in Column 3, this page. ABD00211514 TOLERANCES Untoca otharwiM tpactfiad Angle* 1*. Fraction* 1/3T, XX .01*. JCXX 005 Surtecaa must ba Concentric, PeraDel. Flat A Square (aa applicable) to each othar withinT.l.R. NO. REVISION 0ATE BY APPO. MATERIAL LIST Description________ Dwg. No, Switch Activator V126411-1943 Mounting Bracket V126411-1944 1/4-20 x 1/2 Hex Hi. Screw 1/4 L.W. 5/8 Shakeproof L.W. 5/8 F.W. (1-5/16" O.D.) FIG. 2 INSTALLATION INSTRUCTIONS 1. Disassemble Actuator and Coupling from Valve and remove existinq pointer. 2. Slide Switch Activator (item 1) onto drive shaft. 3. Drill and Tap Actuator Mtg. Brk't. for 1/4-20UNC screws and attach Mount ing Bracket (item 2) with items 3 & 4. 4. Mount QO Switches in Mounting Bracket (item 2) with two jam nuts supplied with switch and washers items 5 & 6. 5. Adjust Switches in slots on Mounting BRacket (item 2) to sense Switch Activator (item 1) in full open and full closed positions. Note: 1. 00 Switches are not included in V.I.P. (Valve Indication Package) and should be orderec separately. 2. Use Model 713774 GO Switches. DWN. BY RON S. CHK. BY APPO. DATE 9-28-03 SSmTAnSmmw STTSJpiU<Sc*. mm. * 76 7 Bi/c 70 SERIES GO SWITCH V.I.P. ON DURC0 6" 150# G411 Valve WITH BETTIS ACTUATOR FOR CONOCO GENERAL EQUIPMENT A MANUFACTURING CO . INC. *K0 FERN VALLEY ROAO , p.o. sox into ________ - LOUISVILLE. KENTUCKY. USA.40233 SYSTEMS ~ (902) m+2m. TWXI10436-27K owd. NO. V126411-1942 REV. ABD00211515 TOLERANCES Untett otherwise specified Anflles: 1*. Frictions; 1/32". .XX .01". .XXX .005" Surfaces must be Concentric. Parallel, Fist & Square (ss applicable) to each other within T.I.R. ACTUATOR MOUNTING BRACKET NO. REVISION OATE BY APPO. ' Item Qty. 11 21 31 44 54 62 72 MATERIAL LIST Description Mg. No. Switch Activator V907310-1951 Mounting Bracket V907310-1952 Set Screw #12-24 x 1/4 1/4-20 x 1/2 Hex Hd. Screw 1/4- L.W. 5/8 Ext. Tboth L.W 5/8 F.W. GO SWITCH ACTUATOR MTG. BRKT. DRILLS TAP 2) 1/4-20 UNC (4) HOLES GO SWITCH DRIVE SHAFT INSTALLATION INSTRUCTIONS 1. Remove Actuator, Coupling and Existing position indication plate. 2. Slide Switch Activator )item 1) onto drive shaft and secure with set screw (item 3). 3. Assemble GO Switches to Mounting Bracket (item 2) with Jam Nuts supplied with switches and washers items 6 & 7. 4. Place Switch mounted on bracket on sides of Actuator mounting bracket and align switch with Activator (item 1) then natch drill Actuator mounting bracket with holes in Mounting Bracket (item 2). Secure' with items 4 & 5. 5. Switches should sense Switch Activator when Valve is in full open and full closed positions. FIG. 2 NOTE: GO Pitches are not included in V.I.P. (Valve Indication Package) and should be ordered as a Separate item. OWN. BY RON S. CHK. BY APPO. fit* ' & (/ OATE I0-5-83 70 SERIES GO SWITCH V.I.P ON W-K-M 310 BALL VALVE \+'' FOR CONOCO SmmS iwSSSm?*M<r GQGENERAL EQUIPMENT & MANUFACTURING CO.. INC. 3300 FERN VALLEY ROAD P.O.BOX 37200 _ __ LOUISVILLE. KENTUOKY. USA. 40233 SYSTEMS (502) 900-23B6. TWX 110-636*2736 |||| DWG. NO. REV. V 907310-1950 * ABD00211516 Anyfes: I*. Fraction*: t 1/32". XX .01". .XXX .005" Suritctt must b Concsnlrtc. PsrsUel. Fist & Square (as sppUcsWt) to each other wltnin T l.R NO REVISION OATE BY APPO actuator MOUNTING BRACKET Item Qty. 1I 21 31 44 54 62 72 MATERIAL LIST Description Dwg. No. Switch Activator V907310-1955 Mounting Bracket V907310-1954 Set Screw 112-24 x 1/4 1/4-2C x 1/2 Hex Iti. Screw 1/4- L.W. 5/8 Ext. Tooth L.W 5/8 F.W. 5% GO-.' SWITCH ACTUATOR MTG. BRKT -GO SWITCH DRILL ft TAP 1/4-20 UNC FIG. 2 INSTALLATION INSTRUCTIONS 1. Remove Actuator, Coupling and Existing position indication plate. 2. Slide Switch Activator (item 1) onto drive shaft and secure with set screw (item 3). 3. Place Mounting Bracket (item 2)onto Actuator Mtg. Brk't. and mark position of two holes. Drill and tap for 1/4-20 UNC holes. Secure Mounting Bracket (iter (item 2) with items 4 & 5. 2) 4. Screw GO Switches into Mounting Brk't. (item 2) till Gap between end of switch & Switch Activator (item 1) is approx. 1/16". Secure with Jam Nuts that are included with pitches 'and with washers (items 6 & 7). 5. Switches should sense Switch Activator when Valve is in full open and full closed positions. NOTE: GO Switches are not included in V.I.P. (Valve Indication Package) and should be ordered as a Separate.item. OWN. B/Y/9fi- H ?// 7 S OATE V RON S. CHK. BY JO- 70 <?</ 76 V SERIES GO SWITCH ON V.I.P. APPO. W -K-M 310 BALL VALVE 6" FOR CONOCO wmtmm*M* *. GQGENERAL EQUIPMENT & MANUFACTURING CO.. INC 3300 FERN VALLEY AOAO P.0 BOX 37200 .______ _ LOUISVILLE. KENTUCKY. USA 40333 SYSTEMS (502) W0-23M. TWX I10433-37M MIMMt OWG. NO. REV. V 907310-1953 ABD00211517 TOLERANCES Unleu otherwise specified Angles: 1\ Frctlors: 1/32". JCX .01". JCXX .005" Surfaces must be Concentric, Parallel. Flat & Square (as applicable) to each other within T.I.R. NO. REVISION DATE BY APPO. MATERIAL LIST Item Qty .1 Description Dwo. No 1 1 Switch Activator V4Q280Q-1948 2 1 Mounting plate V402800-1 949 3 3 #10-24 x 1/2 Rd. Hd. Screw 4 3 #10 Ext. Tooth L.W. GO SWITCH (OPEN) MATCH DRILL FOR THREE 10-24 UNC-28 THREADED HOLES ACTUATOR MTG. BRKT. GO SWITCH (SHUT) INSTALLATION INSTRUCTIONS 1. With Valve Actuator removed slide Switch Activator (item 1) onto drive shaft as shown in figure 1. To Mount Mountinn Bracket (item 2) match drill and tan for three #10-24 UNC screws and attach item 2 to Actuator mountinn bracket with items 4 & 5. Screw GO Switches into threaded holes on Mounting Bracket (item 2) and secure with jam nuts included with Switches . Adjust Switches to sense triangular bars on Switch Activator when Valve is in full open or full closed positions. GOv $WITCH-\ l 3 JAM NUT FIG. 2 FIG. 3 OWN. BY RON S. CHK. BY / OATE 10-3-63 APPD. Nonet owa*MW S'HMiiwar .2 660.. 70 SERIES GOSWITCH V.I.P. ON KTM 6" VALVE E0800 WITH JAMESBURY ACTUATE FOR CONOCO GQGENERAL EQUIPMENT & MANUFACTURING CO.. INC. 3300 FERN VALLEY ROAD P.O.BOX 37290 ^_______ ___ LOUISVILLE, KENTUCKY. USA 40233 SYSTEMS (502) 909-2304 TWX 810-436-2780 MBUI DWG. NO. REV. V402800-I947 ABD00211518 TOLERANCES ItateM OthwwtM apqctfitd AngMC V, Fraction* 1/3T. -XX .01". .XXX .005' Surtacm must be Concentric, ParaDai. Flat ft Square (as apptteablt) to aaeft othar wrtthtn T.I.R. MATCH DRILL SHAFT J29 TO .129 DtA X 3/0 OCEP ORILL a TAP SHAFT FOR \ I/4-20UNC NO. REVISION OATE BY APPO. MATERIAL LIST Item Qty. Description Dwg. No. 1 1 Mounting Bracket V782067-1935 2 1 Switch Activator V782067-1936 3 1 Rollpin 1/8 x 1/2"long 4 1 1/4-20. x 5/8 Flat m. Screw 5 4 1/4-20 x 3/4 Hex Hd. Screw 6 4 1/4 L.W. 7 2 5/8 Ext. Tboth L.W. 8 4 5/8 F.W. (1-5/16 O.D.) SWITCH ORILL a TAP (4)HOLES 1/4-20 UNC x 9/16 DEEP ACTUATOR SWITCH INSTALLATION INSTRUCTIONS 1. Remove Valve Actuator and Coupling from Valve. 2. Machine notch in coupling to 7/8" depth as indicated in view A-A. 3. Drill & tap top of shaft for 1/4-20UNC x 1/2" deep hole. 4. Place Switch Activator (item 2) on shaft and secure with flat head screw (item 4) Then orient Switch Activator as shown in figure 1. >fatch drill shaft with hole in Switch Activator and drive rollpin (item 3) into hole to prevent rotation. 5. Fit Mounting Bracket (item 1) to sides of'Actuator mounting plate support and rark location of four mounnting holes, drilj, and tap four 1/4-201KC x 9/16 dp. Then secure Mounting bracket (item 1) with items 5 fc 6. 6. Insert 00* Switches into slots on Mtg. Bracket (item 1) and secure with two jam nuts that ocme with switches and washers items 7 & 8. 7. Mjust Switches to sense Activator (item 2) in full open and full closed positions. OWN. BY RON 9. ONK.OV StSagSsss. .ESssn&l .11 n5 ? FIG. 2 / 4,^ GENERAL EQUIPMENT 70 SERIES GO SWITCH V.I.P. A MANUFACTURING CO., MC. mm mm vaulkv road ON TUFLINE 067 6" PLUG VALVE P.O. SQM SM lOUOWUf. KOTUCKY. USA. VALVE SHAFT ^ (MR m MM. TWX HMWM , INDICATION tmm----------------------- V782067-1934 % m ABD00211519 TOLERANCES UfifeM otfwrwtM p*cffld Anglw r, Fraction* 1/3Y, XX .01". .XXX .005" SuftoCM mu*t b* Conoantrtc, PtrtiW. FM 4 Square (aa appdoabia) to aacft othar within T.l.fl. MATCH DRILL SHAFT J23 TO .129 DIA. X 3/0 0EEP-! , fORILL 8 TAP SHAFT FOR 1/4-20 UNC NO. REVISION OATE BY APPO. MATERIAL LIST Item Qty. Description Dwg. No. 1 1 Mounting Bracket V782067-1935 2 1 Switch Activator V782067-1936 3 1 Rollpin 1/8 x l/2"long 4 1 1/4-20. x 5/8 Flat Hd. Screw 5 4 1/4-20 x 3/4 Hex H3 . Screw 6 4 1/4 L.W. 7 2 5/8 Ext. Tboth L.W. 8 4 5/8 F.W. (1-5/16 O.D.) DRILL 8 TAP (4)H0LES 1/4-20 UNC * 9/16 06EP INSTALLATION INSTRUCTIONS 1. Renove Valve Actuator and Coupling frcsn GO SWITCH FIG. 1 GO SWITCH Valve. 2. tochine notch in coupling to 7/8" depth ACTUATOR COUPLING as indicated in view A-A. 3. Drill & tap top of shaft for 1/4-20UNC x 1/2" deep hole. 4. Place Switch Activator (item 2) on shaft and secure with flat head screw (item 4) Then orient Switch Activator as shown in figure 1. ftetch drill shaft with hole in Switch Activator and drive roll pin (item 3) into hole to prevent ACTUATOR ( 2 i MTG. PLATE rotation. 5. Fit Mounting Bracket (item 1) to sides of Actuator mounting plate support and nark location of four mounnting holes, drilj, and tap four 1/4-20UNC x 9/16 dp. Then secure Mounting bracket (item 1) with items 5 6 6. J; VALVE- rrni i y.V;K-/ y.\ ^\ii rm --J . j (-- 6. Insert GO Switches into slots on Mtg. Bracket (item 1) and secure with two jam nuts that ocxne with switches and washers items 7 & 8. 7. Adjust Switches to sense Activator (item 2) in full open and full closed 1__\. positions. EISl-2 OWN. BY RON S. out BY Amo. DAfi~~ 9-12-63 GENERAL EQUIPMENT 70 SERIES GO SWITCH V.I.P. 4 MANUFACTURINQ CO.. INC. an NAN VM1CY ROAD ON TUFLINE 067 6" PLUG VALVE po. soKsnm VALVE SHAFT ^ ILOUMUC. MNTUCKV. USA. 4001 mimtm. vta mms SaaCwSvwSiSr" , INDICATION DWO.NO. ...... V782067-1934