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VCM TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
CLASS "A" DESIGN JANUARY 09, 1992
WORK BY
H. T. Harris Coop Process Engineer
WORK BY
W. B. Genetti coop Process Engineer
REVIEWED BY: R. H. Sneed
VAB.0001106427
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VCM TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
JANUARY 09, 1992
A
I. II. Ill VI. V. VI. VII VIII. IX. X. XI. XII
TABLE OF CONTENTS
PROBLEM DEFINITION PROJECT DESCRIPTION JUSTIFICATION PROCESS DESCRIPTION ECONOMIC EVALUATION SAFETY AND ENVIRONMENTAL EVALUATION EQUIPMENT AND INSTRUMENTATION LIST SPECIFICATION SHEETS PIPING SCHEDULE WORK LIST DCS TIE-IN LIST DCS INTERLOCKS LIST DIAGRAMS
VAB.0001106428
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VCM TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
JANUARY 09, 1992
L. PROBLEM DEFINITION
On several occasions the rail car unloading system has shut down. There has been a catastrophic failure of the compressors causing damage to compressor housing and internals. Most failures have caused some emission of VCM. These failures have been caused by liquid entering the compression chamber or the compressor running above its design conditions.
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VAB.0001106429
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VCM TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
JANUARY 09, 1992
PROJECT DESCRIPTION
This project will install instrumentation for safer operation of the Corken compressors in the VCM tank farm. The instrumentation installed will shut down the rail car unloading system should one of the switches be triggered.
The tank farm instrumentation will include the following:
1. INDIVIDUAL COMPRESSOR SHUT DOWN
A. Low oil pressure switch on each compressor crank case.
B. Low pressure switch on the compressor inlet.
High temperature switch on each compressor
D. High liquid level switch on each compressor knock-out pot discharge line.
ALL COMPRESSOR SHUTDOWN
A. High pressure switch on each compressor
B. High high level switch on VCM storage sphere knock out pot.
C. Interlocks with existing instrumentation: 1. Sphere isolation valve. 2. Sphere deluge system. 3. Rail car deluge.
Each of the above switches will provide an input to the DCS. The DCS will also be responsible for providing the output for energizing the compressors. Software can be easily implemented for interlocking the above compressor shut downs.
*
VCM TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
JANUARY 09, 1992
III. JUSTIFICATION
Installing supplementary instrumentation and alarms in the tank farm will decrease the hazards associated with the unloading of liquid VCM rail cars. The end result of every malfunction of the unloading system is a VCM leak. It is necessary to know where the source of the malfunction came from and that the system will be shut down once a malfunction has occurred.
This safety and health project will reduce the possibility of a compressor shutting down and the system continuing to run and cause a VCM leak.
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VAB.0001106431
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VCM TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
JANUARY 09, 1992
VI. PROCESS DESCRIPTION
The existing high temperature switches, TSH-(105-110),
will be tied into the DCS (see P&I diagram) .
The
individual compressors will be shut down at 340 degrees
F.
Compressors CP-(102-105) have existing low pressure switches on their discharge line. These switches, PSL(107-110), will be moved to the inlet line of the compressor. A low pressure switch, PSL-106, will be installed on CP-101. The switches will be tied into the DCS. The DCS will shut down the individual compressor at
The existing high pressure switch, PSH-106, on the emissions recovery system (ERS) knock-out pot, will be tied into the DCS. All compressors will shut down when the ERS pressure reaches 75 psig.
High temperature switches, TSH-(101 and 105), will be installed on the discharge of compressors, CP-101 and CP105. The other compressors have existing switches, TSH(102-104) . These switches will be tied into the DCS. The individual compressors will be shut down at 230
High liquid level switches, LSH-(101-105), will be installed on the discharge line of the compressor knock out pots. These switches will be tied into the DCS. The DCS will shut down the individual compressor when a high level of liquid VCM is detected (see DCS interlocks list).
Low pressure switches, PSL-(101-105), will be installed on each compressor crank case. These switches will be tied into the DCS. The individual compressors will be shut down at 12 psig.
VAB.0001106432
VCH TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
JANUARY 09, 1992
PROCESS DESCRIPTION (Continued..,)
High pressure switches, PSH-(101-105), will be installed on the discharge line of each compressor. These switches will be tied into the DCS. All compressors will be shut down if any of the discharge lines reach 125 psig. A HAZOP of the VCM tank farm determined the flex hoses the weak link in the unloading system. All compressors will be shut down before the flex hoses reach a hazardous
A high-high level switch, LSHH-101, will be installed on an existing nozzle on the sphere knock-out pot. This switch will be tied into the DCS. All compressors will be shut down if high liquid VCM level is detected. This will keep the sphere knock-out pot from overflowing into the compressor inlet.
All switches, both new and existing will be tied into DCS (see DCS tie-in list). A DCS controller card and three additional TRIO blocks will be purchased, as part of this project, to handle the 32 additional discreet inputs and 5 additional decreet outputs that must be tied into the DCS. A VCM unloading graphic will be created. The switches will generate alarms on the DCS when engaged. These alarms will be included in the ladder logic for energizing the compressors. This will provide compressor shut downs when the given alarm condition occurs (see DCS interlocks list).
Interlocks with other equipment will be created to shut down the compressors in the following instances:
1. The sphere isolation valve is closed (DCS NUMBER: 00X120).
2. The sphere deluge system is activated (DCS NUMBER: 00HA001).
3. The rail car deluge system is activated (DCS NUMBER: 00HA105) .
VCN TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
JANUARY 09, 1992
VI. PROCESS DESCRIPTION (Continued..J
The vinyl operator will use two-way radios to communicate with the yard operator. Although the compressors will be energized from the DCS, the yard operator will be required to start the compressors from a local hand switch. The compressors' hand switches will be located at the shed.
A drain line, 1-HX-101-N-A2-1, will be run from the vapor
header of the sphere to the ERS knock-out pot. This line
will be used to drain any liquid out of the vapor line
before the compressors are started. This line will be
tied into the vapor header at the existing bleeder valve
west of compressor CP-103.
A check valve will be
installed in this line.
All lines down stream of the new drain line, 1-HX-101-NA2-1, including the compressor knock-out pots and inlets to the compressors, will be heat traced and insulated.
This design will keep the compressors operating within there designed parameters. The compressors will be shut down before serious problems occur.
VAB.0001106434
VCM TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
JANUARY 09, 1992
V, iCONOMIC EVALUATION
This project has a projected cost of $50M - $100M.
VI. SAFETY AND ENVIRONMENTAL EVALUATION
This project will provide a safer operation of the compressors during the rail car unloading procedure. The ultimate result of the project will be a reduced chance for a VCM emission. This provides an added security to plant workers and the community.
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VAB.0001106435
EQUIPMENT AND INSTRUMENTATION LIST
A
LEVEL SWITCHES
LSH-101 |[NEW
LSH-102 |[NEW LSH-10$ NEW LSH-104 NEW
LSH-105 |NEW
lLSHH-101 |NEW
|
1 ULTRA SONIC LEVEL SWITCHES.
1 INDICATE HIGH LIQUID LEVEL IN
i DISCHARGE LINE OF THE COMPRESSOR i KNOCK-OUT POTS.
1 [CAPACITANCE PROBE LEVEL SWITCH. [located IN SPHERE KNOCK-OUT POT.
TEMPERATURE SWITCHES
TSH-101 NEW TSH-102 DciStiHg TSH-103 Easting TSH-104 |EXISTING TSH-166 [NEW
TSH-106 KiSTfRGTSH-107 EXISTING TSH-108 existing TSH-109 |EXISTING tsh-1 io 1 Existing
3 HIGH TEMPERATURE SWITCH forcoKipressor DISCHARGE LINES. SET POINT IS 230 DEGREES F.
3
HIGH TEMPERATURE FOR COMPRESSOR " HEADS. SET POINT IS 340 DEGREES F.
PRESSURE SWITCHES
PSL-101 PSL-102 PSL-103 PSL-104 PSL-105
NEW
NEW
TTew
NEW
NEW
PSL-106 PSL-107 PSL-108 PSL-109 PSL-110
NEw
Allocated RELOCATED AELQCaTed AElocated
PSH-101 PSH-102 PSH-103 PSH-104 PSH-105
nEW NEW NEW NEW
NfW
|PSH-106 |Existing |
2 LOW PRESSURE SWltCH FOR COMPRESSOR 2 CRANK CASE. SET POINT IS 12 PSIG. 2 2 2
2 LOW PRESSURE SWITCHES FOR DISCHARGE 2 OF COMPRESSOR KNOCK-OUT POT. 2 SET POINT IS 8 PSIG. 2 2
2 HIGH PRESSURE SWITCHES FOR 2 COMPRESSOR DISCHARGE LINES. 2 SET POINT IS 125 PSIG. 2 2
PRESSURE SWITCH FOR THE ERS. SET POINT IS 75 PSIG.
DCS HARDWARE
A DCS CONTROLLER CARD WILL BE PURCHASED FOR THIS PROJECT.
THREE ADDITIONAL TRIO BLOCKS MUST BE PURCHASED FOR THIS PROJECT.
VAB.0001106436
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VCM TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
JANUARY 09, 1992
X. WORK LIST
NO VCM UNLOADING SHUT DOWN REQUIRED:
1. Install the controller card and TRIO blocks on the DCS.
2. Create a DCS graphic for VCM unloading. A. Create Alarms for all switches (see DCS tie-in list). B. Create ladder logic for energizing the compressors (see DCS interlocks list).
3. Install wiring between the DCS (vinyl control room) and the compressors and switches.
VCM UNLOADING SHUT DOWN REQUIRED:
1. Install LSH-(101-105) on compressor knock-out pot. A. Connect to the DCS (00LAXX1-5).
2. Install PSL-(106-110) to compressor knock-out pot discharge line. A. Connect to the DCS (00PAX17-21).
3. Connect TSH-(106-110) to the DCS (00TAXX7-11).
4. Install PSL--(101-105) to compressor crankcase. A. Connect to the DCS (00PAX22-26).
5. Install TSH--101 and TSH-105 to CP-101 and CP-105 discharge lines. A. Connect TSH-(101-105) to the DCS (00TAX12-16).
6. Install PSH-(101-105) to the compressor discharge line. A. Connect to the DCS (00PAX27-31).
7. Connect PSH-106 to the DCS (00PAX32).
8. Install LSHH-101 to the sphere knock-out pot (in existing nozzle). A. Connect to the DCS (00LAXX6).
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VAB.0001106440
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VCH TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
JANUARY 09, 1992
WORK LIST (Continued...) 9. Install 1-HX-101-N-A2-1 from the bleeder valve west
of CP-103 to the ERS knock-out pot. 14. Heat trace and insulate all lines from the drain
line 1--HX--101--N-A2-1 to the compressor inlet.
VAB.0001106441
DCS TIE - IN LIST
INPUT
OUTPUT
DSC NUMBER 00LAXX1 00LAXX2 00LAXX3 00LAXX4 00LAXX5
00LAXX6 00TAXX7 00TAXX8
00TAXX9 00TAX10 00TAX11 00TAX12
00TAX13 00TAX14 00TAX15 00TAX16 00PAX17 00PAX18
00PAX19 00PAX20 00PAX21 00PAX22
00PAX23 00PAX24 00PAX25 00PAX26 00PAX27 00PAX28 00PAX29 00PAX30 00PAX31 00PAX32
1 1 1 | |
| |
1 |
1 | | 1 |
| 1 1
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SOURCE
LSH-101 LSH-102 LSH-103 LSH-104 LSH-105 LSHH-101 TSH-106 TSH-107 1 TSH-108 1 TSH-109 1 TSH-110 1 TSH-101 1 TSH-102 1 TSH-103 I TSH-104 1 TSH-105 1 PSL-106 1 PSL-107 1 PSL-108 1 PSL-109 1 PSL-110 1
PSL-101 PSL-102 PSL-103 PSL-104 PSL-105 PSH-101 PSH-102 PSH-103 PSH-104 PSH-105 PSH-106
00HMX33 00HMX34 00HMX35 00HMX36 00HMX37
CP-101 CP-102 CP-103 CP-104 CP-105
VAB.0001106442
DCS INTERLOCKS LIST
ALL COMPRESSOR SHUT DOWN INTERLOCK
A
00PAX27 00PAX28 00PAX29 00PAX30 00PAX31 00LAXX6
00PAX32 00X120 00HA001 00HA105
HIGH DISCHARGE PRESSURE ON CP-101 HIGH DISCHARGE PRESSURE ON CP-102 HIGH DISCHARGE PRESSURE ON CP-103 HIGH DISCHARGE PRESSURE ON CP-104 HIGH DISCHARGE PRESSURE ON CP-105 HIGH LEVEL IN THE VCM SPHERE KNOCK-OUT POT
HIGH PRESSURE IN THE ERS KNOCK-OUT POT SPHERE ISOLATION VALVE CLOSED SPHERE DELUGE SYSTEM ACTIVATED RAIL CAR DELUGE SYSTEM ACTIVATED
CP-101 SHUT DOWN
PSH-101 PSH-102 PSH-103 PSH-104 PSH-105
LSHH-1Q1
PSH-106
00LAXX1 HIGH COMPRESSOR KNOCK-OUT LIQUID LEVEL 00PAX17 LOW COMPRESSOR KNOCK-OUT POT DISCHARGE PRESSURE 00TAXX7 HIGH COMPRESSOR HEAD TEMPERATURE 00TAX12 HIGH COMPRESSOR DISCHARGE TEMPERATURE 00PAX22 LOW COMPRESSOR OIL PRESSURE ALL COMPRESSOR SHUT DOWN ACTIVATED
LSH-101 PSL-106 TSH-106 TSH-101 PSL-101
WHEN ALL ALARMS ARE OFF, DCS WILL ENERGIZE 00HMX33. AN OPERATOR WILL BE REQUIRED TO START CP-101 THROUGH A LOCAL HAND SWITCH.
CP-102 SHUT DOWN
00LAXX2 HIGH COMPRESSOR KNOCK-OUT LIQUID LEVEL 00PAX18 LOW COMPRESSOR KNOCK-OUT POT DISCHARGE PRESSURE 00TAXX8 HIGH COMPRESSOR HEAD TEMPERATURE 00TAX13 HIGH COMPRESSOR DISCHARGE TEMPERATURE 00PAX23 LOW COMPRESSOR OIL PRESSURE ALL COMPRESSOR SHUT DOWN ACTIVATED
LSH-102 PSL-107 TSH-107 TSH-102 PSL-102
WHEN ALL ALARMS ARE OFF, DCS WILL ENERGIZE 00HMX34. AN OPERATOR WILL BE REQUIRED TO START CP-102 THROUGH A LOCAL HAND SWITCH.
* ... *
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VAB.0001106443
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DCS INTERLOCKS LIST
(CONTINUED...)
CP-103 SHUT DOWN
A
OOLAXX3 HIGH COMPRESSOR KNOCK-OUT LIQUID LEVEL _________________ LSH-103
00PAX19 LOW COMPRESSOR KNOCK-OUT POT DISCHARGE PRESSURE PSL-108
00TAXX9 HIGH COMPRESSOR HEAD TEMPERATURE
TSH-108
00TAX14 HIGH COMPRESSOR DISCHARGE TEMPERATURE
TSH-103
00PAX24 LOW COMPRESSOR OIL PRESSURE
PSL-103
ALL COMPRESSOR SHUT DOWN ACTIVATED
WHEN ALL ALARMS ARE OFF, DCS WILL ENERGIZE 00HMX35. AN OPERATOR WILL BE REQUIRED TO START CP-103 THROUGH A LOCAL HAND SWITCH.
CP-104 SHUT DOWN
00LAXX4 HIGH COMPRESSOR KNOCK-OUT LIQUID LEVEL 00PAX20 LOW COMPRESSOR KNOCK-OUT POT DISCHARGE PRESSURE 00TAX10 HIGH COMPRESSOR HEAD TEMPERATURE 00TAX15 HIGH COMPRESSOR DISCHARGE TEMPERATURE 00PAX25 LOW COMPRESSOR OIL PRESSURE ALL COMPRESSOR SHUT DOWN ACTIVATED
LSH-104 PSL-109 TSH-109 TSH-104 PSL-104
WHEN ALL ALARMS ARE OFF, DCS WILL ENERGIZE 00HMX36. AN OPERATOR WILL BE REQUIRED TO START CP-104 THROUGH A LOCAL HAND SWITCH.
CP-105 SHUT DOWN
00LAXX5 HIGH COMPRESSOR KNOCK-OUT LIQUID LEVEL 00PAX21 LOW COMPRESSOR KNOCK-OUT POT DISCHARGE PRESSURE 00TAX11 HIGH COMPRESSOR HEAD TEMPERATURE 00TAX16 HIGH COMPRESSOR DISCHARGE TEMPERATURE 00PAX26 LOW COMPRESSOR OIL PRESSURE ALL COMPRESSOR SHUT DOWN ACTIVATED
LSH-105 PSL-110 TSH-110 TSH-105 PSL-105
WHEN ALL ALARMS ARE OFF, DCS WILL ENERGIZE 00HMX37. AN OPERATOR WILL BE REQUIRED TO START CP-105 THROUGH A LOCAL HAND SWITCH.
VAB.0001106444
A
VCM TANK FARM COMPRSSSOR UPGRADE ABERDEEN PLANT
JANUARY 09, 1992
LEGEND
DX1
c----^ A CP
HM HS L LSH LSHH PG P PSH LSH T TSH
NEW EXISTING 4 WAY VALVE VALVE CHECK VALVE DCS INPUT/OUTPUT ALARM COMPRESSOR OUTPUT TO MOTOR LOCAL HAND SWITCH LEVEL DCS SIGNAL HIGH LEVEL SWITCH HIGH-HIGH LEVEL SWITCH PRESSURE GAUGE PRESSURE DCS SIGNAL HIGH PRESSURE SWITCH LOW PRESSURE SWITCH TEMPERATURE DCS SIGNAL HIGH TEMPERATURE SWITCH
VAB.0001106445
A
VCM TANK FARM COMPRESSOR UPGRADE ABERDEEN PLANT
JANUARY 09, 1992
NOTES
N1 PSL--(107--110) are existing pressure switches.
The
switches will be relocated from the compressor discharge
line to the compressor knock-out pot discharge line of
compressors CP--(102--105). A pressure switch, PSL--101,
will be installed on the compressor knock-out pot
discharge line for CP-101. 00PAX17-21 will indicate a
pressure of 8 psig or below. When the alarm activated,
the individual compressor will be shut down.
N2 LSH-(101-110) (00LAXX5--10) will shut down the individual
compressors when liquid is detected in the discharge line
from the knock-out pot.
*
N3 TSH-(106-110)
(00TAXX7--11) are existing temperature
switches located on top of the compressor head. All
lines are connected to a control box with a set point of
340 degrees F. The control box will be tied into DCS.
This will shut down the individual compressor.
N4 TSH-(101 and105) (00TAX12-16) are new temperature
switches.
TSH-(102-104) are existing temperature
switches located on the discharge line of the
compressors. An individual compressor shut down will
occur at 230 degrees F.
N5 PSL-(101-105)
(00PAX22--26) are low pressure switches
located on the compressor crankcase.
An individual
compressor shut down will occur at 12 psig.
N6 PSH-(101-105)
(00PAX27--31) are high pressure switches
located on the discharge of the compressor.
All
compressors will be shut down at 125 psig.
' N7
PSH-106 (00PAX32) will shut down all compressors when the Emission Recovery System knock-out pot builds up pressure to 75 psig.
N8 LSHH-101 (00PAXX6) will shut down all compressors before the sphere knock-out pot overflows.
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VAB.0001106446
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