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PITTSBURGH PLATE GLASS COMPANY CHEMICAL DIVISION LAKE CHARLES, LOUISIANA VINYL CHLORIDE MONOMER OPERATIONS MANUAL COWFIDEN'PIiiL ? February, 1967 30MANUAL No. CONFIDENTIAL SL 009760 TABLE OP CONTENTS I. COMPOUND ABBREVIATIONS II. INTRODUCTION III. GENERAL DESCRIPTION OF VC PROCESS A. Uses of VC B. Chemistry C. process Description 1. EDC Drying and Vaporization 2. Cracking Furnace 3. Quench Tower 4. Tar Removal 5. Partial Condensers 6. Vinyl Absorber 7. HC1 Stripper 8. Vinyl Product Still 9. Product Neutralization and Storage 10. Heavies Still D. Process Flow Sheets K. Mechanical Flow Sheets IV. SAFETY FOR VC PLANT A. General B. Definitions C. Chemicals in the VC Area 1. Caustic Soda 2. Chlorine 3. Chloroprene 4. cis-1, 2 - Dichloroetbylene 5. trans - 1, 2 - Dichloroethylene 6. Ethylene D1chloride (EDC) 7. Ethylidene Chloride 8. Hydrogen Chloride 9. Methane 10. Perchloroethylene 11. Sulfuric Acid 12. Sym and Assym. Tetrachloroethane 13. 1, 1, 2- Trichloroethane 14. Trichloroethylene 15- Vinyl Chloride (VC) 16. Vinylidene Chloride (VDC) 17 Calcium Chloride l8. Freon-12 Page 1-1 2-1 3-1 3-1 3-1 3-1 3-1 3-2 3-2 3-3 3-3 3-3 3-4 3-4 3-5 3-6 3-7 3-12 4-1 4-1 4-i 4-i 4-3 4-4 4-8 4-9 4-10 4-n 4-13 4-l4 4-15 4-l6 4-17 4-18 4-21 4-22 4-23 4-26 4-2? 4-28 SL 009761 CONFIDENTIAL* , feuDject to Protective Ordef 14th Judicial District Court No. 91-1145 Page D. Electrical Equipment 1. Relamping 2. Grounding E. Tools F. Pumps and Equipment G. Safety Rules for the VC Plant H. Cleaning of Tanks and process Vessels I. Area B. Safety Permit Form J. Fire Protection 4-29 4-29 4-29 4-29 4-30 4-30 4-31 4-33 4-34 V. RETAILED EQUIfMENT DESCRIPTION 5-1 A. Process Equipment 1. EDC Feed System 2. Vaporizer 3. Petro-Chem Iso-Flow CrackingFurnaces 4. EDC Vaporizing and Cracking Furnace Flame Control Systems 5- Coke Knockout Drum 6. Quench Tower 7- Bottoms Removal System 8. primary Quench Condenser 9- Secondary Quench Condenser 10. Quench Liquor Tank 11. Quench Liquor Safety Drier and Filters 12. Vinyl Absorber 13. Absorber Vent Condenser 14. Absorber Upper and Lower Intercooler System 15* HC1 Stripper 16. Vinyl Product Still 17. Absorber Lean Oil System 18 Recycle EDC 19. Heavies Still 20. product VC Treatment 21. VC Product Storage 22. HC1 Distribution B. Auxiliary Equipment 1. Vent Headers 2. Rework Lines 3- York Centrifugal Refrigeration System 4. Methane Fuel Gas System 5- Nitrogen Heater 6. Condensate System C. Drawings 1. Flywheel No. 1 2. Flywheel No. 2 5-1 5-1 5-1 5-2 5-3 5-12 5-12 5-12 5-13 5-13 5-l4 5-l4 5-l4 5-l6 5-16 5-17 5-17 5-19 5-19 5-20 5-21 5-21 5-23 5-23 5-23 5-23 5-23 5-36 5-36 5-36 5-37 5-37 5.38 SL 009762 COHFtDBNTlMif lect to Protective Order Page 3. HC1 System Flowsheet 5-39 4. York Refrigeration System 5-40 5- Vaporizing Furnace Flame Control System 5-47 6. Cracking Furnace Flame Control System 5-48 7- Alarm Schedule 5-50 VI. START- UP AND OPERATIONAL PROCEDURES 6-1 A. Overall Start-Up Procedures 1. Preparation 2. Plant Start-Up Sequence B. Detailed Start-Up and Operation 1. Reboilers 2. Process Pumps 3- Fuel Gas Supply System 4. Furnaces 5. Quench Tower 6. Dopp Kettles 7. Absorber 8. HC1 Stripper 9- Product Still 10. VC Neutralizer, Product Cooler 11. EDC Recycle Chlorination 12. Heavies Still 13- HC1 Transfer, Absorption 14. Product Storage and Transfer 15. York Refrigeration Unit C. Special Plant Procedures 1. Initial Start-Up 2. Decoking Procedure for Furnaces 3- Furnace Efficiency 4. Automatic Burner Damper Control 6-.1 6-1 6-2 6-5 6-5 6-6 6-8 6-8 6-23 6-24 6-26 6-27 6-28 6-30 6-31 6-31 6-35 6-3b 6-37 6-39 6-39 6-39 6-4s 6-4b VII. SHUTDOWN PROCEDURES 7-1 A. Overall Shutdown B. Detailed Equipment Shutdown 1. Fuel Gas Supply System 2. Vaporized and Cracking Furnaces 3. Quench Tower 4. Dopp Kettle 5* Primary Quench Condenser 6. Secondary Quench Condenser 7-1 7-2 7-2 7-3 7-3 7-3 7-4 7-4 7. Quench Liquor Surge Tank 8. Absorber 10. HC1 Stripper 11. J'roduct Still 12. Lean Oil Exchangers 13. Recycle EDC Cooler 7-4 7-4 7-5 7-5 7 7-b confihehtim.! Sub} ct to Protect^ 009763 * 4th coort 14. product Cooler 15. Neutralizers 16. HC1 Scrubber 17. York Refrigeration 18. Heavies Still C. Emergency Shut-Down ofEquipment 1. Furnaces 2. Quench Tower 3- Primary and Secondary Quench Condensers 4. Absorber 5. Stripper 6. Product Still 7- EDO Recycle Chlorination 8. Loss of Refrigeration 9. Loss of Cooling Water 10. Loss of Steam Supply 11. Loss of Electricity 12. Loss of Instrument Air 13. Loss of Purge Nitrogen 7-6 7-o 7-7 7-7 7-8 7-8 7-8 7-10 7-10 7-10 7-10 7-11 7-11 7-H 7-11 7-11 7-12 7-12 7-12 ANALYTICAL 8-1 A. Sample Points B. Control Samples - 1. Sampling Schedule 2. Sampling Technique 3- Analytical Methods C. Laboratory Samples 1. Sampling Schedule 2. Sampling Procedures 3. Who Takes Samples TABLE 8-1, Sample Points for VCPlant TABLE 8-2, VC Analytical Schedule 8-1 8-1 8-1 8-1 8-2 8-2 8-2 8-2 8-2 8-3 8-5 GRAPHS AND DATA 9-1 A. EDC Feed Rate Vs. VC ProductionRate B. EDC Conversion to VC and HC1 C. Recycle EDC Chlorination D. Distillation Column Design Data E. Process Vessel Outage Tables 1. Quench Liquor and Product Still Feed Tanks 2. Upper and Lower Intercooler Surge Tanks 9-1 f)-2 9-3 9-4 9-5 9-5 9-6 COtfPIDENTZA&t Subject to Protect!** Order Of 14th Judicial Diotrict Court No. $1-H45 3- Product Still Reflux Tank 4. Heavies Still Feed Tank 5- Heavies Still Reflux Tank F. Storage Tank Outage Tables Page 9-7 9-8 9-9 9-10 SL 009765 Of nth Judicial District o. 91-1145 i , NOTES ON PAGE NUMBERING This manual is designed to permit revision or additions without dis turbing the order of page numbers or the figure designations of illustrations and tables other than in the particular section affected by the changes. Pages are numbered using a combination of two numbers, the first being the section number while the second represents a page, illustration, or table in that section. Thus, page 4t6 represents page 6 in section IV; Figure 8.7 represents Figure 7 in section VIII. SL 009766 '"fectivc or<lr Subject VLTToirtrlct Court I. COMPOUND ABBREVIATIONS Abbreviation N2 HC1 ci2 F-12 VC VDC Trans-DCE 1,1-EDC CLP Cis-DCE CHCI3 1,2-EDC TRI 1,1,2-TCE PER Tars or HvCl Name Formula Nitrogen (Light) Hydrogen Chloride (Light) n2 HC1 Chlorine (Light) ci2 Dichlorodifluoromethane(Freon-12,Light) cci2f2 Vinyl Chloride Monomer (Key) c2h3ci Vinylidene Chloride (Heavy) c2h2ci2 Trans-l,2-Dichloroethylene (Heavy) c2h2ci2 1,1-Dichloroethane (Heavy) c2h4ci2 Chloroprene (Heavy) c4h5ci Cis-l,2-Dichloroethylene (Heavy) C2H2C12 Chloroform (Heavy) CHC13 1,2-Dichloroethane (Heavy) C2H4C12 Trichloroethylene (Heavy) c2hci3 1,1,2-Trichloroethane (Heavy) C2H3Cl3 Perchloroethylene (Heavy) Any heavy chlorinated compounds C2C14 1-1 Atm. Boiling Point F -345.75 -121.09 - 29.29 - 21.46 7.93 88.88 119.12 135.10 138.92 140.36 143.11 182.25 188.74 236.79 249.75 __ NOTE: "Heavy" indicates compounds having higher boiling points than VC. "Light" indicates compounds having lower boiling points than VC. SL 009767 ___ VINYL CHLORIDE MONOMER PROCESS 2-1 II. INTRODUCTION This operations manual has been assembled to serve the following objectives: A. As a training guide for the operators in learning the Vinyl Chloride (VC) plant operations. B. To serve as a ready reference for the operating personnel. C. To provide a standard approach for operating the plant so that continuity of operations is maintained. D. To serve as a place where current data, information, procedures, etc., relating to the VC plant are compiled. This manual is designed to provide a logical approach to the start-up and initial operation of the VC plant. As operational experience is gained, it is expected that some of the Standard Operating Procedures (SOP's) will have to be altered. The operators can help to keep this manual up to date by making recommendations to change SOP's that appear to be no longer in use. The information contained in this manual is considered confidential. This manual is the property of PPG and may be recalled at any time. SL 009768 Revised Feb. 1971 III. GENERAL DESCRIPTION OF VC PROCESS CONFIDENTIAL: 3-1 order Subject to Protective ct Court of wti. A. Uses of VC The chief uses of vinyl chloride are in the production of polymers and copolymers. A wide range of properties have made their use possible in many applications. One example of a copolymer which utilizes vinyl chloride is the SaranOO line of plastics; this is a copolymer of vinyl chloride and vinylidene chloride. B. Chemistry Vinyl chloride is produced by the following equation: Cl Cl H C - C H ' H C = C H + HC1 HH 600-975F Cl H EDC VC At high conversions and/or temperatures, side reactions involving acetylene and hydrogen formation become significant, according to these equations: Cl H H C -CH i H C SF c H + HCl VC Acetylene Cl Cl HC -CH HH H4, + 2HC1 + 2C EDC Other side reactions include the formation of chloroprene, phosgene, butadiene (1,3), cis- and trans-1.2-dlchloroethvlene. and vinylidene chloride. The extent of these side reactions is acceptable at around 507. conversion. C. Process Description 1. EDC Drying and Vaporization: The EDC feed to the VC vaporizer is pumped from the heavies still reflux tank. It is first cooled and then passed through the EDC safety driers. It is Important to guard against high water con tent in the EDC feed to minimize corrosion in the process equipment. The calcium chloride driers will keep the water content below 50 ppm as a maximum, and preferably below 20 ppm. After being dried the EDC feed passes through a filter, which prevents any calcium chloride from being carried into the vaporizer. The EDC is next heated to 240F in the furnace feed economizer; the other stream in this economizer is a process stream which will be discussed later. Next a steam heater heats the EDC feed to around 375F. SL 009769 3-2 The EDC then branches into two streams; each stream is flow controlled before entering the two-pass vaporizing furnace. EDC vapor leaves this furnace above 400F. The furnace is gas fired with the natural gas automatically mass flow controlled. The vaporizer has been provided with safety devices and instrumentation to make all foreseeable operations as safe as possible. 2. Cracking Furnace; The EDC vapor from the vaporizer is fed to the two cracking furnaces. One vaporizer pass feeds each cracker. The EDC vapor branches into four passes before entering a cracking furnace. Cracking of EDC to vinyl begins at about 600F; the conversion is around 50% at 900925F. It has been found that excessive temperatures and/or retention times in the tubes of the furnaces will cause coke deposits to form on the walls of the tubes. Over long periods of time coke will build up in the tub s. In order to minimize coke formation, steady feed rates to the furnaces and a constant outlet temperature must be maintained during operations. A flow con troller for each furnace pass has been provided. Natural gas to the burners is mass flow controlled automatically. Each of these furnaces is provided with safety devices and instrumentation commonplace to units of this type. Coke can be cleaned out of the furnace tubes by using the steamair decoking procedure discussed in detail later. 3. Quench Tower: The furnace exit gases must be quenched rapidly to lower the temperature in order to minimize undesirable side reactions such as coking, and in order the prevent the reverse reaction HC1 plus vinyl chloride to give 1,1-dichloroethane. This quenching step is effected in a packed tower which services as a direct contact cooler. The gases enter the column through nozzles who outlets are submerged in a liquid level of EDC. This submerged quenching step is important for three reasons: (1) it provides an effective way for quenching the furnace exit vapors, (2) it prevents carbonaceous material from passing upwards into the column packing and forward into process equipment, and (3) if the entrance nozzles were not submerged, they would rapidly plug up, as demonstrated in pilot plant operations. The quenched furnace gases are contacted countercurrently in the column with recycle quench liquor. This scrubbing action removes from the quench column overhead stream any residual carbonaceous matter. The downflowing quench liquor serves to replenish the liquid lost due to vaporization in the column. There is in addition enough excess quench liquor so that a purge of the carbonaceous and tarry materials collected in the bottom reservoir of the column can be made to the Dopp Kettles. The vapor leaving the top of the quench tower is at its dewpoint. around 266f. SL 009770 etive order Sub. let ttoo prote^cst*tri,ctt court F 14th dudici- _nAS Of 3-3 4. Tar Removal; The removal of carbonaceous and tarry materials from the quench tower is accomplished by draining the bottoms to the two Dopp Kettles. The level in the quench tower controls two on-off automatic ball valves which regulates the bottoms purge rate. Each Dopp Kettle is steam-jacketed and contains a scraper agitator. EDC serves as a carrier to bring the carbon and tar into a kettle and is recovered by being vaporized back to the bottom of the quench tower. These bottoms are periodically transferred tp the tar trailer and then dumped. 5. Partial Condensers; Two partial condensers in parallel (primary quench condensers) are used to cool as far as practical the quench tower over head vapor. The condensate from the primary quench condensers drains to the quench liquor tank, and the gas is sent to the bottom of the vinyl absorber as a feed stream. Liquor that is not used from the quench liquor tank for reflux quench liquor is fed forward to the HC1 stripper. This stream is dried and filtered before being fed forward. 6. Vinyl Absorber: Vapor from the primary quench condensers and the HC1 stripper are fed to the bottom of the vinyl absorber where they are contacted countercurrently with EDC. The bottoms stream contains the absorbed vinyl chloride and some HCl; this is the feed stream to the HCl stripper. The overhead vapor exit stream from the absorber consists mainly of HCl with small amounts of EDC and acetylene. The HCl vent is pressure controlled to maintain a pressure of about 80 psig at the top of the absorber. The absorber pressure control valve imposes a back-pressure on the complete furnace-quench system. A level control valve on the stripper feed stream controls the level in the absorber. Both vinyl chloride and some HCl are absorbed into the EDC down-flowing stream in the absorber. As the VC and HCl are absorbed, an amount of heat is released that is essentially equivalent to the latent heat of vapor ization of these compounds. This heat must be removed from the absorber to maintain the appropriate temperatures. This is accomplished in three ways: (1) by use of a refrigerated lean oil feed to the top of the absorber, (2) by use of two side draw intercoolers operating on trays 8 and 13 of the absorber, counted from the bottom, (3) by use of an overhead condenser operating on the vent HCl stream. The lean oil to the absorber is obtained from the bottom of the vinyl product still. This recycle stream is cooled in four stages from 315F to -28F. These cooling steps are: (1) interchange with feed to EDC vaporizer in the economizer, (2) further cooling in a cooling water exchanger, (3) refrigeration in the 34 lean oil cooler and, (4) refrigeration in the -40 lean oil cooler. SL 009771 3-4 The absorber intercoolers are designed so that liquid from the respective draw trays can be recirculated external to the column through re frigerated heat exchangers, dried, filtered, and then returned to the tray below automatically. The absorber vent condenser cools the exit HC1 vent gas to -18F to recover the organics leaving the absorber in this stream. The condensate from this condenser flows to the upper intercooler surge tank. A knock-out drum is located downstream of the absorber vent condenser and before the absorber pressure control valve. Condensate from this drum is sewered. An HC1 scrubber is used to neutralize HCl gas not normally con sumed by other units. The solution formed is sewered. A very important part of the vinyl absorber unit is the York refrigeration unit. Three levels of refrigeration (-40F, -3F, +34F) using Freon-12 are provided. Two compressors, each driven with a 1250 HP electric motor, provide 1250 tons of refrigeration. 7. HCl Stripper; In theory the vinyl absorber and the HCl stripper could be one column. However, due to the number of theoretical plates required it was decided to make two separate columns instead. The purpose of the vinyl absorber is to remove the vinyl chloride from the HCl overhead stream, the pur pose of the stripper is to remove HCl from the EDC and vinyl chloride bottom stream. The HCl stripper receives feed from the bottom of the VC absorber and the quench liquor tank. The feed contains vinyl chloride absorbed in EDC, which will pass forward through the stripper to the vinyl purification column, and also some absorbed HCl, which must be removed from the forward stream by the separation operation known as stripping. A thermosiphon reboiler located at the bottom of the stripper provides the vapor to strip out the HCl from the forward stream. Steam to the stripper reboiler is flow controlled. Adjustment is made on the basis of the temperature profile of the absorber-stripper system. Vapor from the stripper is returned to the bottom of the absorber. This stream, of course, imposes a load on the absorber heat removal system, just as does the vapor feed passing to the absorber from the primary quench condensers. The level in the stripper is kept constant by a drain line to the product still feed tank. 8. Vinyl Product Still: Feed to the product still from the product still feed tank is flow controlled. This column separates VC from EDC and heavies. The still operates at about 80 psig top pressure, and top temperature of 105F, so that cooling tower water rather than refrigeration can be used. This column, like the absorber-stripper columns, uses Glitsch Ballast trays. All compounds heavier than VC such as chloroprene, 1,1-EDC, and 1,2-EDC, are removed from the bottom of th column. SL 009772 COtoHFFIDtoEtNeTcWtv'e Order ^ CONFIDENTIAL* enMect to protective The bottoms stream from the product still reboilers contains mainly EDC, with some heavies. The major portion of this stream is recycled to the absorber while the remainder is sent to the heavies still for purification. The ratio is approximately 1.3 parts of lean oil to 1.0 part of recycle EDC to the heavies still. These two streams split after passing through the economizer. The lean oil stream is cooled in four stages as mentioned earlier; the recycle EDC stream is cooled in two stages. These two stages are the economizer and the EDC recycle cooler where the EDC is cooled to 165. A level control valve on the recycle EDC stream controls the column level. The flow of steam to the two reboilers is temperature controlled. The recycle EDC stream contains impurities, notably chloroprene, which, if not removed would be detrimental to the subsequent cracking step. Therefore, a small amount of gaseous chlorine is added to the recycle stream after it has been cooled. The chlorine combines with the chloroprene to form heavy boiling compounds that can be easily separated from theEDC in the heavies still. This reaction is shown below: H Cl H H H Cl H H HC = C - C = C H + 2 Cl2 --------- * HC-C-C-CH Cl Cl Cl Cl Chloroprene Chlorine Pentachlorobutane and/or other heavies Cl H Cl H HC = CH + Cl2 ______ * HC - CH Cl Cl VC Chlorine 1,1,2-trichloroethane It is this 1,1,2-trichloroethane which gives rise by cracking to the presence of small amounts of vinylidene chloride found in some of the process streams. These two compounds have no deleterious effects on the process. It is doubtful whether much reaction occurs between the dichloroethylenes and the gaseous chlorine under the chlorination conditions employed. The chlorination of the recycle EDC is a very definite and essential part of this process because there is no other way to remove the chloroprene which is so detrimental to the pyrolysis step. 9. Product Neutralization and Storage: Vinyl chloride with a small amount of HCl is taken overhead in the vinyl product still, condensed, and collected in the reflux tank. Reflux for the still is withdrawn from this tank and returned to the top of the still. The reflux ratio for this still is approximately 1.3:1. Excess production in the reflux tank is pumped to the flake caustic product neutralizers where the HCl is neutralized. It was found in the pilot plant that VC directly off the vinyl still would not meet the rigid specifications for HCl, even though the stripper was under control. This is to be expected since the ppm of HCl in the stripper bottoms is concentrated by a factor of about 8 in the vinyl still overhead product. Subject Of l*th J 3-6 The feed to the neutralizer is first cooled from 105F to 95F. It then flows through a phase separator where it comes in contact with water. The purpose of this phase separator is to insure a wet product flowing into the flake caustic neutralizer and, therefore, better neutralization. Another phase separator and a filter follow the neutralizer so that caustic which is carried from the neutralizer can be removed from the vinyl chloride product. The vinyl chloride then goes to one of eight day tanks, from which It can be transferred to one of three spheres after laboratory approval. 10. Heavies Still: The recycle EDC stream goes to the heavies still feed tank after being chlorinated. Liquid from the heavies still feed tank is pumped to the feed tray of the heavies still; a flow controller regulates this stream. The heavies still separates EDC from heavies. The liquid feed flows downward through the column countercurrent to the EDC vapors. The heavy chlorinated organics with higher boiling points flow down the column to the reboiler. An overflow line controls the level in the heavies still. This line empties into the waste recovery tank. Bottoms are circulated back to the heavies still until a predetermined level is reached in the waste recovery tank. Then they are transferred to the bottoms plant. Liquid in the bottom of the still is vaporized in the thermosiphon reboiler. This produces the upward flow of EDC vapors which become increasingly purer toward the top of the still. These vapors are condensed in the still condenser and the liquid drains to the still reflux tank through a vertical standleg. Any non-condensables are vented out through the stack seal to the vent pipe. The stack seal pressure drop determines the operating pressure (slightly positive at top) on the still over and above the slight nitrogen pad pressure imposed on the condenser. Steam to the reboiler is temperature controlled. The reflux ratio of this column is approximately 0.9:1. The furnace feed pumps also draw from the Btill reflux tank; this stream is also flow-controlled. Pure EDC make-up from EDC or OHC is pumped to this tank. The stream is flow controlled. 11. HCl Distribution: The HCl which passes through the knockout drum can be handled in several ways. Some of it goes to the oxyhydrochlorination (OHC) plant. First this stream passes through a spiral plate heat ex changer to heat the HCl from -20F to ambient temperature to prevent condensation on the outside of the line. The HCl line pressure to OHC is * sufficient so compression is not required. The remaining HCl passes through the absorber pressure control valve. Some of it passes through two activated carbon filter to remove any EDC from the HCl gas. The HCl stream then passes through a pressure control valve and on to the absorbers in the HCl plant. Some of the HCl passes through a manual loading station (MLS) and on to the suction of No. 1, 2, 3 compressors. The HCl is compressed and. sent to the EC plant. Any temporary excess HCl is scrubbed. A back pressure control valve regulates the flow of HCl to the scrubber. Water and cell liquor are used for scrubbing the HCl. SL 009774 > - . '3f;%^sr' r = REVISIONS Ta*e 3-9 Fiv. ?.3 TPo^VeCe s s u ^ a a ^ 5 0 WVtZ-&L<frST _^Ka-/tQa.Og>|^?g_ 7= f*Q./T7P-zP'<//-?/r.oTre'-Q7t*/VtPi&. T-P/S SL 009777 b &Zjygg^/7" 1 na |\ 'r a 11 TV vj TV r PITTSBURGH PCHLIMAKTAEL DGMSLIAONSS COMPANY LAKE CHARLES.LOUISIANA ^asod^g- SZ34.<&<S7~ sgwflirr^ < -MTckl2_l m*&ZAt... DWB NO5"''*507' -&- S3)^ jt. /ja wo 'Avr >UC REVISIONS Page 3-11 Fig. 3-5 d7Z/.g rOAygg PITTSBURGH PLATE GLASS COMPANY ftilMIftl DIV1UOM LAKE CH^mAaReLJEMSC,77eks^ LOUISIANA -deg) ~g~ /rzcn^ **'<** .. J3WQ. no: SL 009780 V.C OAY S7OMW MJ8S# eg*- /on 4 s*`tov /T*-JMO -PC/03 **07 PL/OS $ VC, SPH9MB STO. **e* w/v.c. s TPCH eSA'/OXB .3-.J2A3 - PC/OS---- ^J*aw Atypt'l - Pg/a* Maqetfri pc/os tir-tsot - PC/03 3" ~ /OO* - PC/O/ 3" - /BOS - PttOf S'/TO 7 - Pi/Of 2n- 32// - PC /OS S'-BOI PL/05 a"- 90s - pc/os 73*JST6*M * vsyr r k V/A/fy PttQDOCr MSVgMX -l^ 2"-a*tt -pi/os e"- 1824 - Pi/02 #-!$ X1^4" V-3/9 \ 4*-9700 - PC/OS OP&W/CS **SP CCU'T &WS, 30/7' 994 6M-/OtO *upu*C pips ppcm p*e* 4 mcl scevaste f P/LT86 A&8P V ft Pi/*AJ*C XM.SX ess- lot} r- 6// - pc tot SSfi-fOtQ tVhf&t r- 309 - PZtOS 4"- 7/S - Pl/OS f ss**toti f-t227 - PL/Oi r Sfi`fOt3 /4"- 700 -PC/03 fif-0/3 4*- 608 - PC//0 < ^ 484-/0/3 4"-3it6 ` PUOS 484-/0X2 489-/3/9 43*~/OM 4M-mut 449/0/4 489-:Oi4 V ft PMGCS39 MM9* 4C*~/Oi4 BSP- /Q/9 f-ZQO - PC/04 Cix PBOM Af.C. PCPA/T r V_-/S3U - VPPCM3A y- 4QC - Pj/03 900 MMK8-VP t <?- *Q02 PC tOS 9QC BOTTOMS PJ30M 8DC &CPAST SO C BOTTOMS STOOPS s REVISIONS A Mton/nv/V w.z.r. t-te-et Page 3-12 Fig. 3-6 C O U TIfJU eD OU DWG 20W -10G 3 couvuueo oju d w g . e s a - i o i o CO NTT) FROM OVG. 20A-1063 At REDRAWN MM Page 3-18 Fig. 3.12 N T ` D F R O M DW G., fc S A -lO lA CONT FFOM DWG. CSA-/Q/G ! ca/JT'a o / j o w n 3/1-1017 --W -x o a i - P u t/ coU Titiveo 0/1 owa. esa-zon co vrb rffOM Diva, gsa- /o/a COUTIUUBD OU DW S. B 3f)~ /a /9 C O N T 'p . F R O M D W G . (iS A .-1 0 2 0 CONT'D. F ffO /A DtVS. G S A -/Q 2 / CONTINUED OA/ PRAW//VG 6 5 A -/0 Z 3 SL 009795 REVISIONS A 8Z0KAW/V TGQOQWM /*+'67 Page S-~7 i! 1 * 7 1. u I b* 0 * 8*1* * 0 J* ,'033T Wm o T-Z30 7-ZZt T-Z32. T-233 *w ( If PITTSBURGH PCKLtfAtUTCUE OGMHLOAWSS COMPANY LAKE CHARLES.LOUISIANA VINYL____ CHLORIDE COA/T'D. OA/ OW6. 20A -/0 6 3 4-1 TV. SAFETY FOR VC PLANT A. General Due tc the nature oh the ST2 and Vt operations and the chemicals involved, the VC Plant is resfrxsin:, to authorised personnel only. Company vehicles will 'be permitted to travel the roads skirting the VC plant area during normal operations. Special permits will be required for vehicles to enter any of the other areas in this plant. Never cross a chain, regardless of whe is up or down, with a vehicle without a pass, passes for vehicles will be issued by the operating supervision of the area. All passes are immediately revoked if the Area "B" evacuation whistle sounds. If you are operating a vehicle and the emergency horns sound, shut down the vehicle and evacuate the area as quickly as possible on foot, A new pass will be issued no remove the vehicle. The control room and electrical starter rooms are pressurized for safety precautions; therefore, they are to be utilised by authorized personnel only. The doors and windows must be kept closed. B, Definitions Some of the terms usee, in the following discussion are defined below: 1. Flash Point; The flash point of a solvent is the lowest tempera ture at which vapor is given off in sufficient quantities so that the vapor-air mixture above the surface of the solvent will propagate a flame away from the source of ignition. If is the temperature below which a solvent may be used or stored in open containers without formation of an explosive vapor-air mixture. 2. Explosive Limits s Vflien combustible vapor is mixed with air in the proper proportions, ignition will produce an explosion. The vapor-air mixtures which will form this proper proportion is called the explosive range. The explosive range includes all concentrations of a mixture of flammable vapor or gas in air in which a flash will occur or a flame will travel if the mixture is ignited. The lowest percentage at which this occurs is the low* explosive limit and the highest percentage is the upper explosive limit. Explosive limits are expressed in percent by volume of vapor in air. 3, Maximum Allowable Concentration (MAC); The maximum allowable concen tration for a material is the maximum concentration of that material that can be tolerated by personnel for a continuous 8-hour exposure with no ill effects (given as MAC numbers). C, Chemicals in the Vi Area on the next pag : SL 009799 huits manu.A. at; & uj. vu a,rc ns oca CDBPIBeUTIALl to Protective ftafar 4-2 1,, Ethylene bichloride 2. Chlorine 3. Flake Caustic Soda 4. Actirated fareon t. Freon-12 6. Sulfuric: Aci 1 7= Nitrogen The properties of most of the materials listed in "C" above, together -with others that, are formed in. the process, are given on the following pages,, SL 009800 co*S& 0rder ct to- ?** " Cou, 4-3 NAME; Caustic Soda (Sodium Hydroxide) FORMULA; NaOE MOLECULAR WEIGHT; 40.00 BOILING POINT: 253^? MELTING POINTI 60 5.1P VAPOR PRESSURE: @ 1362!% limn,Kg USED IN; V ^ Product Neutralisers LIQUID DENSITYt Normally a solid PLASH POINT; Non EXPLOSIVE LIMITS None MAXIMUM ALLOWABLE CONG ,,: 1 ,, 2 ppm 'by Volume HAZARDOUS PROPERTIES: This material, both solid and solution, has markedly corrosive action upon all body tissue. Gasutic solution is detectable by the slippery feeling of soapy water. Its corrosive action on tissue causes burns and frequently deep ulceration, with ultimate scarring. Prolonged contact with dilute solutions has a destructive effect upon tissue. Mists, vapors, and dusts of this compound cause small burns, and contact with the eyes, either in the solid or solution form, rapidly causes severe damage. Ingestion either in the solid or solution form causes very serious damage to the mucous membranes or other tissues with which contact is made. It can cause perforation and scarring. Thus effects of inhalation vary from mill irritation of the mucous membranes to a severe pneumonitis. It can cause an irrriant dermatitis. Caustic soda will react with water or steam to produce heat and will attack organic tissue. TREATMENT: Where large quantities are handled the area should be well ventilated and face masks should be worn. Speed in removing caustic from contact with the skin is important. Remove all contaminated clothing at once, then flush the skin with water thoroughly. The use of small portions of water, such as by sponging, may cause more serious Injury due to heat liberated on, dilution. After flushing with water, use liberal quantities of a neutralizing solution such as a 0.3%o solution of boric acid, citric acid, or ammonium chloride. If any caustic soda contacts the eyes, they should be irrigated immediately with an abundant amount of water for at least 15 minutes. The eyelids should be held apart during Irrigation. The eye should then be washed with a mild saline solution If available. Wash the eye with water for an additional 15 minutes. A physician should be seen immediately after the eye is thoroughly washed. SL 009801 4-4 NAME; Chlorine (Clg) FORMULA; Cl2 MOLECULAR WEIGHT; 70.91 BOILING POINT: -30, l0'? MELTING POINT; -l49.8E SUPPLIED TO: Cl^ Vaporiser Recycle EDC Chlorination VAPOR PRESSURE: @ ?5I\ 47&0 mm. Kg LIQUID DENSITY; @ 77F 86.34 lbs. per Ft3 RELATIVE VAPOR DENSITY'; 2.45 (air - l.C) PLASH POINT; None EXPLOSIVE LIMITS; None MAXIMUM ALLOWABLE CONG.: 0.35 to 2 ppm DETECTABLE ODOR CONG.; 3.5 ppm. HAZARDOUS PROPERTIES; Chlorine is a skin, mucous membrane and respiratory irritant. Because of its pungent odor and irritating effect, traces of chlorine in air are readily detected. As the duration of exposure or the concentration increases, general excitement follows as indicated by rest lessness, irritation to the throat, sneezing and copious salivation. This is followed by retching and vomiting and by difficult or labored respira tion. Respiratory distress increases until eventually death may occur from apparent asphyxiation. Liquid chlorine and high concentrations of the gas in contact with the skin will cause marked irritations and blistering of the exposed area. Clothing contaminated with liquid chlorine will continue to be a source of chlorine gas and irritation to the patient until the liquid is completely evaporated. In any event, clothing thus contaminated should be removed immediately and the exposed areas flushed with water. In any atmosphere containing chlorine, short,shallow breathing should be used. Chlorine produces no known cumulative effects, and recovery from mild exposure usually occurs. Chlorine is particularly irritating to persons afflicted with asthma and certain types of chronic bronchitis. SL 009802 4-5 TREATMENT; The following First, Aid procedures are suggested, but it is recommended that emergency measures prescribed by your physician be followed. 1. Carry patient from gas area. Preferably, patient should be kept in a room at about 70F. Supply blankets if necessary. Keep patient warm and quiet. Rest is essential. 2. place patient on back with head and back elevated. 3. CALL A PHYSICIAN IMMEDIATELY 4. Clothing contaminated with liquid chlorine should be removed promptly and the exposed areas flushed with water. Keep patient warm with blankets. 5. A mild stimulant, such as essence of peppermint, may be given as a relief from throat, irritation, provided the patient is conscious. 6. If the patient has inhaled chlorine but still has practical control of his own breathing, oxygen, under intermittent positive pressure, may be administered. Be sure to follow the instructions which come with the oxygen-administering equipment which you are using. All persons working with chlorine should be acquainted thoroughly with the proper methods of handling this commodity, the use of a gas mask, and procedures in an emergency. Each person liable to exposure should be provided with a gas mask of a design approved for chlorine service by the United States Bureau of Mines. All gas masks should be inspected frequently and the instructions accompanying a mask, concerning it,s care and use, should be followed implicitly. Too much emphasis cannot be placed on the fact that a faulty gas mask is worse than no mask at all. Gas masks of the eannister type do not supply oxygen, but merely absorb the chlorine present in the air breathed. Where the chlorine content of the air is greater than 1$, a fresh-air hose mask or an oxygen supply mask is necessary. All personnel who may be required to use gas masks should be instructed properly and required to practice in their application and use. Brills in safety work and evacuation should be held at frequent intervals. In case of emergency only those persons authorized to make investiga tion and who are properly equipped with safety equipment should be permitted to enter the contaminated area. Chlorine is loaded and shipped in carefully inspected containers, but on rare occasions a leak may develop through the failure of mechanical devices beyond human control. SL 009803 CQMPID&MTXAlit Subject to Protective of 14th Judicial District Court No. 91-il45 SL 009804 4-6 Leaks must be given immediate attention because they will become progressively worse. All corrective measures must be performed by trained personnel wearing proper safety equipment. All other persons should leave the affected area until safe conditions have been restored. If the leak is extensive, special effort must be made to warn all persons in the path of the fumes. To locate the point of leakage, a rag tied on a stick and soaked with ammonia water should be passed or swabbed around suspected points. Dense, white fumes will indicate the exact point of leakage. Always keep on the windward side and at an elevation higher than the leak, if possible. If the leak occurs in equipment in which chlorine is being used, the chlorine container valve should be closed immediately. A leak around a valve stem can be stopped usually by tightening the packing nut. If a leak on a chlorine container cannot he stopped readily, an effort should be made to remove the unit to an isolated spot. If the chlorine is escaping as a liquid from a cylinder or ton tank, the container should be turned so that the leak is at the top of the container, thus allowing chlorine gas to escape. Only one-fifteenth as much chlorine will escape as a gas through the same size hole. Water should never be applied to leaks. Chlorine gas is only slightly soluble in water. The application of water is hazardous because the leak will become progressively worse due to the corrosive action of chlorine and water. The heat supplied even by cold water may cause the liquid in the container to evaporate faster. If chlorine gas can be withdrawn rapidly enough from the leaking container into the regular operating system, the pressure on the container will he lowered and the leak will be less serious. If the regular process cannot utilize the gas as fast as it can be withdrawn, provisions should be made to absorb it in an alkaline solution. Caustic soda or soda ash can be used for this purpose in the following proportions; Chlorine Container Size 100 pounds 150 pounds One Ton Caustic Soda Lbs. Water 10Off, (yells Soda Ash Lbs. Water Gals. 125 4o 300 100 188 6o 450 150 2500 8oo 6000 2000 ______________CONPTf>BjNTI AT. Subject to Protective Order of .14th Judicial'District Court .No. 91rll45' 4-7 Alkali and suitable containers to hold the solution should be kept available for emergency use. The chlorine should be passed into the solution near the bottom of the container by means of an iron pipe or a weighted rubber hose,. SL 00985 BllK. _ CONPIDEIfTTAL: fo.n-m 5 4-8 NAME: Chloropene (2-chloro-l, 3-butadiene) FORMULA: CH3 CHCCICHg MOLECULAR WEIGHT': 88.5^ BOILING POINT: 138.2F LIQUID DENSITY; @ 32F, 59.831bs, per Ft3 RELATIVE HAZARD: Chloropene is an impurity in the Product still bottoms and is only present in dilute concentrations, FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE OONC.: 25 ppm, HAZARDOUS PROPERTIES; Animal experiments have shown that a concentration of 250 ppm in air is toxic, and a concentration of 75 ppm. may be toxic with continued exposure. Exposure to the vapor first causes irritation of the respiratory tract, followed by depression of respiration and if exposure is continued, asphyxia. The vapor is a central system depressant; in animals it causes severe degenerative changes in the vital organs, particularly the liver and kidneys. Blood pressure is lowered. Lung changes accompany exposure to the higher concentrations. Humans exposed to chloroprene have been reported to develop dermatitis, conjunctivitis, corneal necrosis, anemia, temporary loss of hair, nervousness and ir ritability. Chloroprene is dangerous when heated to decomposition. It emits highly toxic fumes of chlorides. TREATMENT: Areas where chloroprene is used should be well ventilated. If a person should be overcome by vapors, he should be removed from the area immediately and a respirator should be used. If not available, use artificial respiration. SL 009806 CONFIDENTIAL* Subject to Prot ctive Order of 14th Judicial District Court No. 91-1145 4-9 NAMEt eis-1,2 -DICHLOROETHYLENE FORMULA: CXCHOHC1 MOLECULAR WEIGHT; 96.950 BOILING POINT; 138.2F MELTING POINT; -112.9? RELATIVE HAZARD; An impurity in all process streams of the Plant in dilute concentra tions . VAPOR PRESSURE @ 105.89? , 400 mm. Hg. LIQUID DENSITY @ 77F, 79-54 Its. per ?t3 RELATIVE VAPOR DENSITY; 3.34 (air = 1.0 ) FLASH POINT: 43F EXPLOSIVE LIMITS; 9.7 to 12.8f0 by vol. MAXIMUM ALLOWABLE CONC.; 200 ppm., 794 mg./m.3 HAZARDOUS PROPERTIES; In high concentrations it is irritating and narcotic. It has produced liver and kidney injury in experimental animals. It is a dangerous fire hazard when exposed to heat or flame. It is a moderate explosion hazard when exposed to flame. When heated to de composition it emits highly toxic fumes of chlorides. It can react vigorously with oxidizing materials. TREATMENT; Remove the patient from toxic area. Remove all contaminated clothing. Wash all exposed skin surfaces thoroughly with soap and water. Flush the eyes with copious quantities of water. Notify a physician. For fire, use water, foam, carbon dioxide, dry chemicals or carbon tetrachloride. SL 009807 CONFIDENTIAL* Subject to ?rfoltiHcfSurt of Utb Judicial No. 4-10 NAME; trans-1,2-Dichloroethylene FORMULAS C1CHCEC1 MOLECULAR WEIGHTS 96.950 BOILING POINT: ll8,,4F MELTING POINT'S -58F VAPOR PRESSURE @ 87,,4F, 400 mm. Hg. LIQUID DENSITY @ 77F , 79T$ Its per Ft3 RELATIVE HAZARD: An impurity in all process streams of the Plant in dilute concentra tions . RELATIVE VAPOR DENSITY: 30*4- (air - 1.0) FLASH POINT: 43F EXPOLSIVE LIMITS: 9.7 to 12.8% by vol. MAXIMUM ALLOWABLE CONC.s Unknown DETECTABLE ODOR CONC.; Unknown HAZARDOUS PROPERTIES: Exposure to high concentrations of vapor can cause nausea, vomiting, weakness, tremor, and cramps. Recovery is usually prompt following removal from exposure. Dermatitis may result from defatting action on skin. TREATMENT: See cis- dichloroethylene. SL 009808 TTil order trict court CONFIDENTIAL* Subject to Protective Order I4th Judicial District Court No. 91-1145 4-11 NAME; Ethylene Bichloride (EDC) (1,2-dichloroethane) FOBMULAs Cl^ClCHgCl MOLECULAR WEIGHT: 98.966 BOILING POINT; 102.3F MELTING POINT; -31.9F OCCURENCE IN PROCESS; EDC is the feed and main process liquor of the plant. VAPOR PRESSURE; @ 84.9F, 100 mm. Hg. LIQUID DENSITY; @ 68F, 78.4? lbs. per Ft3 RELATIVE VAPOR DENSITY; 3-35 (air = 1) FLASH POINT; 64.9F open up; 55.4F, closed cup EXPLOSIVE LIMITS; 6.2 to 15.9% by vol. MAXIMUM ALLOWABLE CONC.: 50 ppm., 200 mg./m.3 DETECTABLE ODOR CONC. ; Much less than maximum allowable AUTOIGNITION TEMP.; 84oF HAZARDOUS PROPERTIES; Ethylene dichloride has a distinctive odor and strong local irritating effects, which give warning of its presence in relatively safe concentrations. There is irritation of the eyes and upper respiratory passages. Ethylene dichloride has a specific effect on the cornea. Exposure to the vapor, or, in animals, injection under the skin, produces a clouding which may progress to endothelial necrosis and infiltration of the cornea by lumphocytes and connective tissue cells. The narcotic action of the compound is strong, probably of the same order as chloroform. Its toxic effect upon the liver and kidneys are less than that of carbon tetrachloride, hut animal experiments indicate that these organs may show congestion and fatty degeneration. Edema of the lungs has also been reported in animals. Dermatitis in man has been observed. In short exposures to high concentrations, the picture is one of irritation of the eyes, nose and throat, followed by dizziness, nausea, vomiting, increasing stupor, cyanosis, rapid pulse, and loss of conscious ness . Chronic poisoning, where exposure has occurred over a period of several months, may cause loss of appetite, nausea and vomiting, epigastric distress, tremors, nystagmus, leucocytosis, low blood sugar levels, and possibly dermatitis if there has been skin contact. Employees exposed regularly to ethylene dichloride should he examined at least semiannually, by a physician acquainted with the occupational hazards involved. Physical examinations should be required also when any systoms of poisoning occur. SL 009810 Employees who may he subjected to severe exposures of ethylene dichloride vapor as in tank cleaning and repairs in intermittent operations where general ventilation is not practical, in cases of failure of piping or equipment, and in cleaning up spills, should be provided when indicated with proper eye and respiratory protection as follows: (a) Suitable gas-tight chemical safety goggles, (b) Rescue harness and life line for those entering a tank or en closed storage space. An outside attendant should maintain constant observation. (c) Positive pressure hose masks with hose inlet in a vapor-free atmosphere. Air-line masks with proper reducing valve and filter suitable for use only where conditions will permit safe escape in case of failure of the compressed air supply,or Self-contained breathing apparatus with stored oxygen or air, which allows greater mobility but usually requires more highly trained men. In tank work small manholes may make this apparatus unsuitable because of its bulk, although the type known as self-generating is specially designed for entrance and egress through small openings. Masks and breathing apparatus should be approved by the United States Bureau of Mines and should be equipped with full face pieces. (d) Industrial gas masks, approved by the United States Bureau of Mines with canisters approved for use in ethylene dichloride vapor should be used only when it is certain that the concentration of vapor is less than 2 per cent by volume (20,000 parts per million) and the atmospheric oxygen is not lower than 16 per cent, and then only for exposures not exceeding one-half hour. TREATMENT: All contaminated clothing should be removed at once. Clothing, including shoes, soaked in ethylene dichloride should be removed and not worn again until thoroughly dry. All affected areas should be washed thoroughly with warm water and soap. After this an ointment containing lanolin should be applied in order to replace the natural Skin oils. For serious or persistent cases of skin trouble and for signs and symptoms of generalized poisoning, a physician should be consulted. If liquid ethylene dichloride has entered the eyes, they should be washed promptly with copious quantities of water for at least 15 minutes. It is advisable to irrigate the eyes gently with water at room tempera ture in order to minimize additional pain or discomfort. Ethylene dichlo ride vapor can produce injury to the eyes if the exposure is intense or prolonged to higher concentrations. Eyes should be irrigated for vapor in the same manner as for the liquid. Medical attantion should be obtained in all these contacts with the eyes. NAME; Ethyl!dene Chloride (1,1-diehloroethane) FORMULA; CK^HGlg MOLECULAR WEIGHT: 98.966 BOILING POINT-: 135.1P MELTING POINT: -l42F RELATIVE HAZARD: Found as an impurity in all Plant process streams in dilute concentrations. VAPOR PRESSURE @ 77F, 230 mm. Hg. LIQUID DENSITY @ 68F, 73*29 lbs per Ft3 RELATIVE VAPOR DENSITY; 3.^ (air = 1.0) FLASH POINT': 42P EXPLOSIVE LIMITS; 5.6 to 11.k% MAXIMUM ALLOWABLE CONC.; 100 ppm., 405 mg./m.3 DETECTABLE ODOR CONC.: 100 to 500 ppm. AUTOIGNITION TEMP.: 855F HAZARDOUS PROPERTIES: Limited data available. It is detected by its aromatic ethereal odor, hot saccharin taste. Liver injury has been reported in experimental animals. It is dangerous as a fire hazard when exposed to heat or flame. When heated to decomposition, it emits highly toxic fumes of phosgene. It can react vigorously with oxidizing materials. TREATMENT*; For fire, use water, foam, carbon dioxide, dry chemicals, or carbon tetrachloride. For treatment of a patient, remove him from the toxic area. Remove all contaminated clothing and wash all exposed skin surfaces with soap and water. Flush eyes with copious quantities of water. Notify a physician. SL 009811 CONFIDENTIAL* Subject to Ol 14th Judi 4-14 NAME % Hydrogen Chloride : t/RMULA; HCl MOLECULAR WEIGHT: 36.47 BOILING POINT: -122.6P MELTING POINT s -173.7F VAPOR PRESSURE: @ 64P, 304o mm. Eg. By-Product Of: By-product of the EEC cracking operation, and sent at high purity to other units or to disposal in the HCl Scrubber, it is an impurity in the stripper feed and is in highest concentration in the plant in the rent gas stream. LIQUID TENSITY: Normally a gas RELATIVE VAPOR DENSITY: 1.268 (air = l) FLASH POINT: None EXPLOSIVE LIMITS; None MAXIMUM ALLOWABLE GONC.: 10 ppm. for 10-hour working day. DETECTABLE ODOR CONG.: Unknown HAZARDOUS PROPERTIES: Anhydrous hydrogen chloride is a gas which has a corrosive action upon the skin or mucous membranes. In this form it will cause rapid and severe burns. It is particularly dangerous to the eyes. It is not flammable; however, the gas is highly soluble in water forming hydrochloric acid, which attacks most metals with the evolution of ex plosive hydrogen. TREATMENT: Immediate removal from the toxic area and thorough flushing of the patient's body and/or eyes with large quantities of water is of primary importance. Contaminated clothing should be removed from patient while he is being showered with water. It is essential that all affected body surfaces be washed with copious quantities of water for a sufficient time tc remove all hydrochloric, acid. No attempt should be made xo neutralize the acid with alkaline solutions. Medical assistance should be summoned at the earliest possible moment. SL 009812 Ho. NAME: Methane (marsh gas) FORMULA; CH4 MOLECULAR WEIGHT: 16.04 BOILING POINT; -258.7F FREEZING POINT's -297.8P VAPOR PRESSURE; @ -115.8?, 34,900 mm. Hfe. LIQUID DENSITY: @ -263.F, 25.91 lbs per Ft3 RELATIVE HAZARD^ Is the main constituent of the fuel gas burned in the furnaces. RELATIVE VAPOR DENSITY; 0.555 (air = 1.0) FLASH POINT: None EXPLOSIVE LIMITS: 5-3% to ikM by volume DETECTABLE ODOR CONC.; Odorless AUTOIGNITION TEMP.: 1000F HAZARDOUS PROPERTIES; A simple asphyxiant. A dangerous fire and explosion hazard. TREATMENT; Fir* should be fought with carbon dioxide or dry chemicals. SL 009813 4-16 NAME; Perchloroethylene (tetrachloroethylene) T . RMULA; 3C10-- CC10C. MOLECULAR WEIGHT: 165,848 BOILING- POINT: 2^+9.7F RELATED HAZARD: A potential heavy compound that might form in the Dopp Kettles; present in dilute eoncentrations. MELTING P0II1T; -8.07E VAPOR PRESSURE: @ 71.6? , 15.8 mm. Hg, DENSITY-: @ 59F, 101 ,,82 lbs, per Ft-3 RELATIVE VAPOR LENTIIY; 5,,83 (air = 1.0; PLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONG.: 100 ppm. by volume, HAZARDOUS PROPERTIES: Not corrosive or dangerously reactive, but toxic by inhalation, by prolonged or repeated contact with the skin or mucous membrane, or when ingested by mouth. The liquid can cause injuries to the wyes; however, with proper precautions it can be handled safely. The symptoms of acute intoxication from this material are the result of its effects upon the nervous system. TREATMENT; Wash any perchloroethylene from the exposed skin with soap and. water. If a person has been overcome by vapors, remove him from the area immediately and begin artificial respiration if a respirator is not avail at le. Rooms with perchloroethylene exposed to the air should be well ventilated. Sl_ 009814 CONFIDEHTXA^* 0rder CO"'` NAME: Sulfuric Acid F SMULA; HAifSC -.,f MOLECULAR WEIGHT; 98.08 BCTLING POINT: 6?6F USED IN: Not. used ir. process, but used a: a chemical in the area for cool ing tower water treatment. MSITING' PCINT: 50.9F VAPOR PRESSURE; @ 094.00?, 1mm. Kg, LIQUID DENSITY: @ 77F, 114.97 lbs per Ft.3 RELATIVE VAPOR DENSITY: Normally a liquid FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONG.: 0.25 ppm by Volume SL 009815 DETESTABLE CDOR CONC.; 0.12 ppm. HAZARDOUS PROPERTIES; Contact with the body results in rapid distruction cf tissue, causing severe burns. Repeated contact with dilute solutions can cause dermatitis, and repeated or prolonged inhalation of a mist of sulfuric acid can cause an inflammation of the upper respiratory tract leading ic chronic bronchitis. Sensitivity to sulfuric acid cr mists or vapors varies with individuals. Formally sensitivity is as follows: G.125 to 0.50 ppm - mildly annoying 1.5 to 2.5 ppm - definitely unpleasant 1.0 to 20 ppm - unbearable. Workers exposed to low concentrations gradually lose their sensitivity to its irritant action. Sulfuric acid nan ignite upon contact with com bustibles. It will react with water to produce heat. The acid should always be added to water upon dilution, never vice versa because spitting may occur. TREATMENT: Large quantities of water should immediately be used to wash the material off the body. Remove contaminated clothing during washing. Do not attempt to neutralize the acid in contact with the skin until all areas of contact have been thoroughly irrigated with water. Then applications of mild alkaline solutions may be used,, Do not apply oils or ointments to burned area without instructions from a physician. If eves are involved they should be immediately irrigated with copious quantifies of water for at least 15 minutes. conw>**rtI*l:'~ NAME Symmetrical and Assymmetrical Tetrachloroethane (S.TeCE & A.TeGE) A: CKr.^oOHCXv and CCl^CH^s: RELATIVE HAZAKP; MOLECULAR WEIGHT; 167.864 FILING POINT-: S.TeCE 295.2F, A.TeCE 266.8F Usually present in all stil bottoms streams, especially from the heavies still. 7AP"?. PBESrCBE @ ~-o~ ,TeOE 4 mm. Hg^ A.TeCE 1.3 mm. h. KITTING KINT; S.TeCE -46.8F, A.TelE -94.4F LCQ'.Ih LENITIY @ 77? , S.TeCE 99.l4 lbs per FtP; A.TelE 95.7C lbs per Ft-' RETTTITS 7AP0R lEETTTYs 5.78 (air = 1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONC.: 5 Ppm for 8-hour exposure FEIECTAKLE OBOR CONC: Approximately 5 ppm. FAZARITUS PROPERTIES; The tetrachloroethanes are not flammable or explosive tut are -she most toxic of the chlorinated ethanes that will be handled in the plant. The tetrachloroethanes are toxic by inhalation, by prolonged ana repeated, vert act. with skin or mucous membranes or ry oral intake. At'tw; toxic, vetrachloroethanes may be handled safely if proper precaution- are constantly observed. Prolonged or repeatet exposures to the prodvo1 in any form are hazardous. The signs and symptoms of excessive absorption usually appear- gradually and only after repeated exposures. In order of appearance trey commontv are unusual fatigue, loss of appetite and weight, sick stomach and vomiting, constipation, abdominal pain, jaundice, drowsiness, going on in severe cases to unconsciousness and death. Some cases show marked involvement of the nervous system with headache, numbness and tingling in fingers and toes, trembling and twitching of muscles and even paralysis of some muscles. The signs and symptoms of tetrachloroethane poisoning given above are due to systemic poisoning characterized hy marked damage to the liver, kidneys, heart, blood cells, and nervous system. The clinical picture varies with the type of exposure and the amount cf the material which has been absorbed either at one time or at repeated times. Most serious effects are usually on the liver and the blood. The principal route of absorption is by breathing the vapor, although it may be absorbed by the skin. Tetrachicroethane is currently considered the most toxic of the chlorinated hydrocarbon, solvents in industrial use. Continued exposure to high concentrations of the tetrachloroethanes leads to local irritation of the eyes and nose. There may be sick stomach and vomiting, but since tetrachloroethane is less volatile than other hydrocarbon solvents, it does not often have an anesthetic effect. Subacute tetrachloroethane poisoning is the form usually encountered. This develops gradually as a result of prolonged or repeated -work in an atmosphere containing more than 5 parts of tetrachloroethane per million parts of air but under conditions where the amount absorbed causes no immediate reaction. Repeated exposure even to low concentrations seems to increase sensitivity, and may lead to subacute poisoning. For some time, workers with subacute poisoning may show only such signs and symptoms as unusual fatigue, loss of appetite and weight, constipation and abdominal distress or pain. At any time they may develop more severe evidence of absorption such as vomiting, dizziness, tenderness and pain over the liver, and jaundice. Even if removed from further exposure, the illness may persist and grow worse over a period of days, weeks or even months, and may finally even end in death. However, if after a few months there has been steady improvement, complete recovery is the rule. Some conditions under which subacute poisoning may occur in employees are as follows: (a) Where the ventilation is inadequate, resulting in high concen trations of more than 5 parts of tetrachloroethane per million of air. (b) Where the vapor concentrations are high intermittently, due to faulty handling of the liquid, (c) Failure of the individual to observe percautionary measures. Tetrachloroethane is absorbed through the skin so that systemic poison ing can occur by this route with the same signs and symptoms as described above. Tetrachloroethane may cause dermatitis after repeated or prolonged contact with the skin, such as that which might occur in the handling of rags wet with the chemical product, dipping hands into the liquid, or wearing clothing saturated with it. Reddening, burning and, rarely, blisters may follow such exposure. In certain rare cases, the dermatitis may be caused by hypersensitivity to tetrachloroethane. The skin becomes rough, red and dry due to the removal of skin oils. It cracks easily and is readily susceptible to infection. The skin has a chapped appearance. Tetrachloroethane may enter the eyes either as a vapor or a liquid (spray or splash). The resultant irritation produces lacrlmation, burning and other symptoms of inflammation. It can cause serious eye damage if immediate care is neglected. SL 009817 CONFIt)W,Tl^* The first symptoms after toxic amounts of tetrachloroethane are taken by mouth are those of irritation of stomach and bowels, such as sick stomach, vomiting and diarrhea with bloody stools. It is absorbed very rapidly and even a small amount may go on to produce unconsciousness and a deep flushing of the skin. Death is apt to occur before such systemic changes as liver and kidney damage occur. TKSATM3UT; Most important in the case of any poisoning is quick removal from exposure. In the case of tetrachloroethane poisoning, this means first removing the patient from the contaminated atmosphere and, insofar as possible, removing the tetrachloroethane from the patient's skin, or gastro-intestinal tract, if those areas are involved. The patient should be kept quiet and comfortably warm, but not hot. A physician should be called immediately. He should be told briefly and clearly what has happened and the exact location of the patient. A person showing symptoms of tetrachloroethane vapor poisoning should be removed promptly from the contaminated area. In case breathing has stopped, effective artificial respiration, such as that obtained by the prone pressure method or the Eve rocking method should be started immediate ly, but only if one familiar with the operation of the apparatus is present to administer it. If the patient is conscious, hot tea or coffee may be given as a stimulant. A physician should be called at once. All contaminated clothing should be removed at once. Clothing, including shoes, soaked in tetrachloroethane should be removed and not worn again until thoroughly free from tetrachloroethane. All affected areas hould be washed thoroughly with warm water and soap. After this an ointment containing lanolin should be applied in order to help in replacing the natural skin oils. For serious or persistent cases of skin trouble, and for signs and symptoms of generalized poisoning, a physician should be consulted. If liquid tetrachloroethane has entered the eyes, they should be washed promptly with copious quantities of water for at least 15 minutes, (it is advisable to irrigate the eyes gently with water at room temperature in order to minimize additional pain of discomfort.) Medical attention should be obtained in all cases involving contact with the eyes. If a person has swallowed tetrachloroethane he should be made to vomit, if conscious, by having him drink a glassful or more of lukewarm water in which a teaspoonful of salt to the glassful has been dissolved; a similar amount of warm soapy water may be used. If necessary, the patient should be encouraged to stick his finger down his throat to induce vomiting. When possible, vomiting should be induced at least three times. Following this, a tablespoonful of Epsom Salt dissolved in a glass of water should be given. A physician should be called at once. SL 009818 COHFIDENTI^ ordet . to protect! CoUrt 4-21 NAME: 1.,1,2-Triehloroethane (TCE) FCHMULA: CHGl-CH-CI 2^ MOLECULAR WEIGHT; 133-415 BOILING POINT: 236.8p RELATIVE HAZARD: Usually present in all still bottoms streams, especially from heavies still. VAPOR PRESSURE @ 75F, 22 mm. Kg. FREEZING POINT': -31F LIQUID DENSITY @ 77F, 89.39 Its per Ft3 RELATIVE VAPOR DENSITY: 4.6 (air = 1..0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONG.: 25 to 100 ppm. DETECTABLE ODOR CONC.: Unknown HAZARDOUS PROPERTIES: Trichloroethane can cause burns of the eyes and has a seriously harmful effect upon the liver. It has a local irritating effect upon the mucous membranes, particularly of the eyes and nose. All contact with the eyes and skin should be avoided. This material should generally be handled with caution, because its toxicological properties have not as yet been adequately evaluated. TREATMENT: Remove patient from toxic area. Remove all contaminated clothing and wash all exposed skin surfaces thoroughly with soap and water. Flush eyes with copious quantities of water. Notify a physician. gL 0099^9 order NAME; trichloroethylene (ethylene trichloride) MOLECULAR WEIGHT; 131-399 ROILING POINT; l86,,8F MELTING POINT; -124.3F VAPOR PRESSURE @ 89.6F, 100 mm. Hg. LIQUID DENSITY @ 77F, 90.87 lbs per Ft3 RELATIVE HAZARD: A potential heavy that may be found in the Dopp Kettle bottoms stream in dilute concentration. RELATIVE VAPOR DENSITY; 4.53 (air = 1.0) FLASH POINT': None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONG.; 100 ppm. AUTOIGNITION TEMP,: 770F HAZARDOUS PROPERTIES: Inhalation of high concentrations causes narcosis and anesthesia. A form of addiction has been observed in exposed workers. Death from cardiac failure due to ventricular fibrillation has been reported. Prolonged inhalation of moderate concentrations causes headache and drowsiness. There is some question as to damage to liver or other organs from chronic exposures. Cases have been reported but are of questionable validity. High concentrations of trichloroethylene vapor in high-temperature air can be made to burn mildly if plied with a strong flame. Though such a condition is difficult to produce, flames or arcs should not, be used in closed equipment which contains any solvent residue or vapor. Trichloroethylene is dangerous when heated to decomposition. It emits highly toxic fumes of chlorides. TREATMENT: If a person in overcome by vapors, he should be removed from the area immediately and given artificial respiration if a respirator is not avail able. Notify a physician. Employees in continual contact should have regular physical examinations by a physician familiar with the hazards of trichloroethylene. SL 009820 -.MMOESTlW'' NAME: Vinyl Chloride (MVC) CK,-GKUi MOLECULAR WEIGHT: 62.501 rPILING POINT': 7.9? MELTING POINT: -244.7F VAPOR PRESSURE @ 77F, 2660 am. Kg. LIQUID DENSITY @ 77r, 61.92 Its per FtJ PRODUCT C? ___________ __ _ Main irciu. ` RELATIVE VAPOR DENSITY: 2.15 (air - l.C; FLASH POINT; -108.4P open up EXPLOSIVE LIMITS; 4% to 22% by volume SL 009821 MAXIMUM ALLOWABLE CONC.: 500 ppm for 8 hours. VISCOSITY: @ 77F, 0.187 cp. HAZARDOUS PROPERTIES; Present toxicological information indicates that vinyl chloride exhibits a low order of toxicity, but when present in sufficiently high vapor concentrations it has an anesthetic action. Vapor concentrations in work areas should be kept below 500 ppm for eight-hour exposure periods. Concentrations of greater than 500 ppm may cause warning symptoms of dizziness disorientation, and disturbances of equilibrium and. coordination similar to drunkenness. Vapor concentrations approaching the lower explosive limit may cause helplessness and unconsciousness on very short exposure. Pure vinyl chloride has a weak sweet odor, while the commercial product has a faint phenolic odor due to the presence of the phenol `t'r'Vv? h t 4- , Far more important than any other hazards are the dangers of fire and. explosion from vinyl chloride vapor. .Precautions must be taken to keep vinyl chloride enclosed and to eliminate all sources of ignition. Fires involving large quantities of vinyl chloride are practically impossible to extinguish. Diking and draining should be provided for confining and disposing of the liquid monomer in case of tank ruptures or spills. TREATMENT; Liquid vinyl chloride is a primary irritant to intact skin. If sufficient quantities remain long enough in contact with the skin, the rapid evaporation may result, in freezing or "frost bite." Consequently, anything which tends tc hold vinyl chloride in contact with the skin, such as clothing, shoes, or bandages, increases the risk of freezing. If spills occur, all contaminated clothing should be removed immediately and the contaminated area washed copiously in running water. If mild irritation has occurred, no further treatment may be required. If inflam mation is severe, loose dressings of petroleum jelly should be applied and confidentim** the patient placet in the care cf a physician. if freezing nas occurre: the area should he loosely cover? wi 4* y. r blear,, perierally z ;erile, gaune cr towel and placet in the care of a physician. Vinyl chloride which has gotten into the eyes should he washed out immediately with copiers amounts c:f Hewing water. Water at room temperature will prodi'ia less pair, than very celt water, hut ir_ an emergency a drinking fountain is a satisfactory source of water. The washing should continue lor at. least 15 minutes. If injury is apparent in the tissues of the eye after 15 minutes of irrigation, the washing should he continued for another 15 minutes. In, all cades except; cf very minor irritation, the patient should he placed in the care cf an ophthalmologist- immediately. because of the mildness and slow development cf" symptoms, it is very unlikely that any workman will he overcome to the point where he will require help in escaping the environment cr meaical care following exposure. Any person with evidence of intoxication from vinyl chloride should he put at rest, either seated or lying, in an uneontaminated atmosphere. If trapped in an area of high concentration where escape is impossible, deep anesthesia can result. If such an exposure has occurred, the patient should be placed in bed, preferably with the head slightly lowered and with no pillows. If respirations have ceased, artificial respiration will he required. In any ease, medical attention should he obtained immediately. Employees who may he subjected to severe exposure to vinyl chloride, as in nark and equipment cleaning and repairs, in decontaminating extensive areas, after large spillage, or In cases or failure of piping or equipment, should he provided, "when indicated, with proper eye, respiratory, fuln, and mucous membrane protection as follows; (a) Old table gas tight safety goggles. (t) Rescue harness and life line for those entering tank or erufievei s torage space. (c) Hose masks with hose inlet in a vapor-free atmosphere, air lire masks with proper reducing valve and filter, suitable for use only where conditions will permit safe excape in case of failure of the compressed air supply, or self-contained breathing equipment with stored oxygen or air (such equipment allowe greater mobility but usually requires more highly trained men). Vinyl chloride should always he handled with full recognition of its volatility and its flammability. In general, precautions should he taken both to keep the material enclosed and to eliminate all sources of ignition. In small laboratory operations, where vinyl chloride vapors may escape, reliance must be placed upon the elimination of sources of ignition and the provision of sufficient ventilation to keep escaping vapors at non flammable levels. Vinyl chloride vapors can form flammable mixtures with SL 009822 CONFIOBNTIAI** Subject to Protective 14th Judicial ^istri Order ct Court So. 9l"1145 4-25 air at, all temperatures above -106.4F. 'ires involving large quantities of liquic are difficult to, extinguish : inee vinyl chloride is net miscible -with water and is lighter than vatf.r (will float on top oVf - -a ^ r-V Most small fires can be extinguished with oarcon lgtiuo or chemical agents if properly applied. Adequate fire evornguiohing equipment of < areor. dioxide or dry chemical hype, fixed ana per tat It:, ohoul: be provided. ::r spray is also satisfactory fer ex- ."ires, A direct stream c/Jf water cn turning vinyl chloride liquid intensifies the fire, liking and drainage should be provld.ee. for ng and disposing Of tt;2 liquid in cas 'ions ;hiOUld be i;aken ,.;o guard againu . sever system. or leaks cr;nur. all sources of igniti on must be removed rom immediately and only properly ; remain in the area. Spills, unless very large, usually evaporate rapidly, but ample ventilation must be provided to prevent the accumulation of toxic or explosive mixtures. Spills and leaks must not be allowed to enter the sewer system because of the explosion hazard involved. An approved flammable gas indicator can be used in testing for vinyl chloride leaks. At the site of leaks, the phenol inhibitor in vinyl chloride may accu mulate by evaporation of monomer and reach sufficient concentrati.cn to cause local burns of the skin. In case of such accumulation of inhibitor, the area should be thoroughly hosed down with water after all traces of monomer have evaporate!, ~ SL 009823 4-26 NAME: 'inylidene Chloride (VDC) MOLECULAR WEIGHT: 96.950 BOILING POINT: 88.9? RELATIVE HAZARD; Impurity found in dilute concentrations in the plant process streams. FREEZING POINT: -l87.6F VAPOR PEESSURE @ 75F, 560 mm, Hg,, LI QUID DENSITY @ 77I% 76,04 lbs. per Ft 5 RELATIVE VAPCR DENSITY: 3-35 (air - 1.0) FLASH POINT: 50? open cup EXPLOSIVE LIMITS: 7 to 16$ by -volume in air MAXIMUM ALLOWABLE CONC; 220 ppm for 8 hours DETECTABLE ODOR CONC; 500 to 1,000 ppm. HAZARDOUS PROPERTIES; Yinylidene chloride is a flammable and toxic material. Vinylidene chloride is moderately irritating to the eyes and to the stein. The greatest danger from vinylidene chloride is inhalation. A single exposure for a few mintues to a high concentration of vinylidene chloride vapor rapidly produces a "drunkenness" which may progress to unconscious ness if exposure is continued. Even concentrations too low to cause an, anesthetic effect, may produce organic injury to the liver and kidneys. A secondary danger from vinylidene chloride exists. Unstabilized vinylidene chloride in contact with air will decompose and form explosive peroxides. These peroxides are evident by the presence of a white solid. For this reason, all vinylidene chloride will be stabilized and all equip ment will be padded with an inert gas such as nitrogen or methane. TREATMENT: When the skin is contacted by vinylidene chloride it should be thoroughly -washed with soap and water and all contaminated clothing removed and washed. If the eyes become contaminated they should be flushed with water for 15 minutes or more. If a person is affected or overcome from breathing vinylidene chloride vapors, he should he removed to fresh air at once. Medical attention should be obtained immediately. Artificial respiration should be administered if breathing stops. All pipelines, tanks, etc. in contact with, vinylidene chloride after its phenol inhibitor has been removed should be thoroughly rinsed with water if they are to be drained and left standing for any length of time. SL 009824 4-27 imi, Calcium Chloride F'RMULA; CaCl^h.i KOL-EC'jLAK WEIGH'D: 110.99 USED IN;_________ All driers, BAILING POIND: 2912F MELTING POINT; l422F SCLLLILIIY IN WATER; 59-5 pari;? Taty/lCC par"-.: K70 at lfc.F 347 parts CaC.1,-,/ ICO parts li.7/0 at 680F BEN:'IDS': 156. S lbs per Ft.3, @ 7? RELATIVE VAPOR "ENTITY; Normally a solid FLASH POINT; None EXPLOSIVE LIMITS; None HAZARDOUS PROPERTIES; Generally speaking, calcium compounds should be considered toxic only vhen they contain a toxic component (such as arsenic, etc.) or as calcium oxide or hydroxide,. SL 009825 -rf***^ TcoV tict ^ >0<i^ 9V^% V4-^ #* 4-28 PAY!; Preen - 12 (dichlorodifluorcmetnaneJ USED IN; MOLECULAR VEItfHT; 120.92 BCILINC PCINI'; -20.21' Use: as reirigorant :rr tr Yota refris:era` ici sys*`jm. MELlIHC POINT; -OV.^'P VAPOR PRESSURE; @ blC3', 0 a' i>- - . PSLAUIVS VAPOR I3KbIDx 4.17 {air --- i.C) PLATE' POIir; None EXPLOSIVE LIMITS; None MAXIMUM ALLOWABLE CONC.; 1000 ppm in air DETECTABLE ODOR CONC.: Unknown HAZARD...VO PROPERTIES; Dangerous; when heated to decomposition. It emits highly to?:.ic fumes of phosgene and. flourides. Never allow any open flame:,-; tc come in contact with P-12 or any vessels containing it. SL 009826 COBFIDENTl^V' Elec rlcal Equipment ;hat. the material;: art; c-laififisd in Group B, Class I by the V, S, National Electrical Code., Tr* method and materials of installation are those recommended by Factory Insurance Association. In general, the installation is Class I, Group 1, Division 1 victors are TEFC (Totally Enclosed, Fan Cooled), lighting is vapor-tight, ana all arcing devices are explosion-proof with seal-offs. Since the Control loom pressurised and isolated from the process area, general purpose equipment i? u: laboratory is not pressurised and is essentially furnished atmospheric air. f' us squiring all explosion proof equipment inside. 1. Relamping and Receptacles; Vapor-tight fixtures are used in tr.e process area. The relamping procedure will be to first determine the lamps which need changing by turning on all lights. Then , turn off all lights ana relamp. Globes and guards must be replaced after relamping. 2. Grounding; Grounding in the VC plant has been given special attention due to problems peculiar to the handling of hydrocarbons. Motor change-outs should be checked to see that the ground has been replaced. Due to the tendency for hydrocarbons to build up a static electricity charge as a result of movement, agitation, or free fhll through a gas space, a system of jumpers for pipe flanges has been installed to provide continuity of the piping system containing flammable materials. All vessels are grounded at two points. The result is a system of lines, tanks and vessels operating at ground potential. This will not prevent the generation of static charges bur thould provide adequate leakage to ground to prevent the accumulation of dangerous charges. A particular hazard is created by the use of cranes with long: booms, 'jnder certain conditions, depending on boom length and crane location, it is possible to pick up a voltage high enough to burn the person handling, a lead teat :i o suspended from the crane. This will occur even if1 the crane is grojnde is also conceivable that an arc would occur if the crane hooks roue1'* a grounded object. It. is obviously important that the grounding system bo maintained intact. This should be kept in mind when performing maintenance work on any equipment in the area. E. Tools Special npark-proff or alloy tolls are not required in the area. However, precaufcihns should be utilized in the handling of tools and equipment. In other words, do not strike a metal object that could cause a apart in the presence cf EDC, or VC, and air. SL 009827 Pump' and Equipment Any piece of equipment that is removed from the VC process must be thoroughly cleaned and inspected at a specified work area before it is permitted to leave the area for the plant shop or other work areas. G. Safety Rules for the VC Plant `Ike following list of safety rules is applicable to the VC Plant. These safety rules are designed to provide a systematic approach to safety in the VC area. They are general enough so that the operating personnel, if they have a fundamental grasp of the reasons for the rules, will he able to extend their knowledge to situations not covered in this Manual. Rules 1. Personnel entering the VC area will deposit lighters, matches, regular flashlights (as opposed to explosion-proof flash-lights), etc. at the gate to the area. 2. Smoking will be permitted in the Control Room only. 3. The usual safety equipment will be required in the VC area, as follows: a) Safety hats b) Safety glasses c) Respirators d) Neoprene-coated gloves 4. The established general plant procedure will apply for locking-out electrical equipment and for safe-to-work permiton process equipment. 2- Company vehicles only will be allowed to travel without, s permit on the road around the Control Building. 6. A vehicle permit signed by the operating supervisor will be required for any vehicle to go into the VC plant proper. 7. An equipment permit signed by the operating supervisor will be required before the following equipment can be carried into the VC area; a) Welding machines b) Cutting torches c) Electrically-driven drills d) Any electrical equipment except explosion-proof flashlights e) Gasoline engine driven equipment not previously covered f) Lighters, blow-torches or any flame producing equipment g) Grinders or chipping equipment, 4-31 8,, Criy . 'iplocion-prc::1' flashlights will be permitted in the area,. v tegular rubber plant utility hoses are not. to be use! for W transfer or handling purposes. All light, circuits outside the Control Room or Electrical Starter Room must be off and tagged-out before relamping Is undertaken. 1. Do not dump flammable organics into trapped sewers or openings where vapors could be evolved that woulu bs either harmful to realih or create ar, explosion hazard. Z"c not leave an open sample or container of organics sitting around tc give off vapors. fee Pull-face, Chemcc: or Scott Air-Pac mask for prt ecticn again organic vapors. 4, Bo not trap liquid chi' -ine in the vaporizer or surge drum,. 2- Clothing that has been vet with organics should be removed immediately and the body thoroughly washed with soap and water. These- clothes should be properly laundered before they are used again. j. Do not. permit air to enter any of the process equipment that contains organics. 7. In toe case of an emergency warning, all vehicles and equipment, in the ares, cr. permits will be shut off immediately. Ail stearn-out nozzles or hose and purge equipment must be pr ,porly grounded to prevent, the possibility of an arc from aceumulathf static charge. 9. Do net allow" chlorine to be heated above 302P cue to the possibility o' decomposition or reaction with metals. Wo smoking or open flames will be allowred in the Control Laboratory. L. The Laboratory hood fan is to operate continuously. Do not. attempt to run analyses unless the fan is in service. i- Always put liquid organics into tanks through stand legs or through nozzles in the bottom of the vessels. Falling liquid can generate static electricity. Cleaning of Tanks and process Vessels !ho area supervisor and maintenance supervisor will see that all vessels or arc cleaned and checked with an explosion meter before delating them :le- for maintenance. SL 009829 2ns recommended cleaning procedure is; 1. 2he tank or vessel will be emptied and all valves will be closed and tagged. 2. The vapor contents of the tank will be purged with nitrogen. 3. Blinds will be inserted in all connecting lines 4. The equipment will be steam purged where possible tc vaporize and remove all flammable materials. If steam cannot be utilized, nitrogen will be used. t. purge the equipment with plenty of air. 6. The equipment will then be checked with an explosion meter before work is begun. 7. Safety belts and safety lines will be required in top-entry tanks. SL 009830 AREA E. - SAFETY PEB1IT FORM ot ORGANIC AREA SAFETY PERMIT ^3A STD 4-66 To be used to pass restricted equipment into the Organic Area and to be endorsed for the use of such equipment in the Unit. To:_____Date: Location: Equipment: Please Check 1. Have workmen been provided with proper safety equipment? 2. Are adjacent areas and equipment safe? 3. Has adequate fire protection been provided? Yes No 4. Is presence of operator required? Remarks: ______ Approved: _ If a siren or emergency horn sounds, I am to turn off my equipment immediately and" evacuate the area on foot. Employee's Signature WELDING OR BURNING PERMIT This permit, when signed, allows welding or burning at: (Location) It is good for: Date TimeAM To: Date TimeAM Special Comments:_______ __ PM PM Signed: (Area Production Supervisor) SL 009831 J. Fire Protection CONFIDENTIAL! Subject to Protective Order of 14th Judicial District Court Ho. 91-1145 4-34 Fire protection in the VC area is provided in three forms--water, dry chemicals, and C02. The dry chemical is the only effective way of fight ing a VC fire. Water is good to partially contain the fumes and to keep the vessels and structural steel cool. The. C02 cylinders are good only for small fires or small electrical fires. CO2 cylinders are located in the switchgear room and are to be used on small electrical fires. The dry chemical is very effective against VC fires. 30-pound dry chemical units are located throughout. A large portable unit is available at the perimeter of the process area. The water protection is a manual or automatic sprinkling device, tripped by a deluge valve. The VC still area, the cooling tower, the VC day tank area, and the sphere tank area are each protected with its own deluge system (two for still area). Heat Activated Devices (HAD's) are located through out each area and a sudden rise in the HAD temperature will cause the de luge valve to open and the respective area to be covered with a water spray. The still area sprinklers may also be tripped manually from the control board or the automatic sprinkler building. The other areas have no manual trip for their systems. The deluge valve must be manually reset each time it is used before further automatic protection is available. The column skirts and all vertical structural steel is protected with "albi" fireproof paint. The support legs and bottom of the spheres are also protected with this paint. A post indicator valve southwest of the control building can be open to separate the furnace area from the still area with a forty foot high blanket of water. This valve also supplies a water sprinkle on the Dopp Kettles and the bottom of the quench tower. Turn this water on if there is a danger of organic fumes blowing toward the furnace area. SL 009832 CONFIDENTIAL* Subject to Protective Order of 14th Judicial district Co t 5-1 V. DETAILED EQUIPMENT DESCRIPTION A. Process Equipment 1. EDC Feed System: The furnace feed pumps (maximum output pressure of 300 psig) withdraw EDC from the heavies still reflux drum and pass it to the furnace feed cooler where the temperature is lowered from 190F to 105F. EDC is in the 2-pass shell side and cooling water is in the 4-pass tube side of the exchanger. The cooled EDC then passes to the furnace feed safety driers. These 3'6" diameter by 21' T/T driers are packed with calcium chloride and should lower the water content of the EDC feed to a maximum of 50 ppm. Two Fulflo filters follow the driers to prevent carryover of CaCl2. The filter elements in these furnace feed filters remove particles down to 5 microns in size. After being dried, the EDC feed passes through the furnace feed economizer. This stream passes through the fifteen-shell Smithco heat exchanger on the tube side. Its temperature is raised from 105F to 290F. Each shell of the exchanger contains 7 tubes; each tube has 20 external fins. The shell side fluid is the EDC lean oil from the bottom of the product vinyl still. 2. Vaporizer Description: EDC enters the top, or convection, section of the vaporizer. The EDC feed to each of the two passes is flow controlled. The Petro-Chem Iso-flow furnace consists of an upright cylindrical structure with an integral self-supporting stack. The inside of the cylindri cal casing is lined with insulation which in turn is protected by a layer of insulating refractory brick to form the combustion chamber. The shell of the convection section forms a 3'10" by 11'5 1/2" rectangle which is 6'11" high. The combustion chamber O.D. is 11' 5 1/2". The total height of the furnace from the ground to the stack top is 63'6". The two passes of 4" carbon steel pipe next enter the radiant section of the furnace; they descend through this section in a double helical coil pattern. The liquid EDC will vaporize in this section and in doing so will result in a large increase in the volume of EDC being passed through the tubes; therefore, the tube size increases to 6" about halfway through the radiant section. The tube coil diameter is 9'0", Four burners are installed in the floor of the furnace so that all tubes are equi-distant from the flame burst. Uniform heat transfer rates are obtained by subjecting the heating surface nearest the flame to a con trolled amount of radiant heat while the upper sections of the heating surface are subjected to varying proportions of direct radiant, secondary radiant and convection heat. The furnace firing is controlled by regulating the fuel gas feed to the four burners, which is set by the vaporized EDC outlet temperature. The inlet feed tubes are protected with safety relief valves set at 315 psig. These valves vent to the heavies still reflux drum. SL 009833 C0W10ENTI AL i Subject to Protective Order si*b Judicial district Couj 5-2 Nitrogen at 100 psig is piped to the furnace inlet piping for purging purposes. Snuffing steam at 100 psig is piped to the lower part of the vaporizer shell and can be turned on manually from the panel board or the field to snuff out the flame in the furnace in case of a tube rupture. During operation there will always exist a certain pressure drop between the inlet and outlet tubes depending upon the EDO feed rate and the extent of coking in the tubes. This pressure drop is indicated in the field and on the panel. An increase in the pressure drop across the furnace tubes will result in an increase in the feed inlet pressure. The outlet pressure will remain the same, provided everything else is unchanged. When the inlet pressure increases to a point where the feed control valves are completely open, the feed flows will start to drop off and the furnace will need to be decoked or acidized. Extensive coking is not expected to occur in this par ticular furnace. Only the non-volatile solids will be laid down in the tube up to the dry point. 3. Petro-Chem Iso-flow Cracking Furnaces; Vaporized EDC is flow controlled to the cracking furnace in four passes. An identical cracking furnace will be installed parallel to the present one at a later date. The cracking furnaces are similar in design to the vaporizer. The following changes should be noted, though. The shell of each convection section forms a rectangle 3'1 1/4" -by 19'8 3/4" which is 7'8" high and the radiation section is 20'6" O.D. The total height of the furnace is 73'11". The convection section contains steel tubes, while the radiation section con tains type 304 stainless steel tubes. There are twelve burners at the bottom of each cracking furnace. Fuel gas flow is controlled by the outlet process temperature. Although there is one temperature sensing device in each outlet pass, only the temperature of one of the passes in each cracking furnace will be used to set the firing rate. The remaining temperatures will be recorded for comparisdn^purposes and can be switched to "control" if desired, leaving the other passes "recorded". The tube wall temperature of each pass outlet is recorded and will be used as a guide to determine the degree of coking. Coke formation will provide resistance to heat transfer. The differential pressure across each tube will be monitored as another aid in determining the degree of coking. Snuffing steam at 100 psig may be admitted by remote manual control to either furnace. These steam valves can also be opened in the field manually in case of a tube rupture inside the furnace. It is expected that coke deposits will build up on the walls of the tubes in the furnaces. Therefore, provision has been made for decoking the tubes. The decoking elements are steam and air; these can be admitted for forward or reverse flow through any pass of the two cracking furnaces. SL 009834 CONFIDENTIAL: Subject tp Protective order of 14th Judicial District Court NO. 91-1145 5-3 For safety reasons the decoking elements cannot be turned on to a tube until blinds ("Figure 8" blinds are used) are removed and a removable spool has been replaced in the lines conducting air and steam to the pass to be de coked. In like fashion, the discharge piping from the furnace to the coke knockout drum must be connected up to whatever end of the furnace the effluent gases will be coming from. The steam and air flows for the decoking operation are measured and transmitted to field indicators. It will be possible to "spall" with steam (200 psig) in both directions, but air will be used only in the for ward direction. In the event routine or emergency purging of a furnace pass must be done, 100 psig nitrogen is piped to, but valved off from, the inlet passes to each furnace. The turndown ratio of the cracking furnaces is 80%. This is different from conventional reactors becuase the coking rate increases rapidly as velocities decrease and retention time increases. Methane fuel gas is supplied to the plant at 90 psig. This pressure will be further reduced to 30 psig before the gas is disttibuted to each furnace. Each furnace has a pressure control valve, which controls the pilot supply pressure at 2-5 psig. The fuel gas flow to the burners of each furnace is controlled by the outlet temperature of the process stream from that particular furnace. The combustion air to each furnace is automatically controlled. Continuous control analyses are run to check for the percent oxygen in the flue gas streams (exhaust gas from the furnaces) and the necessary changes in the air flow to the respective furnace is made accordingly. 4. EDC Vaporizing and Cracking Furnace Flame Control Systems: a. The flame control systems for each furnace are basically identical. The essential differences between the two systems are: (1) The vaporizing furnace is interlocked with the cracking furnace so that under operating conditions at least one pilot burner on the vaporizer must be in operation with the Maxon gas valve armed before a crack ing furnace can be operated. (2) In the vaporizing furnace a contact on the Maxon valves is used to operate a relay, VRG1-VRG4. Contacts from these relays are used to operate a local indicating light, a remote indicating light, and furnish the interlocks described above. In the cracking furnace system, two Maxon contacts are used, one to operate a local indicating light, the other to operate a remote indicating light. SL 009835 CONFIDENT!*^ b. Furnace Start-Up (1) The following discussion relates specifically to the vaporizing furnace, but is applicable to the cracking furnaces. Refer to Drawing 65A-7625 or Drawings 65A-7626 and 65A-7627. (2) Purge Sequence (a) Assume that the furnace is down, the horn and alarm lights have been acknowledged. Relays VRC1-VRC4 are energised, relays VRDlVRD4 are de-energized, relays VRY and VRZ are de-energized. Assume further that the bypass switches VSBP-1 and VSBP-2 (safety bypass switches) are off, relay VRBP is therefore de-energized. Indicating light VLBP on the field panel is off, and a green indicating light at the VSBP-2 control station on the control room panel indicates that the bypass is off. (b) The operator first closes all factory mutual gas cocks, thereby causing pressure switch PS-2040 contact to close. The furnace damper must be opened completely, thereby causing limit switch VSA1 to close. With fuel gas pressure at the furnace exceeding the set point of pressure switch PS-2038, relay VR4 is energized and contact VR4-1 is closed. With temperature at the bridge wall below the shutdown setpoint of TI-2161 and temperature at the outlet of the quench tower below the shutdown setpoint of TS-3031, contacts TS-3031 and TI-2161 will be closed energizing relay VR2 and closing contact VR2-1. (c) When "Purge" pushbutton VPBP is operated, the clutch to timer VHP-2 immediately energizes and seals in thru N.O. clutch contact VHP2-1, With contacts PS-2040 and VSA1 closed, the timing motor of VHP2 and the "purge in progress" indicating light VLPP (located only on the field panel) energizes thru N.C. motor contact VHP2-2. N.O. clutch contact VHP-4 temporarily shuts the low outlet pressure shutdown contacts VR3A-2 and VR3B-2. The clutch of feed shut down timer VHP-3 then energizes thru VR4-1, VRZ-5 and VK2-1. (d) At the end of the purge period, motor contact VHP2-3 times closed energizing relay VRB, Relay VRB immediately seals in thru contact VRB-1. Contact VRB-2 energizes the ignition bus IGN-1 and establishes a permissive circuit to start timer VHP1. Contact VRB-3 energizes the pilot solenoid valve bus PS-1 and VRB-4 establishes a permissive interlock for the Maxon safety valve bus MS-1. (e) After a short interval contact VHP2-2 times open de-energizing the VHP-2 timing motor (hoteiat this point that the clutch of VHP2 is still energized) and the "Purge in Progress" indicating light VLPP. 009836 su CONFIDENTIAL D-ritectlV When shunt contact VHP2-4 closed, the clutch of feed shutdown timer VHP3 energized (see section b) . N.C. clutch contact VHP3-2 opens, resetting the motor contacts VHP3-1 and VHP3-3 to the closed position. (f) At this point the purge sequence is complete. Re lays VR2, VR4 and VRB a^q energized, feed shutdown timer VHP3 has been reset, a premissive interlock for the start sequence has been established, and the ignition and pilot solenoid buses have been energized. (g) By operating one of the bypass switches VSBP-1 or VSBP-2, the Maxon bus MS-1 can be energized. After lighting off one of the pilot flames and arming the Maxon valve for that burner, either of the crack ing furnaces can be started. (3) Start Sequence (a) To initiate the "Start1"2 3sequence, "Start" push button VPBS is operated, energizing the clutch and timing motor for start timer VHP1. The clutch and motor immediately seal in thru N.O. clutch contact VHP1-2.N.0. clutch contact VHP1-3 immediately closes, energizing startup by pass relay VRX. Since indicating light VLB? is not in this circuit, VLBP (on the field panel) remains off and the indicating light at VSBP-2 control station (on the control room panel) remains green. (b) When startup bypass relay VRX energizes, N.O. shunt contact VRX-1 closes energizing low feed flow shutdown relay VR1; N.O. shunt contacts VRX-2 and VRX-3 close energizing low outlet pressure shutdown relays VR3A and VR3B. When relay VRl energizes, N.O. interlock contact VR1-1 closes energizing the Maxon safety valve bus MS-1, completing the last step required for main burner lightoff. (c) When relays VR3A and VR3B energize, N.O. interlock contacts VR3A-2 and VR3B-2 close (note at this time that these contactsrare still bypassed by contact VHP2-4, since the clutch to timer VHP2 is still energized). N.O. interlock contacts VR3A-1 and VR3B-1 close energizing feed solenoid valves SY-2193 and SV-2194 respectively. With solenoid valves SV-2193 and SV-2194 energized, feed flow control valves FCV-2008 and FCV-2015 can be opened and feed flows established after the manual block valves are opened. (d) To complete the "Start" sequence, assume during the timing interval of VHP1 that: SL 009837 (1) All burners have been lighted off, (2) Minimum feed flows have been established closing contacts FS-2019 and FS-2170, (3) Minimum pressures at the furnace feed outlets have been established closing contacts PS-2165 and PS-2163. confidential order subject to rrti,,.r;ct Com When timer VHPl times out, N.C, motor contact VHPl-4 opens first, de-energizing the clutch for time VHP2. N.O. clutch contact VHP2-1 opens the seal around pushbutton VPBP and N.O. clutch con tact VHP2-4 opens the shunt around contact VR3A-2 and VR3B-2 (since these con tacts are closed VRB, VHP3 clutch and bus MS-1 remain energized. Motor con tacts VHP2-2 and VHP2-3 reset to the closed and open positions respectively. After a short time delay, N.C. motor contact VHP1-1 opens, de-energizing the VHPl clutch and motor. Seal contact VHP1-2 opens immediately. Contact VHP1-3 opens to de-energize VRX and open startup shunt contacts VRX-1, VRX-2 and VRX-3. Relay VR1 remains, energized thru FS-2019 and FS-2170. Relays VR3A and VR3B remain energized thru contacts PS-2165 and PS-2163. At this point sustained operation of the furnace is totally dependent on the safety shutdowns. (4) Burner Lightoff (a) Since the lightoff procedure for all burners is identical, the lightoff of burner #1 only is detailed. Previous steps in the sequence (see section b.2.d, and b.3.b.) will have energized the Maxon safety valve bus MS-1, the pilot solenoid bus PS-1 and the ignition transformer bus IGN-1. (b) The ignition pushbutton VPB1 and "Pilot Established" indicating light VLP1 are mounted together. When the ignition pushbutton VPB-1 is operated, contact VPBl-4 closes across fireye terminals 3 and A and energizes relay RLl of flame control unit FFC-2018 (see drawing 65A-7629). Contact RL1-2 (in FFC-2018) then opens de-energizing alarm relay VRCl. Contact VPB1-2 closes energizing the pilot solenoid SV-2334 and contact VPB1-1 closes energizing the ignition transformer VIGT-1 and lighting the pilot flame. When the scanner (FFD-2167) "sees" the flame, the flame detector circuit energizes the flame relay RL2 (in FFC-2018). Relay RLl then seals in thru contacts RL1-3 and RL2-2. Contact RL2-4 closes en ergizing the "Pilot Established" indicating light VLP1. (c) When VRCI de-energized, N.C. interlock contact VRCl-5 closed sealing the pilot valve around pushbutton contact VPB1-2. N.C. interlock contact VRC1-4 closed enabling the Maxon safety valve holding coil to energize when VPB1 is released. (d) De-energizing VRCl also closes contact VRC1-1, energizing relay VRD1. Relay VRD1 then seals in thru contact VRD1-1.. At this point contacts VRD1-2 and VRDl-3 are closed and contacts VRC1-2 and VRCl-3 are open. (e) When VPB1 was first operated, energizing relay RLl in FFC-2018, contact RL1-4 closed energizing the total flame failure bus TFF-1. When the bus TFF-1 enereiepk. relay VRY energizes thru N.C. lockout contact SL 009838 TT/ot^tive order District Cou. Of contact VRZ1. Contact VRY-6 closes to hold the purge complete relay VRB energized. Contact VRY1 seals in relay VRY, contact VRY-2 closes energizing relay VRZ which then seals in thru contact VRZ-2. Shunt contact VRZ-5 opens leaving relay, VRB, timer VHP3 and bus MS-1 dependent on the total flame failure interlock contact VRY-6. At this point contacts VRZ-3 and VRZ-4 are closed, contacts VRY-3 and VRY-4 are open. Contact VRY-5 is open de-energizing the control room panel alarm A-2308. Contacts VRY-7 and VRY-8 are closed estab lishing power to the control circuits of the cracking furnace flame control units. (f) When the Maxon safety valve is armed, an integral limit switch closes, energizing relay VRG1. Contact VRG1-1 opens.de-energizing the main burner failure alarm indicating light VIM-1 on the field panel. Con tact VRG1-2 opens de-energizing the main burner failure alarm A-2369 on the control room panel. See also section d. (g) See section b.3.d. c. Furnace Shutdown (1) Emergency Shutdown by Operator; Two emergency shutdown pushbottoms are provided, VPBE-1 at the field panel and VPBE-2 at the control room panel. Operating either pushbutton de-energizes the RL1 relay in the flame control units and initiates a total flame failure sequence (see section e.5) . (2) Shutdown Conditions: The following conditions initiate shutdowns of varying degree. Condition (a) Low feed flow in either pass. (b) High bridge wall temperature Safety Device FS-2019 & FS-2170 TI-2161 Pilot Relay VRt.1 \ VR-2 (c) Low pressure at the PS-2165 & outlet of either pass PS-2163 VR3A & VR3B (d) Low fuel gas pressure PS-2038 VR-4 (e) Total flame failure Contact RLI-4 of flame control units VRY (f) Quench tower high outlet temperature TS-3031 VR-2 SL 009839 (g) Individual burner failure Contact RL1-2 of flame control units VRC1-VRC4 CONFIDENTIAL: Subject to Protective Order f 14th Judicial District Court No. 91-1145 5-8 (3) Reaction to Shutdown Condition (a) Reaction to the various shutdown conditions are one or more of the following actions; as tabulated below: (1) Trip the Maxon safety valves in the main burner fuel gas lines, (2) De-energize the pilot solenoid valves in the pilot burner fuel lines, (3) Indicate an alarm condition at the field panel by means of a red indicating light and an audible horn. (4) Indicate an alarm condition at the control room panel by means of an indicating light in a first out sequence and an audible alarm. (Control room alarm system has remote horns in the field.) (5) Closes all of the feed flow solenoid valves after a time delay, (6) Close any or all of the feed solenoid valves immediately. (b) The reactions to the. various shutdown conditions are of the furnace. To Shutdown Condition aV b r'i c4. c.- v d \- . > i " fa gt.. . Correspond Reactions 1 and 4 1,4 and 5 |4 1, 2,4 and 6 1, 2, 4 and 5 1, 2, 3, 4 and 5 1, 4 and 5 3 and 4 (see section d.7) Emergency conditions c, d, and e require a repurge d. Detailed Descriptions of Shutdowns (1) (1) Low feed flow in either pass: A low feed flow in either one or both passes will de-energize relay VR1. Contact VRl-1 opens de-energizing the Maxon safety bus MS-1. When bus MS-1 de-energizes, the Maxon safety valves trip shutting off gas to the main burners. Enclosed limit switches on the Maxons open de-energizing relays VRG1 - VRG4. Contacts VRG1-1, 2-1, 3-1 and 4-1 energize indicating lights VLM-1 to VLM-4 on the field panel. Contacts VRGl-2, 2-2, 3-2 and 4-2 energize the Maxon indicating lights (A-2369, A-2368, A-2367 and A-2366) on the control room panel. Flow deviation switches FDS-2005 and/or FDS-2152 indicate a low flow condition (A-2006 & A-2153) on the control room panel. 009840 SL coNfWEKTiW;; Refer to Drawing 65A-7626. Contacts VRG1-3, 2-3, 3-3 and 4-3 open in the cracking furnace Maxon safety valve hus MS-2, de-energizing the cracking furnace Maxon safety valves. In addition low feed flow is sensed at the cracking furnace with the same actions described above taking place in the cracking furnace flame controls, Maxon safety valve alarms on the con trol room panel for No. 1 cracking furnace are A-2370 to A-2380 (these alarms are energized by integral limit switches in the Maxon safety valves, rather than relay contacts as in the case of the vaporizing furnace). Indicating lights for the Maxon safety valves on the field panel for No. 1 cracking furnace are VIM1 to VLM2, Low feed flow alarms on the control room panel for No. 1 cracking furnace are A-2178, A-2188, A-2189 and A-2190. (2) High bridge wall temperature: When the bridge wall temperature reaches 1400F, alarm A-2261 on the control room panel is energized. When the bridge wall temperature reaches 1500F contact Tl-2161 opens dropping relay VR-2. Contact VR2-1 opens de-energizing the Maxon safety valves. The sequence detailed under d.l. then takes place. In addition contact VR2-1 de-energizes the feed shutdown timer clutch. Clutch contact VHP3-2 immediately closes, energizing the timing motor of VHP3 thru N.C. motor contact VHP3-1. After a time delay motor contact VHP3-3 times open, de-ener gizing the feed solenoid valves and stopping feed flow. (3) Low pressure at furnace outlet: Assume a low pressure occurs at the outlet of pass No. 1. Pressure switch PS-2165 opens de-energizing relay VR3A. Contact VR3A-1 opens immediately de-energizing SV-2193. The flow in Pass No. 1 immediately stops. Contact VR3A-2 opens de-energizing the pplot solenoids, Maxon safety valves and relay VRB, Contact VRB-2 opens de energizing the ignition bus IGN-1. The feed shutdown timer clutch is de-ener gized and feed flow in Pass No. 2 is timed out as in d.2,, above. Alarm A-2166 is energized on the control room panel. (4) Low fuel gas pressure; Pressure switch PS-2038 opens de-energizing relay VR4. Contact VR4-1 opens and the sequence described under d.3. takes place. (5) Total flame failure: The RL1-4 contacts on all flame con trol units open de-energizing total flame failure bus TFF-1. When TFF-1 de energizes, relay VRY de-energizes. Contact VRY-6 opens de-energizing the purge complete relay VRB. Contacts VRY-7 and VRY-8 initiate * total flame failure sequence at the cracking furnaces by de-energizing the Rtl relays in the flame control units. Contact VRY-3 closes energizing indicating light VLT (on the field panel) and contact VRY-4 closes energizing the alarm horn at the field panel.. Contact VRY-5 closes energizing alarm A-2508 on the control room panel. SL 009841 CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court NQ. 91-1145 5-10 When the acknowledge pushbutton VPBA is operated, bns AL-1 is de-energized and relay VRZ de-energizes. When VRZ de-energizes, seal contact VRZ-2 opens preventing VRZ from re-energizing when the push button is released (contact VRY-2 is open since VRY is de-enerigized). Contacts VRZ 3 and VRZ-4 open de-energizing the horn and indicating light VLT. Contact VRZ-1 closes to allow VRY to energize when TFF-1 is energized. Contact VRZ-5 closes to allow the purge sequence to be completed after initiation of a new purge sequence. d.2. (6) Quench Liquor Failure; This sequence is identical to (7) Individual Burner Failure: The following description applies to burner No. 1. Assume that the scanner (FFD-2167) detects a loss of flame at burner No. 1. The flame control unit detector circuit de energizes the flame relay, RL2, in that unit. Contact RL2-2 opens de energizing relay RL1. Seal contact RLI-3 opens to lockout relay RL1. Contact RL2-4 opens de-energizing the "Pilot Established" indicating light VLP-1. Contact RL1-4 opens. Contact RL1-2 closes energizing relay VRC1 (note that VRDI is already energized). Contact VRC1-2 closes energizing indicating light VLB1 (on the field panel). Contact VRC1-3 closes energizing the alarm horn (contacts VRDl-2 and VRDl-3 are closed since VRDI is energized). Contact VRC1-4 opens tripping the Maxon safety valve, MS-2338, and contact VRC1-5 opens de-energizing the pilot gas solenoid valve SV-2334. Contact VRC1-1 opens. When the Maxon safety valve MS-2338 trips an integral limit switch opens de-energizing relay VRG1. Contact VRG1-1 closes energizing indicating light VIM1 on the field panel. Contact VRG1-2 closes energizing alarm A-2369 on the control room panel. Control room panel alarms for burn ers 2, 3 and 4 are A-2368, A-2367 and A-2366 respectively. Contacts VRG1-3 and VRGl-4 open in the cracking furnace Maxon safety valve control bus, but the bus remains energized as long as one burner is operative. When the acknowledge pushbutton VPBA is operated, bus AL-1 de-energizes and relay VRDI de-energizes. Seal contact VRDl-1 opens to prevent relay VRDI from re-energizing when the pushbutton is released (con tact VRC1-1 is open since relay VRC1 is energized). Contacts VRDI-2 and VRDI-3 open de-energizing indicating light VLB1 and the alarm horn. The disposition of the VRC and VRD relays for various alarm contact conditions are given in the following table. SL 42 Subject to Protective Order Of 14th Judicial District Court No. 91-1145 5-11 Alarm Contact VLB Light Normal (open) Off Off-Normal (closed) On Acknowledged Before Return to Normal Off Normal Before Acknowledge Off Horn Off On VRC Relay VRD Relay De-Energized Energized Energized Energized Off Energized De-energized j Off De-energized Energized d. Bypass Switches are provided at both the field control panel and the control room panel to bypass shutdown conditions a, b, c, and f. (shutdown conditions a, b, and c on the cracking furnaces). Operation of either switch, VSBP-1 or VSBP-2, energizes relay VRBP, Contact VRBP-1 energizes relay VRX. ContactsVRX-1, VRBP-2, VRX-2 and VRX-3 shunt the safety shutdown contacts for shutdown conditions a, b, c and f. At the field panel, a red indicating light, VLBP indicates that the system is in bypass condition when either switch is operated. At the control room panel, red and green indicating lights (integral with the switch assembly) indicate that the system is or is not in bypass condition. An integral push button provides a lamp test for the indicators. f. Vaporizer-cracking furnace interlocks Two interlocks are provided between units. Contacts VRY-7 and VRY-8 (on the total flame failure relay) VRY are placed in the power circuits to the RL-1 relays of the cracking furnace flame control units. Ordinarily this will prevent light-off at the cracking furnaces until the vaporizer has been lighted-off. Further, the VRG relay contacts are interlocked with the Maxon safety valve busses of the cracking furnaces, so that the Maxons at the cracking furnaces cannot be armed until one of those at the vaporizer has been opened. For dryout purposes these interlocks may be bypassed by: 1. Purging the vaporizing furnace, 2. Placing the system in "bypass" made (by operating VSBRl or VSBP-2). This bypasses the low flow shutdown and energizes VR1, SL 0098A3 C0F1^-Ctive oru * . *.0 protec ct Co Sublet YJnial lSA 5-12 3. Lighting off one pilot burner at the vaporizer (energiz ing VRY and closing VRY-7 and VRY-8), 4. Arming the Maxon safety valve for that burner. This energizes a VRG relay and the -3 or -4 contact of that relay completes the Maxon safety valve busses in the cracking furnace controls. 5. Coke Knockout Drum; A coke knockout drum is provided as a re ceiver for the vapor and residue discharged from the cracking furnaces during the decoking cycle. The knockout drum is 5'0" I.D,, by 7s8" tangent-to-tangent. The ends are closed with dished heads. The vapor inlet enters tangentially 5'1" from the bottom and is aimed to impinge upon a wear plate. The vapor outlet is at the top through a dip pipe which extends 5!5" down into the vessel. The quench and flush water containing the unburned coke particles pass out the bottom of the drum to the sewer. The vapor stream from the knockout drum passes to a stack. A 3" water line is piped to the bottom of the coke drum, and will be used, if necessary, to flush the drum to remove settled carbon particles. 6. Quench Tower; The quench tower is constructed from carbon steel and is 10* I.D. by 30' tangent-to-tangent. It is packed with 13' of 2" Porcelain Intalox saddles. The packing support plate is mounted 10'4" from the bottom so that there is adequate room for the liquid pool and disengaging space as well. The outlet passes from each cracking furnace into the liquid pool above the bottom of the tower. A rod-out assembly has been installed on each vapor inlet to the quench tower. These will be used to push carbona ceous material into the quench liquor pool. Operational experience will dictate the frequency for using these rod-out assemblies. The quench tower is dumped batchwise automatically into the Dopp Kettle. As the level rises to a pre-set value, a field control circuit will open the dump valve and then close it when a pre-set low level is reached. The level is also trans mitted to the control board. 7. Bottoms Removal System: Tars are removed from the front end of the system by withdrawing a small purge stream from the bottom of the quench tower to the Dopp Kettle, where the tars are concentrated and the EDC solvent is vaporized and recycled to the quench tower. Another Dopp Kettle will be installed along with the second cracking furnace. SL 009844 CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court No, 91-1145 5-13 A steam jacket utilizing 175 psig steam covers the bottom and a little more than half the sides of the kettles. Individual pressure con trol valves maintain this pressure on each kettle. Each kettle is provided with a scraper-agitator that turns at 25 rpm. The fcraper blades are spring loaded so that contact is made with the wall of the vessel. A double mechanical seal with one ceramic and one graphite face seals the agitator shaft as it passes into each kettle. Each seal is cooled with EDC that passes through the chamber between the two seals and out with some leakage through the seal faces? perhaps. EDC at the proper pressure (at least 15 psi above the kettle pressure) is supplied for this purpose with a pressure control valve. The flow of EDC to each seal is manually controlled. The seal coolant effluent is fed into the kettle for disposal. Tars are drained from the kettles through Strahman ram-type plug valves. Each kettle is protected against excessive process pressures by pressure relief valves, which open at 135 psig and discharge into quench tower vapor line. 8. Primary Quench Condenser: Vapor from the quench tower is partial ly condensed in the primary quench condenser with cooling water. The vapors enter the. top shell side of the exchanger in the middle and the uncondensed vapors leave the top at both ends. There is a divided shell side pass and four tube side passes. Condensate leaves ,the bottom of the exchanger at each end and flows to the. quench liquor tank. An identical exchanger will be in stalled parallel to the existing one during the expansion of this plant. 9. Secondary Quench Condenser: Vapor from the primary quench condenser enters the tube side of the secondary quench condenser. Refrigerant F-12 is on the one-pass shell side and effects further cooling and partial condensation of the forward vapor stream, which is also one-pass. The liquid flows to the quench liquor surge tank while the vapor passes forward to the absorber. Freon-12 is fed to the exchanger through a level control valve to maintain a constant refrigerant level. Excessive shell pressures are relieved through a rupture disk, set at 300 psig, and a safety relief valve mounted on top of the monel disk; the SRV (safety relief valve.) is set to open at SL 009845 CONFIDENTIAL: Subject to Protective Order f 14th Judicial District Court No. 91-U45 5-14 300 psig also. The +34'JJ'F f reon-12 vapor leaves the top of the exchanger and passes to the +34 Freon 'knockout drum. Here the entrained liquid is re moved from the freon vapor and returned to the +34 lean oil cooler. The vapor leaves the tap of the knockout drum 1ar return to the Freon compressor. 10. Quench Liquor Tank: The inlet streams to the quench liquor tank enter through dip seal legs to avoid static charge build-up. The horizontal cylindrical tank is 11*10 3/8'' l.D. by 24'- tangent-to-tangent. A level is recorded on the control board, A monel rupture disk is mounted under a safety relief valve for pressure relief', both are set at 135-psig. Quench liquor is pumped hack to the quench tower through a flow control valve. A flow control valve is also used to maintain a steady level in the tank by sending the excess quench liquor to the stripper-. A sightglass is mounted on the tank, to provide a visual check of the tank level. The quench liquor pumps are provided with start-stop stations in the field and at the panel. The discharge line from each pump contains an on-off ball valve which is activated with its respective pump. This set up will enable the operator to quickly establish the quench liquor flow to the quench tower if one of the pumps should fail. It is important to always maintain this flow. 11. Quench .liquor Safety Drier and Filters; The quench liquor pumps discharge into the quench liquor safety drier, which is packed with calcium chloride. This 2*6" 'Ll), by 21 tar.gent-to-tangent vessel is -protected against excessive pressures by a monel rupture disk mounted under a safety relief valve; both are set to relieve at IbO psig. Two parallel Initio filters nave been installed downstream of the safety drier to prevent calcium idlerIde carryover. The filter elements are capable of removing particles down to microns in size,, 12. Vinyl Ahsorbet; The vinyl o-s.r1c r is designed to remove essentially all of the vinyl chloride ir,m the HO vent gas stream. This is accomplished by contacting the vinyl t hi tide-rich vapor stream with a re circulating stream (lean oil) of EDC. Ifit absorption of the vinyl chloride into the EDO lean oil stream is favored by a told EDC temperature. Since heat is evolved during the absorption operation, this is the reason intercoolers, a vent condenser, and a chilled EDC lean oil must be used. SL 0098A6 CONFIDENTIAL: Subject to Protective Order f 14th Judicial District Court No. 91-1145 5-15 The absorber is constricted from carbon steel and is 5*6" I.D. by 68*9' tangent-to-tangent, A cylindrical skirt f>' tall supports the column, The column contains 35 Glitsch ballast trays spaced 18" apart with the foil,ow mg exct p t i on s r a. The spacing below trays 12 and 14 are 3!0" for manway open ings to the column. b, The I'91' spacing below trays 7, 8, 9, 10, 13, 14 and 15 is needed for draw-off sumps for the intercoolers. Only two will be used at any one time. The trays are numbered from bottom to top. Draw-off sumps for the intercoolers are located at the trays named above. These sumps are designed to seal the vapor on the tray at minimum liquid back-up in the downcomer from the tray above. The design is such that if the external withdrawal system should fail, the liquid passing to the sump will overflow automatically to its respective tray. Liquor withdrawn from a sump for refrigeration in an intercooler is returned to the tray below for passage on down through the column. The downcomers on all even-numbered trays are rotated 180 from the downcomers of the odd-numbered-trays. This assures that liquid flowing onto a tray will have to travel completely across the tray before any further downward flow is possible and is the normal situation in any tray column. It is planned t< use trays 8 and 13 tor draw-off points to the intercoolers. It may be found in operations that these draw-off locations ate not properly matched t, the ci luinn heat-load requirements. In this case there are already piped up these alternate draw-off selections: (1) in place of tray 8, tray 10 may be substituted, (2) in place, of tray 13, tray 15 may be substituted. There are two vapor feed streams to the column,, One comes from the secondary quench condenser and the other from the top of the stripper. Both enter the bottom of the column under the lowest tray. The bottom of the column is used as a surge reservoir for feed to the stripper. The liquid is maintained at a constant level by a level control valve. A sigh'.glass is located on the bottom of the column. The column will vent to the atmosphere through a monel rupture disk and safety relief valve if the pressure should reach 135 psig. 00984? SL CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court No. 91-1145 5-16 13, Absorber Vent Condenser: The vent from the absorber passes to the vent condenser where it is cooled from 50T to -29F. The vapor stream enters the top of one end of the one-pass tube side and the vent (HC1) and condensate leave the other end. The vent then goes through an entrainment separator, which has a Teflon mesh mist eliminator, for further condensate removal. The condensate from the mist eliminator and vent condenser combine and flow to the upper intercooler surge tank. The vapor, which is 99+% HC1, then passes through a pressure- control valve; this valve controls the ab sorber pressure at 50 psig. The one-pass shell side of the absorber vent condenser contains Freon-12 at -40F. The liquid level is controlled by an inlet level control valve. The freon vapor flashes to the -40F knockout drum where the entrained liquid is removed from the freon vapor and returned to the -40 lean oil cooler. The vapor leaves the top of the knockout drum and returns to the freon com pressor. 14. Absorber Upper and lower Intercooler System: Vinyl absorber tower liquor flows by gravity into the upper intercooler tanks, from which liquor is withdrawn for refrigeration and return to the absorber. Each intercooler tank is vented back, to the same tray at which the overflow sump is located. The upper intercooler system will be described, with the analogous items for the lower intercooler system indicated in parentheses. Liquor is pumped from the upper intercooler tank through a drier, a filter and the upper refrigerated intercooler. The absorber liquor tempera ture is lowered from 63''F to 42F (from 65(,>F to 5F in the lower intercooler) in the six-pass tube side of this exchanger (eight-pass for the lower inter cooler). Liquor may be recirculated from the intercooler tank, through the intercooler and back to the tank by means of a hand regulated bypass to main tain good tube velocity. The reLurn flow of refrigerated liquor to the column is controlled with a level control valve, which is operated to maintain a constant level in the intercooler surge tank, The flow of liquor to the inter cooler is measured and field-indicated. If this flow drops below a preset level, an alarm will sound and cause an on-off valve which is on the liquid inlet line to the intercooler tank to close. This signifies a pump failure. The intercooler rank is 5`11" T,,D,, by 14' tangent-to-tangent. The vessel is constructed from carbon steel, and is enclosed with dished heads. The liquid inlet passes nearly to the bottom of the tank for seal purposes. A sightglass and level controller are mounted on the tank. The tank is pressure relieved through a monel rupture disk and a safety relief valve; both are set at 135 psig. The shell side of the intercooler is protected with a monel rup ture disk and a pressure relief valve set at 300 psig. The intercooler driers are 2'6" T.D. by 21'O" tangent-to-tangent and are packed with calcium chloride. Each is protected against excessive pressures with a monel rupture disk mounted under a safety relief valve (set pressures are 150 psig). SL 009848 The Fulfla filters have 5 micron filters to remove calcium chloride from the process stream. They also have 150 psig safety relief valves. 1`5. HC1 Stripper; The HCl stripper is used to strip essentially all of the HCl from the EX' stream that passes forward to purification. To effect this separation the stripper contains 40 Glitsch valve trays on 18" spacings. The stripper is constructed from steel, and is 5'6" X.D. by 71'6" long tangent-to-tangent. Vapor leaves the column from the top. The absorber bottoms stream is pumped to the stripper's top tray. Excess quench liquor from the quench liquor surge tank is also fed here. There are three alternate feed points for this stream: trays 35, 37 and 39. Operations will determine the correct feed tray location for this stream. It Is desired to introduce the quench liquor on a tray having the same composition as the quench liquor. The two feed streams to the stripper are measured on flow recorders. A thermosiphon reboiier is vertically mounted on the side of the stripper. Feed to the reboiler is withdrawn from the bottom of the column. The vapor re-entry point to the column is located about 6' above the bottom of the column. The steam flow to the reboiler is flow controlled. The steam flow will be adjusted to control the HCl content of the reboiler liquor. The stripper bottom level is maintained by an overflow pipe which goes to the product still feed tank. The tank is vented back to the stripper just below the first tray. A sightglass is mounted on the bottom of the column. The stripper is pressure relieved through a monel rupture disk mounted under a safety relief valve set at 135 psig, 16. Vinyl Product Still: The material in the product still feed tank is pumped through a flow control valve to the product still. Here vinyl chloride is separated from the heavies and taken overhead as a pure' product, with the exception of HCl contamma t ion, which will be removed in a later processing step. The vinyl still contains 30 Glitsch valve trays with 18" tray spacing. Two different diameters are used in the vinyl column design be cause of the large differences in vapor and liquid loading between the top and the bottom of the column. The column changes diameter between trays 35 and 36 from 7'0" T/D. to 4'9" l.D,, The lower section is 63*4 1/4" from the bottom tangent line to the reducing section. The top of the still is 25'10 1/4" from the reducing section to the top tangent line. The reducing section itself adds 2'0" to the column height. A thermosyphon reboiler provides the boLl-up for this column. The steam flow is controlled by the temperature on tray 19. This temperature controller measures the temperature of tray 14 in the still. It may seem strange that this ternnerature is the one selected for reboiier control, and SL 009849 CONnW^'ive order N. *-n prptct . ; ,,e COUJ not the temperature of the reboiler itself. However, it should be seer, that the reboiler liquor is essentially pure EDC, and as such the reboiler will have only one temperature for a given operating pressure. Temperature at this point would thus be a poor point to control from: either the liquid would boil or it would not, and if boiling were taking place excessive, heat could be applied to the reboiler without any change taking place in the* reboiler tem perature. However, in the. column, and tray 19 is a reasonable, choice, the composition of the major components E'Ot-Vi- is not "fixed", and so a variation in temperature with boilup rate will be possible. Tray 19 was selected be cause there the temperature change will be greatest for a given change in composition. The reboiler level is held at the desired setting by a level control 'valve, an the EDI recycle stream to the heavies still teed tank. Ad ditional reboiler liquor is pumped through a flow control valve to the absorber as lean oil. The vinyl still is protected against excessive pressures by a monel rupture disk and safety relief valve set at 13b psig. The overhead vapors are condensed on the one-pass shell side of the product still condenser with cooling water. The tube side consists of 4 passes. The condensate leaves the exchanger at the bottom and flows to the product still reflux, tank through a stand leg. Vapor leaving the condenser must pass through the refrigerated vent condenser before being vented through the still pressure control valve. The still is pressure controlled through split ranging by either adding dry nitrogen to the vent condenser cutlet or through bleeding off excess pressure through another parallel pressure control valve. Thus much of the vapor space in the upper pari of the vinyl still system contains nitrogen. The vent condenser is then necessary to keep vinyl chloride from being vented from the still with the nitrogen purge stream. The. vent condenser contains one tube pass through which the still condenser vent stream passes. Refrigerant F-12 is fed to the shell side through a level control valve. Treon vapor leaves the top of the exchanger and passes to the -3PF- Freon knockout drum. Here the vapor is separated from the en trained liquid and returned to the compressor suction. The freon liquid is returned to the shell side of the lower intercooler. The condensate (vinyl, chloride.) from the product still vent condenser dr bins to the product still reflux tank through a stand leg. The product stil.1 reflux drum is 6*5" I,,D. by 16!0" tangent to tangent. Reflux for the still is pumped from this tank to the top tray of the still through a flow control valve, A constant vinyl chloride level is maintained in the tank by a level control valve, which allows the excess liquor to pass forward to the product neutralization system and on to the, day tanks. SL 009850 CONFIDENTIAL: Subject to Prf^"Jtc?rcourt Of 14th judicial ^strict 17. Absorber Lean Oil System: EDC from the bottom of the vinyl still divides into two streams; one stream (29% of total) is sent to the heavies still and the. other (71% of total) is cooled and returned to the top tray of the absorber as lean oil. The lean oil stream is flow controlled, while the recycle stream is controlled by the product still reboiler level. The lean oil stream undergoes four stages of cooling in the fur nace feed economizer., 90 lean oil cooler, 34 lean oil cooler, and the -40 lean oil cooler. The furnace feed economizer has already been described. The lean oil passes thru the shell side of this exchanger and is cooled from 315F to 170?. The 90 lean oil cooler lowers the lean oil temperature to 105F. The lean oil passes through the one-pass shell side while cooling water is on the two-pass tube side. The next exchanger that the lean oil flows through is the 34 lean oil cooler. The lean oil's temperature is lowered to 40F on the onepass tube side. 34CF Freon is on the one-pass shell side. The Freon level in the exchanger controls the Freon feed rate, freon vapor leaves the ex changer and passes to- the 34 1 rt.n knockout drum, which has already been discussed. The shell is pressure-relieved at 300 psig through a monel rupture disk and a safety relief valve. The final lean oil cooling step takes place in the -40 lean oil cooler. There are six tube passes through which the lean oil flows. The exit lean oil temperature is -29T, Freon at -40F is vaporized on the shell side of the exchanger. A constant Freon level is maintained by a level con trol valve on the liquid Freon inlet line. Freon vapor leaves the top of the exchanger and passes to the -40" knockout drum. The exchanger shell is pressure relieved at 300 psig. Proper control of the effluent lean oil temperature is very im portant because the. EDC is near its freezing point, which is -32,,2F. The temperature of the lean oil from this exchanger can be controlled by use of a manual by-pass around the 34 lean oil cooler. This allows a stream of ''hot" lean oil to be mixed with the "chilled" lean oil from the 34 lean oil cooler before entering the -40 lean oil cooler. In the case of impending freeze-up, the by-pass valve can be opened completely until the absorber feed temperature is sufficiently high to avoid freezing. 18. Recycle EDC1; The level at the bottom of the vinyl still is main tained by withdrawing EDC for recycle to the heavies still feed tank. This stream is equivalent to 50% of the EDC fed to the furnaces at 50% conversion. There is adequate pressure at the bottom of the still to provide the head neces sary to transfer the recycle stream to the heavies still feed tank. SL 009851 Cl 009852 v CONFIDENTIAL: Subject to Protective Order ot 14th Judicial District Court NO. 91-1145 5-20 The recycle EDO stream first passes to the EDC recycle cooler. Here its temperature is lowered to 180F on the one-pass shell side. Cooling water is on the tube side, which has two passes. The stream next passes through a level control valve, which is controlled by the product still re boiler level. A gaseous chlorine stream is then injected into the recycle EDC line to carry out the chlorination of chloroprene A two-minute mini mum retention time is required for this reaction to take place; therefore, the chlorinated stream goes to a 2' I,,I). by 9* tangent-to-tangent reaction tank. The recycle stream then passes to the heavies still feed tank. Gaseous chlorine is obtained from the. Tri-Ethane plant chlorine vaporizer. A connection is also available for hooking up a ton cylinder of chlorine during a vaporizer outage. A flow control valve, will regulate the gaseous chlorine flow. 18. Heavies Still: The heavies still is designed to remove all high boiling impurities from the liquid EDC. The carbon steel still is 7'0" I.D. by 95'3" tangent-to-tangent. A cylindrical skirt 16'6" tall supports the still. The temperature of the ^liquor in the reboiler will vary propor tionately to the EDC concentration; therefore, the bottom temperature is used to control the steam flow to the reboiler. The column contains 54 Glitsch valve trays with 18" spacing. Feed to the column can be introduced on tray 27, 31, 35, or 39. Reflux is returned to the column*s top tray. A monel rupture disk is mounted under a safety relief valve to prevent pressures on the. still from exceeding 50 psig. The bottoms stream from the heavies still is pumped through a level control valve to the EDC plant bottoms storage tank. This control valve maintains a constant heavies still reboiler level. This bottoms flow is fieldindicated and also recorded on the control board. Vapor from the heavies still passes to the heavies still con denser where complete condensation takes place. The EDC vapors enter the top shell side of the exchanger in the middle and the condensate leaves at the bottom of each end of the shell side. Ihere are two tube passes through which cooling water flows. The condensed EDC flows by gravity to the reflux tank. The reflux pumps withdraw liquid from this tank to provide reflux for the column and the furnace feedpumps withdraw liquid for feed to the EDC vaporizer. The condenser and reflux drum are both maintained at a constant pressure (slightly positive) with a nitrogen pad. The still is, therefore, held at a constant pressure, which is necessary to prevent temperature fluctuations. The vent passes to the heavies still stack seal. This 3' I.D. by 12! tangent-to-tangent Haveg 41 vessel is packed with 7' of 1 1/2" Intalox saddles. Water is;introduced through a rotameter into the top and rnNFlDEf11^;. it absorbs the HC1 in the vent stream. This vessel is vented through a Haveg pipe which extends up the side of the heavies still. 20. Product Vinyl. Chloride Treatment: The vinyl chloride product is pumped from the product still reflux tank to the product cooler. It passes through the one-pass shell side and is cooled by cooling water, which is on( the four-pass tube side. The product stream next goes to a 2' I.D. by 4' tangent-totangent phase separator and is contacted with water. A wet product stream is much easier to neutralize than a dry one. Two flake caustic neutralizers are provided so that one can be infservice while the other Is being recharged. Each is 3' I.D. by 17! tangentto-tangent and is filled with flake caustic. A roll of fiberglass will be installed above the flake caustic. Each vessel is protected with a monel rupture disk and safety relief valve set to relieve at 200 psig. When a freshly charged neutralizer is being put on the line, the contained vapor in the. vessel will be vented to the vinyl still condenser. This venting must be done, slowly so as not to cause an upset in the still pressure. When a neutralizer is to be taken off the line the vinyl chloride in the unit will be purged to the inlet of the other neutralizer by putting nitrogen pressure on the top of it-. Another 2* I.D. by 4' tangent-to-tangent phase separator follows the product neutralizers. The function of this vessel is to prevent any phase water from passing through to the storage tanks and to provide a means for visual inspecting for caustic, carryover. Any caustic-water solution entrain ment can be drained from this phase separator. The product stream next passes through two parallel product fil ters, which contain 5 micron filter elements. 21. Vinyl Chloride Product Storage*. The vinyl chloride next passes to one of eight horizontal cylindrical day tanks. These tanks are 12' I.D. by 78' tangent-to-tangent each. The liquid feed to the vessels enters through a stand leg to reduce the hazard of static electricity formation. Monomer that has been given analytical cleanance, will be transferred to eigher the 54"9" I.D. spherical tank or a larger 60'6" I.D. sphere. All of these tanks have level indicators and transmitters (the level is shown on the control board). Each tank is pressure relieved through a monel rupture disk and safety relief valve at 150 psig. A 3-way plug valve is mounted under the rupture disk to allow for maintenance to be performed on the disk or safety relief valve. This valve opens to a line which has only a monel rupture disk SL 009853 CONFIDENTIALt Subject to protective Order 14th Judicial District Court 5-22 on it for protection. The tank should be vented to this rupture disk only for short periods of time as the. top of the disk is open to the atmosphere. The product transfer pumps canbe used to circulate a tank's contents, to transfer material from one day tank to another, or to transfer a day tank's contents & one of the spherical tanks. If either of the day tanks or spherical tanks should reach a higher pressure than is desired (say, over 80 psig), then this pressure can be bled through a special line to the bottom of the absorber. Also, equilt zation lines connect all of the storage tanks. Therefore, vinyl chloride should never have to be vented from this area. 22. HC1 Distributi on; The HCl which passes through the absorber pressure control valve can be handled in several ways. Some of it will be passed through two activated carbon filters, which will remove the remaining organics from the HCl gas. These 4E I.D. by 12' tangent-to tangent vessels are piped such that they can be operated in series or parallel. Hot nitrogen can be used to regenerate these filters. The pure HCl effluent stream then passes through a pressure control valve. This valve controls the pressure on the downstream side, which is the suction line for No. 3 HCl compressor. The discharge from this compressor combines with that of No. 5 HCl compressor to supply an outside, customer. The HCl which does not pass through the carbon filters goes to the suction of No. 1 and No. 2 HCl-compressors,, These compressors also draw from the wet HCl system. They will be used to supply HCl gas to the Ethyl Ghloride Plant and the. Oxyhydrochlorination (OHC) Plant. The suction line to these compressors from the Vinyl Chloride. Plant will have a manual loaded valve on it. This valve will be set manually in the field so that no HCl gas flows to the HCl scrubber. If the pressure in the HCl distribution line reaches a pre-set value, a backpressure control valve will open and let the gas flow to the HCl scrubber. As soon as a flow passes through this line a cell liquor pump in the caustic area will start and a flaw control valve on the cell liquor line will open, allowing cell liquor to flow to the. top of the scrubber. Water is also added to the scrubber; the rate is determined by the temperature of the neutralized solution flowing to the sewer from the bottom of the. scrubber. The vent line is constructed from Haveg 41 and extends to the top of the tails tower structure in the HCl plant. The 4'0" 1.1), by 16`0" tangent-to-tangent scrubber is constructed of Haveg 61, The by-pass valve on the inlet water temperature control valve will remain slightly open to keep a small water flow going nto the scrubber at all times. This should prevent corrosion on the steel water line. The HCl gas enters the scrubber through a loop which is 4 feet higher than the scrubber. This keeps liquid from getting into the steel distribution header. A small nitrogen purge will be kept or this loop as a further precaution. SL 009854 CONFIDENT!^ B. Auxiliary Equipment 1. Tent Headers; Most of the process relief valves are tied into a 36" header,, which vents to two 6" stacks. One stack is mounted on the heavies still and the other is on the stripper. In addition, a 12" header is provided for vent streams from the eight day tanks in the vinyl storage area. This line has a vent stack also. Each header ir ontinuously purged with nitrogen to maintain an inert atmosphere. Liquid which collects in the 36" header can be drained to several pump suction lines within the plant. 2. Rework Lines; During start-up operations or in the case of plant upsets, off-spec, material will likely be produced. If this material reaches the plant storage area it will have to be reworked. A rework line has been provided so that this material can be returned to practically any vessel with in the plant. A double-block-and-bleed-valve arrangement has been installed wherever this line connects to a process vessel or line to prevent possible contamination. 3- York Centrifugal Refrigeration System; There are seven exchangers in the Vinyl Chloride Plant which require refrigeration. A P-12 York centri fugal compressor will supply the refrigerant at the following temperature levels: Temperature (P) -4o -3 +34 Tons of Refrigeration 160 158 307 625 The 625 ton unit is driven by a 1250 HP motor, which is sized for 2300 V. operation. An identical compressor and motor will be installed parallel to the existing one at a later date. below: Pertinent operating details of the refrigeration system axe given Suction Inlet Size connection, inches Pressure, PSIA Temperature, F Side Connection #1 Size connection, inches Pressure, PSIA Temperature, P SL 009855 10 8,8 -ko 2-4's 21.9 -3 Side Connection #2 Size connection. inches Pressure, PSIA Temperature, F 2-4's 45.9 +34 Side Connection #3 Size connection, pressure, PSIA Temperature, F (Economizing Only) inches 3 81.8 68 5-24 Condenser Condensing Temperature, F Condensing pressure. PSIA Water Flow, GPM 108 l47 2130 Following is a description of the refrigeration control system: GENERAL The refrigeration system consists essentially of two centrifugal compressors operating in parallel on a three stage cooling load. Refer to drawing 65A-6008 and York drawing 5-7403-1. The compresser freon vapor leaving the compressor is liquified in two freon condensers and collected in a surge receiver, T-201. Freon vapor from the surge receiver is returned to the fourth stage suction of the com pressors as a side load for economizing purposes. Liquid freon from the surge receiver flows to the first load, which consists of three process chillers, primary quench condenser, upper intercooler and the +34 lean oil cooler, operating at +34F. Freon vapor from these exchangers is returned thru a knockout drum, T-228, to the third stage of the compressors as a side load. Liquid freon drawn from the 34 exchangers flows to the second load consisting of the lower intercooler and the product still vent condenser, operating at -3F. Freon vapor from these chillers is returned thru knockout drum T-227 to the second stage of the compressors as a side load. Liquid freon drawn from the -3 exchangers flows to the third load consisting of the ahsorder condenser and the -4o lean oil cooler, operating at -4oF. Freon vapor from these exchangers flows to the first stage compressor suction thru knockout drum T-226. PNEUMATIC CONTROL SYSTEM SL 009856 A. General Refer to drawing 65A-6OO8 and York drawings 5-7403-3 and 5-7403-4. SL 009857 rONFXt>EMTl*V** cNr ____^.'tive The pneumatic controls consist essentially of pressure and flow controls for each compressor suction load, motor load override (to prevent overloading the electric driver) and balancing controls for the compressor side loads during parallel op eration. Hot gas by-passes are provided to return hot vapor from the Compressor discharge to each suction stage. These by-passes are utilized during start-up (when the refrigeration load is low) or during sustained periods of operation with low refrigeration requirements. Valves are also provided to inject liquid freon into the hot gas by pass streams to control compressor overheating while hot gas is being utilized for compressor load balancing. During the following discussions control system components will be referred to by the process number appearing on the flow sheets, followed by the York designation in parenthesis, e,,q., SOL-4l45 (l-SOL). B. First Stage Suction Controls (-4oF) 1. The -4oF refrigeration temperature achieved by establishing a pressure parameter for the freon vapor from coolers E-204 and E-210. The con troller used to establish this pressure is PRC~4098(PRC) located on the control room panel. The controller output positions the prerotation vanes on the first wheel of the compressor to control the suction pressure. Controller output also positions hot gas by-pass valve TCV-4lOl(BV-5) (pressure switch PS-4102 (pE-1) energizes liquid injection valve FCV-4120(lIV-1) when hot gas is flowing thru TCV-4101). Solenoid SQL-4l60 (7-SOL) functions thru a reverse acting positioner to keep closed prior to startup. Controller PEC-4098 is also provided with a manual loading station, MLS-4099, mounted on the field panel. The control set points on both the board mounted controller and the field manual loading station are automatically synchronized for "Bumpless" transfer of control location. The #1 compressor cannot operate at less than 10$ of the 625 ton design load capacity. The prerotational vanes enable the first wheel to operate down to 4o$ of design without hot gas by-passing. Hot gas is required from 40$ of design load down to 10$. At that point, the unit must be shut down or surge will occur with likely damage to the compressor. 2. One Compressor Installed; With one compressor installed the output of controller PRC-4098(PRC) will position the prerotation vanes of #1 compressor (j-206) thru the current limiting relay CLR and solenoid valve SOL-4ll8. The current limiting relay, CLR, will modulate the controller output signal in response to the current drawn by the driver to prevent motor overload. Solenoid valve SOL-4ll8 (5-S0L) is energized during startup to allow the prerotation vanes to open while the driver is accelerating, subject to permissive action of CLR. This is especially important as the motor current acceleration time curve SL 009858 roanDENTiM.* Sublet ^ cpu-- 5-26 has been adjusted (electrically) to be compatible with the compressor torque loadacceleration time curve. 3* Two Compressors Installed; With two Compressors installed, the out put of controller PRC-4098 (PRC) will determine the set point of a flow controller in each first stage suction line. With identical flow parameters established for each first stage suction line, the individual flow controllers position the pre rotation vanes thru the current limiting relays CLR and solenoid valves to main tain the flow parameter. The current limiting relays and solenoid valves operate as described under B.2 above. C. Second and Third Stage Suction Controls 1. General; The second and third stage suction controls are basically identical. Only the second stage controls are described. The second stage (-3F) refrigeration load is determined by estab lishing a pressure parameter for the freon vapor from coolers E-205 and E-212. The -pressure controller, PIC-4107 (PC-), maintains the pressure parameter by positioning a control valve PCV-4103 (BV-l). During operation a minimum flow parameter is established with flow controller FIC-4l42(FC-l). The 2nd and 3rd stage wheels cannot operate below 70% of design freon flow thru each individual wheel. Flows below 70% will result in compressor "surge" with likely damage to the compressor, therefore, automatic hot gas by-pass control is necessary. The flow controller FIC-4l42 positions hot gas bypass valve FCV-4l43(V-6) to maintain a minimum freon flow, and pressure switch PS-4l44 (PE-2) energizes liquid injection valve S0L-4l46 (LIV-2) when required. 2. One Compressor Installed: With one compressor installed the set point for PIC-4107 will be manually adjusted and the pressure control system will function as described in C.l above. The output of the flow transmitter FT-4505 will be sensed by FIC-4l42 (FC-1) thru S0L-4l45(l-S0L) and the low selector relay SR-4700, (whose second input will be a dummy 20 PSI load). Flow controller FIC-4l42 (FC-l) will then function as described in C.l above. 3- Two Compressors Installed; With two compressors installed, the second compressor will function as the master unit and #1 compressor (j-206) will function as the slave unit. The pressure control loop for the second compressor will function as outlined under C.2 above. The output of the flow transmitters in the second stage suction lines will serve two purposes. In the first ease, the output of the flow transmitters will each be connected thru a solenoid valve to the low selector relay SR-4700. The lower of the two signals (indicating the smaller of the two flows) will be sensed by FIC-4l42 (FC-l) and the remainder of the flow control loop functions as described under C.l above. The purpose of each solenoid valve is to apply a SL 009859 dummy 20 PSI signal to the low selector relay when the unit with which it is associated is not in operation. Tn the second case, the output of the flow transmitters are utilized to balance the side loads. The side load flows are continuously compared thru the balancing control, 30-4708, and the set point of the slave unit (j-206) pressure controller, PXC-4ll3, is manipulated to balance the side load between the two compressors. The pressure control loop for the slave unit then functions as described under C.l above. D. Fourth Stage Suction Controls The fourth stage s-uction controls are identical to the second and third stage suction controls with the single exception that an external liquid injection valve is not required since hot gas superheat is removed in the surge receiver. ELECTRICAL CONTROL SYSTEM A. General Refer to drawings 65A-7632 and York drawing 5-7403-2. The electrical controls for each compressor are identical and with the exceptions noted below are all contained in a unit panel furnished by York.Specific exceptions are field mounted devices and switches SW-4603, 4605, 4607, 4609, 46ll, 4613, 4615. These switches are mounted on the field refrigeration panel. Although a distinction has been made between the "York" panel and the "field refrigeration" panel, these panels are located side by side for con venience of operation. B. Compressor Startup 1. Prior to attempting to start a compressor, the following steps should be taken; a) Check to be sure that the Oil Cooler cooling water is shut off. Compressor oil heaters (electrical insert heaters in Compressor base) should be energized. Start auxiliary oil pump by turning switch to "manual" position and circulate oil until a temperature of 170F is reached. b) Using the 15 HP pumpout unit compressor, pump down the main Compressor to a pressure of at least 4o PSXG. This lower pressure allows PS-1 pressure switch to open to a permissive startup posi tion for the main compressor protection circuit. Red light on control panel will stay on, however, until reset by pushing 1 PB "Reset" button. 2. Operate reset pushbutton 1PB, thus de-energizing the malfunction indicating lights 1LT to 8lT, and tripping relays 3R thru 9R and relay 12R. T *t i SL 009860 5-28 With these relays de-energized, interlock contacts 3R1 (24-25), 4RI (25-26), 5RI (26-27) 6ri (27-28), 7RI (28-29), 8ri (29-30), 9RI (30-6), and 12RI (7-31) are closed. With freon surge receiver level, motor bearing temperatures and suction pressure conditions normal, interlock contacts LS-4159 (6-6), TS-4501 (6A-7A), TS-4205 (7A-7), HP (31-32) and LP (32-33) are also closed. The auxiliary oil pump switch 2-SW is now put in the "automatic position." 3. When the compressor "on-off" switch 1-SW, is placed in the "on" position, then a closed circuit exists thru the interlock contacts described above to wire #33. The "ready" light (green), , 9I/T, immediately energizes. Relay 2R energizes thru AOP (33-37), 2TR (37-38, times closed) and 2-SW. Contact 2R closes energizing the motor starter, 2M, for the auxiliary oil pump motor, 2MTR. The auxiliary oil pump,starts contact 2R de-energizes the motor heaters, 1H and 3H. r When the differential pressure in the oil system (referred to sump pressure)reaches 30 PSI, pressure switch COP closes energizing relay 10R. Contact 10R (4l-42) opens to prevent 3R1 from energizing 1TR thru contact HR (34-36). At the end of the 1TR timing interval (field adjusted), contact lTR(33-9) closes energizing wire #9. When wire #9 energizes, S0L-4l60 (7-SOL), SOL-4ll8 (5-S0L) timer 2TR, timer 3TR and relay 11R immediately energize. When relay HR energizes, contact HR (9-34) closes sealing in the devices described above thru contact 10R(33-34). Contact HR (34-36) opens de-energizing timer 1TR, resetting the timer contacts, 1TR ((-34) to the closed position. An 11R contact energizes the starter 1M for the compressor driver, and the main motor starts. When timer 2TR energizes, all 2TR contacts transfer immediately (the auxiliary oil pump is momentarily de-energized during contact transfer but for all practical purposes continued to run). Instantaneous contact 2TR (37-38) is now closed and instantaneous contact 2TR (38-39) is now open. Timed contact 2TR (37-38) is now clos'ed. Timed contact 2TR (37-4l) is now closed. When the differential pressure in the oil system (referred to sump pressure) reaches 40 PSI, pressure switch AOP operates opening contact AOP (33-37) and closing contact AOP (33-36). The auxiliary oil pump continues to run thru contact 1TR (33-37). When contact AOP (33-36) closes timer,1TR reenergizes and begins to time. At the end of the timing interval,contact 1TR (9-33) closes and contact 1TR (33-37) de-energizing 2R and the auxiliary Oil Pump motor. As long as the differential in the oil system remains above 40 PSI, AOP remains operated, 1TR remains energized and the auxiliary oil pump remains off. 4. When wire #9 was energized, 3TR began to time. After a time delay of 30 seconds, to allow oil pressure to develop in the gear increaser, contact 3TR (12-45) closes. If the oil pressure in the gear increaser is 20 PSI or higher, contact GLOP is open and 8R1 does not energize. SL 009861 cqhfidbOT^U oia . ,.0 protect court Bubjec^ttnlal oisttic o a"^lU-U 5-29 5. When wire #9 was energized, solenoid S0L-4l6o (7-SOL) and S0L-4ll8 (5-SOL) energized admitting controlled air from PRC-4098 (PRC) to TCV-4l01(BC-5), PS-4102 (PE-l) and the prerotation vane of the compressor (see section II),, 6. With the compressor operational,the operator closes switches SW-4603 thru SW-4615, then closes switches 3-SW, 4-SW and 5-SW, in that order. These switches energize the dump solenoids which have held the cooler level controls and suction pressure controls inoperative. They also energize the dummy leading solenoids which have held the suction flow controls, liquid injection valves and hot gas bypasses inoperative. 7. The cooling water tc the main compressor oil cooler is then opened up. C. Shutdowns 1. General" Circuitry is provided to shutdown as individual unit under the following conditions? a) Low oil pressure (shutdown @ 27 PSI differ.) b) High oil temperature (shutdown @ l85F.) c) High discharge temperature (shutdown 250F.) d) Low suction pressure (shutdown @ 15" Hg,,) e) High discharge pressure (shutdown < 157 PSIG.) f) Gear increaser low lube oil pressure (shutdown @ 15 PSIG.) g) Gear increaser high oil temperature (shutdown @ l65F.) h) High suction pressure (shutdown @ 147 PSIG.) i) High motor bearing temperature (shutdown @ F.) In addition, circuitry is provided to shutdown both units in the event of freon receiver high level. Indicating lights are provided on the unit panels for shutdown conditions "a" thru "h" alarms are provided on the control room panel for shutdown conditions b(A- ), c(A- ), g(A- ), i(A-) and high freon receiver level (A- ). " 2. Operations of Shutdown conditions a) Shutdown Condition A; If the compressor oil pressure falls below 35 PSI differential, then switch AOP (33-36) opens , de-energizing timer 1TR. Relay 2R energizes and starts the auxiliary oil pump. If the compressor oil pressure then drops below 27 PSI differential, switch COP opens, de energizing relay 10R. When 10F de-energizes, contact 10R(4l-42) closes, ener gizing latch coil 3R1. When 3H"latches, contact 3E1 (XX1-47) closes , SL 009862 to . ,ect \\& 3ax 9^ f \**> #o* 5-30 energizing indicating light 1LT. When 10R de-energized contact 10R (33-3*0 opens, de-energizing wire #9. Relay HR de-energizes to stop the main motor. Relay 2R de-energizes closing instantaneous contact 2TR(38-39)- Contact 2TR(XXI-39) remains closed (times open) energizing relay 2R and starting the auxiliary oil pump. In stantaneous contact 2TR(37-38) opens and timed contact 2TR (37-38) remains open to prevent wire #33 from energizing. At the end of the time delay 2TR (S31-39) times open de-energizing 2R and stopping the auxiliary oil pump. Contact 3R1 (24-25) is now open and the motor cannot be re started until 1PB is operated, resetting the alarm relays. B. Shutdown Conditions B thru H The operation of each of these shutdowns is identical, hence only shutdown condition "b" is described. In the event of high oil temperature (l85F), contact HOT (XX1-10) closes energizing latch coil 4r1. Contact 4r1(X3CL-48) closes energizing indicating light, 2LT. Contact 4R1 (25-26) opens to de-energize wire #33* When wire #33 de-energizes, relay, 11R de-energizes to stop the motor. Timer 2TR de-energizes and starts the auxiliary oil pump as described under C.2a, paragraph 2. C. High Motor Bearing Temperature Shutdown If a motor bearing temperature exceeds the set point of temperature switch TS-4501 (fan end) or TS-4205 (shaft end), either contact TS-4501 (6a-7A) or contact TS-4205 (7A-7) opens, de-energizing wire #33 and relay 11R. thereby stopping the motor. When oil pressure drops below 35 PSI differential, AOP operates and starts the auxiliary oil pump as described under C.2a, paragraph 2. D. High Freon Receiver Level The operation of the high freon receiver level shutdown is identical to the high motor bearing temperature shutdown, except that both units are shutdown. SEQUENCE OF OPERATION A. One Compressor Only 1. Normal Startup; a) Auxiliary oil pump switch should be in "auto" position. b) Startup-normal switches should be in "normal" position. c) All safety shutdown relays should be in normal position. (Relays are 3R1 thru 9R1, 12K1 and 13R.) HLSB and two BTD safeties will be closed. d) When compressor "on-off" switch is turned to "on" position control power will be supplied to relay 2R, which will start the auxiliary oil pump. Cil pressure will close COP, which energizes relay 10R. Normally open 10R contact closes to energize timer 1TR. Two minutes later ITS contact closes to energize Relay HR which energizes the compressor motor starter to start the compressor. Timer 3TR is also energized. At the end of 30 seconds 3-R contact closes. If gear oil pressure has not been established, GLOP will remain closed to energize relay 8R1, which will open the circuit, to 11R and, thus, stop the compressor. e) When HR is energized, prerotation vane air dump solenoid 5S0L is energized which permits the pneumatic controller to open the vanes. f) Solenoid valves 1S0L, 2S0L, 3S0L, 4S0L, 6S0L and 8S0L are energized which opens compressor side connection butterfly valves and permits flow controllers to open hot gas bypass valves, if necessary. g) Solenoid Valve 7SQL is energized to permit opening of low stage hot gas bypass, if required. h) Normally open,11R contact also permits energizing liquid injection valve, LXV-1, LIV-2, and LIV-3 are energized respectively by closing of pressure switches PE-1, PE-2 and PE-3 (See York Xwg. 5-7303-4), i) After the compressor is close to design speed (which occurs a few seconds after startup) auxiliary oil switch AOP transfers contacts. Two minutes after relay 1TR is energized, 1TR contact opens to de-energize relay 2R and stop the auxiliary oil pump. j) Off delay contacts on 2TR timer will operate auxiliary oil pump for two minutes after 2TR is de-energized, This occurs on any shutdown, except on an electric power failure. Identification Of Symbols Temperature Level Line Number Hot Gas Air Dump Value -40 d.F. A 7S0L -3 d.F. B 1S0L +34 d.F. C 2S0L +65.4 d.F D 3S0L SI- 009864 Pressure Electric Switch Liquid Injection Valve Hot Gas Bypass Valve Suction Line Butterfly Air Pump Valve Suction Line Butterfly Valve COSM^ctiie order Subject restrict Court 14th -'"bo. 91'1145 * 5-32 PE-1 PE-2 1IY-1 LIT-2 Y-S V-6 PE-3 LIV-3 V-7 * * V-8 4sol 6sol 8S0L 7-1 V-2 V-3 * PE Switch and LIT not required for Line D C. Safety Controls The following safety controls will, on malfunction, prevent startup or cause shutdown; Annunciator Light Provided DESCRIPTION Symbol on York Panel 1) Compr. Discharge Pressure HP Yes 2) Compr. Suction Pressure LP Yes 3) Compr. Main Oil pressure COP Yes 4) Compr. High Disch. Temperature HBT Yes 5) Compr. High Oil Temperature *6) Gear Low Oil Pressure 7) Gear High Oil Temperature HOT GLOP GHOT Yes Yes Yes 8) Compr. High Suction Pressure 9) Compr. Motor High Bearing Temp. 10) High Level Shutdown PS-1 BTD HLSD Yes No No 11) Motor Starter Control Power Relay 13R No * Timer 3TR permits startup without gear oil pressure. Oil pressure must be established 30 seconds after the starting sequence is initiated; otherwise a gear oil pressure failure will be indicated and the compressor cannot be operated. Cl 009865 SL UU* CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court HO. 91-1145 5-33 Malfunction of Item one thru eight above will open circuit to stop compressor. At same time red annunciator light be energized. Light will stay on until "Reset Button" is pushed. If malfunction has been corrected, light will turn off and compressor can be restarted. If malfunction is still present, light will stay on when button is released and unit cannot be re started. Note light for GLOP and COP will stay off once reset button is pushed. Alarm contacts have been provided on BTB's, HOT, HDT, GHOT for use by Pittsburgh Plate Glass Company. Six motor winding temp detector switches (RTD) have been provided in motor windings for us by Pittsburgh plate Glass Company. D. Compressor Sump Oil Heaters The oil heater circuit is designed to he energized any time the compressor is stopped and the auxiliary oil pump is stopped. Relay HR is de-energized when the compressor is stopped. Normally closed 11R contact in heater circuit is then closed. Relay 2R is de-energized when the auxiliary oil pump is stopped. Normally closed 2R contact in heater circuit is then closed. When 11R and 2R are both de-energized, oil heaters will he energized (except heater 3H will be off if thermostat is satisfied). E. Pump Out Compressor Pump out compressor motor can be started with on-off switch provided by PPG. Two safety switches have been provided for compressor protection as follows: 1. High Pressure cutout. Open at 150 psig. 2. Low Pressure cutout. Open at l6 psig. P. Parallel Operations (Reference: York Dwg. 5-7^03-4 and 5-7^03-3.) Low stage suction pressure controller PRC senses suction pressure. As the suction pressure decreases below the set point, PRC pneumatic signal reduces which lowers the set point of controllers EC. EC controllers sense flow to low stage suction of respective compressors. EC adjusts position of compressor prerotation vanes. As required flow reduces, EC closes vanes to reduce compressor capacity. PRC also opens the hot gas bypass valve to maintain minimum flow to low stage suction. Butterfly valves in side connection suction lines are controlled by pressure controllers to maintain design upstream pressure. Signal from flow transmitter of Master Compressor and Slave Compressor is received by balance COBFXOESHf- controller EC to readjust pressure controller pc on slave compressor, which readjust butterfly valve to maintain flow' equal to that on master compressor. Flow transmitters send signals to .selector relay SR.. Lowest of two signals reaches flow controller PC which controls bypass valve to maintain minimum blow into compressor side connection. 3-way solenoid valves are required as shown on Dwg. 5-7^03-^- to posi tion butterfly valves and PRY operator to closed position on respective compressor on shutdown to prevent tack spin. Current limiting relays CLR are shown on each compressor. This relay senses motor current. When motor current reaches overload condition, CLR throttles PRY closed to reduce motor current preventing shutdown during over load condition. Speed of response in control system should be adjusted. For example: slave compressor control system should be slower than master compressor to prevent hunting. G. Special Startups Some "hot" startup conditions may require that "startup-normal" switches for the -3> +3^- and +65.4F level be placed in the "start-up" position prior to starting. When two compressors are operating, in parallel, startup of the second compressor, when the first compressor is operating, will always require that these three switches be placed in the "start-up" position PRIOR to startup. Safety switch settings on the following page. 009866 st CO r o o tO CD CP SAFETT SWITCH SETTINGS KATC'T'AOTIKBR MFG. MODEL NO, ' United Electric J99A-272 DESCRIPTION Discharge pressure United Electric United Electric United Electric J95-3TO J99K-357 J99K-337 Suction pressure Gompr.Main Oil Press, Oompr, Aux, Oil Press, United Electric C99A-10S Ocsnpr, Discharge Temp, United Electric G99A-102 Compr, Oil Temp, United Electric ~j95a"~TM Gear Cdl Pressure United Electric United Electric J95-270 Gear Oil Temp, High Starting Pres,Switch SIM30L CIRCUIT OPEN yju;vtDSi`PJ HP LP COP ACP HOT HOT GLOP GHDT PS-1 148 197 15 I.n,, fig. "ptlTuIti. ~~ 242 232 179" "T65 ~ i BT" _ 179 169 +0 # 1 r,n 153 13 In, Kg. 3C# lift. 33# diti. 250 '?b!J 185U -17xf3~ f I.FT 175 Alarm (Jut Out Cat Out Alarm Cut Out Alarm " Out Out f Alarm J O 0 * 1 V* o 1r S S 1-5 1 *r*- >tr* tder CoUl^ ct 4. METHANE FUEL GAS SYSTEM 5-36 Methane is supplied do the process area at 90 PSIG, but a pressure control valve lovers this pressure tc 3- PSIG. Individual pressure control valves maintain 2-5 PSIG pressure to each furnace's pilots. The outlet process temperature of each furnace controls the gas rate to its main burner gas header through a temperature control valve. Electrically-operated valves have been installed in th line to each pilot and burner; these valves are connected electrically to t.cc s nut lev's system and can be closed immediately if furnace malfunctions varrant such action. 5. NITROGEN HEATER The nitrogen heater is used tc supply a Lot nitrogen stream for regenerating a carbon filter which is no longer removing a sufficient amount of organics from the anhydrous KC1. Approximately 100,000 SCFH of 100 PSIG nitrogen will be heated to 35CF by 200 PSIG steam in this exchanger. Nitrogen passes through the shell side while steam is on the tube side; both sides are one-pass, 6. CONDENSATE SYSTEM; The steam condensate from the VC plant will flow through the condensate collection header to the condensate collection tank. This tank is vented through a stack to the atmosphere. Cooling tower water may be injected into this stack to prevent excess venting of steam. The condensate is pumped through a level control valve, controlled by the condensate collection tank level, to a header which returns condensate to the powerhouse for boiler feed. SL 009868 SL 009869 HC| VENT SL 009870 , We IAJ SutT, BurTLfc ) Foft ** 3 Corn p. 0 <P X fi'o r/T StacV HCl Scrub 6er (VC I'^Anri 1 ,.Y 5t r>cvj ^ Jtff Pi^s __ iT-J? Pcv CL A03OKBE: R Con D.wsk (VC Plrnt) HCl rt- jfv :PIC ('iftfvr 2o p;' 3 ---- 1 Suti-T. BoTTVJt /' ro* "1,1 f 3 Comp- ; fo rtpcv fc. w5 HCl Co<>i p. Sue t. (Bori t-t oC CXI \/flC HU It, i 1 \/fC nutw To *1 Ae SORB6K (i?fcL/t/ 5y;rm) I J?-.t. 0; rr j I3 MCi Corrtf*. DlSCN _ 6'JTTLt FOR / * t, 1, } 3 He v. Comp tel,f oj >1 ki flf TtRcooues i 0 ---------- V f\ r; u * ["* Comp j ' HCl Comp. - Pi ICK, Bor 7 L Arref?cooth` < l Per - ,T>i r cvVc Ik? p\ EC Plhnt &t PCV SL 009871 VACUUM AC I D TO a>K (Dry HC,.') M PCV 5"* /-'-W j --. SrftCF ,-s? ^ rut -H-- f-R -------------(t------------- --Ancon j CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court liO, 91-1145 Old HCl Scrubs rJ r Sewer TITLP HCl PITTSBURGH PLATE GLASS COMPANY CHEMICAL DIVISION LAKE CHARLES, LOUISIANA SYSTEM FLOWSHEET DRAWN BY J*B DATE 3-l-W SCALE None CHECKED by tntTE CHARGE DWG. NO. TPPftffiftb BV DATE felLLOf^ hlAtERlAl SHEET___ !__ OF____ L en n tr o% o aw * ff 5-41 SL 009873 SL 009874 r a--(fiw From Liq. LIV-2 Inject.Hdr.------- Cp pe_20 J-206 (Slave) T* Freon From Users Hot Gas Header 5- From Compressor Discharge YORK REFRIGERATION PARALLEL OPERATION -3F SYSTEM O .S * O' rur o -*^ :Q L ft O -o * -- *13 M 1o h- o w rt a 3H* (OB th-3* to ft > ft H-P H< H* (D "O ft o o. O (0 cn LIn N5 5-43 SL 009875 J SL 009877 Page 5-45 Figure 5.9 r' oevtasifks rTefl-AayY'7 1 l > 5_ PTTe--rotation vAHt (pr?v) OPERATOR C.-i5 Lft. RANGt IMCfJfcASt IN SIGNAL, pens PJ7Y MCUHTtP <ON oor-ipae-sseoR OPErt^TCC poetpcHca ft] t?B3TfRi opoR- usec*re J APPrtox. 4 pt. pRoni FRV OPgATBri IPE-tl.k VM_vfc politic?neo CP&VtffSE: ",>J " 17 soi-1 H r ~l Y-9 I HOT GAS GY-PASS ^VALVE- 3-<=l L&. RO. If AIR To oPfcrt I SfcB UAVS! NOS. 1 H 1 S $-7+03-1 * | 4-*--*t 7-< 4*way ^___y 35 rA'-S ___I CONFIDENTIAL: Subject to Protectiv Order o Hth Judicial District Court Ho. 91-H*5 constant P(?essut?fc-Raeoeo Per Clean i nsyrunteht Supply AtO 50-107 PSI&-C0T PUr3tHA*&2j <)!< - TYiS JNE*jndu[o --------------/ PffE-SSUI?& !3*T?UC:MS V4iVE -. ILf-VE*OTJOf0r I ^CANTaPLAR*l*rVh. FROM PRC *UT(OH PRftBSaRfe 0rfrOLLHa. 5-&3L ] 1 /- pL*J_l___ 3 -I$1-9+, 4tfc tTOVMO n $- 74<7$-4 FoU LOerA-TlePt-l. 1~ Z FoTvge CWNTKCL AR &SWN. FROM FLOW oriTa*u.trt FC Lr3CA-fec> IH line A $te OA'tfj 5-7AOJ-4 Fofit LocAT7<?r*. "Y` I ' MO WIRE- Pe-J in Sfc&lES WITH LkPUiP l-CKTiOH \04VE UV-t Sfc6 VV40. H 9-7403-2 jowrfSON secvice c-211 ' AOJU-&TALBr NKN.fYLtKT i^JTfTJT FReSS. CUMLLATOC^PIBECT ATpAS) AFUSRNGI^tNHOeYPJNPiPUCJ Of TO GUlkh&APS |riTER*ONN6LTlNG TUBiNG *1 HoujfN, PMfcUMATIC COnTCOL PlPlMG F'VR? PUe-CtTT^T'^M VArtfeti 41 HOT <SAS e>Y PASS TO SUCTION uirffr A VAuve PfcR*mO!N6P ^DIRECT ACTING) HOT GAS r3r-PA*4 vAilve 3-15 a- baimoc Air TO OPEN DRAWING* 5-740*-I * $-7403 -4 Supply a r. (By FlJCLt-Astw Afloug Nape PQStV>UR a*C>UClN0> AJ/e /JiRE PE. SW.1M sefcic*. -WiTH UC?UIP tiiuEFT'CH vAL-/fc uv **e two Nft 0-7403-2 pc 3-IJ*RAWG SEE PWO. h. 5-7433-4 FcaR locatioh Signal iNC(teA*e oh Pi?oP IN FAw -- ff-A- ctfnT^OLLent PhEUMATic conTCOL Piping PfeRK Hot <3lA& esY-PASS T<=- euCTUTH LIHtt & C . * O see scBeouL.& at Risht HOMfiens of iTtM ITErMS line e> ITEM N2 line c ITEY YS LiNF. D ITEi- Hi AIR PUMP SOLENOlp VAL'ie L SOL PRESSURE ELECTRIC 4WTCH . PE-2 2 Sol 3 SOL H* Pfi-3 UOUIP INjECTlOrt VAu/6 HPT GAG- BYF^GS YALVE ahr Dump solei.oip vAcVff atTwp>H per tf control valve COHTftX VALVE LlV-2 UY- 3 -A V-G V- 7 v-& 4 Sol 4 SOL &<OL ____ ------y*2 -- \| -3 CHWiSl COMPANY uwsiCW - LAKE CHARLES. LOUISIAN. TM*CTN0.p.74l p. 0. EQUfPMENT^XEa-.g?-^, servicf 'ft. rrj^ f9 imbs^iSS yj>* .dffrrfc: 1. t-iof sas vAlv^ clo^E on sm:.j7 iju^h. 2. p-1 ,^-i.S COfA TAFTS ON PROP In Si&nal PRESSURE To OPt.n ln-I. 3. PE.-2 ,?t,i Pt-4 HdA<.tS &OHTAOT-, ON Rise. 'H ^i&hal PijEsiutig to open -IV/-2. . i_lvJ-S , I-iY-4 ReSP&f"iV(LY. 4 @ - oehoTES FuRHiSHfcp &Y tor a 5. 0 - pEhoTE'S 2ro* oontR_ A|R SUPPLY i$Y cu spaNieR. ts. CF) PEHCT6S FUTURE -iTM. 1.. SR - PEhotes SE-LEOToR. RELAY ppg pocuacr CMFOGe n. p-t4i-4is PPG ftOUlPMBHT H*. 4>EA-54-l6l 4 *$A-5o-H43 1NO- P G-Z-H Yoeit oapeR hl G5-7eo,a>4iP CONTHACT. 5-7+U/3 | CU. OBDKIt 7--H PlTT5e0aH PUAJC CoUAS CHfrrlfCAL. P1VISIOM LAKE- CHASiM, LA. PHfeUMATIC- Ce?WTOL PlPtMOr SCHEMATIC ^ pfe 4vHiYcA (uV HOT REfijo FOR one 'P" (I' uj n RA^. O otr e pc .m ciMet i,c *p l-Hfc A DATE 3-1+- Li RI VIS i O N S C.u BY REV e ANTpRISfi pod. eaestMT unit )t&Kcx adoco 4 0 , REV. C. 5/1^ iU ftontn noT. u al f1 &PLSu Adqcu (FI Sol ^R AOOED 4* PiF'MG. e YHMU OATS DISTRIBUTION DATE OIITRIIUTI N YORK CORPORATION SUBSIDIARY F B RG-WARNER CORP. YORK, PENN. SOUTHWEST REGION, HOUSTON, TEXAS DATE____ll-1# ~ j& n.ww CUB c.l. riPwE XjvL ntAWINQ NO___^>-T4i27 ^ - S 009878 SPRAY' rtOtZBL SUCTMPH syMeoi^> jt- l&6&hp - RReUR& SWITCH -- PWSUR& Brt*CP<lC SWITCH a- -<4o saw Llc*u(P iKaecffOh* VAU/e SCLtCTOR PS-AT Ad PUMP SPLtnoiP VAwv6s> 1 -- F-UPW TrtAhSM'TTEd -C-fx) -- Flow eoNTdOLLCfR. ( pe 1-- PRESSudfc ccrtTftPWLftR ES- 0ALAHCIN6 COI-lTdOL &- CONTROL VALYS VB prv'Q-------FWe-ncrATioN vahe motor on compresses: |pgcl -- SuojioH &5M1TOU.6R CO -- MINIMUM OUTPUT CUMUiATPR ClR -- CURRENT UMiTINO RELAY VP --" 1/AL-VE FteSlTiOHER (F) -- PfcHOT&S FUTURE______________________________ Page 5-**6 Figure 5-10 CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court Mo. 91-1145 Suction -- Lie . INJECT!^ UN6 ngT&;, 1 566 PRAWIHS N*. 5-74<?3-`J PE PNEUMATIC PETAIL5 Of PITV * hot 6as roH-rraoi. <1. ConjPO\Jt FPK UlHft C <0 WHICH ARft HOT SHOWN- TP 3fc 4*M6 A* SHOrtH FOfc LiNfe 3- 4* 3. SEE PBAWINO N4 S-74P3-1 Fd CoHTIZcn. i/alv/5 UPCAfCfri piPirt&, THIS DW<Sr. CPNTfaOfc. SCHEMATIC ONLY* 4. See PWO. He 9-74P3--2 Rod W| R/NCA. 5. ALL POTTEP LINES equiPMENf ARE; Port FUTURE- SO|_fp LINES REPRESENT C^uiPlMEHf Fte-td PRESENT IHSfAwAT'UH6. SPraw-f NOM.EL.S NECESSARY PO wifi?ijio iHJ&cnort 7. (^ee t a6o/e) encfepr mme -o" does Not R6RUIR.6 A pe SW. oR liV. oiscHAcaie CC7NC7. (P) Pittsburgh plate glass company CHEH,c*- ~-m^K0!S325m KKMECT NO. P-741 p. 0. M____ Y-A-/ EOWMENTWOsonacc F/Zeau (&*, /ZUSSerZ. BSE BECH. tesssuBtt. 507 PPS PRouecT CHAR&fc MC P-741-4(1 PYFoffel!< lH<(*?a.oHua* fc-Z-H ha unao.i.iiF______ CONTRACT___5 * 74<73 1 CU. CM T-H PtTTS&uRaH plate <3lass CHEMICAL. Division LAKE CHARLES t I--A . Oor-i J [^O*L. SC H iSrHMlAT IC. -t,' Ci-lAU.., L 'iiWiuLo'-Mion To V-l V-T-Y-i DATE | R E V 1 9 IONS BY A & DATE KSK -VF D a TO-TlTf'UX# To Li<i-^:(T * F JTJUIs . L.U VRAr I-H1 DISTRIBUTION c D DATE 5|l4l<e(o Added *5R' U0T6Y - TICD r3i*tUM>fcS Tol.I.OM, E|U.1,*U6tRrA*LH.Trt >* *c- n DISTRIBUTION YORK CORPORATION SUBSIDIARY OF BO RG-WARNER CORP. YORK, PENN. SOUTHWEST REGION, HOUSTON, TEXAS 3-n ~6=t0 DRAWN G U6 SCALE___ HQHfc TA L. DRAWING NO. 5-7403-4- SL 009879 Page 5-47 Fig. 5.11 cerrom motes : 1. All Relay Cjr.lacts shown with, coll deenergized. For device ide't-. fi catiw see Drwi\g Ko.65A- LZ'i. Haxon aafct valve li it swit ches are shown w.th vil^e n tripped position. KEFEKENCR DRAWTNUS1 65JU5~ 4 VC Equ p- .-nt-Fia Control Gyet^' P Shew ] nr : 5A-52C5 VC Eqn p-rnt-F!\ Cor.trri Sysfti* P cl, Sheet _ r-" 6SA-7t-A VCFVrtr-'l TricLr. V-ipnr' nr Funvsrc WHn* IH-rra , 5hi*p(. of P. 65*--7fc-'S C Electrical Instr Vaporising Tuma'-c WririP Diarran, Sheet a rr /, 4 h U3 0O TVJ* U O 41 <-s**--*i *h*ui tn *r OQrt * O - t - OM u Ok >H m fe SB 040 0* O u ju*o 3 at IT fOi*J>S Xt * 5 - tt Vcrrt, %ocoit & i>avii (CoutadiMi Oocpottiiai t,*-, ti <,* PITTSBURGH PLATE GLASS COMPANY CHEMICAL 01VISION LAKE CHARLES, LOUISIANA VINYL CHLORIDE ELECTPl AL, INSTRUMENTATION EOC VAPORIZING FURNACE FLAMf CONTROL SYSTEM SCHEMATIC HAWN y.aCANTcaem.y am 6-66 _DWG. N0.65A-7625  SL 009880 REVISIONS ^ mTTRC.ttKML,rtl O.BH'i \Al O**, Wit 1 Mtff luTli, fltLl> UPC *** HO- cn* v tm Vo i>-u v* Page 5-48 Pig. 5.12 1- MTO: 1. All Contact* shown - with coll ^HwrjlHd. 1. For 4rrie* Mortification as* Droning "* 6V-',fiT 3*. Kaxan HfHjr vtlvo llut wit- chM or* Asms with ml*s la fcgippod ^hIUhii grtKBtg MAWftOg: KHm&soi, EeridpB Control 94^ > i5*~92GJ Shoot I o' 3 TD Equip cnt--Tlsrt Control 5jrstp Fajwl, Sheet 2 o' ? tyU7i,f TC-Slsetrieal Iw',r, CHWriuritnUg2ngiipfuTf*f-l"i'c* tSheet 6^,^-7'jri FC Elc1 rical ftioi CraeHnc Furrui 2 of 2. 3SJC0I1& jPavig PITTSBURGH PLATE GLASS COMPANY CH1MKAL OtVtUOK LAKE CHARLES,LOUISIANA V C PLANT-- -ELECTRICAL INSTWUMEhFTflTrQN EDO CRACKftJG FURNACE FLAME CONTROL SYSTEM SCHEMATIC-SHEET 1 OF 2 . -- M BXM3CH iftC a^. AWXt kA MT?- tfj<ifrua- Hw< owa NQ. 65A-7626J SL 009881 REVISION!t n*sc 5fe AlMWWHlit; CART'S It* OR VAkfSl |4M> WITH PJ6L0 Cit.eH6*j/P'i'`TrJi ,. , . kw-k-tpfc Fags 5-5p Fig. 5.13 S3 o*, <? B o JfJ f$*F l*!s W* S'3 JE-c I* * 0M1 art* mt Mw Jfrtt, yacott & Itavte --faim U-. 11-l.t PITTSBURGH PLATE GLASS COMPANY LAKE CHARLES LOUISIANA VCPLAWT- -ELECTRICAL INSTRUMEMWKW eoc cwcwfas_F_U__R_N_A__C_E__ FLAME CONTROL SYSTEM^ SCHEMOTtC-SHEET* OF 2 DWG. NO. 65A-7627,1- ALARM POINT SCHEDULE ALARM UNIT ALARM PANEL OR POINT NS RELAY NS RELAY CHASSIS N9 DWG. NR name plate engraving PRIMARY DEVICE PRIMARY DEVICE PRIMARY DEVICE N2 LOCATtOH FUNCTION DWG, HO. MARA NO COPE 5FQL1AIT SEQllSUT PROCESS NO. flLBRM Oi^ouP ALARM 5ET POINT l \ 1 C. & 1 &5A- 5031 AS. Tje&C-*.A/ 70 KC tt-SlArr jQ&SSSiS/GZ 5f'. T< f FWLOL CPP pj - eo+o J Fl -&<>/& \ L10 c t 1, V* A > S3/& r& i/C. S7~ COOSSO/PF S Wircc /DC. AZJ&V&4SS *t FECD FLOW FZz><S3&S/FST/C&/SX///CA CFWZL FRwez LFP A-/ZFP ps-ao+r F&5 - ZOOS' O. P-&O/S c P-2006- YES / \ 9 %1 ' i1 C i >C lfW=`0&/Z/.&Af F&SS *2 FEED FLOW FZOuS/^tr/FfC/CDA/3-KS/XX OC &j&'><Z. MF1tUr*&` TF\FRFTVR W&ICATQP FYfWtrL F/EL& SSZPF S-/TP fos - ;/jv T/-Z/6/ c P-2/S3 a P-Z2&/ YES YES / / \ \ 10 1 4447Z//&et. Cr<S 7& L'C FZ/^MFfCFS F^OSSC/FO SWITCH /=i9A/L t-f-F>F PS-2000 A P-20S3 \ \ l 'O l OC. FZS&A/'&tSS */ Ot/rfi*FZSS Ft&rsscze OM// rc/r S*#Aji. ZPF PS-2/6S 0 P-Z/&<s YES / \ 1A A \ ^<DC i/s&z&e, AZJ&AS, O^SS^2 Ct/T.&QTSS p/eossuco sx//rcsz FHWeFL CPF PS-2/63 0 F}-2//S<3 YES / \ \S C \ OC resets, OEFteiCT 77M/=! 7STA4& ccwt: &0-3C&S /?#//&/. A/LTP \ \V ' Ci " OC I4#=&e */ Ofcfv z&A/rp*.:r F/ELD M&FA TRC-203S <5f-2 c P-203 6 P-2363 YS / \ \ 4r O V V tS A \ FCC FT^'sPS/ &j&AJje .>C i44sOXe SZ/<e*S- OtFL/*-/ trzs/rA&r <er/Fv c&A/r/*cr FiEL 0 F/ELD MBFF MBFP WZ<?Z-2 <f3-Z 3 ^-2363 3 P-2367 \S % \ roc OZ/sCXS. oolfy oes/rFcr FsL> F&FP ypcr*- 2 e Ff-?366> \ \A t es4-9o%i roc FZ*e<s ccmf&cfe; *&ZC?y CC2<y77RC7- r/ELQ FS5/9 ypy-s 8 p?-230a YES / \ \ 5- . ^ ' \ \ a1 > \9 ^ 1 \ V <ft c 1 roz C&4Cer.FZ4*tSOFFOOZOKS FZCDWyOZK-/7r/CM/StO/H/, PC CJ&tCC FZA&*' &LS~2 FZZGFZO& FZ opsOFCOPFOF/OU's/r/, eoc cF&cr, orsorzo^ FZOwsCdsyr/TCXsS-M/j7C* COCCOrKTF FZte*.*/Piss** /?<->FZM, FZO*OZ3&s/&F/CXSS*6'/7C/> FHWisi. F&A/tSL F/HvEL F&A/FL A/fiFA F/fiFA HCFA AVCF/t FOS-20C/ FOS-2069 F>S - ZOTT FUS`ZOSS c P -2/ c P E/33 c F1-Z/&B c P 2/2>0 YES YES YES yEs 2 2 2 2 l 11 % \ iiDC , rr^?sS OOT&&5S rPOOsy/sczr s w/ren PFA/PC IPH ps -z/sr 0 /4-Z/93 YES 2 2 It A l t tt ?> i iOC C.&TCAr FZ//?M&11S5' *2 eX/77/2Q&. F3BSS<S/?e 5YV/TCH COCC&?CA?OZF&V/?4SS*3 <&r7TF&'<3. &&CSSt//e CA'/TC/* PFWSt. P0A/FL IPA ZPP PS -2/36 PS -2/97 p 4 ae/so YES D F! ZZOf YES 2 2 1 It c > 1 t\ A h 1 \ t ts \ \ 11 a i \ \T c t zoc CttCArrz/&r*F?fjsA'if- {xsr&ezs^' /=>*.SS//P 5W/7CH tTOC CG-*C,CFZ/&Ot C^FFZLSF rZA*>0. 7Zst/F?^OCOFX COtsO OC &&/*-, K&9& 7CFFF> TMft*nT/. AC lArOinTO# OOC CttCATFZ/&(/ */ /Y!A > C'/ SAFE ~> VAL Y FOC {?,&FT. FZSAFAF. &O&0SO& *^Z W v// CA'cry //ova 09-3660 P*/SPt jmn LPA r/L> F/CLZ MQfP lYiBEH \ r PS-2/9S TPC -2//J TV - 22*/ AV3 2354 A4S- 235S O P-Z202 YES c Ft-e//<} YES 3 Ft 2306 YES 3 P 2370 j3 Al 237/ 2 2 2 \ \ O T> i OCC&4C*m/ttfrf *3 M/z 0/ J a >- rr valy& r/L0 AABFA VJ3 23SL 3 P 2372 > \ S A. 1 OC COTJCK, /rtsAJ & U&tJC/? *4 Yi/X CA 'y ML VC ciL& M&FA MS E37 3 Ft-2373 \ \ % 'ft. \ \ \m c s \ \B 01 iOC C'&4CACrF7r^O\ '30/^AJO't*O DC CJ04CK. Z/&M &OC'Ajr^ ^ roc CJ&4CJC Ft/^JU. eojpF^je -**7 Max *t i/rtrr valy /X4*t\ l *>-ery v/lsz WA * ,,M CA rt rr ML VO F/CLO F'Fi.fi F/L> MBFA AABFp 7>BFA M9-03S0 M5-Z3S9 MS 236C 3 P-237+ a P-237S 8 P-iS"* \ 1, m a i \ \9 i 1 9 c. \ OOC C&4CAT CZJ<e*J &U&JU3?j3 toe C/&4C/er.F'OjE`AS t$S&AS&*& roc cCftcat fzsf'af* &&/&**'& */ 0 MA*CY SAf'eFV SAL/e Ma * 0// la ft rr * y 5AFTt VALVC F/L> rti,> F/EZ.O 4 BFfi A*BF4 f*BFH MS 236/ M3 2362 MS-2363 3 P-2977 3 F - 237E S F 2979 1 1 9 ^5 \ \ HO A i \ \ 'A A \ 1 *1 t A \ 4 4- t % V tOC cssccr FZF&i/ OOCFyOyC **/ / A1A/Q,V `.AFZry ALV roc CFCCC. COOFS So&rjoe */2 MA*0f' LAFEiyVALYa roc c&ica: F&eA/ coAwr^m-OM/rFC*&b ttcrtr cgastric r~ GOF>F> FrFOTLF s9Ci/7>7 F&SP AFOF-O^' S m^CO^' 'QfjOAO-O rOHsOF> ZFCCO ZZCZLZ /&CCjCCZC'C' eo-36>73 F/CL& F/U> F/Zi> AfCC P9ASSL M&FA &BFF* FS>P PryoA f/EZP A?S-23*4 MS 2363 /cpy-s LR - 30/0 3 Ft-2326 3 F 232/ a P 2309 CT F -3003 C P JO / r YES 2 A- -V t A \ 3&COCF/ reX/SO <OC/7Z.T TOF^fO, TOAFFOtt Tt/GTJSM'STC// F/L> /4T4 TS -303/ e F -JO 2/ 4- 4 1 C 'h 9 \ A ii 9 9 1 Bi ^ A- A- 1 O 1 A 4- 9 0 ' A 4- 4- A 1 A- 4- S, ft l 5 %Z ^ t A- 4- 1, C 1 4- 4- 4 A 4 4- T> 1 A- 4 (d A 1 S 9t A1 4- 4 9 C t >UOiTCz/oo<y2 '7& <2<r<F/crY 7&&X. FZOur X>V4TX3ASSW/TC* &/FMCW /$sG& FUfrtO / AstOTO<C FC/C ty/OWCW C /C/C /I'///1F> #a Z f/57y cy<^oae 7>t/'<zetsjrz. sCrfC??&3C OTsf'CrCO' LEVEL RECORDER zcWOFAFSF)7~S FkS/rtF* s^/orO'C OTF/pro/e OOr^OAC /A/ro/ZFCC C O/C PL/MF reo^ orr*9C,rzr/e FtVCZ: /As'/FF FC/A4F s**yenoe>^-7?9^>7Z-1G> STF/COlF FSOO />////f UFCSOO ///rsr^COCt^4p FlOCpXr VP/*re sA/nrcmcz.-^osfc*f j&ezrsxcsFir r fzczc'ctqc'e: s**/ rr-v OO/OC^ F~Z. OKS O&CSOOFiES~HsyTC// Cc.Cz*^M//&ee&c>c- SZs&r*e rtr.oetATC FF>F*ocyvsjPO^yi//Trf/ ^OiO^^eOSr' ZOT*r<00 f?3SC*Cj/5,<'^ S^CO^OOjCO FttSALf&ff y/Y/TCA/ f}&frr.FFmop. a/r C0-3C 77 EC-36 94 PFA/EL AfCC AACC PPWiFC W)CC SFCC. //ZrA AstyOP PtOOP //ZLP PsryoP Msfi/9 pf?CC MCC FV?AS. MsfiP 'M>SOF MF/f FPA/FL help P&A/OL MFA mg- Iz* PF/JGZ f/LFA Fi>S~ 30/+ c FJOJO 3 PJ03B 3 P SO<70 LR-&6SZ c F JOSJ FT - *4003 PS -4073 PS -4/33 PS -4073 PS - +/3S S F- <6&2<Z 3 F <?& 0 / 3 x) <7033' 3 F--7tS/7 C F- 4020 8 F-<?077 c F +029 Pis-+033 C F -9(032 cPRC-6073 AFO7 __________ 1_______________________ REVISIONS 5, irL.-r Ki. Page 5-50 Figure 5.1 SL 009882 RTA - High Tamperature Alarm RLFA - High lew Flew Alarm HLLA - High Low Level Alarm HLPi - High Low hmiwi Alarm HLTA - High Low Feaperature Alarm LPA - Low Praaeur* Alarm MPA - fealn Burner Feller* Alarm HSDA - Kotor Shutdown Alarm UFA - Ho Flow Alarm A1A1 QQM STHHMI A - Bulla 7* - Tricolor B - Bulla By* - Hormal Groan - Off Bed C - Back lighted lama Plata - Tri- Color 0 - Bulla Eye - Hormal Groan - Low Baber K - Back Lighted Kama Plate - Grean Hormal - Bed Off F - Back Lighted lame Plate - Groan lafcer Off e u ua Vo Tu O O 4J .o > I* *t c 44 mw JH t> *a g; oi Uni SS-i & u mn h a, -m fc o * q -3 O3 V ** fit J3 rs m** 1. Seqwantlal Alexm Colon ladleatee Alamo in a Firatumt Tieual aequence. Seqmmttlal Group Culm ladl- * cateo those Alarms In each FtfiKBlESCE. OllWnGS VC Electric Itatr. Alarm Poi-t Schedule* Grieet 2, 65A-7622 VC Elec, lnstr. Alam Point Schedulet Sh.3 36aco & "Stovie PITTSBURGH PLATE CUSS COMPART LAKE CHARLES, LOUISIANA VINYL CHLORIDE------ELECTRICAL INSTRUMENTATION alarm POINT SCHEDULE SHEET t OF 3 1 ONDON -------- -- muenunauL Uout .... NONF .. P-T4I DWG. HO&SfV~7F>?Q X ALARM P^INT SCHEDULE m ? ;m A(.ARM UlgiT 4UUIM PANEL 0* POINT NO RELAY NB| DWG. Hfi RELAY CHASSIS Hi S sa A 1 s 53 e i s 53 D 1 3 53 C1 5 5 4 C I 5 54 1 5 S9 > 1 5 35 1 S 54 A1 S 54 i 5 3L ot i LI B ^ 1 1I A 1 1 1L A 1 1 1L s 1 1l C| 1 1L 0L 5 55 C 1 3 55 tk i S 54 A 3 54 3 i 9 33 A3 5 54 C i 3 33 Y l 5 5 2 C. 4 3 35 A T 3 a5 31 3 3S C1 3 3 S 1 NAME PLATE ENGRAVING PRIMARY1 DEVICE PRIMARY DEVICE PRIMARY OEVICC HE /?eoo<>4c r .jv^ 4 >=3r<c<5 tm/jat eeute ' LEVEL RECORDER F&ooter ~sr<i_ need fh/m/=* F^OOt/CT STY 1TFiT&MTZS&E FNEOGt/C ? J"r>c -- Morxye stm&t-ejP 7ERfFiR^CQOCCPJr. A*eSSi/ SHf/rCff SEN*/ &//. Wfo r&fe ter CPftdR/N/6. 7X> fDC &EC YC.LE 77t. FEOM/ OEPVFirVEWSftMXA MENKES.ST/tt TEEOPtA/st if>CL N/SRy/S STULL FMBO AiH#A LEVEL RECORD CQMT AforcNC /QeOOi/C TST/E L REFZ.OX TPQA/Art*BL AAPESSCPetE JYt/S?C/V fPe&E&CF" #P1U/)C. PRODUCT 5T.LL PRESSURE PRESS. RECORD. CONTROL. EEPSL F$RS3Ae ^SMf/FCW /VXX)*VX-S J'TTi.X. 7\*f>. nnrv/ee sr/tt bctfipnas wmm AL'MNRCC PWgO pxsHtN /*#WJjr/U JREFt. UX 7ANR LEVEL refy/rs fsttsl men/ox ptuva^ >*Y TP/AMT *v**. GAY T/4XSAT * CCtNTt 7?tA.SE *lT/NS~e 14Y7r*-W *?&. f C. /EENTO/CNT /=***/' XC TPHNSAV/T PUNHR FRCQ* COMPRESSOR, fpioN ca/AP. svc/voN PRESS. theon compressor o/scm. press. FREON COMPRESSOR 0/SCH6- TEAAR 72**/9 &TCOPQ, CQt/77 pt& TOfR AfO rcve MEC fCC*eCte A40710& ^?7PLe7fe it*cc /asgyc*7cae PZ /AJOVCfRr&Yp ^4/4/0^0^70^ . Ey /AFG/OQTCSf^ Aidroue sLf&TOve ^E7PNC 7SEVP more* SPARTEP MEESSOAV stwrzst PRESSURE SW/TCJV JEMPEPATVRE SWtTCM freor comp. REQOcno# 6ar on new* FREQ# COMP LUBE ON* FENiRgeRTt/gg FSN9F4EERFNEE 3WFCM Te/*9R&EAT/E SWfTTJt ao so-rs BO-SEAT BO-SLBC> OO-BASE SO-34*3 00-3433 OO-STO? OD-S9P0 0P-BMP3 BO-BV/0 ' YORK ft* HP YORK #+ HOT YQRX #* GROT YORK #a ROT LOCATIOH ,r FUNCTION dwg. Ha AWNEL AAEC A99NHt. RPMEt AOCC AAANtFL P4RMBC PACE | ,HLLA ) M 1 HLTR r HLLA t MSDR 1 NLFR ,; HLLA ` MSQR NRMSL mcc F99WRL Awmsbl HLLR i AMOR 1 MLPA \ HLLA P40N&L AACC HTR AtSOA ARCC MSDA PWMSEt HLLA NfCC MSOA fRRNCL . /PANEL HLLA fff-f-if RPNEL RU9MBL HLLA HLLA APCC AtSOA NiCC MSOA AACC yPPNEL. jPfELO fK~ NS ON NLPR MLPA HLTA ^ NTR H7A ^ 3 33 C 1 3 37 A1 3 a7 ni 3 3 S i 3 37 C 1 3 f7 l 3 39 4 l a 33 31 a I9 C1 V 4l Al 4 4J 5l 5 57 A 1 5 59 A1 5 59 B L S' 5 9 C 1 S 59 i s 54 D | 3 a 9 1 fpECH comp moron mnwn* temp. freq# comp, moron bear/no temp FREiN RECEIVER LEVEL FREQ* PUMPOUT COMPRESSOR 30* FREQ# RNOCNOUT QRiM LEVEL wf- / " xwxxcur nftum levcl 4-0* FREON NN0CFOOT PRi/M LEVEL */ iMSTROMEHT AtR com* */ tRSTRUMERT 41* COAtR LOSE Oft. TEMPERATURE prscw rsMtRssArt/ss F34* mesCAA rgAtRSXA72/*Jr VC TX CAR LOADING RUMPS ABSORBER TRAY m& absorber TRAY m30 STRfRRER VAPOR OUr STRfRRER TRAV m/P VC - SRRR **f LEVEL */ AfR COMP OfSCHO TEMP temperature SN/TCP TEMPERATURE SR/TCP LEVEL EWfTCP MOTOR STARTER LEVEL SWITCH LEVEL SWfTCN LEVEL SWtTCR MOTOR STARTER TEMPERATURE SW/TCR FE/TP. jPEe&MO&Z rsMjp, &tsec&0&p MOTOR STARTER TP! TRi TRf TRf LEVEL /NOfCATOR TEMPERATURE SWATCH YORK H* RTD 30-B346 BO-33HS 30-JEA4 SO -33S6 30-SBSe RO-39SS 00-3953 SO-3953 30-3953 &0-4f4t A9CC RVBLO R/tSLO P9CC N/EtEf PVNLO PfSLO NfCC. PTRLB MAMBC PtMStTL AiCC PANEL PANEL PANEL PANEL AMNJSM P/EL0 tfTA HTR HLA MSOA HLA HLA HLA MSOA NTA NTP HTR MSOA NTA RFA HTA HTA HLLA HTA MKRK NO. LRSOE* . TR/THC-LOOt PS-S/30 POS-SfAT LPC-LOSE PS- 6/4/ PRC-SOS/ P3-/04S rxt/m-mt LR-/OE9 Li- TCOS Lf-TOif Lf-TQOl L/-7009 PiO-MAOO PS-*/95 T3-+/97 TJ-A/93 rs-ASOf 73 -*203 TSPOT3----- rs- 50/ LS-*/E9A LS-+/SX LS-R/S* LS-+/6S rs- re-/ TEH TRi-t TRf-3 TR/-JO TR/-9 Li-900/ 75-5/ CODS SCQUFAJT SEQUENT FVHJCESS HO. ALftRM GfEDOP C 3, C a Q C C 3 C 3 c C C 3 a c e c c c c e C E E E E E E R E e E C A-SOZ7.. A-E.&S3 A-<S<?eDB /4-GOOp P-&0/& AS/// F1&CXS7 A-GOS-/ A-aaeo A-BOAE A-A/+E <4-/003 J4-/0/5 /f>/00 F/-/OBE A-/QSO NT-/OSB Ht- TOOG /A- 70/3 /4-TOC& m-TOdQ P*- 7<DZS Pf-Tder A-*037 A-4/9+ A-4-/94 A-+/9B A~*JtDC A-4E0E A-+XO* A-410H A-+Z03 A -HAS A-+/S3 A-*/4 A-S/ET A-3000 A-fSOOt P-4S/2 R-RS/0 A-9030 A-+5MA-*5/S A-SOSO ASPS/ A'-9002 ASOT ALARM SET POINT 4- 4S A3 4 45 Ol 4 44 : t 4 4? A1 4- ** fli 4 45 B1 4 41 Cl FREOV COMPRESSOR FREON COMPRESSOR SCR<$, PRESS. FREER COMPRESSOR 0/SCM<+, TEMR FREOM COMA RELUCT tOAf <$E4R Oft TEMP, FREON COM# CURE Oft TEMA FREON COMF MOTOR jVfNOfA/ti TEMP FREON COMA MOTOR BEARfNG, TEMP MOTOR STARTER PRESSURE SH/rCH TEMPERATURE SMUTCH TEMPERATURE SMffTCH rSMPERATVAE SMUTCH TEMPERATURE StVtTCH TEMPERATURE SN/TCR YORNNO-ftP HORN NO. HOT kOMt'MO fif/OT AORHAfO MOT VORHNO RT) , MCC F/ELD F/ECO FfEtO F/EtC MCC FfEtO RS04 HtPA HLTA HTA HTA HTA NTA A-*739 PSRT45 .4-47*6 TS-*7*3 A-*7** TS-4T3T A-F730 TS-4739 A-*7*0 7S-*7*/ TS-*73* rs-*rse A-*7*Z 4-4736. 9 REVISIONS X\^C^T^> 300M CjVO fi- 741 /-/O-.T -me Page 5-51 Figur 5.15 a a j 4 < a a a a s < SL 009883 a ; 9 < a a a 4 c a fSU htmu* M4aa Utm m - RiJ) Tapnlw Ain Bit - K10I Low nw Alan UA - Ui low Uni Ain lft-BOlMtPrwMtUn A - Ujh Law Tafintwi Alam LM - Low Prawaro Alam MPA Mala Bomar Vallwra Ain MM - Hater SmMm Alam m -It Flow Ain a a < J iUBUSBUmBE A - Halle If - Trloolcr * Halle >7* - Bonal Qreoa - Off tel C - Beet Llgtitol Baa Flat* - Trl- Oalar 4 0 - lallo l|w - low1 Dim - Lew * Uw ,, t - lack Lighted m Flat* - Oran Serai - tel Off * f - Back Lighted Ira net* - Oran* Suraol labor Off ** o *c y u o > u fl> ~rA f > U w -m ** m <JJ ^ o -w Wi S 0-.J. fe _ u 2 0 Hht 0 P ** V VL Va *i <-} o JC JQm w** %4 0 1. tliqaitfl Ain Colra lalleetee Alara In * NM- b ewt Tieaal mnbm. iwfm tlal Imp Col--i UttMtM thoae Alara ia oaek flrat- j eat Ore^. j 6?A-?62C TC Sloe. Inotr. AUra Point Sehodul*! Sh.L 65A-7&22 VC Hoc, Inotr. lln Point Schodulo, Sh,3 vtem SebbDWWHok- . rlTT5B(iKbll rUltU LURrAH 1 LAKE CHA1LES. LOUISIANA VINYL CHLORIDE-EUECTHCAL WSTRLVEN "r/iTJON ALARM POINT SCHEOULL SHEET 2 OF 3 1 --LONnOtl * ?-7-f.S -----------------HCNF --------------- THAW ---------3/S-LL------------ w________ ,_____ ________im [)vm NPk 65A-76?I.X tC0NpJDENTIAL: t I4th^ ?rotective Order 1i"i-?i;Srlot Court 6-1 VI. START-UP AND OPERATIONAL PROCEDURES A. Overall Start-Up Procedures 1. Preparation: The following conditions must be satisfied prior to the initial start-up. No assumption is made in the outline below as to the previous history of the VC plant. Thus, the plant could have been down for several months, or for a few hours, and the procedure would not be affected. However, certain of the procedures may be abbreviated or omitted during start up if adherence to these procedures would be redundant. a. The plant process equipment must be clean, dry, leak-tested and in operating condition before any start-up attempt is made. In particular, the furnace refractory must be dried and cured using procedures covered in detail later on. b. Water must be removed from the system by adequate purging with air and then with nitrogen to remove the air. A final flush with dry EDC should have been made. c. The system should be pressurized to 30 psig with dry nitrogen. This will prevent re-contamination with air or moisture;.. d. All utilities must be readied to supply the demands imposed by full-scale plant operations. Check to see that the following utilities can be supplied at the stated conditions: (1) Instrument air at 100 psig. (2) Nitrogen at 100 psig. (3) Steam at 200 psig. (4) Well water (5) Electrical power at 440 and 2300 volts. (6) Fuel gas at 90 psig. e. The. fire water system must be in working condition. f. The cooling tower must be in operation with water circulation through the following: (1) Primary quench partial condenser. (2) Refrigeration :'Freon condenser. (3) Pump out compressor condenser. (4) 90 lean oil cooler. ^5) Recycle EDC cooler. SL 009884 SubWfC?NFlDENTIAL** Of 14th Judicrder 6-2 (6) Product still condenser. (7) Product vinyl cooler. (8) Heavies still condenser. (9) Furnace feed cooler. g. The safety valve vent header nitrogen purges should be set. h. Make certain filters, driers and neutralizers contain their proper charge. i. The system must be filled with dry EDC to the correct operat ing levels. j. Have the HCl scrubber and carbon filters ready for service. k. Make sure that chlorine is available for the recycle EDC chlorination. The chlorine line should be pressurized up to the chlorine flow control valve. pressures. l. Make sure methane fuel gas is available at the desired If these conditions are satisfied, the plant is ready for start-up. 2. Plant Start-Up Sequence; a. Start the heavies still and put it on total reflux. b. Start up Flywheel No. 2 (Purification Train--see Fig.5,2) (1) Pressurize the product still to 75 psig with nitrogen and activate the still pressure controller. Make sure that there is no leakfcage through the relief valve and that the system is otherwise tight. Put the product still on total reflux. Pressurize the absorber to 50 psig with N2* Have the valve on the vent line from the secondary^quench condenser closed so that the two flywheels will be isolated. (2) Start the York refrigeration system and F-12 flows to all users. This will serve to load the unit until the stripper reboiler is started andwill begin to cool down the system. (3) Immediately after Step 2 above, start the lean oil cir culation in the purification train (Flywheel 2). By-pass the furnace feed economizer for the time being. (4) When the absorber is cool about halfway down the column, start fthe stripper reboiler. Set the steam rate as close as possible to that used when the plant is in full operation. SL 009885 SL 009886 CONFIDENT!^ order subject VL^f^Strict Court i4tn Judicial^ (5) Start the upper and lower intercooler systems. Make sure lean EDC is flowing into the tanks from the absorber and is being proper ly returned, (Mote: A recirculation rate will have to be established through the by-pass lines before the cylinder-operated valves will open, allowing liquid to flow from the absorber to the surge tanks.) (6) Check the sightglasses and level controllers for the Freon level in all refrigerated exchangers. (7) Start vinyl chloride recycle from the product still reflux drum through the recycle flow control valve to the bottom of the stripper. Set a flow consistent with the lean oil flow (keep approximately 15% by wt. VC in the stripper bottoms stream to duplicate design conditions). c,, Start up Flywheel No. 1 (Quench System--see Fig 5.1) (1) Check to see that the desired level of EDC is in the quench liquor surge tank, quench tower, and Dopp Kettles. (2) Check to make sure that the ten pass outlets from the two cracking furnaces are closed. (3) Open the Dopp Kettle vapor lines to the quench tower and the Strahman rod-out bottom valves on the quench tower. Also open all liquid dump line valves except the automatic dump valves. liquor flow. (4) Put one quench liquor pump on and establish a quench (5) Turn on the Dopp Kettle agitators and automatic dump control valves from the quench tower. Turn on steam to the Dopp Kettle jackets. Make sure seal liquid is flowing through the mechanical seal be fore starting the agitator. d. Start the vaporizer (1) Start the furnace feed pumps and establish an EDC flow up to the vaporizer feed flow control valves. This can be done by using the recycle line which returns the EDC to the heavies still reflux tank. Put the furnace feed economizer in service. (2) The furnaces to be started should be purged on the tube side with N2, then pressurized to 50 psig and isolated from each other. (3) Turn on the by-pass switches for all low flow and low pass outlet pressure shutdown relays. ., > f'tkn (4) Start the purge cycle for the vaporizer and cracking furnace to be used. Light all pilots after purge is completed. Factory Mutual plug valves have been installed upstream of the Maxon valves on the line to each main burner. These valves have been drilled and tapped and then connected pneumatically so that all of them on a particular furnace must be closed before any of the pilots on that furnace can be started. CONFIDENT!^' SL 00987 (5) Put EDC through the vaporizer to the Popp Kettles (use the start-up line which by-passes the cracking furnaces) and increase the vaporizer outlet temperature as fast as good furnace operation permits (100F/Hr) by starting up the burners individually. Use manual control on all flow valves when starting up. (6) The objective now is to raise the EDC exit temperature from the vaporizer so that complete vaporization is being accomplished. When the vaporizer outlet temperature reaches 400F, light all burners on the cracking furnace. Burners should be at low rates. Bring the bridgewall temperature on the cracking furnace up to that corresponding to that on the vaporizing furnace. (7) As this temperature is reached, slowly valve off to the kettles while opening to the cracking furnace. Use manual control on the flow controllers for the cracking furnace pass flow control valves. Do not open the valves downstream of the cracking furnace until the pressure on each pass is greater than that on the quench tower. This will prevent the carboneous material from getting into the pass outlet lines. (8) Balance the forward feed rates to all of the passes. (9) Check quench liquor flow. Flow enough material to maintain a level above the gas inlets to the quench tower. (10) Bring the cracking furnace exit temperature up step wise to 800 F. Get conversion analysis run and balance the system before proceeding. After checking conversion, raise the above temperature to 850F. Then repeat the above sequence every 50F until the proper percent age conversion is attained. (11) Light off the other cracking furnace in a similar manner. Bring the furnace exit temperature up stepwise at the same rate of rise as the other cracking furnace, checking conversions along the way. (12) Whenever there is a recycle EDC flow to the heavies still feed tank, start the chlorine flow to the recycle line and control the chlorine rate analytically by testing for chloroprene in the reaction tank. (13) Reduce the recycle vinyl chloride to the stripper from the product still reflux drum as the conversion from the furnaces increases. (14) As soon as the level in the product still reflux drums starts to increase, begin forward flow of vinyl chloride to the product neutralizers. (15) Either one or the other of the product neutralizers will be used at a time. The neutralizer to be used should be piped up so that vinyl chloride can flow through it to the product storage area and into one of the eight monomer day tanks. When vinyl chloride begins filling the neutralizer, the neutralizer should be manually vented back to the product still condenser. When the neutralizer is full of monomer, the venting should be discontinued. SL 009888 (16) Adjust flows and levels of refrigerant, flows of cooling water and by-pass EDC flow to the lean oil cooling exchangers so that the de sired lean oil feed temperature to the absorber top tray is obtained. It is intended that during normal steady operations, the lean oil by-pass around the 34 lean oil cooler should be closed. (17) Feed to the heavies still, which is already bn total reflux, should be started as soon as the vaporizer receives feed. There is no need to start the make-up EDC flow" to the heavies still feed tank until the cracking furnaces start converting EDC to vinyl chloride and HC1. Then add make-up EDC to hold a constant heavies still feed tank level. (18) The HC1 gas sent out the top of the absorber will vent to the HC1 scrubber initially, but it can be started to any of the consumers as soon as a sustained flow has been established. B. Detailed Equipment Start-Up 1. Reboiler Start-Up and Operation: Three thermosyphon reboilers are used in the vinyl chloride plant; one is on the stripper, one is on the product still, and one is on the heavies still. The principle of the thermosiphon reboiler is to obtain a rapid circulation through the exchanger tubes by vaporizing the liquid in the tubes and allowing the vapors to leave the top of the exchanger and enter the side of the column below the first tray or support plate. The vaporized material is replaced by liquid which comes down from the first tray in-the still through a liquid leg into the bottom of the exchanger. This vaporization creates a natural circulation of liquid (thermosiphon) through the reboiler, thus eliminating any need for pumps. The rapid circulation rate through the exchanger accomplishes two purposes; first, a high rate of heat transfer to the liquid is effected due to the high thermosiphon liquid velocity obtained; secondly, this high liquid velocity makes the formation of scale or tars on the exchanger walls more difficult and thereby either eliminates the need for cleaning the exchanger walls or greatly extends the period of operation between cleanings over what would be experienced in a static kettle-type reboiler. Three very important items must be remembered when starting up and operating a thermosiphon reboiler. First, never let a reboiler run dry or operate with a low level. This allows some or all of the tubes to be come dry and heat up to the temperature of the steam. This excessively high temperature can cause baking of the tars on to the tube, decomposition of the material in the reboiler, or even formation of more tars which can plug the reboiler tubes. The liquid level in the column should always be operated at a level which can be seen in the sightglass. Secondly, when starting up a cold reboiler, drain all"accumulated steam condensate out of the shell of the exchanger and start the steam feed Slowly. Gradually increase the steam until the reboiler comes up to tempera ture, Leave the steam condensate valve at the bottom of the reboiler open a slight amount and purge wet steam until the tubes have a chance to warm up. This procedure prevents bumping which occurs when live steam contacts cold condensate and it also prevents slugging of the liquid phase in the reboiler tubes. Either of these conditions can damage a reboiler if they become violent enough. SL 009889 CONFIDESTIAM ..V.4art Thirdly, never run a reboiler with a high level, especially when the liquid in the reboiler blocks or partially blocks the vapor outlet of the reboiler. This will stop the thermosiphon and drastically reduce the heat transfer. If this happens, the still must be shut down, the reboiler level lowered to the proper level and the still started up again to re-establish circulation. If a reboiler is failing to supply the design heat flux, and fouling is not involved, check out the steam supply and/or the condensate trap. The trap may be inoperable and cause water to back up into the re boiler. When steam is at the proper pressure, and the condensate trap is work ing, but there is still no heat transfer, chances are the tubes are fouled. 2. Start-Up and Operation of Process Pumps; All process pumps in the VC plant are centrifugal pumps with internal mechanical seals, with the exception of the condensate pump, which has a packing gland. Mechanical seals are susceptible to damage, and care must be taken when starting up or operat ing a pump with a seal in order to prevent seal damage. The mechanical seals used in the plant contain a ceramic and a graphite seal ring. The ceramic seal ring should be protected from mechanical or thermal shock or it will crack. Do not spray water (during washing down the area, for example) on a hot seal. Mechanical shock to either a running or an out-of-service seal will probably damage the seal. The seals used in the plant are balanced and are Crane model 9. The seals are equipped with a back-flush line so that the seal faces can be flushed with clear liquor to wash out foreign matter. The seal can be damaged if particulate matter remains on the seal faces. A high seal flush line pressure can cause the seal to leak. Therefore, regulate the flush flow to prevent this difficulty. If the seal leaks and the flush flow is off, then the seal is probably defective. A centrifugal pump produces the greatest head at no flow; this is also the point where the power demand is the smallest. It is good practice to start up a pump at the point where the power demand is the least, so close completely the pump discharge valve until the pump is up to speed. Then slowly open the discharge valve to keep from slugging liquid through the pip ing. When starting a pump on dead shut-off, the discharge pressure could cause the mechanical seal to leak if the flush line control valve were open too much. For this reason, always have the flush line valve almost closed when starting the pump. The flush valve should be opened to the proper setting when the pump discharge valve is opened all the way. A centrifugal pump can be run with a closed discharge valve for a short period of time only without harm being done to the seal. When run for any length of time with a closed discharge, the liquid in the casing will heat up due to friction and cause vapor lock. The seal will then run dry and begin to heat up, and if the condition persists the seal will be permanently damaged and will probably crack. This also points up another axiom: A centrifugal pump with a mechanical seal should never be operated dry. The seal must always be completely wetted with process liquor to prevent damage from over-heating. Therefore, open the discharge valve as soon as possible after achieving pump speed at shut-off. SL 009890 CONFIDENTIAL: Rub-tect to Protective Order Judicial District Court A# A centrifugal pump should not be operated at the no-load condi tion of reduced flow for very long, because excessive forces may bear on the shaft, thus leading to deflection and consequent mechanical troubles. Excessive flow can also cause cavitation with consequent reduced output, lower efficiency and vibration, which in turn can damage impeller, casing, packing, seals or bearings. Cavitation is characterized by a rattling noise in the pump. It is corrected either by increasing suction pressure or suction pipe diameter, or by reducing flow by throttling the discharge. Pumps should be primed fully before starting. Adequate suction head to prevent vapor locking should be provided. If discharge pressure does not develop a vapor lock is indicated. Try priming the pump (bleed vapor from pump casing until only liquid is with drawn). If this still does not start flow, cool the casing with water or other means to insure that the liquid being pumped is not being continually vaporized. Another item to check is the pump suction, which could be plugged or starved. A starved suction can generally be traced to plugged screens in the intake or to a suction pipe that is too small. A leaking seal that allows air to be sucked in may be another cause of vapor lock. When a fluctuating pressure is noted on a pump, pinch back on the discharge valve to eliminate surging. Be sure the pump impeller rotates in the right direction. If the motor is hooked up to run in the reverse direction, it is possible that threads will be stripped or the impeller run off the shaft. This condition will also cause the pump output to be much less than the design value. This rotation direction check should be done specifically after each overhaul where the Electrical has been disconnected. If there appears to be no valid reason why the specified output can not be obtained, check the operating curves for the pump to be sure the proper design has been installed. Caution is necessary when using pumps on liquids other than those for which they were designed. Thus checking out a pump designed for EDC by using water will not give true performance characteristics. In general, remember that the quantity of liquid delivered by a centrifugal pump is proportional to both impeller diameter and impeller speed. Discharge head is proportional to the square of the speed, and horsepower to the cube of the speed. Thus, if the speed of a pump is doubled, twice the flow is obtained at four times the head, but eight times the power is required. The operating personnel should be thoroughly familiar with these relationships. CONFIDENTIAL: Subject to Protective Order 14th Judicial District Court H . 91-1145 6-8 3. Fuel Gas Supply System: Start-Up Procedure a. Close block valves and by-pass valves at each of the six TRC and PRC stations (one of each for each furnace). b. Place the 90 to 30 psig PCV on manual and pressurize the 30 psig header. If the PCV does not seat off (or hold 30 psig pressure at no flow), close one of the block valves. c. Open the appropriate pilot PCV and burner TCV block valves. These valves should also be started on manual control. d. Fuel gas is now ready to be fed to the furnaces (see furnace start-up procedure for purging, etc. before start-up). 4. Furnaces; The procedures for the start-up and operation of the three furnaces will be very similar. Therefore, their operation will be treated in one section. Differences that exist in operations between the vaporizer and the cracking furnaces will be pointed out. The reader is re ferred to the Petrochem-Isoflow Furnaces OPERATING MANUAL, 1957 edition, for much useful general information on furnace operation and control. GENERAL INFORMATION ON FURNACES a. Definition of Terms Brevity makes it advisable to use terms throughout this manual with which the operator may not be familiar. For this reason they are defined here. Fluid Stream The term "fluid stream" is used to designate the stream of fluid to be heated in the tubes of the furnace. The term "fluid" is defined as any substanfe, liquid or gas, or combination thereof possessing flow characteristics. Pass By a "pass" is meant the bank of consecutive tubes through which the fluid travels from the point it enters until it leaves the furnace. Thus, for example, in a two-pass fur nace the fluid would divide into two streams at the inlet, flowing separately through their respective tube banks and recombining as they leave the furnace on the opposite side. A two-pass furnace with 32 tubes, for example, would have two coils of 16 tubes each, one half the total flow going through each coil. If the same furnace were four-pass there would four coils of 8 tubes each, etc. CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 n Inlet Tube The term "Inlet tube." designates the first tube through which the fluid passes after entering the furnace. A two-pass furnace would have two inlet tubes, a four-pass furnace, four inlet tubes, etc. Outlet Tube By "outlet tube" is meant the last tube through which the fluid flows before leaving the furnace. Radiant Section By "radiant section" is meant that section of the furnace in which the surface of the tube Is exposed to direct radiant heat from the burner flames. In this portion of the furnace by far the major portion of the heat absorbed by the tubes and, therefore, by the fluid, is transferred by means of radiation (75% of total duty). Convection Section The "convection section" of a furnace is that portion in which the tubes are mechanically screened from "seeing" the flame burst and which, therefore, deppnd upon con vection transfer from the combustion gases sweeping over them for the major portion of their heat absorption (25% of total duty). Bridge Wall Temperature This temperature is measured at the point where the pro ducts of combustion enter the convection section in integral radiant-convection furnaces. Draft Gauges Location On Petro-Chem Iso-Flow heaters customary practice is to connect the draft gauge to the following points: 1. The top of the radiant section. 2. The top of the convection section on integral radiantconvection types. 3. Both top and bottom of the convection section on sep arated radiant-convection types. The furnaces are built with 4 draft taps at the proper locations for attachment of the draft gauge connections. CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court Ho. 91-1145 6-10 Method of Hook-Up The most satisfactory method for connecting draft gauges to the furnace is to bring tubing (preferably copper) from the 1 1/2" couplings mentioned above to a point near the draft gauge and merely let the ends of the tubing han& free. A length of rubber tubing permanently attached to the draft gauge can then be temporarily coupled to any tube for the purpose of measuring the desired draft. The practice of putting valves in all tubes or pipes leading from the draft connections and bringing them into a common manifold permanently attached to the draft gauge is not recommended since cross leaks are prone to develop and thus give erroneous readings. Drafts Expected A draft gauge capable of recording in the range +0.2 to -1.0 inches of water is usually satisfactory for PetroChem heaters. All drafts on the natural draft Petro-Chem furnace should always be negative. Snuffing Steam Snuffing steam connections are supplied to the combustion chamber and header boxes of all Petro-Chem furnaces. The amount of steam needed for purging a heater depends entire ly upon the operating conditions at the time steam purging is required. The concentration of steam in turn is de pendent entirely upon the air admitted to the setting and is not affected by the amount of fuel burned or the amount of fuel present in the combustion chamber due to a burst tube. The correct rate of steam introduced will extinguish a fire in a very short time. However, it will be necessary to continue, some steam flow in order to maintain conditions and cool the setting to the point where it will not re-ignite. The amount of steam required after the initial introduction to extinguish the fire can be reduced by partially closing dampers either in the stack or at the intake to the burners. There is a definite advantage to closing dampers at the bottom of the furnace. Closing a stack damper tends to force the fire back out through the burner block. A damper at the intake to a plenum chamber around the burners elimi nates this possibility. CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-114S-11 d. Preparation for Start-Up (1) GENERAL INSPECTION: The first step to be taken is a careful physical inspection of the furnace. The major points to be checked are the following: (a) Burner Alignment & Placement-- Verify the burner position against the suppliers prints. Make sure burner tips are placed correctly and that the con necting piping permits proper vertical alignment of the burner core and tip. Make sure that all air shutters and dampers function freely. In the case of directional burners be certain that all threaded joints which must turn as the burners are rotated have been graphited. It is important that the operators be able to make the necessary burner adjustments freely after the furnace is in operation. (b) Instrumentation-- All flow controllers, recorders, thermocouples, and safety shut-down devices should be checked prior to start-up. Flow recorders should be properly zeroed. Thermocouple leads transmitting outlet temperatures are sometimes reversed thereby making proper furnace adjustments impossible. Leads should therefore be carefully checked. After start-up, removal of the thermo couple from the well for a few moments will indi cate very quickly if the proper points are being read. High temperature or low flow shutdown de vices should be tested prior to start-up. Flame failure devices should be checked by simulating the hazardous condition with the "Fireye" system. (c) Sampling Points-- All 1 1/2" couplings not used for draft or thermocouple connections should be sealed off with a pipe plug. (2) BLOWING OUT TUBES SL 009894 Prior to lighting off, it is important to make cer tain that tubes are clear and unobstructed. Some water may remain in the tubes after the hydrostatic test, or other foreign matter-may have accumulated. Compressed air should be forced through the tube coil at a high enough pressure and in sufficient quantity to assure satisfactory flow. In the case of multipass units, each pass must be blown inde pendently. The inlet valves to the other passes should be closed and air forced through one pass at a time. Finally, nitrogen should be purged through the unit before start-up. All tubes must be thoroughly dry. CONFIDENT1^** Subject to ^^n^trict Court of-14th Judicial ; trie (3) BLOWING OUT BURNER PIPING All burner piping should be thoroughly blown out with compressed air, On multiburner units fed from a single header each burner should be blown independently, Control valves for all burners ex cept one should be closed and full pressure and flow applied to each burner in turn. Failure to remove mill scale and rust in this manner prior to start-up can result in severe operating difficulties over a period of several months, Far tides of scale and rust interfere with the proper functioning of the atomizing tips and result in Idng flames, drip ping, and coking. Repeated shut-downs are necessary until all the foreign material has finally worked itself out of the system. (4) DRYING OUT REFRACTORY In order to insure maximum life for the furnace refractory, it is necessary that it be thoroughly dried before the furnace is put in service. As a general rule the brickwork can be adequately dried by the following procedure; Run steam'or any other available fluid through the tubes, using the lowest flow possible consistent with prevention of overheat ing of the tubes.* The purpose of this is to get high flue gas temperatures without firing so hard as to overheat the brickwork. If EDC stands in the tubes without circulation even at low firing rates the tubes will fill with coke. Table 6,1 lists recommended drying-out periods for furnaces having linings commonly used with PetroChem heaters. SL 009895 Lining TABLE 6.1 -RECOMMENDED DRYING-OUT PERIODS Total Time of Drying Out Temperature Time, Hrs. Cycle, Hrs. 9" 2600E ins . firebrick, 7'' block ins. 4 1/2"2300F ins. firebrick, 7" block ins. 4 1/2"2000F ins. firebrick, 2" block ins. 4 1/2"1600F ins. firebrick 72 60 36 24 24 20 12 8 *NOTE; A small fire should be kindled in the furnace to warpi the tubes and setting before introducing steam into cold tubes; this will prevent severe water hammer from condensate. CONFIDENTIAL: Subject to Protective Order 14th Judicial District Court No. 91-U45 6-13 SL 009896 For the first cycle the furnace should have only a low fire, starting with sufficient flame to give a tempera ture of about 300F at the top of the radiant section, raising gradually during the day to 500F. On the second cycle the temperature on the thermocouple in stalled at the top of the radiant chamber can be raised to 750F, and during the third cycle it should be main tained at approximately 1000F. Normally the brick work and insulation will then be dry enough to permit placing the furnace in operation. However, the most accurate indication of readiness of a furnace for oper ation is the shell temperature. When the fires are started in a new furnace the moisture at the outer surface of the brickwork evaporates into the combustion gases but much of the moisture held deeper in the brick work is driven back into the insulation next to the shell. During this period the furnace shell remains cold. Then as the heat density in the combustion chamber is increased the brickwork heats through and the moisture from the insulation begins to evaporate. This causes the furnace shell to heat up due to the generation of steam in the adjacent insulation; but when this moisture has been thoroughly evaporated the shell temperature will again fall. If the operator keeps some progressive accounts of the shell temperature he will note this rise and fall during the drying out process and when the shell temperature has decreased to approximately 150F or to a point where the hand can be held on it for 8 or 10 seconds the furnace can be considered ready for operation. Definite requirements for drying out time vary with the moisture content of the brick and insulation which is in turn affected by the length of time the furnace may have been idle between completion of erection and beginning of operation. The longer a furnace is in operative the more moisture is taken up by the brick work and insulation due to absorption from the at mosphere, rainfall running down the stack, etc. e. Furnace Start-Up With the several steps outlined in the above sections completed, the actual furnace start-up can proceed. The following outline will give the proper sequence for this operation: (1) START FLOW TO FURNACE The circulation rate should be set as close to design as possible. In addition, the operator must be sure that circulation exists in all passes by checking CONFIDBimAM oraej. rt.Wi.t outt su 009897 his flow indicators or controllers. Flow distribution between the passes should be adjusted as closely as possible before the burners are ignited. (2) PLACE FIFING CONTROL ON MANUAL OPERATION All firing during start-up must be done on manual control. Upsets in various areas of a plant fre quently occur during these periods and with the fuel feed system on automatic control any upset which causes the temperature of the fluid passing through the heater to drop suddenly will actuate the. automatic fuel valve. The fuel valve will then open wide and permit severe overfiring, A similar condition will result if the charging rate is suddenly increased. Sometimes a furnace is lined out satisfactorily at flow rates considerably below design. If the feed rate is stepped up rapidly on automatic fire control overfiring will again be the result. (3) LIGHT OFF BURNERS AND HOLD ON LOW FIRE Light off the individual burners as described in the sections on burner operation. Trim the burners proper ly and hold on a low fire. (4) CHECK OUTLET TEMPERATURE ON EACH PASS Immediately after lighting off check the outlet tempera ture of each pass by noting the thermocouple readings. In some cases where inlet temperatures are low a more rapid and purely qualitative check can be made by plac ing the hand very briefly near an outlet flange to determine any tendency toward a temperature increase. If any outlet tubes remain cold, the fire must be immediately extinguished until the reason for the blocked pass is determined. Experience has shown a wide variety of causes for flow obstructions. On gas heaters or steam superheaters with a low pressure drop, accumulations of condensate or water remaining from a hydrostatic test frequently block one of the passes. On new furnaces blinds are sometimes left on flanges. Frequently waste material, rags, etc., are carried along through the system and deposited at the inlet valve or in a return bend. Other sources of trouble are improperly marked plug cock shut-off valves, faulty flow controllers, vapor locks on inlet manifolds, etc. Subject Of 14th 0 6-15 (5) BRING FIRE UP GRADUALLY ONCE FLOW HAS BEEN ESTABLISHED The circulation of the feed stock through the furnace should be brought up to design as rapidly as possible. How ever, to present overfiring and overheating of the fluid streams the firing rate should be brought up gradually. During this period heat must be supplied both to the charge stock and the cold setting. An attempt to reach design outlet temperatures too quickly can result in severe overfiring. The outlet temperatures of the passes should be watched carefully and the various fluid streams trimmed accordingly. If one pass overheats or vapor locks, the flow to this pass should be temporarily increased until normal flow is restored. As charging rate and temperature approach design conditions the pressure drop through the furnace will increase and the unit will tend to line out. Bringing up the firing rate too quickly does not per mit making the necessary intermediate adjustments and may make, it impossible to line out the furnace at full rate. Depending on the type of prpcess and the furnace design involved, the time required to reach design outlet conditions will vary. The recom mended increase in outlet temperature of the feed during start-up of a Petro-Chem furnace of standard design is 100F per hour. (6) WHEN OUTLET TEMPERATURES REACH NORMAL OPERATING LEVEL SWITCH TO AUTOMATIC CONTROL When the furnace has been brought up to the expected operating level the swing to automatic control may be attempted. In some cases it is advisable to line out the furnace on hand control before switching, parti cularly on new units where the automatic control may not have been completely adjusted. On a routine start up, however, where the instrumentation is reliable considerable time may be saved by making the swing from manual to automatic control as the outlet tem perature approaches the desired level. Under such circumstances the automatic temperature controller may stabilize furnace outlets more quickly than would be the. case on hand control. Requirements of Good Furnace Operation The normally accepted operating procedure of most refineries will result in satisfactory performance with Petro-Chem furnaces. However, there are certain important requirements, peculiar to the Petro-Chem furnace, which must be met. SL 009899 CONFIDENTIAL! Subject to Protective Order of 14th Judicial District Court No. 91-1145 6-16 Flame Condition The ideal length for the flame pattern is between onehalf to two-thirds of the distance of the radiating section. Under no circumstances should the flame be permitted to touch or lick the tubes. In the case of multi-burner installations the fires should be kept as uniform in length and size as possible. Excess Air Continuous checks will automatically be made of the flue gas to determine the excess air in the furnace. The furnaces are designed for 20%, excess air. Apart from the benefits obtained from greater operating efficiency, the bridge wall temperature is reduced as well as the rate of oxidation of the tubes. Overloading Good operating practice must recognize that while ex cessive firing is at times necessary and the furnace design allows for a limited percentage of overload on a continuous basis there is nevertheless a definite limit beyond which it is both uneconomical and unsafe to go. Overload capacity varies with the size and type of heater as well as the individual design. PPG's furnaces are overdesigned for 20% additional load. g. Operating Precautions Pressure at Top of Furnace Standard Petro-Chem furnaces are not designed to operate under pressure. A negative pressure at the top of the convection section is utilized to pull in cold air from the atmosphere to cool the structural steel work. If the furnace is fired too hard or allowed to operate with too much ex cess air the large quantity of flue gases may cause a positive pressure to build up and thus blow hot gases out through the openings intended for the admission of cold air. This is particularly true with the separated radiant convection types and with those types equipped with an air preheater, since both have a greater con striction than would normally be offered by the stack. With such units, pressure on the furnace can be easily recognized by the burning of the paint from the header boxes at the top of the radiant section. SL 009900 CONFIDENTIAL: Subject to Protective Order t 14th Judicial District Court Ho. 91*1145 6-17 The possibility of building a positive pressure usually occurs during a start-up, when the furnace is being fired excessively, or the excess air for combustion has not been brought down to the normal operating re quirements Due to its vertical construction the IsoFlow furnace has a high draft at the burner level and to control the excess air it is necessary to close the dampers much farther than an operator would expect on the basis of experience with other types of heaters. Firing too hard, that is, burning an excessive amount of fuel in the furnace, can usually be attributed to the use of an automatic temperature controller to bring the furnace up to temperature. Upsets in various areas of a plant frequently occur during these periodssand with the fuel feed system on automatic control any up set which causes the temperature of the fluid passing through the heater to drop suddenly will actuate the automatic controller and may allow it to open the fuel valve too wide, thus forcing an excess amount of com bustion products through the furnace. In order to protect the upper structural steel work, it is important that the operator watch draft condi tions at the top of the furnace. Any tendency for a pressure to build up at this level should be cut to a minimum by keeping secondary air damper doors closed as far as possible, consistent with good flame condi tions. The furnace should always be brought up to temperature by hand control. In order to assist the operator in maintaining satis factory draft conditions in the heater, draft gages are installed as described earlier. The draft at the top of the radiant section should be logged each shift and become part of the permanent operating data of the furnace. Flame Impingement on Tubes Flame impingement on tube surfaces will greatly de crease tube life and may result in a serious tube failure. The furnace should be checked for any signs of flame impingement at regular intervals and parti cularly after any change in load. In gas fired fur naces at high firing rates, the true flame pattern may not be visible to the naked eye. However, local hot spots on the furnace walls, especially if of vary ing intensity are indicative of impingement by the nonvisible portion of the flame. Mis-alignment of the burners, insufficient combustion air, or enlargement and corrosion of the. burner ports are frequently the cause of incorrect flame pattern. CONFIDENTIAL: SL 009901 6-18 Afterburning Operation of the furnace with insufficient combustion air may result in loading the unit with carbon monoxide. As a result, afterburning may take place at the base of the stack where the cooling air is admitted or even at the top of the stack depending on the amount of CO present. The burning at the base of the stack will not be visible from the outside and the only evidence will be a rapid increase in stack temperature. Permanent damage may result due to overheating of stack metal and the upper structural steel. The immediate remedy is introduction of more combustion air by opening of the burner dampers in the following sequence: (1) cut firing rate; (2) open burner dampers; (3) increase firing rate. If the additional air ad mitted is insufficient to halt burning, or if the dampers are already in the wide open position when the afterburning first occurs, a substantial temporary cutback in firing rate must be made. As soon as the afterburning has ceased and the furnace has cleared itself of carbon monoxide, the firing rate may be incraased again. Corrective steps in the case of after burning must be immediate and drastic to avoid serious damage. Whenever afterburning becomes a problem it is an indication that a program of more adequate com bustion control and flue gas analysis is in order. Keeping P6dp-Holes Closed Peep-hole door hinges are occasionally tight enough to prevent the doors closing completely by their own weight. Consequently the operator should take care to see that the peep-hole doors are pushed tightly closed at all times. If this precaution is not observed, con siderable air leakage may occur with resultant lower ing of furnace efficiency. Also a greater amount of air leaking in at one peep-hole than at another will tend to cool off one section of the furnace, thereby making if difficult to balance the temperatures in the various passes of a multipass furnace. Low Flow--Loss of Flow The operator must at all times be watchful of lowvflow or temporary loss of flow to the. furnace. Check mul tipass furnaces to insure that flow is going through all passes. There are flow controllers for all passes because proper flow is critical. SL 009902 Testing Tubes When placing hydrostatic test on tube coil, it is necessary to expel all air from tubes. This is best done by circulating water at full main volumes through each pass until a full flow of water is noticed at each outlet. Allow water to run out of outlets to sewer for one-half hour, then shut off drain valves and bring up to test pressure with test pump. t Cleaning Extended Surface and Outside of Tubes The tubes in the convection section of radiant-con vection furnaces are equipped with extended surface studs welded to the tubes. With continued operation, particularly on fuel oil, this surface may become coated with carbon, sulphur, etc., so that its efficiency will be reduced. When this happens the convection surface can be cleaned in several ways. The easiest and frequently the most satisfactory method is to pass cold EDC through the tubes after the furnace has been shut down and at the same time introduce steam into the combustion chamber. The steam will condense on the outside of the tubes and remove the deposits. An alternate method when the furnace is shut down is to water-wash the extended surface from the inside of the furnace. This can be done by stationing an opera tor on the baffle sleeve cover plate, which is located at the top of the extended surface. The water hose, should be equipped with a right-angle nozzle to direct the stream down along the extended surface, thus keep ing the wetting of the surrounding area to a minimum. Start-up of the furnace should be doneggradually to permit excess moisture to steam off. The drying-out procedure as outlined for new furnaces may be used. If the deposit is loose in character, it can be removed to a considerable extent by entering the furnace through the stack access door and blowing down the convection surface with a steam lance in a similar manner to the water wash. The furnace can also be designed to permit cleaning of the extended surface while it is in operation. The top tube sheets are then provided with openings to allow use of a steam lance while the furnace is running. de* v COvHt If the coating is so adherent in character that it does not respond to any of the foregoing treatment the tubes should be raised from the furnace and cleaned with a wire brush* Some radiant convection heaters are fitted with demountable top headers and special Y-type bottom headers of which only the plug projects through the tube sheet. This allows any tube hairpin to be hoist ed from the stack monorail by merely unbolting two adjacent top headers. The only joint that is broken by this procedure is the concrete around the bottom header. This break should be patched before operating the furnace. Always make an explosionmeter check at all burners before light-off to check for possible fuel valve leakage. If the test is positive, find and stop the leakage before light-off. Gas Burner Operation Once the individual burners have been lit off and are being controlled by the main gas valve, the condition of the flames should be checked. (1) Open completely the gas valves to the individual burners. The main gas control valve should directly affect all the burners without any intermediate throttling action by the individual shut-off valves. Only in cases where unequal burner pressures result from a poor gas distri bution header, should the individual gas valves be used to trim the burners, (2) Close off the secondary air shutters until the desired excess air is obtained. For initial operation this should be checked by an Orsat analysis of the flue gas. Gas Burner Problems Once burners have been ignited and the furnace operation has lined out, very little difficulty should be encountered. However, listed below are several causes of burner trouble along with the necessary corrective steps: PROBLEM: BURNERS GOING OUT Cause No. 1: When aspirating type burners are operated at pressures considerably over design, sufficient primary air may be aspirated to lean out the gas-air mixture to a point where it will no longer ignite. C0HFI^ctive order Solution: Close down on primary air damper, Cause No. 2: Liquid in the gas line of both aspirating and raw gas burners may cause them to go out. This is particularly true at higher rates. As gas velocities go up, liquid may be en trained that has been accumulating for some time. Solution: A knock-out drum properly drained and of ade quate capacity should be installed in the fuel gas system ahead of the burners, PROBLEM: FLASHBACK OF FLAME TO GAS MIXING ORIFICE Cause No. 1; Operating at too low pressure. Flame propaga tion velocity exceeds gas velocity at ports. Solution: On multi-burner installations shut off sufficient burners to raise the pressure level more nearly to design conditions, Cause No, 2: High hydrogen concentration in fuel gas. Solution: Close off primary air doors completely and seal with tape. This in effect results in a raw gas burner. However, for continued operation a permanent burner revision must be considered. PROBLEM: INSUFFICIENT CAPACITY Cause No. 1: Insufficient gas at burner. Solution: Check gas pressure at the burner. Design pres sure is given in PSIC at the burner not in the header or at some intermediate point upstream. If gas pressure is too low check piping and control valve for trash and obstructions. Cause No. 2: Heating value of gas below design. Occasional ly the fuel gas as fired has a BTU value con siderably below design. This results in in sufficient heat release despite the fact that the burner is operating at design pressure or above. Solution: The gas limiting orifice on aspirating burners should be enlarged. The drilling should be in creased by 1/64" at a time and the results noted. However, before any changes are made, the BTU value of the gas should be compared with the design and the heat load on the furnace should betchec'ked. On raw gas burners check with manu facturer for burner port revision. CONFIDENTIAL; Subject to Protective Order of 14th Judicial District Court H . 91-1145 6-22 PROBLEM: ERRATIC FLAME PATTERN Cause No. 1: Lack of combustion air. Insufficient combus tion air will result in long, lazy irregular flames, with a tendency to wander. The flame will reach toward any available oxygen, con sequently leakage of air around peep-hole doors or from other burners will cause the flame to deviate from its normal pattern. Solution: Open air dampers until flame steadies out. Cause No. 2; Excessive firing. High firing rates, partic ularly with gas-mixing orifices or burner ports enlarged above design will result in long irregular flames. Solution: Check with manufacturer for information on allowable port or mixer drilling and gas pres sure for overload condition. Do not make changes unless properly advised, Cause No. 3: Obstructions in burner ports. When operating at high pressures, aspirating burners may pick up loose trash paper, insects, etc., with the primary air and lodge them in the burner ports. Solution: Disassemble burner and clean ports. If condi tion seems likely to repeat, install screen over primary air intake. (This should not be done unless absolutely necessary since it also reduces amount of aspirated primary air.) Cause No. 4: Improper alignment of burner and tips. (Par ticularly likely to give trouble with raw gas burners.) Solution: Check burner for alignment, centering, and proper distance of tip inside muffle block. PROBLEM: PULSATING FIRE, "BREATHING" Cause: Lack of draft. As the available draft is ex hausted in the furnace the flame begins to pulsate badly, finally reaching the point where it will alternately ignite and go out, sometimes with almost explosive force. CONFIDENTIAL: Subject to Protective Order 14th Judicial District Court H . fl-1145 6-23 Solution: Reduce firing rate immediately. After pulsa tions have ceased, check furnace. Stack dampers should be checked if the furnace is so equipped. If no obstructions are found, furnace duty should be calculated to determine if ex cessive overload is responsible for lack of draft. Difficulties may arise from a wide variety of causes and the fore going is not intended as a complete list of possible trouble spots. 5. Quench Twer Start-Up: Start-Up Procedure a. Close all valves connecting the quench tower and cracking fur naces (ten vapor inlet lines). b. Establish an operating level of EDC in the Dopp Kettles, quench tower, and quench liquor surge tank. c. Start a cooling tower water flow through the primary quench condensers. d. Open the valve on the vapor line from the Dopp Kettle to the quench tower and the manual block valves on the quench tower drain line. e. Start a steam flow to the Dopp Kettle through the pressure control valve. f. When EDC vapors start passing through the quench tower, as indicated by the temperature rise, start a quench liquor flow to the tower from the surge tank. g. The quench liquor system is now in service, ready for the for ward flow from the furnaces. Check Points a. Make certain there is a starting level of EDC in quench tower. Hold this level by recycling quench liquor to the quench tower. This level must submerge the gas inlet ports. Never run the quench tower dry. Care must be used in starting up so that dirty EDC does not back down into the furnace passes. This is prevented by letting the cracking furnace outlet pressure in crease until it is;"higher than the quench tower pressure before opening the valves connecting the two. b. Any large temperature increase at the top of the tower may indicate failure in the quench liquor supply system. The furnaces will have to be shut down if this flow is not restarted immediately. SL 009906 SL 009907 CONFIDENTIAL: Subject to Protective order 14tb Judicial ^strict Court No* 6-24 c. In the pilot plant it was important to eliminate cooling of the furnace gases in the line leading to the quench column. Cooling resulted in carbon deposit formation. This will occur normally, however, at the inlet nozzles according to pilot plant experience. This means that the rod-out assemblies will have to be stroked to clean the inlet ports as pressure drop increases. Always null out the plunger as far as it will go when rod-out is completed. 6. Popp Kettles: At full production, both Dopp Kettles will be floating on-stream continuously receiving periodic dumps from the quench column and vaporizing EPC and VC back into the system. Since this is a scraper-type kettle agitating a carbonaceous, block, tarry mass, level indi cation could be some problem. However, a workable system has been provided via a pair of top-mounted sight ports, one lighted and one for view. The ports are cleaned internally with an EDC flush stream. Start-up Procedure kettles. a. Turn on all steam tracing for the liquid dump lines to the b. Open valve in vapor line from top of kettles to the quench tower. Open valve in the vent by-pass between feed and vapor lines. This allows the tarry liquid to drain completely into each Popp Kettle after the batch automatic valves close thus lessening the chance for line make-up. If it is found that steam-tracing is 'a detriment to such an empty line part time, the tracing will be left off. Perhaps the tracing will evaporate all remain ing solvent leaving a coating of tars-carbons on the inside of the pipe. c. Start flow of EPC seal flushing liquor to the agitator seals. This EPC comes from the lean oil stream. Whenever this flow is off, the agitator must bf necessity be turned off so the seals do not run without coolantlubricant. Regulate the pressure control valve on the inlet line to give de sired EPC pressure at the seal faces of 95 psig. Regulate flow of EPC to the seals with the 1/2" manual valve provided so that the seal is running cool. d. Set steam pressure regulator to give desired steam jacket pressure. Open valve in steam line to kettle to be used. Check steam trap for proper functioning. Vent the jacket to remove non-condensables, normally air. e. As indicated by the quench tower bottoms temperature and level, the dark liquor should be manually or automatically withdrawn to the Popp Kettles. To effect this operation, open the two Strahman ram-type plug valves in the draw lines passing to the kettles. Leave these valves open all the time except when the outlet gets plugged and needs "ramming" clean or the automatic valve is out for repairs. Open the manual block valvep in the draw lines downstream from the level control valves; the automatic on-off control valves will remain shut if the selector switch is on "manual" or if the level is low and the selector is on "automatic". Use the selector switch provided to have eifher "manual" or "automatic-batch" dumps. On "manual", the operator must observe the sight glass and push the proper button for dumping at the proper time keeping it 6-25 depressed until the level has decreased to the proper place. On "automatic", alternate batch dumps will be made to each kettle whenever a pref-set high level is reached in the quench tower. The valve will automatically close when the level reaches a pre-set low level in the quench tower. Therefore, the level will fluctuate up and down in a given frequency of dumps depending on the specific excess amount of quench liquor pouring into the tower. f. Normal operation on "automatic" batch dumping will cause the level in the quench tower to fluctuate as mentioned above. If this frequency is too rapid, lower the flow of quench liquor slightly to see the effect; if conversely the frequency is too infrequent and the dump liquid consequently too concentrated in tars and carbon, raise the quench flow and watch the effect closely. Make slow changes here. NOTE % The design of the kettles at full production rate requires both in operation. They will work at the end condition except when a fresh dump is made into the kettle and EDO is being evaporated. They will always contain a mass of hot tars being agitated around at a high 325F temperature to provide a heat sink. As the tars build up to the top of the external heating jacket, they will be dumped out the bottom into a portable "buggy" for disposal. Even then, the kettles should not be emptied completely of tars, g. To isolate either Dopp Kettle for some reason like maintenance, only the Strahman valves and the kettle vapor outlet line and vent need be closed. h. Drain tars from the full Dopp Kettle to the portable "buggy" for disposal. Operator must wear gloves and face shield during this operation to protect his person in the event of a leak. The hot tars cause very painful burns. These dumps are made while the kettles are in operation in order to take advantage of the 70 psig Internal pressure for dumping. A vent line is provided to vent the "buggy" to the vent header. i. The sight glasses located on the tops of the kettles will coat with splashing tars. The tars can be flushed off with a clean stream of EDO, which can be turned on to the underneath side of each sight glass with a valve. Check Points a. Make certain the automatic dump control is functioning and the material is being withdrawn to the kettles. If purge liquor will not flow, the drawline will have to be cleaned out. In this case, isolate the Dopp Kettle to be worked on and use the clean-out flanges provided for getting to the pipe lines . b. Make sure EDC seal flush liquor is flowing at proper rate and pressure (15 psig above the internal pressure). Seals ghould be cool to the. touch. SL 009908 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 6-26 c. Make certain the real level in the bottom of the quench tower is being indicated on the sightglass. d. Do not let unit cool off while it contains concentrated tars. All tars should be dumped out before steam is ever turned off. 7. Absorber: Start-up Procedure a. Set the absorber pressure controller at 50 psig. Open block valves around this PRC. b. Determine where vent HC1 stream is to be sent and line up the proper HC1 transfer system. The HC1 scrubber will always float on the 1 ine. c. Pressurize the absorber to 50 psig with Nj. d. Make certain operating levels are in intercooler tanks and in the bottomspof the absorber, stripper, and product still. Now the refrigera tion unit and lean oil flow (Flywheel No. 2) can be started. e. The intercooler pumps must be started in order for the control valves in the gravity overflow lines from the trays to open up to the inter cooler tanks. Open valves in the draw tray lines to the respective intercooler tanks. Select the draw tray to be used at this time. Open the intercooler tank vent lines to the respective draw tray. All other valves in liquid draw lines and tank vent lines should be closed. Unblock the intercooler level control valves. Set level controllers at desired control point for the inter cooler tanks. Start intercooler pumps. f. The absorber is ready to accept vapor and liquid feed streams from the quench system. g. When vapor feed to absorber commences see that the pressure control valve is holding the set point value. This is the main pressure con troller for the front end of the plant. tj. Lean oil temperature to the absorber top tray should be regu lated so that the EDO will not freeze on the tubes in the -40 lean oil cooler. Close control of this temperature will be obtained by automatic regulation of the suction damper in the 14" line to the refrigeration compressor. Fine con trol of the lean oil temperature may be obtained by manually adjusting the flow of hot liquid by-pass around the 34 lean oil cooler. If there is danger of a freeze-up, the by-pass allows a warming-up of the effluent stream. i. If it is found during operations that the proper draw trays are not being used, the other available draw tray to each intercooler unit will be used. At any one time, only one tray should be open to each intercooler tank. SL 009909 "?NFp?otecUve Order Subject to f^p^trlct Court Of.ittb Judicial^Distr Check Points a. See that proper control over the lean oil temperature is obtained. This temperature must be maintained at -29F as it enters the absorber. EDC freezes at -32.2F. Check the field-indicated temperature and the temperature recorded on the control board for agreement. They must agree or be checked. b. Be sure the draw trays are taking the full absorber downflow stream. If not there may be plugging or vapor lock in the draw line. Flow indicators measure the flow to the intercoolers, but will represent more than the overflow if the manual by-pass valves are open back to the intercooler tanks for recirculation. c. The HC1 vent transfer system from the absorber must be con nected up properly with the correct valves open. Otherwise excessive and detri mental back pressures may be built up on the absorber. d. Check the absorber level control valve in the field for proper functioning. This controller is not in the control room. 8. HC1 Stripper: Careful operation of the stripper is important, since whatever HC1 gets through the stripper bottomsswill end up in the vinyl product and will have to be neutralized with flake NaOH. The reboiler steam flow will be controlled on the basis of control chemical analyses made on the stripper bottoms stream for HC1. Start-up Procedure a. See that proper start-up level of EDC is in reboiler. b. Select the tray that will be used to receive the excess quench liquor from the quench liquor tank and close all alternate feed line valves. c. Open block valves around the level control valve in the feed line to the stripper from the absorber. d. The York refrigeration unit and Flywheel No. 2 may now be started. Turn on the stripper feed pump. Open the block valves on the liquid overflow line to the product still feed tank and the equalization line from it to the stripper. e. Start-up stripper reboiler. Open block valves around the steam flow control valve. Open the 100 psig steam to the flow control valve, then set it at a steam flow to give desired stripper boil-up rate. Check the steam trap for proper operation. f. Stripper is now ready to receive the EDC-VC-HCl stream from the bottom of the absorber. SL 009910 CONFIDENTIAL* S_ ubject ttoo prrrootective. Ot rCdeour rt f 14th J2lC1-liS g. Make fine adjustments with the steam flow controller set point so that the stripper bottoms will analyze less than 10 ppm in HC1 con tent. Remember, the temperature is already fixed by pressure and composition of liquid which must pass through this point. Therefore, boil-up rate is the only variable available to do the HC1 stripping effectively. Check Points a. Maintain proper level in the reboiler sight glass. This should be done automatically due to the overflow arrangement. b. Very careful handling of the flow controller must be exercised to establish the proper boil-up rate so that the stripper bottoms stream will be essentially free of HC1. No more than 10 ppm HC1 should be in the bottoms liquor. The operator can prevent a loss of flake caustic handling if the stripper is operated correctly. c. Make sure that the material equivalent to the EDO and VC in the furnace discharge plus the EDC lean oil is being sent through the stripper reboiler and on to the vinyl still. This stream cannot be tempera ture controlled, since concentration and pressure have already been set. The concentration at this point should be 12-15 wt. % VC. d. Check the steam trap at the reboiler for proper functioning. 9. Product Still: This still is designed to operate critically at both the top and bottom of the column. This is, EDC and other minor heavy constituents must be kept out of the still product, and in like manner VC must be kept out of the bottoms. The production of pure vinyl product is the controlling limitation, so it should be met first. However, it should be pointed out that in general all VC appearing in the still bottoms will be lost from the system either by (1) being sent to the absorber and vented with the HC1 or (2) being sent with the recycle EDC to the chlorination step and there converted to 1,1,2-trichloroethane which represents a loss to the system. Start-up Procedure a. Set the pressure controller at 75 psig. Turn on 100 psig N2 supply and open the block valves around the pressure control valves. The still will now pressurize up to the 75 psig set point. b. Make sure recycle EDC chlorine, is available up to the chlorine flow control valve. c,, See that cooling water is on the still condenser. d. Open valve in feed line to proper tray. This initially will be tray 30. Close valves in alternate tray feed lines (trays 22, 26 and 34). e. Start-up charge of EDC should be in reboiler. Drains should be closed. A start-up level should also be in the reflux drum. SL 009911 CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court 11 . 91-1145 6-29 f. The recycle EDC level control valve, should be blocked off. g. Follow the reboiler start-up procedure. h. The VC in the column will pass overhead to the condenser and reflux drum. If there is no VC inventory in the still at start-up, then pump some to it from storage. Otherwise, the column will have EDC from bottom to top and it will not be possible to use the automatic temperature controller. i. When there is a level build-up in the reflux tank, start re flux to the still. To do this turn on the reflux pump and open the block valves around the reflux FCV. Set the FRC so that some level is maintained in the tank. Increase the reflux flow to the desired set point as soon as possible. This will take some time for at least two reasons. First, the still is cold and it has to be warmed up. Secondly, the first overhead product will contain a lot of EDC and some time will be required to work the EDC and/or other impurities out of the reflux tank. The still cannot be put on full re flux at once or it will flood. All impurities must be removed from this reflux tank or the first material produced will have to be reworked later on. j. Leave the still on total reflux until the top tray temperature, at 75 psig is 100F and the reflux receiver is over half full. k. The still is now ready for the York unit and Flywheel No. 2 to be started. l. After VC is being sent to the product still and the reflux tank level starts increasing, open up the proper valves so that VC product can be piped to storage via the following route: (1) from the level control valve through the product cooler to one of the flake caustic neutralizers; (2) from the flake caustic neutralizer to be used to one of the eight monomer day tanks. Be sure to pass through both phase separators. m. As product VC fills the reflux receiver past half full, open the isolation valves around the level control valve and slowly birLft'g up the set point on the level control valve to the desired level control point. Until the flake caustic neutralizer on line is filled completely with VC, vent the top of the neutralizer through the line provided to the vapor line to the still condenser. n. The EDC hat does not crack in the furnaces (the recycle EDC) will begin to build up in the vinyl still reboiler. To lower and control this level at the proper value, adjust the set point on the controller and open block valves around the control valve. Open up any other valves in the line between the product still reboiler and the heavies still feed tank. The re cycle EDC stream will now begin to flow. o. Open up block valves around the chlorine FCV and adjust the chlorine flow to the proper setting for the recycle EDC chlorination. SL 009912 NTI"we order p. Check to see that the product still controller is giving the approximate temperature desired in the vinyl reboiler. Refine the set point value b*y obtaining analyses on the still bottoms. Raise the set point (higher temperature) if too much VC is in the reboiler liquor. The VC should be 0.5 wt. % or less at this point. q. Check the pressure controller to see that the still pressure is at its control point, r. Have F-12 system adjusted on the vent condenser if the proper temperatures are not being obtained. Troubleshoot with the process inlet and outlet temperatures. Also, the liquid refrigerant temperature and the F-12 vapor pressure in the exchanger shell will be helpful in checking out a poorly functioning system. s. The proper still feed tray location will be determined after operations have commenced. Sample analytical traverses will be obtained from the trays so that the feed composition can be matched to a partic$l^*' tray. Check Points a. See that the reboiler steam trap is working. b. Adjust the temperature controller set point so(that the bottoms VC concentration is as low as practicable without causing heavies to appear in the VC overhead product. Remember, keep EDC out of the overhead VC product as a first priority. c. The vent condenser must be in operation to keep the V6 losses at a minimum. 10. VC Neutralization, Product Cooler: Product VC from the still will contain some HC1, It is necessary to remove this by neutralization with flake NaOH. This is where it pays to run the stripper bottoms as free of HC1 as possible. Start-up Procedure a. See that cooling water is on the jacket of the product cooler. b. Select one of the two dried flake caustic product neutralizers for service. Be sure an adequate charge of NaOH remains in the neutralizer selected. Isolate the other one with the valves provided. Open up valves around the neutralizer to be used so that liquid flow will be from the cooler through the phase separator (which should be about 1/2 full of water) to the bottom of the neutralizer, then out the top of the neutralizer to the downf stream phase separator and on to the storage tank area. stil c. The vapor vent line from the top of the neutralizer to the ' be opened. SL 009913 6-31 closed. d. Be sure the drain valve at the bottom of the neutralizer is e. The product cooler phase separators, and the on-line neutralizer are ready for feed. Check Points a. The VC passing through the downstream phase separator must be perfectly clear. If entrained solids are present, switch to the other neutralizer. Drain the VC liquid from the offending neutralizer. Recharge the neutralizer with fresh NaOH and fiber glass packing. b. Closely follow the water analyses of the effluent VC from the flake neutralizers. These analyses will be used to determine when a neutralizer is no longer able to retain the water of neutralization. The analyses will also show when the neutralizer is losing its effectiveness to neutralize the HC1 present in the VC product. c. Some water may have to be added to the upstream phase separator to open up a blocked neutralizer. 11. Chlorination of Recycle EDC: More than the two-minute minimum retention timeaof recycle EDC with chlorine at a temperature of 180F has been allowed for the chlorination of unsaturates, especially chloroprene. IT WAS FOUND THAT CHLOROPRENE IN VERY SMALL AMOUNTS IN THE CRACKING FURNACE FEED HAD A DEFINITE, DELETERIOUS, EFFECT ON THE CONVERSION. IT MUST BE REMOVED FROM FEED TO THE FURNACES. Start-up Procedure a. Bring gaseous chlorine to the flow metering station. This will come from the chlorine vaporizer in the Tri-Ethane plant. b. Open up the block valves around the flow control valve. c. When recycle EDC is flowing, add chlorine by adjusting the automatic controller to the proper flow rate. Use analyses of the chlorinated recycle EDC stream to determine whether further adjustments are required in the chlorine flow. Check Points a. If furnace conversion ever falls off necessitating a higher cracking temperature, SUSPECT CHLOROPRENE. 12, Heavies Still: This still is designed to remove the heavies from the recycle EDC, It will also remove heavies ftrom the make-up EDC from the EDC plant until the second cracking furnace is installed. Then a new heavies still will be installed in the EDC plant to remove the heavy impurities from the make up EDC. The purified EDC make-up stream will then be added to the heavies still reflux tank. SL 009914 Start-up Procedure a. Make certain cooling water is on the still condenser and that 200 psig steam pressure is available at the temperature control station. b. Open the proper feed tray valve. For initial start-up opera tions open the valve to tray 27. The exact feed valve to use will be determined by operating experience and analyses. c. Open manual valves on each side of still reflux control valve and on back through the reflux pump to the reflux drum. Leave the reflux pump discharge valve closed. d. Open manual valves in the still feed line between the feed tank and the still. Leave the discharge valve on the still feed pump closed. e. Check the still reboiler level. The initial start-up level for the reboiler is at the top of the sight glass. f. The start-up level should be in the still reflux drum. A higher level can be used if the unit was recently shut down. g. Turn off the nitrogen pad that has been held on the unit since it was cleaned for start-up (or after a shutdown was made). h. The still bottoms discharge line should be blocked off. i. Turn on steam to the reboiler. Follow the reboiler start-up procedure. As the reboiler temperature starts to ri$e, the still pressure will come up. When a slight positive pressure is obtained, open the still vent line to bleed off the inerts. j. As the reboiler temperature comes up, the level will drop. If the level goes below the normal operating level, add some reflux to the still from the still reflux drum. Watch the reboiler level closely, as it can easily change during start-up. k. Slowly raise the steam flow until it is approximately at the desired operating value. l. As the still vapor line comes up to 183F and a level rise is indicated in the still reflux drum, start the still reflux flow. Begin the flow low and increase it to hold a constant level in the reflux drum. Increase the reflux until the proper flow for a 1:1 reflux ratio is obtained. Base the re flux ratio on the still output. Regulate the reboiler steam flow to hold a con stant level in the reboiler at the set reflux rate by remote-manual opening or closing of the temperature control valve. m. Close the still vent after the temperatures are established and open the nitrogen pad to the still condenser. All inerts should be vented from the still. SL 009915 CONFIDENTIAL: Subject t Protective Order f 14th Judicial District Court No. drawal. n. The still is now on total reflux with no feed or bottoms with o. Put the steam controller on automatic if enough heavies are present for automatic control. p. Start feed to the still from the feed tank. Slowly increase the feed to the still until the still feed is equivalent to the vaporizer feed. q. Increase the set-point on the temperature controller to the desired reboiler temperature. This must be done slowly as the reboiler can be boiled dry if a sufficient quantity of heavies is not present. r. When the desired reboiler temperature is reached and the level begins to rise above the set level, begin bottoms withdrawal by opening the block valves around the level control valve and turning on the still bottoms pump. s. The still bottoms should be transferred to the still bottoms storage tank in the EDC plant. t. At this time the EDC make-up stream should be adjusted to hold the heavies still feed tank level constant. Check Points a. Hake certain cooling water flow is on the condenser. b. When the still is in operation a N2 pad should be on the units to keep constant pressure, c. The reflux flow should be adjusted to give a 1:1 reflux ratio. reboiler, d. The reboiler level should be below the vapor inlet from the e. The still production rate will be twice the EDC recycle flow. This fact should be remembered when flows around the still are being set. Trouble Shooting There can be many operating difficulties associated with distilla tion columns, particularly when they enter service for the first time. Such problems include flooding, entrainment and similar occurrences that interfere with proper fractionation. How can the operator recognize and correct these situations? Temperatures, pressures, and product purity are the diagnostic tools for the difficulties described below: You must have vapor pressure-temperature data on the materials being fractionated when you are operating distillation columns. Pressures (read on process gages) can serve as a temporary guide to performance when key SL 009916 CONFIDENTIAL: of ntn U ^ ^ n_u45 temperature control is inoperable or not dependable. Grabbing samples from various trays for check analyses is another conventional technique for deter mining performance. Operators should check the temperature profile across the column to be certain that it is consistent with the anticipated pattern. Excessively high temperatures in upper parts of the column may indicate vapor bypassing, due to excessive velocities or inadequate liquid tray-loading. Insufficient liquid on trays can be caused by inadequate weir height or missing or leaky valves, Note that inconsistent temperatures may not always indicate process upsets. Checking thermocouples or seeing that thermowells are properly installed can sometimes eliminate what at first appears to be a process probelm. Be cer tain that thermocouple immersion liquids are provided where required and see that insulation is sufficient to stop heat leaks around thermocouples or thermometer bulbs. Column flooding is most frequently confirmed by differential pres sure readings. When much higher than normal &p's prevail, particularly with fluctuation or surging, it is very likely that there is flooding. Typical techniques for "dumping" flooded columns are:: withdrawing or curtailing feed, dropping reboil heat, or temporarily increasing pressure. Usual cause of flooding is excessive liquid downflow at high vapor loading. Plugged trays can also cause this condition. Too cold a feed can also result in flooding and poor column operation. Finally, don't overlook the possibility that the bottoms takeoff line from a still may be plugged, causing the liquid level to rise above the reboiler vapor inlet to the column. Entrainment of liquid can be traced to excessive vapor velocities through the valves or the column proper. This can be reduced by cutting back reboil heat. Engineers should recheck liquid and vapor velocities to be certain that design considerations have not been overlooked. Inygeneral, the columns have been sized at 40-60% of loading conditions. Foaming-over is another problem in distillation. This is ascribed primarily to properties to the materials being handled under the turbulent con ditions in the column. Column design (tray spacing) should consider this potential difficulty. Defoaming agents such as silicones have eliminated the problem in many cases. Experience with EDC stills indicates that foaming will be little or no problem. Packed columns are particularly vulnerable to certain of these operating difficulties. If packing is not properly loaded into the tower and provision made for even liquid distribution, poor separating efficiencies, if not flooding, may result. SL 009917 6-35 13. HCl Transfer, Absorption: It is intended that HC1 will be distri buted to an outside consumer (via the carbon filters and No. 3 HC1 compressor) and to the Ethyl Chloride and OHC plants (via a manual loading valve and No. 5 HCl. compressor). The HC1 scrubber will be floating on the line at all times to catch upsets and mis-match of HCl consumption and production. Start-up Procedure a. Open the block valves on each side of the absorber pressure con trol valve. b. Close the block valves to the carbon filters and open all block valves to the HCl scrubber (HCl, water, and cell liquor). Also close the block valves to the manual loading station which goes to No. 1 and No. 2 HCl compressors. c. When a sustained HCl flow has been established, open the block valves to No. 3 compressor and slowly open the pressure control valve on manual control until a sufficient amount of HCl is passing through the compressor. This will have to be coordinated with the rate of conversion in the cracking furnaces and the subsequent rate of rise of HCl flow from the absorber. d. Put the pressure control valve to No. 3 HCl compressor on auto matic control. r e. Check the HCl gas -stream from the carbon filters to ascertain whether one or two filters are needed. f. As the HCl flow increases, an increasing amount of gas will be passing to the scrubber. Open the block valves to the manual loading station and then slowly open this control valve until no HCl is being scrubbed. This valve will have to be manually adjusted from time to time to avoid scrubbing HCl gas. g. The block valves to the back-pressure control valve leading to the scrubber should remain open at all times. This valve will open whenever the pressure downstream of the absorber pressure control valve exceeds a preset value. Check Points a. Check the sprubber effuent stream passing to the scrubber to make certain enough cell liquor and water are being fed to the scrubber. b. Keep all block valves on the cell liquor and water lines open so that these two flows will start automatically at the proper signal. The cell liquor flow control valve and pump are actuated by an HCl flow to the scrubber, while the temperature of the scrubber effuent to the sewer determines the amount of water flow through the water temperature control valve. SL 009918 CONFIDENTIAL: Subject to Protective order of14th Judicial District C 14. Product Storage and Transfer: Eight storage tanks have been pro vided as day tanks for VC storage. As each of these tanks is filled, it will be analytically cleared and pumped to one of the three spherical tanks. All eight day tanks are piped up identically. Start-up Procedure a. Make sure that everythingris operable on tanks, i.e., gauges, relief valves, level indicators. b. Air in tanks must have been purged out with nitrogen. c. tfill tanks to 90% of capacity only. d. Use product storage transfer pumps to transfer the i\^C from one tank to another, to circulate a tank's contents, or to transfer the VC in a day tank to a spherical tank. e. Make certain the proper valving is used in making a transfer. f. If a tank does not meet the monomer specifications, transfer the batch back as feed to the vinyl still via the rework pump and rework line. The batch will have to be worked off slowly so as not to flood the still. Check Points a. Check for leaks from the system on a continuing basis since much monomer can escape in a short period. St- 009919 CONFIDENTIAL! Subject to Protective Order f 14th Judicial District Court Ho. 91-1145 6-37 15. York Refrigeration Unit Start-up Procedure It is assumed that the unit has been charged with Freon-12. All exchangers will have a normal operating level and be completely valved off. a. Start the pump-out compressor. If the low stage suction pres sure is too high, the compressor motor will not be capable of accelerating the compressor to design speed. A pressure switch will prevent the motor from starting if the suction pressure is above 44 psig. All of the compressor suc tion and discharge valves must be closed to pump out the casing. The compressor must be started with the suction valve closed, but it must be throttled open immediately on starting to prevent shutdown on low suction pressure. Start-up under this condition must be done with ttie "start-up normal" switch for the 2nd, 3rd, and 4th stage switches in the "start-up" position to keep the side suction line butterfly valves closed until the com pressor is up to full speed. Then the switches can be put in the "normal" position. Some "hot" start-ups may also require manual throttling of the side connection hand valves to prevent motor overloading, b. Energize the control system and compressor oil heaters at least four hours prior to start-up. Set the thermostat at 160 F. This boils the F-12 from the oil to prevent foaming during operation. c. Make sure cooling water is on the F-12 condenser, gear oil cooler and compressor oil cooler. d. Open the cylinder-operated valves in the F-12 vapor line from each refrigerated exchanger to the K.0. drums. e. Check the five drain valves on the bottom of the c.ompressm casing to assure that all liquid has been eliminated. f. Turn auxiliary oil pump switch to "auto" position. g. Start the compressor. Manually throttle the suction damper open immediately after pushing the button. Put the switches for the 2nd, 3rd, and 4th stages in the "normal" position. Start opening the block valves for the level control valves which supply liquid F-12 to the heat exchangers. h. Check to see that compressor oil pressure is being maintained and that the oil is not foaming excessively. i. Reduce the system temperature by manually adjusting the suction pressures (all stages). When the system pressures start lining out and the unit is not surging, put the pressure controllers on automatic control. 009920 SL CONFIDENTIAL* Sufcj Ot to ?rtgtrict Court 14th Judicial District RECURRING RESTART PROTECTION NEMA STANDARD 2 starts cold or ambient or 1 start @ rated temperature Any subsequent starts require that motor returns to normal rate! tempera ture before they can be made. This is accomplished by an electrical timer that must ime out after the attempted starts. The timer cn the O.E. starter is adjustable from 3 to 100 minutes It came from the factory set at of minutes, which G. E engineering in Houston suggested for our motor. SL 009921 CONFIDENT lAi,. e,,bA At to Protective Order .iiidicial District Court C. Special Plant procedures 1. Initial Start-up: As in any new plant, the initial start-up will differ from a routine shut-down/start-up in many ways, The following item.' am pointed out as being especially associated with new start-ups; a. The system must be cleaned, dried and purged to rid it. rf water and oxygen, It is particularly helpful to circulate EDO through the system a:, operate the vinyl still reboiler no that the water can be azeotroped nvsrhaa. the reflux receiver, where it can be phased off and discarded with some improvinir b. A new or freshly decoked cracking tube in a furnace seems tr ho quite active in converting EDO to VC, This activity, however, will subs!da 'h<'rhl and stabilize at a given conversion as the tube becomes finely coated vit1^ a laye- of carbon. The temperature to produce 50lo conversion lies in the range 9S%.Q?",i; y. C,, particular attention mush be given to keep water from onkering the system at all times. Water that leaks into the system wi.ll collect ln~the vinyl reflux receiver. Never leave permanent a tie-in of steam or water to the process side. 2. Decoking Procedure for Furnaces; In the pilot plant it was necessary on occasion to decoke the furnace tube when carbon build-up caused excessive tube pressure drops. With good steady operation below 6(3% conversion, though, coking of the cracking tubes should be of minor concern. The Ptero-Chem recommended procedure for tube decoking is given below, a. Type of Deposits Deposits can be of a powdery type, scarcely adherent t. Ihe pipe internal walls, or c.f a compact type, highly adherent; to the pipe w-;: They may build up within either the vaporization furnace during heating r.~` `V,-; product,part of which, not cracked in the cracking furnaces, is recycled, or within the cracking furnaces owing to the process in course. Product overheating may likewise contribute to build up deposits, which, when increasing in volume, will result in more or s-v!..'./.,'- pressure drops. b. Decoking Intervals The tubes decoking operation must be carried out at var:3 at h: intervals depending upon the flow nature, purity, rate, outlet, temperature, art particularly upon the furnace operation system,. In our case, the frequency of the decoking operations might be such as to require cleaning of the cracking furnaces every two hundred hours at full load operation, whereas the decoking intervals might be far longer for the vaporization furnace. It must, however, be considered that the above data, are merely indicative and subject to broad variations, as a furnace net overloaded and correctly operated may be operated for as long as a year without decoking. SL 009922 6-4o e. Conditions Requiring Decoking In order to establish when decoking has to be carried out the furnaces are fitted with the below listed instruments(besides those normally required for the operation of furnaces); Vaporization Furnace (l) One indicator of pressure differential between ahe incoming and the outcoming flow. Cracking Furnaces (for each furnace) (1) One flow recorder-regulator for each pass. (2) One outlet temperature indicator for eaco pass. (3) One recorder of pressure differential between the incoming and the outcoming flow. (4) One tube metal temperature for each pass. The decoking operations can be started under the following conditions; For the vaporization furnaces when the pressure drop in the coil exceeds by approximately 20% the normal pressure drop under clean pipe conditions. For the cracking furnaces; both when the pressure drop reading shows such a value as to indicate the metal temp erature is reaching the maximum allowed temperature, and when the flow differential between the 4 passer rise"? to an abnormal value, than might, be i nil natively fixed' an approximately 30% above normal. Also, the tube modal temperatures should, be a primary indication. Of course, the above data are given just; as an indication, and they can be change! according to practical experience. d. Operating Principles of" ine Suggested liecoking Process It is felt a convenient decoking method for the diihloroethane vaporizer and cracking furnaces Is by thermal means. This method, speedy and scarcely expensive, is based upon the alternate circulation of steam and air within the process pipe?, externally heated 'tv the furnace burners. Thus, the chemical reactions of water-steam and air-oxygen with 'the hot coke take3 place at a controlled temper ure. To this chemical action the mechanical deposit scaling action is added as ell as the dragging action of stam(spallir. SL 009923 CONFIDENTIAL: subject to Prptective Of 14th Judicial No. Order t e. Decoking Method Each complete pass (convection and radiant areas) of the cracking furnaces shall he decoked separately, When one of the four passes of the above furnaces has to be decoked, it will be possible, for instance, ho decoke one of the passes of one furnace while maintaining in the ether passes cf the same furnace a steam flow such as to avoid overheating of the pipe metal. After it is established at what frequency decoking is re quired, it may be desirable to decoke all passes at the same time. However, it is suspected that such close control will be required for this,that it will be discouraged unless decoking frequency has become a problem in meeting production demands. Temperature points are provided for checking the temper ature of the outcoming decoking fluid. These are also the process temperature points already mentioned, f. Piping System for the Decoking Process In order to reduce the time required tor the decoking of a furnace, it is advisable to prepare beforehand the steam and air supply system. This system is particularly interesting owing to the fact that it enables supplying steam in the two directions of circulation to the passes to be decoked and decoking air in a forward direction. g. Description of the Decoking Process (1.) After the furnace has been shut down and purged, connect the air/steam supply system no the pass to be decoked, and put in operation the air and steam flow indicators, the gauges and the cooling water system. There are many figure blinds which must be manuevered properly. Also, the steam inlet allows to the furnaces mus..; be put in place. After the furnace is shut, down and purged with kb and isolated from the rest of the system: a) Install removable spools for steam-air entrance into the convection coils of each pass. b) Close the Figure 8 blinds downstream cf the EDC flow control valves so that steam will not back dovn into the valves and so no EDC by chance can leak through. Of course, close the block valves around these two con trol valves. THIS PERMITS THE INJECTION OF STEAM OR STEAM AND AIR INTO THE FRONT END OF EITHER 0E THE FURNACE PASSES WITH FLOW METERING FOR AIR AND FOR STEAK. SL 009924 c) Install the removable spool pieces in the pass outlet pipes which carry the decoking products to the coke knock-out drum. 6-kZ d) Close the Figure 8 blinds on the outlet of each pass which carries the process stream forward to the Quench Tower so that no steam will enter this system. Open the manual valves in the lines going into the header entering the coke knock-out drum. YOU ARE NOW SET UP TO KEEP WATER OUT OF PROCESS PIPING EXCEPT THE FURNACE PASSES AND TO CARRY DECOKING PRODUCTS TO THE COKE KNOCK-OUT DRUM WHILE FLOWING FORWARD,, e) The quench water entering the knock-out drum should be turned on. Also, turn on water at each funnel sampling point so that when the outlet decoking gas is sampled it will be immediately quenched into the funnel and drained away allowing a visual check on the progress cf the decoking spalling. NOTE: All of the Figure '8' blinds and removable spool pieces must be put back as they were prior to decoking after the decoking is completed. No decoking connection can be left permanently attached to the process piping because of danger of steam leaking into the system. If to complete the spalling, it becomes necessary to reverse the steam flow through the furnace passes, these things must be done: (a) Make sure steam is available at the respective pass outlet. (b) Two operators are required for this operation of switching. (c) When fee forward flow is coming through, open the reversal steam flow to the desired "ate. It will simply be purging into the coke knock-cut drum with the forward flow products. (d) One operator is stationed at the header entering the coke RO drum and the other is near the forward flow stations, (e) To reverse the flow, the operator near the header going to the KO drum must close the valve in the line from the pass outlet to the coke KO drum while the other operator opens the sralve from the same pass inlet, to the coke KO drum. The forward flow of steam will probably not have to be turned off since it will simply flow to the coke KO drum with the reversal steam flow coming out the front end of the furnace to the drum. It must be determined first that the step (c) flow acts properly as well as the forward flow feed when reversal is tried - i,,e., they simply by-pass their Job and go direct to the coke KO drum. CAUTION ON REVERSAL: Make sure the steel convection tubes are not subjected to temperatures above 690?. SL 009925 SL 009926 CONFIDENTIAL! Subject to Protective O^er of 14th Judicial District Cou No. 91-1145 (2) Insulate tubes net to be decoked by conveying through them such a steam flow as to have the temperature not exceeding 900? during the whole process. (3) Keep a burner operating at low rate and raise the smoke temperature up to approximately 300? within one hour time. (4) Increase heating gradually, always at a rate of approx imately 300F per hour, until a smoke temperature of approximately 1350F (at the top of the radiating section) is reached. (5) Increase the steam flow proportionately, so as to have its outlet temperature not exceeding 1000*17 ,, o (6) Keep the smoke temperature at 1350 F during the steam spalling-decoking. During this period the steam flow in passes being decoked shall be as follows: - for the vaporisation furnace .............. approx. - for the cracking furnace .................. approx. (7) In principle, a large part of the coke deposits shall be removed, and in order to improve the removal, and detachment of these particles the below listed recommendations are given: - quickly invest the direction of circulation in the coil; watch that the design temperatures of the convection sections are not exceeded. (690?) by this reversal of flow; - quickly re duct:; and increase the steam flow; - reduce and raise the smoke temperature by alternately reducing and increasing tne burner rate; - add a small air quantity over few minute periods. (8) During the steam spalling-decoking operations examine the nature of the coke deposits removed from the coil, and if they are too greasy reduce the steam flow to avoid erosion. (9) The decoking operations progress can be checked by look ing at the below listed details. Use is made of sample points and funnel drain? at the furnaces to see a quenched pass sample. - appearance of the effluent at the initial and final decoking stages (milky gray); - appearance of the effluent during the removal of fine particles (light gray hr Hack). - appearance of the effluent, during air blowing in (reddish). - the more o' less considerable quantity of coke particles. CONFIDENTIAL: Subject to Protective Ord^r of mh Court g )* b O-T-f (10)When coke particles are nr longer seen at, the ceil out let sample tap, an::- it io ascertained that the possible fine powder collected is not caused by a too high steam speed, the steam flow shall be reduced, (11) deduce heating until a smoke temperature of approximately 1200 F is reached, anu adjust as fol' the steam flow to the tube pass being decoked; - vaporization furnace ........... appro:: ,, - cracking furnace, each pass , .approx. (12) 0-racj.ually introduce some air to reach a steam/air weight ratio cf approximately 9:1., (13) Carefully check the temperature of the pipe metal and the appearance of same; on seme pipes b.ct spots, sometimes movable, will be noted, indicating that erk-' deposit? are burning. If this operation is carried out by night, the position of the not spots will be more noticeable. listed values: (] 4-) Don't let the pipe metal temperature exceed the below -for carbon steel . .approx, 690F vaporising furnace, and cracking furnace convection sections. for 16/I ofairiles5 steel furnace radian'"- sections. ............. approx,, 800F cracking !H; r she other hand the furnace temperature must 'be kept sufficiently In* n. sen,if pipes becoming red with the exception of the hot spots? where coke is hj",' ; y, fits) lie pipe temperature check might be done, for pipes that are visible, by meir ' of an optical pyrometer. (17; By means of the Or sat apparatus check the Cly, contents in the effluent and keep it at. 3 9$ by setting the temperature in order^to main tain an even combustion (maximum ounet temperature 65Q"F), (l8) when r.o is contained in the effluent and when no hot spots are any longer noted in the ""pipes, the following checks are to be made: shut off the extinguishment water and place a burring brand at the effluent cutlet point. If the brand Is extinguished this means that decoking is not yet complete, -whereas if the brand becomes even more incandescent decoking can be considered, as completed. in the latte1" case shut off the air supply and raise the steam flow to the same level. a-- in the initial rtage, in order to remove the residual, as nos ,, SL 009927 CONFIDENTIAL! ^rSuNldafDfetnct Court - si.op .c-linc while maintaining the same steam flov ir order tc cccl the furnace. When a temperature of approximatsly lv> reachac, clear; the tube by N.-, purge and then carry out a hi- pressure test, - dismantle tne air/steam decoking system and, if reeded, clean the other passer- as above described. Always disconnect the steam line from trie furnaces afrer_decoking in finished, g. Ma.jor Precautions (.1; Avoid overheating tubes. "Water closely for local hot spots, jio exceed 1311 *1 metal temperature. He optical pyrometer is available:. {') Avoid oveesri /* velocities through tubes. Coke particles are very abrasive and can cause serious erosion cf return bonds. (']'* If heater has a separated convection section, maintain steam flov at -all times through convection section to keep out] et ^rr.perature below yOQF. (9) In reversing steam flow through the furnaces, make sure that the steam temperature does not exceed 690F as it passer through the carbon -steel convection passes. Keep the velocity high enough to keep below 690F. (5) As 1 /he color is more pronounced at night, some operator:-', porter t'f- conduct burning in the dark, ; tl-v- it--- 'temperature must be kept down so that tubes u"'-11 ly no net b'W rod. The only hrt spots or tubes '"'"V,be where coke is burring. 3. Furnace Eh'Ti ilonoy 1 ,'he efficiency of the furnace in controlled, by the amount of excess air used ir-, combustion, fi-ensraily the furnace should be operated vith a minimum of excess air us long ar the flames do rot reach excessive lent. i> or impinge or the tubes or core. These furnaces are designed for 20t excess air. Visual, examination of the flames in a furnace is not a satisfactory means of arriving at excess air and the Orsat should be depended upon to give this irformat]on. hue to the fact that the liquid ir- the tubes ilovs progressively around the Iso-Flnv Furnace :1'1, ir difficult to obtain a true average flue gas reading bef'ere me one frig air is introduced at, the base of the stack. For cal culating efficiencies and stack lose the temperature cf the flue gas should be taken in the stack al.rv-: the V1 are art the flue ga*. samples should he taken at this same io'-athn". Ir air:,lion, it is important that tine thermocouple and the gas sampling pm H vsC: he exten iet the same distance into the stack. SL 009928 CONFIDENTIAL* Subject to Protective Order of 14th Judicial District Court No. 91-1145 ^ V' r" .'-j > h ^ sr-rul" "be tare:. cron trie upper observation "v- r*; V.'j^ n-*v < - operation ah Hi excess air rather than -will require .trrer attention from tre operate: r. =ir_ ivouempt zc- reoure maximum lurnaee c.b..i dene.. : wit.r -,. minima meat re rnmerrf'ereb erafc-'- each >,f_l P- :: -T V"* --1 W'j j r- limey tr-p, oft 'ey IH/o. amour.'." . r 1. p",eosv' a*`. my "' a 1 rarer i" more detrimental ft an. firi::.," ait. c* I ~ - 7; "l. v - j-v v*: a gi cm,' i <l*4 r* > v, g L`,V*C 'f>-W" 'r/y Vj al "\ -i y 'urt"eiir.crp, tbs1"1; i? a considerable c.ar.yr'` rl" ' J t\ "/s ">*#* r" :H t;. cr 2^>i ^ * a;-'-6 esT', -^v*r "j''1' '. cuartltle:; r.l yv,'W',r, merexitiu :.J may b^om^s leaded vddd . air ,; r- rj 1 "* *y)vi 'i-` vo^as, r-o ' "1 1> g-*- ,_ crpraer. certe'" i In ;'jj sjn ,J '/_: n^p'!1 *.'4--' fj k*i "V-Vj'',` h,-, * ' ,'T/ \ jr^V-ZZ'J C7 FIFNACF Z^.HZ 2''"71 FOR OIL AICO GAbSOT! ICISlr H Measure percent 00oanc. 0.- by or,3at analysis. ''" a stair.! so r cvp.t.rv tube to prevent error from oxiratior;. Inter no cH frv'jj': s'houln copper tubing be used .s gar aampumo uute. Tibs taupe nature >ref erally win- , . } ;,rl vsloeit'o eoripTe) . ', w y- . ?> -_rt :ts s Koulu be mac, s at tha sa,me it vCA ov F'arnaC'g*-:. -1; 4- 4 c rec emmer ' b . r" '4 ion provii^.ed i*cr p'urpona ir 'u t,. 4 1 *2i`V'TYf. f' jn '.if'-! 3'n" ^ J ,, j. , l* 1 ai" 'cemperaturo. " r, , ;i v ' "i "' rt ^r,,;r:if ufcr li^3 rr'j r; `'SB.I.v,oj"J ^'vjoXo r , 'betermine r.taeli lor,."or by calculation. (H/Q ratio of e^a^aj relb nery gas varies from . ?4 to . .11 and of fuel oil from ,,09 to ,,i;"' Avt; vatic burner Damper Control; Flue gar. r.amp'ier. vill continue July be sent to a P,ai?.ey Arafyie,1 vhere "'tie pa' t n--mm an" percent, combustibler a fvs 0ofeimi nsi,, '.Ho bea.t .1; 1 V4fc(''nitirr; increase in tb.e t rnporntui e of a filament are p-c per nun a.i it,-". of mygen or combustible" :!,n tr.e gar, rample. ob.i:': signal . centre,: ier1 or: trie parrel 'hoard. the eo'utrr b.i.c1;- trie-; rer: vicr, control: the air- tamper position. If ttc set- point or- tie ccrrlrrl': er ant tle signal from the tran'*mi"!;ter be ole cent:'*,.lie:- a?: SL 009929 COHPIDENTI^* nr<1er to Prot ctive Order then the controller signals the control drive to rapes, necessary for the desired percentage oxygen in the flu: ga ng is one : Svo switches are provided for operation of the -,ir d ..mps One is for automatic (supply) and one for manual control, description of the position of these switches fer 'v.racus Manual Opezaation : '.) Supply valve in closed position. V>) By-pass valve in open position, o' hand loci: lever pulled up tight when hand lever ir net he?'..a operated. a) kith the hand lock lever released, position the Drive by saa ; operation of the hand lever. Pull the hand lock lever up tight to hole) the Drive in any position. Transfer from Manual to Automatic: a) Adjust the loading pressure to the positioner sc that, beam is centered between the upper and lower stops. ? balance h) Turn by-pass valve to"Closed-Autc" e) hale ass hand. lock lever. por-1vionor- suppiy 'A, to-Ope DriVi: nc? for automatic operation' Actom -tic Oparation: 0 Supply valve in "Auto-Open" position, tf "fy-pass valve in "Closed" position. c) Hand lock lever released, d) The Drive piston is now positioned automatically. SL 009930 CONFIDENTIALt 8ubj ct to Protective Ord r f 14th Judicial District Court No. 91-1145 7-1 VII - SHUTDOWN PROCEDURES A. Overall Shutdown Procedure (Furnaces, Flywheel #1, Flywheel #2) 1. Notify EDO and the shutdown, HC1-consuming plants of the intended 2. Shutdown the Dopp Kettle agitator and seal liquid,. The agitator must he off before this liquid is stoppei, 3. Lower the furnace exit temperature on automatic to 90>' 'T am held for 15 minutes, then drop 100F more and hold for 15 minutes, put the fuel temperature control valves for each cracking furnace on manual control. Open the by-pass around each feed flow control valve tor each cracking furnace pass and establish the same flow as on automatic, Shut off burners and pilots on cracking furnaces, 4. Put the vaporizer feed FCV on by-pass control to provide a- KDC flow after the time-delayed shutdown of the FCV, Shut off the burners and pilots. 5. Add Ng to .the quench tower and absorber to keep the flywheels OK on pressure. 6. Lower the quench tower level to the bottom of the sightglass bydumping into the Dopp Kettles. 7. Turn off the furnace feed pumps and start adding N into the vap orizer simultaneously. 8. Close all cracking furnaces pass outlet valves and phut- the "'id <\'C,, f. 9. Decrease the quench liquor flow until the need for it has -*a Then shut it off, turn off the quench liquor pump, and close block valve around the quench liquor FCV, 10. Shut off steam to the stripper reboiler and product, still re'tniier, 11. Shut off the York refrigeration unit-.. 12. Shut the Flywheel #2 pumps down; these are the product still .feed pump, the lean EDC pump, and the stripper feed pump, 13. Turn off the intercooler pumps. This shuts the tray overflow valves 14. Turn off recycle EDC chlorination when recycle EDC flow falls off. Close block valves around the FCV. 15. Close block valves around the recycle EJDO LCV, the product vinyl take-off to neutralizers LCV, upper intercooler ret,urn LCV, the .lower intercooler return LCV, the absorber bottoms LCV, the product still FCV, lean oil FCV, and the vinyl still reflux FCV- SL 009931 CONFIDENTIAL* Subject to Prot ctive Order of 14th Judicial Di trict Court o. 91-1145 '7-2 16. Maintain a positive pressure on all the columns (20-40 PSIG-) by carefully bleeding in N2, where needed, manually. Do not let equip ment go on vacuum. 17. Close off block valves around the absorber PCV and the y on the: liquid line from the quench liquor surge tank to the stripper. 18. Keep positive Ns pressure (20-40 PSIO) on the furnace-quenchabsorber system by adding N2 as required. 19- If this is a short shut-down, leave cooling water circulating through heat exchangers, and leave steam on Dopp kettles,, If a long term downtime Is foreseen, shut off cooling water flow to ev: dangers and dump tars out of Dopp kettles into the tar "buggy." Shu- '>wn Popp kettles. 20. Check to see that the Ell Scrubber has been shut down,. Close block valves around all 3 PRV's on the HG1 header, 21. Close valves in VC transfer line being used to the storage area,, 22. Close block valves around main fuel gas PC? (90-30 PSIC). 23. Isolate the EBC safety drier in use from the system if a long-term shut-down is expected. Shutdown the heavies still and stop the make-up stream. 24. Expansion chambers in VC lines are provided where needed so that when equipment or lines are Isolated between two valves, liquid expan sion when the temperature rises will not cause ruptures. Those for VC will need periodic filling with nitrogen as the pad is dissolved in the VC and carried away. 25. For long-term shut-downs, shut down all utilities in the following order: a) Refrigeration machine b) Steam supply c) Cooling tower water d) Instrument air e) Electrical system Detailed Equipment Shut-Down Procedures 1. Fuel Gas Supply System: a) Close manual valves in fuel gas lines to furnace burners and pilots. b) Close block valves around all three temperature control valves c) Close block valves arount the 90-30 PGIG pressure .reducing station. CONFIDENTIALi Cttbj ct to Protective Order of 14th Judicial District Court No. 91-U45 2 ,, Vaporizer and bracking Furnaces ; a) Lever ine 1 urna - exit- vmpw xr or. automu'i noli lor lr minutes,, Kr:;. , 1: v,r bub 7 napera ,ar' hold for 15 minute.-... Jr the fuel -Gpri'rr -re 1 manual control. '.pen the bbT by-pa.: vb. v1-' ar . 1 block valves for each cracking irna ? pa,-.1- U.1. . same ETi& flows th-rough the by- pa: r ,, . b) hlose the manual 'lehr vale-:."'. Ir ;~v 11 furnace burner.. Ixls vi;, allow fu- p.,... If not, ''.lose the main burner Mater va.iv.,;. arc. J hen on the gas to the pile c) Pi.t the vaporizer fsee. 1.1' or 1'. p,; 1 * '-tv. v i allow the EJ?C flow to . rvi.nue aft-"'' tv ; tlnw lx yie FCV,, d) Shut off the gas Low th 't'U"nsrs and pi e) After the quen.h tower lov1-.-.-! i". Lcwarer b*.to th-.. pi. nozzles, shut off the furna ibrx porap<b f) Simultaneously close the block valves on bV: E3S f-v.i l:u open the NoPurge lines into the vaporizer par - inlet.: steps together so that there will be no flow int-rrrup' "... 3. Quen_".n 'love'-; a} Stav". wiring the qur : lover level as soon a : hav.; - e*.: o ui of*"., m;:.to ovr t.v borw v do -ruy .1 lienv r lb 1) vlos*' ail ora .-kirr: bxrrw: pa rubivv through them for several minut-* 1 c) When no more vapor:, ar-, pay dry llwub off the quench liquor pump, ana IV- I'll each,, d) Work off the quench tower but vm: liquor '-/ s 1 - pp , It may be necessary to recycle some yarn-l lug. t- 1 aid the flushing; of tars/carbon material to ''to ."-pp * ... dumping >t#0 Givi'S kettles should be per'blue rw il t'v v of.11 4, Lopp Kettles; The Popp kettle agitators rieprnu on ED*' fl uso-v^- ,j -v \ double mechanical seals from Flywheel Therefore., ww ' Flywheel #2 is shut down, the lopp agitators mus . al-'- 1" o a) Shut off agitators wnenrver llywteel $b ir ;:I: .. r SL 009933 CONFIDENTIAL: Subj et to Prot ctiv Order Of 14th Judicial District Court No. 91-1145 b) Shut-off the Strahman valves at the quench "c*T .r ar.~ 1- * line empty into kettles, e) Leave steam on kettles and vapor Line open for- -Vv - - d) Before steam is ever turned off the kettle:-., fra.!.: :.1" ' :v out into the tar "buggy" for disposal, Piu-Th vifl 1 e) Turn off steam and close vapor lines to quend NOTE: To take kettle off the line for maintenance peop.-s ow e.-cr . vessel, the kettle must be flushed with EDO to wash cub tars an!, purr nitrogen before opening up. Purge with air before entering! rb 5, primary Quench Condenser: a) Leave cooling water on unless lony-Y-orK r;h ob-lP-a-:':.. 1'' -vp-' . It this is the case, however, shut ft rfit 6, Secondary Quench Condenser: a) This refrigerated condenser is shut, ciown when the York re eration unit is turned off. See earlier part of this vrlbv--up : timing on refrigeration shut-down, b) To shut off P-12-liquid supply to exchanger, close w.e i,p; block valves, *?) Drain ?-12 from exchanger shell to refrigeration system for some reason -work is to be dons on the shell, i) IX' necessary, isolate exchanger from o.'mpre.vour cc , " closing the cylinder-operated valve in the disctiarwY -/w K. 0. drum, 7 Quench Liquor Surge Tank: a) When level rise ceases, indicating r-v forwaru flow !.J Fit: VC, close block valves around the ''17 on the fee7 Hr,-., t stripper, b) Leave the quench liquor pump on until It-1 rbiiS'dov' bo by quench tower operations,, , o-.o, 8. Absorber; a) Turn off pump the stripper feed to cease the absorb vr'o -:o; tribution to the lean E3C flow, Phut. these pump? d,- \n fdlo forward flow of EDC and VC have ceased. See covarag** " bbr;y--- earlier section. This should be done immediately aft't trv 'o ?*, unit has been shut down. SL 009934 b) Isolate the absorber PCV with block valves (absorber venv' k.r*' c) Turn off upper and lower intercooler pumps when lean oil :'.sw is stopped. This shuts automatic valves in the gravity ovrvCl.-< lines to the intercooler tanks. fi) Close block valves around the intercooler surge bank. I b-" ... e) Close manual valves in tray sump overflow line,--, f) Leave the Intercooler tank vent lines open. These are .jo <**.-' only for special reasons, such as maintenance., g) Turn off 7-12 valve in line upstream of the upper interj * LCV. To Isolate exchanger from compressor suction, chore tV' cylinder-operated valve in vapor outlet line to the K,v , hr This will not normally be necessary. h) Turn off F-12 valve in line upstream of the l.ower intercorf!''r LCV. To Isolate exchanger from oomprescor suction, dc;e th~ cylinder-operated valve in vapor cutlet line to the KVCt '"'.rum,, rtf will not normally be necessary. i) Close manual valve in line that supplies liquid F-12 to tt* absorber vent condenser. This exchanger also has a cylinderoperated valve in its 7-12 vapor vent line for isolation, 10, HOI Ptripper* a) Whan the Fork unit has been shut down, shut off steam to m br:> ppcreboller and isolate 'the steam FCV. b) Turn cff the product still feed pump when the re?:t re; tv-! oil circulation system is shut down, 11. Product Vinyl Still: a) When formward flow of EDC and VO cease;;shut off tv *>. re f EBC chlorination FCV and isolate jL'b,, b) Close block valves around the recycle EDC LC7,, c) When the York unit has been shut down, shir'; off steam -Lr ,; b.'kd reboiler by closing block valves around, the steam TUT,, d) Shut off reflux flow to still by dosing bio .k valve1, n,w ir." the reflux PCV after lowering set point of controller to r:^f tshut the FCV itself first. a) Close block valves around product flow to nevfcrallr.'vv. I/!.*,. Turn off reflux pump. SL 009935 SubAecVt Protective ord f) " . H'. off leer of] pump w r a orf.e" .* turns! off,. :t ' p ", r ff, ClOSo (look V,i ! v - r (J j 11 .1 t CAUTION; Be sure no -HO "n >'-1;. e:: 1 BSC lean oil is turns.: r'- 1 ' ,* * rL ` ' \ `l :r\ '.ar; -s ap. . . * > n t perhaps. Keep lean ei.1 "ir `.uLa'Srit i * V">rv, a f operation. h'f Turn off oof: Hr g VI ; . .-r '' H 1 I , r_ : :j..own . ,, i) Refrigera f v- vee valve in line T .; 0 (Hose r.y 1.in lei1 -open;i f " ncnUenser shell from "rvion ' ;i . . , ' vapor : pvff - , if' ' ' if. , ; + , - wT, y *1 1 ; ^ ,r, 1 i k `1r * jr ;r 1 . i 1 fio-;e 1 ,lo v v" ,VV : ' ' !' pressure on the vinyl ,, j., ill. -1 `J -'"'vi,' r mu.".;. *,, v p" ize] with N,,. as r^q!;: re- ' `O' keep 0 o'm*" p"'* ' . " ' u .' * v ` v Should it be desire! .T aSe .rf V'tj.n ; J r:,-, `. L k`> * ' .CV" '' pr on the PC? to 'f'-V, PS.T-- are. foayr ;...h: ,, , i >; 'XA \ ve- op":r a" the pc?. If. lean r'l 1 St1 Hangers f, ) 0 ,r."| - rij.; water f.;", fbo QOl` l.eru: hI.3 .Soio3 err ;'! orly for Jr 'jpn f- 'frtnv, l ,'i 'i ; j v j- h ~ fhr` ,t lean *11 ler nor." ]'e " .ith: , . ^.-v J tf(1: v,\ < -1 : i ]. \Fi. - P- :r lit'" v j., t *]:PP 1 - ' 1 H1 ;> . ' 1 ! " 4e, f f `* ...,,, err hanger la., ; /TT'prf"' 1 f r ^' f> *') "1 ,e( `o'* * * M .1 ** a h ^ ; 'odlns, the mam a, 1 '~a1 Vf_ *ti r1 ` ' V, r : ,, ' l,v 11 nder- opera fee ; a \ v ._a hr f"- ho of ;!'< fxt.c"hanger from 0 o.vtuprfy , . '.I'! , 0 ; u or fo ", - O'- v 1 <(1 Recycle EDO CooHt; a.) Turn off rooting; v a;fen V UT 10 oh I Vr j Tip 3 k ,, pro duet Cooler; a) Turn off eon.Hng u a V-t ho eov; 'jaryor only or I Hr-'5 Pi ake CapsIs it; Huntii T.^r'TJ 0 u) pr-ooes-' Hut- Crvr 1 Hoivl',; a tv!, 00' ! "* \ V ,-0 1 0 r-dr 71 1 v - - - - SL 009936 awfiow*1";' 2. Close Inlet valves to storage tank In -use at himf- cl down. b) Regeneration Cycle 1. Switch VC flow to neutraliser containing frerh Na /jur., 2. Isolate spent neutralizer from system. 3. Force the VC in the spent neutralizer to the inl'-'h o:" other neutralizer by adding pressure to tie top. k. Vent neutralizer to still vent header. Purge v.Vh ri > v-.' to make neutralizer safe to work with. 5. Unbolt and remove the top flange cover on neutralir"':1 take out the fiber glass packing. Unbolt unpacking marl/.>; flange on side Just above support plate, 6. While wearing protective clothes, including face nhleld, apron, and gloves, manually unload, the flake caustic through manhole. 7. Flush any remaining spent NaOH to sewer with proo.tj,, o wit u ,, Be very careful during this operation because caustic, soda ha. a very high heat of solution - - thus the water in the caustl ; bed will become very hot and might make caustic solution nplaher or? the operator. Face shield and gloves are require! for t*-wash-out operation. 6, Dry wet neutralizer with steam and then air or nitrogen. kec.rit.rge neutralizer with proper amount of flake cau.-.i.i '. the top of the 'bed with fresh fiber glass. Close up i tralizer. Make sure it is dry., 9. Purge neutraliser with nitrogen to remove air. "" r;1, purge valves and vent valves. 19. Neutralizer is now ready .for mrvine. 16. HC1 Scrubber; a) When the absorber pcv is closed, flow to scrubbier will b) Close block valves around all distribution header phi'-' i',, c) Block off water and cell liquor automatic valves tu y. vi , 17. York Centrifugal Refrigeration System: please refer ho ihr operating procedures prepared by York for this system. Fhe op<`v*-4 must be thoroughly familiar with the shut-down procedure: ir 'ri-.r prevent mistakes which could cause severe damage to the ".nmpr'vi and/or auxiliary equipment. SL 009937 a) Push "stop" button on the control panel- The oil heater circuit should continue to be energised when the compressor is stopped. b) Close the block valves on the liquid F-12 LCV's for each exchanger. The LCV's should have closed automatically. c) dose the valves on the F-12 vapor lines from each exchanger. d) Isolate the compressor. 18. Heavies Still; a) When the level in the feed tank is worked down to half full, shut off the still feed. Close block valves around the FC7. Shut down still feed pump. b) When the bottoms level control valve closes, turn off steam to the still reboller. Turn off the bottoms withdrawal at this time. c) Gradually reduce the reflux flow by lowering set point on the FRC. Maintain a constant level in the reflux drum. d) When the reflux flow is essentially off, close the reflux flow control valve and close the manual block valves around the automatic valve. Shut down the still reflux pump. e) The nitrogen pad should be on the still condenser and the vent of the system to prevent a vacuum from forming. f) Shut off cooling water to the still condenser after column cools down, but only for long-term shut-downs. C. Emergency Shut-Down of Equipment In the event that trouble arises in the VC plant that cannot be handled by normal operating procedures, it may be necessary to make an emergency shut down of one or more pieces of equipment. Emergency situations may involve fire, explosion, vessel or line rupture, instrument air failure, electrical failure, water failure, steam failure, etc. Each emergency will dictate its own procedure to be followed and it should be handles accordingly. Following is an explanation of some situations that may arise and a general outline of what should be attended to: 1. Furnaces: If an explosion, uncontrolled fire or tube rupture occurs at the furnaces, a rapid furnace shut-down should be effected. To do this punch "Total Shutdown" button; turn on snuffing steam to the ^ offending furnace(s) using manual loading stations in the control room or op by manually opening the valves in the field; lower set-point on vaporizer EDO feed controller to zero to shut this valve; then try to get a nitro<5 gen purge started through the furnace tubes. In the case of a tube ca sublet to Protective Orde of .D rupture, the vaporizer FCV will close with no time delay: c - r,h it will remain open, and the valve will have to he shut ty ,, - -ori: _ the set-point indicator to effect an immediate valve closure,, . - tube rupture, follow the 'te.pi? addition a" iy .ir'vi/f.: i If an uncontrolled fire (normal burner operation in furva "controlled fire") occurs and is ; upper cl by tr~ fuel nr., source of fuel gas can be turned off by ..Icring, the main roo-t p-i y ,, at the panel, A tube rupture or brokers fitting ir : "r farrier--. pro:-- : of:., will, of course, allow sysrem press'; to rs 3 err,, an:: a. a - v vapor and possibly liquid in the quer:.::. av pur ifi ci.Ti.cn par" h plant will want to "dump" <La..k. tc rt-, tVon pre:^,u7u par", -r When it appears: this is th-- 'are, the tu! oo or t.:.". ;I the secondary quench condense", Al.;l`, tfm -uen ,:i liquor purr: . , .' turned off and the tie charse valve elc -w.. ; . ' : r;" vri .r: i~ from the panels FURNACE TUBE RUPTURE - FIRE (letailed Emergency 3fcu*Oown) Tube rupture in one of the three furnaces will be the m: . ,,,iKev, cause of fire in the plant. Certainly it is the most susceptible spec., i,/"1, how EDC -will act when spilled out into the furr.a m setting is not known, it is a combustible so we can expect, a fire. Fortunately the amour::: < i air available in the fi.-elov is limited tc that entering through the st --- rur. ports of the burr;.-1. DETECTION; a, Visual `observation of stack emoke) b,, e.'jtomef* - (vlfv automatic qK'f-royr,) j.; lev Pas:-: Outlet Preo -ure (2) Hugh Bridgewall Temperature (po-'vibt TrTKCS 70 I'd WEEN TUBE RUPTURES! a. Notify plant, fire department b. Open snuffing steam tc firebox c::. rapture,.: tube, c. Shut down all furnaces if not already shut town tv art cm:: detection system by pushing all three "Total Shut tv? " . 0 1 on panel. CD CO b. Close vapor line from secondary quench con tenser to, a: CD CD O e Shut down quern: liquor pump from pane] board - p O f. Fellow through: with plant shut-down. CO 2. Quench Tower: The quench tower is quite important: to the p- because it prevents tars and carbonaceous matter from passing for#: a* into the purification end of the plant. Therefore, there shoulc : concern whenever anything o rur- to **.~.p the flow cf quer l: : the tower. If this flow is lost permanently, try fur nut .... shut down as quickly and as orderly as possible by the cpr ' . . 3- Primary and Secondary Quench Condensers; Less cl coclinc m . .:r: to either of these partial condensers will result in los-' of Jcy - * liquor. The primary condenser normally provide;" m: ;,t cf the 1 liquor condensate for the surge tank. However. i,f ,ir. 1: lo;.* . v; secondary condenser will try to p:. .r. up the full partial vy "v ,-r " and may therefore become inoperable due to fleering. In ei-"-r a. is best to shut down the furnace:: sc to.n't the .faulty ^orJ) .r_1 repaired. If the seconda-.:" condenser i: loot alone, J'v:i 1 shut-down if it can be brought back or, :-,ccr.. since iv ' duty .1 v comparison to the other freer eke banvers . 4. Absorber; Several situations car. be visualized which might br n v as a basis for shutting down the absorber, If the absorber ppp 1' /v control over the control valve, the valve may either close cr opsv, it" valve fails open the absorber will vent down to the pressure cf 4 be i:L`tribution header. The absorber will not operate efficiently her*1:; but i" can be done If repairs to the control system will not take long, cp^ya'on by-pass manual control in the meantime if valve and/or controller r* out. If the control system fails shut, then tne absorber should be immediately venter by using the by-pass around the PCV, If the sltsai..-* persists, the furnaces should be shut down,. Otherwise the relief va.v".: will open and vent the system down. Loss of refrigerant to the vent condenser will not raateri,C,sv h". , . the absorber operations per se, EDO and Vi lo/rses to the ;,fl 1 -vl stream will be higher, however. Loss of either intercooler system is serious, and if the w . v_ can't be repaired quickly the furnaces should be situ town t; ,,, heat load on the absorber. It may be possible re opera'*'.- cr, y; cooler for short periods of time, but Vf-EDC looses will be Increase Loss of cooling medium tc any one of 'the lean oil coolers' (11nr-- v--three direct coolers and an intercooler in this loop) will res elf in higher tray temperatures in the absorber,, ET-C art V" losses i,.vt t.-e p of the absorber will consequently be higher, Tne v-ibing 'vcler chru 1 be put back on line as soon as possible. If this can't be (..one, i'-.*;. furnaces should be cun back in rate or shut down completely. 5. Stripper; Loss of steam to the stripper reboiler will mean an Immeciu4 increase in the amount of KGl passing tc the vinyl still, if t-"; am supply to the stripper cannot be restored very quickly, the furrm:--. will have to be shut down,. SL 009940 CWFIDEMTIM^ or()er CUtt 7-1 High HC1 content in the vinyl still product could easily overl..u the flake caustic neutralizers, resulting in off-grade product, rednr made. 6. Vinyl Still: Loss of steam to tne vinyl stij.1 receive:' v.L. in an immediate rise in the amount of vinyl chloride in the ; hi .. 1 bottoms. If steam cannot be restored reasonably scon, the luma-:-., should be shut down. Turn off reflux to the still tc prevent is.-4,h'r losses of vinyl chloride out the bottom cf the still. Try to keep tt recycle of high vinyl chloriae-c.or.tent EDC to the heavier-- stiff tv-. tank at a minimum. Loss of cooling water to the vinyl concenter is a ssriou-' pro-. 1* - , and if not remedied immediately will result in heavy ventihi* the PCV. Shut down reboiler to reduce heat input to still. 1 -w reflux on until column has cooled a little, trier, turn, re flue - 1,1 i down furnaces to step input cv VC tc system Loss of refrigeration to the still vent condenser is not sericur:, but will mean higher VC losses from the still. Repair difficulty ao soon as possible. 7. Recycle EDC Chlorination- It is important to continuously chlorinate the recycle EDC stream to remove chloroprene. If the -on ' system fails in any way, open up the by-pass valve to the Iff sc f a chlorination can continue. Repair chlorine system as soon a." peon:1 . f. Less of Refrigeration; If the refrigeration system fails, tl - turns ' >; must sr.ut down immediately. Shut down stripper an. I fr. . still re toilers tc lessen heat input into the system., Bnut cow Flywheel tr'z 9. Loss of Coding Water; If the cooling water system fail .... , input to ite system mus* be turned off immed.ifi.tely. In parr. -...I.1.'.; , furnaces and refrigeration system should be shun down rigk' ,. off the stripper and vinyl cclumn reboilers a<- coon as pos. remainder of the plant should then be shun down as orderly a,-, n ' If the cooling tower fan should fai-, iv is still pcssltl-'. op o the plant. The cooling water temperature will rise ant a vr^e -pc'' rise in condenser and cooler temperatures will result. The system , operate poorly as best under this condition, and if not. remrhisi sw, the plant should be shut down. IQ. Loss of Steam Supply: If steam supply is lost the plan" .-t,ou.V shut down. There are several good reasons for this statement" Cl,'' snuffing steam safety protection in the furnaces wilx be lost. f-t HC1 concentration will immediately increase ir the feed tc the viryu still, (3) the vinyl still cannot be operated at all without rcb'.i.I : steam. SL 009941 CONFIDENTIAL* order 1 District Court 1-1145 ?_12 11. Loss of Electricity; The loss of electrical power will ; i" a rapid shut-down of the plant. Some instrument air may be ave.ii.alI for a brief period, but manual block valves,should be closed where necessary. 12. Loss of Instrument Air; The loss of instrument air will also necessitate a rapid plant shutdown. The entire plant should shut down automatically in the fail-safe position, but check to make sure. Block each control valve station. Immediately put a no purge through the furnace tubes. 13. Loss of Purge Nitrogen; Check before shutting down to a- -.-ur air if the return of the normal supply will be soon. If not, shut the plant down. Make sure no foreign material (organics in particular) pets into the Ng header. ~" SL 009942 VIII. ANALYTICAL A. Sample Points The sample points have bev"1 "v,-* h* - - d r' 'Ts-r'"> - Please refer to the fiOV S t. L S p, a > t h ",`i ; ^ i p * . v n of the sample taps. Some of the sample taps will -or m d are included in case a sample is desired at , 'Lite" dam,. ' . T--'', , >v. - In describing a sample, always use m sutuT p-i-i; as its description. This infermatic- snould dlvv. i m m . rdm ' : tag. The complete description requested h*. re s pr* tv ; of a sample mix-up, -n ' - B. Control Samples 1. Sampling Schedule? ft,-, sw d Tv , ,, -.t; Table 8.2. This schedule will be revised _j( p experience gained in operating thr- glvi: . ' - i; . obtain as much information as pust.jh.ne u . r on ^ , , <. : : : ... When there is trouble i; tb- r"", t vm,vj. r.:s,lvu t > . .f- > * - quired.Do not hesitate to take and rir- fm m, q-,,iv : e -.-lvses, he. - answers so obtained may save a lot of useless effur: lamo on, nr will in- y the operator make the right process correction pon-r, 2. Sampling Technique: The glass sample hnt< j^s -rs , . 17 ................. or clear glass. They must be clean ok! on -r, hL t b - s i-ill ,, r-vl. m m. care of by the laboratory. Each bottle should r-t stnl.-d 11 n ^ * a, . I; tin bottle has been exposed to the atmosphere, do not usr trie botrl< . hot tie must have polyeth;/lene liners, or equivalent. To take a sample, first wipe to- sa;r,:"ii mr wv a,, - collected moisture and then purgt tht tap i-.u a r,i.- r:oi:l- , that use them). Purge at least a su f f ic i1 nt qiun p! of ruto: , -t \ i, i . replace stagnant liquid in the sample tap i tunes a-d died ) tv poriL;. move the bottle cap and completely fill the bot' ;i u Ajjv ' as little time as possible between epe: ing tiv- bnr. ti'e a , 1 rtn < 11, , Some of the samples will haw tr-. tv mne:- i- sue ivi<-- s`-w sample bombs. Bombs have been purchased in suftiu n-ou. quantity to, r one service only. Each bomb will be tagged writ we na-m- of the wnp'L a is to be used for. The bombs are equipped with f< ein.dleg to maintaw, u vay1 space. Always fill the bombs in a vertical position. To order i.u otter:' o true sample a high pressure liquid stream will be Circulated i.hro,.gh me bomb to some low pressure process stream,, i.t., u pump dis'tiargt to a pumn r-tf in. Any time a bomb is filled it should be checked (tilting or shaking) m 'v s- .r< that it has some vapor space in it. If there is none, caretuilv dr vt : ,, rol 1 amount of sample from the bomb. SL 009943 Wo. 91-1145 3. Analytical Methods; A ru'r\ i acL. m tht a n-; '- * a, ;m'.'r 3. used in the control tests is included 1 Liu A-' = iv ;c0j 'hr ju L i " h; ' plant. Table 8.2 gives the sample points ,-od Ltu. a-dlvsi. s in=u wi:i -'e i ; on the control analyses. L. Laboratory Samples 1. Sampling Scheduler 'Jbe -.uni,i in"-.: * - to i v i ; ' _i; t m 1 t < sampling and testing during theinitial star-up period. I'm" ; r - , l,,r- operation lab schedule will he pie part d r. sampling impost:-.. i' mi necessary, usually, for the midnight opera cor t- taki ' ``tse ;~amr M > -m' ' : them to the laboratory. Ai the- sm/ mmr. tm o' `-u = im n,1 nh lab all used control containers .-7 wil1' ma, > *nt: m\: a,-.- - - . i o' clean, dry, sample containers. 2. Sampling Procedures: i- ' care full v to avoid water contango - , fid : > !.-r=m ' '<- from the bomb. The process stream^ mutm - ; > fi'm-. o, .< , trace oi water from an external .muo. ; [ . . mm ,, course, will give an inccrretr dc*. * n . " u . " . o - '> m ih, ,j g Most of the sample tec m t i qne- a.-cm bee" disci ini Pe"e. addition, furnace gas samples will be tdi-v into -in i .-i L glass traps tilUu with ether. The traps will be immersed in a mixtcoe ui drv in arid methyle chloride. The glass trap has two fittings, an nie* and an outlet. When n in use but in the process of cooling down, a piece of flexible tubing will connect both openings. 'When a furnace gas sample is ready to be taken, era the sample tap to purge it, then connect the flexible tubing to the tap are the inlet fitting on the trap and slowly bubble trie furnace gas mixture? i'"' the chilled ether. Keep t be trap in tne drv ice bath. Sample b,,hiding mu. be slow enough that no b'holes escape out the top of the etnei hath. Win " sufficient amount of sample inis been taken, close the sample tap and mr:' the flexible t. hinc iurvm^ > tht 1 u- ' and o m bu . : tin. in i ` 1 dry ice bath directly to bmors1 >ry im analysis. Be sure to attach a uomot. ltd samel*- tatj l^ii mv , to the sample. (>n the sample tag time tup__oesu i p.l ? m Ji, with date, time and the sample point mmioc i . n^e m. - ! 3. Who Takes The Lab Samples ' . r , f i o,lo r tui ut_ e > -r;> t n t i c approach be followed in taking the planL ana i v l i; nl samples,,I ms > t q , i i < the assignment of specific shift;, to obtain i r<-- lequrrci .samples. i i gmm all laboratory samples will be taken Py the i: 30-3 ; 30 opeia^i at b;:30 />. M The furnace gas samples will be taken on he dm shite. Tin suit, ie-. i h" storage tanks will be taken whenever a taul; is i j lied,. St 009944 Sample Point No. V-l V-2 V-3 V-4 V-5 V-6 V-l V-8 V-9 V-10 V-ll V-12 V-13 V-14 V-15 V-16 V-17 V-18 V-19 V-20 V-21 V-22 V-23 V-24 V-25 V-26 V-21 V-28 V-29 TABLE 8.1 Sample Points for VC Plant 8-3 Container B C C C C B W C S C S S s c s s s s s s s S/C S/C B s s B B B Description Furnace Feed Furnace Outlet Pass -7/1 Furnace Outlet Pass #2 Furnace Outlet Pass #3 Furnace Outlet Pass M Quench Tower Bottoms Dopp Kettle Bottoms Quench Tower Overhead Primary Quench Condensate Primary Quench Condense! Off-Gas Quench Liquor before Drier Quench Liquor After. Drier Secondary Quench Conden sate Secondary Quench Conden sate Off-Gas Upper Intercooler Liquid Upper Intercooler Liquid After Driers Upper Intercooler Before Surge Tank Absorber Condenser Con densate Lower intercooler Liquid Lower Intercooler Liquid After Drier Absorber Bottoms Absorber Overhead Gas Stripper Overhead Gas Lean Oil/VC Still Bottoms Stripper Bottoms VC Still Feed Recycle EDO Before CI2 Recycle EDC After Cl2 Heavies Still Feed Location After Filters Furnace Discharge (Crack mg) Furnace Discharge /Cracking') Furnace Discharge t'Cracking") Furnace Discharge 1 Cracking) Discharge Tine to Dopp Kettle Kettle Discharge line Inlet to Frimarv Quench Cuudenser Liquid Outlet from Primary Quench Condenser Vapor Outlet trum Pr imar v Querch Condense! Discharge Quench Viquur Pumps Que uch Liquor PcV Liquid Outlet firm- Seconderv Quench Condenser Vapor Outlet from Secondary Quench Condenser Discharge Upper Intercooler Pump Upper Intercooler Surge Tank LCV Liquid Inlet Line to Upper Intercooler Surge Tank Liquid Out of Absorber Vent Condenser Discharge Lower Lott u wier Pump 'Lower Tntercoolcu Surge Tank LCV Discharge of Stripper Feed Bump Vapor Inlet to Absorber Vent Condenser Stripper Vapor Line Outlet of 900 lean oil Cooler Stripper Bottoms Drain Lint1 Discharge of VC Still Feed Pumps Alter VC Still LCV Outlet of Retention Tank Suction to Heavies Still Feed Pumps SL 009945 OMFXMMriM.t ub$fic to lrotfcctiv Order Of Utto Judici 1 'District Court No. 91-1145 Sample oi'it Mo. V-30 V-31 v - 32 V-33 V~34 V-35 V-36 V- 37 V-38 V -39 V-40 V~41 V-42 V- TABLE 8.1 (Cont'd) Sample Points for VC Plant Container- B S S S s B B B S S S S S Description Make-Up EDC Yt Still Ret lux VC Still Vent Gas VC Product After 1 hast- Separator VC Neutralized Product Heavies Still Bc-Ltoms Heavies to FD>_ IT a-it Hea,v ies Still Re f Lux VC Day Tank 1 VC Day Tank J-`2 VC Day 1 -k 3 VC Day Tank M VC Sphere *1 Freon C=Chilled Ether B=Brown Bottle S=Stainless Bomb 8-- location LCV on Inlet to feed Tank Discharge at kr l l ux >' .ont ^ still nv Discharge ol husi .u paiac ' -Before Mtutraliztr Atter f rodn, t 'i il U r s Sue tic- -> 1 in< i Hi n\ j t Still hallo -ji > amp nischaigt oi sol i. urns i amps ktfl-ax lump Suction Pine Discharge of 1 induct Irons it-: i amps i'Lscba'! yt ot < ( fd.it t Trans itit f j'npf' K*r ^ t rra*it- ter iamps Discharge of Product. Jraos fer lumps Discharge of Leading lumps J- re.on Receiver SL 009946 6^*CVi0lS,\'U' t it* o. 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O /Ztix7>C7jz /COC -y- vy/.- ~y> :,vC'c'<oa. cry/rr>y ossi SL 009948 PinSBURGH PLATE GLASS COMPANY CHEMICAL DIVISION LAKE CHARLES, LOUISIANA TITLE t/c /^Z AV7' - DRAWN BY DATE CHEdkeb BV TF3ETE ----------------- ---- ----------------4 SCALE DWG. "cBIRSET ,aLUs6r#MATERIAL NO.^.e g, j ^ SHEET ^ OF 5 CdAM^CEL F&/AJ7~ V-Z3 (D /yi^zpyv^s S't'/l.c. Fk:szc> V-3Q V-37 V-2V*38 F /DC /y'?s)SdM& FgFZ? //1Z1 V/Z*5 5V/z.z_ T^/^CZ>C/<ZT~ F/Oa V/&ZS S' rvz, Z/3<?3ry~cjAsi s l/C iCC; v 7a?/s/< \A39 V+> v-f/ VC CV>y Z/va/at \/C /Osny ~7?ea//< *3 VC ZDa? y 7D?aaaC 4VC 1 VC Tap/VAT 0?/A 7Y&&. .5/3/w/^E TV/^^ S7c?/WAV<f ?b/AS7~ *5a/WPL Cbr/779**/*? Oa//CU YS/A 1FjCdSQes&AJCy /=&&$<>/ ZC0z//<0 Borrco \A/G7~ |J^5>y/ycr^ - /Z?A/f)C.''/5'/ *> F3*=>&JZr 72?c-7 TV/^scTA?. A/bfiSt&MC'l&TUKE X3v^K3/S <5*0* V- /Vb. cz :/zcz, y-2 //?o A>i<5. S77S /V>. C/c?cs/G ZSp77zjz: /L/<Z>c//o TS&aJ /SorrLGL ZD/^Y W<.r JDfic'/ \aAzt / /-5V/v'r l/DKf o?cr a/ci, /=&, t/?o V- A/o. ,CGC AsPaa&u/? Cb* V-aVo. A/\S5. 79i*o&. /' C/c?(S/ey CDtesV &OT7-L.&. 4/c?<l//o ad?Sv7G // /t ZD*ZV Welt zd&v Wzlt // / /s*//rr~ //?gy 6aZ? ZdS/Crp/ (/oa 4 /&Av*rs\ \ MO/eA/WCi. Y / // /' ccc V-/Vo "?a A/yS, 3.77dd <cc * a/cC; Fk., /v?a Cr^ctc. ~72^jrz V-A/o. VC ZtoY7k *1 // // // // */ // // // /* ! Court- L/C/G'O /f /3cp/V7 b Djfv W&T / / O&Y // (CO F&#?/ L/CGU'G f3c?AS//3 >/?y 1/V&.7- ZF<E<$GG$TiCO // // e?c * //Cl; FtZ, //?0 Cr?LC. ~72z.sts V- /Vo. *V CC Z5phg&as. A?S *** /^%Oz*r3/zr> i/C Te C?P/e ^ V* 4^ j' >> OhI S-"S* 'ott-'c5 -g to <M o -%X-** /7a/^K?75 TC> ;a/C<SZ2GC CZA/CC^'<0 T^^ZZASVIZ *,, /Ga/aJl. y-/;; -r?Z> //JCCCSAx=r Y^/sAE Y/Od. idS/SAS 7^<E<Z? CScE ^ SL 009949 PITTSBURGH PLATE GLASS COMPANY CHEMICAL DIVISION LAKE CHARLES, LOUISIANA Tin p KC Sa?/w^z^ T^cc&SS Sctay<e zz><sy zc DRAWN BY DATE SCALE DWG._ CHECKEb BY ism-- CHAR6E ^pS'-A? NO. 1*6lc 2,,Z c. F?7 BILL OF MATERIAL SHEET -5 OF ^ f\/o (2 > l3 /\A / ? 7 J- N BD y 3 N r* ^ 4 0 R '1 0 O IC T Z O rN R R APH PAPER 9-4 SL 009953 TOP PRESSURE (PSIG) BOTTOM PRESSURE (PSIG) % FLOODING AT FULL RATE ABOVE FEED TRAY BELOW FEED TRAY MINIMUM EFFICIENT OPERATING RATE (%) REFLUX RATIO TABLE 9.1 DESIGN DATA FOR DISTILLATION COLUMNS HEAVIES STILL PRODUCT STILL 2 75 9 70 66 81 65 64 39 40 1:1 1.35:1 STRIPPER 55 59 ABSORBER 50 55 35 64 63 -- 30 30 ^bjecttnrDBNTlALi no. SI-1145 1 COUrt 9-5 VINYL CHLORIDE PLANT Vessel - Quench Liquor Tank (65A-60-694) and Product Still Feed Tank (65A-60-697) Length - 24.0' Tangent to Tangent I.D. - 11* 10 3/8" Level Ft. In. 01 2 3 4 5 6 7 8 9 10 11 10 1 2 3 4 5 6 7 8 9 10 11 20 1 2 3 4 5 6 7 8 9 10 11 30 1 2 3 4 5 6 7 8 .9 10 11 Volume Gals, 27 63 110 167 232 305 384 469 560 657 758 865 976 1,091 1,211 1,335 1,462 1,594 1,729 1,867 2,009 1,154 2,302 2,453 2,608 2,764 2,924 3,086 3,251 3,419 3,588 3,760 3,935 4,111 4,289 4,470 4,652 4,837 5,023 5,211 5,400 5,591 5,784 5,978 6,174 6,371 6,569 SL 009954 Level Ft . In. 4 0- 12345678910 11 5 012345678910 11 6 012345678910 11 7 012- 345- 6- 78910 - 11 - Volume Gals. - 6,769 - 6,969 - 7,171 - 7,374 - 7,578 - 7,783 - 7,989 - 8,196 - 8,404 - 8,612 - "8,821 - 9,031 - 9,241 - 9,452 - 9,664 - 9,876 - 10,088 - 10,301 - 10,514 - 10,727 - 10,940 - 11,154 - 11,367 - 11,581 - 11,785 - 11,999 - 12,213 - 12,426 - 12,639 - 12,852 - 13,065 - 13,278 - 13,490 - 13,701 - 13,912 - 14,123 - 14,333 - 14,542 - 14,751 - 14,959 - 15,166 - 15,372 - 15,578 - 15,782 - 15,986 - 15,188 - 16,389 - 16,589 Level Volume Ft . In. Gals. 8 0 - - 16,788 1 - - 16,985 2 - - 17,182 . 3 - - 17,376 4 - - 17,570 5 - - 17,761 6 - - 17,952 7 - - 18,140 8 - - 18,327 9 - - 18,512 10 - - 18,695 11 - - 18,876 9 0 - - 19,055 1 - - 19,233 2 - - 19,408 3 - - 19,580 4 - - 19,751 5 - - 19,919 6 - - 20,085 7 - - 20,248 8 - - 20,409 9 - - 20,567 10 - - 20,722 11 - - 20,874 10 0 - - 21,024 1 * - 21,170 2 - - 21,313 3 - - 21,453 4 - - 21,589 5- 21,722 6 - 21,851 7 - - 21,976 8 - - 22,097 9 - - 22,215 10 - 22,327 11 - - 22,435 11 0 - - 22,539 1 * - 22,637 2 - - 22,730 3 - - 22,818 4 * - 22,899 5 - - 22,974 6* 23,042 7 - - 23,103 8 - - 23,154 9 - - 23,195 10 - - 23,221 10 3/8 - 23,230 ,, . . confidential. Subject to Protective Order f I4th Judicial District Court No. 91-1J 45 9-6 VINYL CHLORIDE PLANT Vessel - Upper and Lower Intercooler Surge Tanks (65A-60-696,695) Length - 14.0' Tangent to Tangent I.D. - 5'11" Level Ft. In. 01 2 3 4 5 6 7 8 9 10 11 10 1 2 3 4 5 6 7 8 9 10 11 20 1 2 3 4 5 6 7 8 9 10 11 Volume Gals. -- 9 -- 24 -- 44 * - 68 -- 95 -- 125 -- 157 - 192 --- 229 -- 269 *- 310 -* 352 -- 397 *- 443 -- 490 -- 539 -- 589 640 -- 693 -- 746 -* 800 - 855 -* 911 *- 968 - - 1,025 - * 1,083 - - 1,141 - - 1,200 - - 1,260 - - 1,319 - - 1,379 - - 1,440 - - 1,500 - - 1,561 * - 1,621 Level Volume Ft. In. Gals. 3 0 - - - 1,681 1 - - 1,742 2 - - - 1,802 3 - - - 1,863 4 - - - 1,923 5 - - * 1,983 6 - - - 2,043 7 - - - 2,102 8 - - * 2,161 9 - - - 2,219 10 - - - 2,277 11 - - * 2,335 4 0 - - - 2,391 1 - - - 2,447 2 - - 2,402 3 - - - 2,556 4 - - - 2,610 5 - - * 2,662 6- - 2,713 7 - - - 2,763 8 - - - 2,812 9 - - - 2,859 10 - - - 2,906 11 - - - 2,950 5 - - 2,993 IV- - - 3,034 2 - - - 3,073 3 - - - 3,110 4 - * - 3,145 5 - - - 3,178 6 - - - 3,208 7 - - - 3,235 8 - - - 3,258 9- - 3,278 10 - - . - 3,293 11 - - - 3,301 SL 009955 VINYL CHLORIDE PLANT Vessel - Product Still Reflux Tank (65A-60-698) Length - 16.0' Tangent to Tangent I.D, - 6' 4 7/8" Level Ft. In. 0 1- 2345678910 11 - 1 01234- 567- 8- 910 11 2 0- 123- 45678910 11 3 012- Volume Gals. ------ 11 -- 29 -- 52 -- 80 -- 112 -- 148 -- 186 -- 228 -- 272 -- 318 -- 367 - - 418 - - 470 -- 525 -- 581 -- 640 -- 699 -- 760 - 822 -- 886 -- 951 - - 1,017 - - 1,084 - - 1,152 - - 1,220 - - 1,290 - - 1,360 - - 1,431 - - 1,503 - - 1,575 - - 1,648 - - 1,721 - - 1,795 - - 1,869 - - 1,943 - - 2,017 - - 2,091 - - 2,166 Level Ft. In. 3 3-4- 5- 6- 7- 8- 9- - 10 - 11 - 4 0- - 1- 2- 3- 4- 5- 6-7- 8- 9- - 10 - 11 - 5 0-- 1- 2-- -*v- 4- 5- 6- 7- 8- 9- 10 - 11 - 6 0-1- 2- 3- 4- '.4 7/8 - Volume - 2,239 - 2,314 - 2,388 - 2,462 - 2,536 - 2,610 - 2,684 - 2,757 - 2,829 - 2,902 - 2,973 - 3,044 - 3,114 - 3,184 - 3,253 - 3,320 - 3,387 - 3,453 - 3,518 - 3,581 - 3,643 - 3,704 - 3,764 - 3,821 - 3,878 - 3,932 - 3,984 - 4,035 - 4,083 - 4,130 - 4,173 - 4,214 - 4,253 - 4,288 - 4,319 - 4,347 - 4,370 - 4,387 - 4,395 SL 009956 y-t> VvjI.NinYiL.Lj CHLORIDE Prj-LiAAiNNXT CCOONNFrlIwDEN*iTt*M\wat% Subject to Protective Vessel - Heavies Still Feed Tank (65A-60-711) Judicial ttUfefiet feUfk Length - 24.0' Tangent to Tangent I.D. in ;/" |)qs 91-1J.4& Level Ft. In. 0 123456789- 10 11 1 0- 12345678910 11 2 0, 12345678910 11 3 01234567.8 * 9- 10 11 - Volume Gals. - 27 - 63 - 110 - 167 - 232 - 305 - 384 - 469 - 560 - 657 - 759 - 865 - 976 - 1,092 - 1,212 - 1,335 - 1,463 - 1,595 - 1,730 - 1,868 - 2,010 - 2,155 - 2,303 - 2,455 - 2,609 - 2,766 - 2,926 - 3,088 - 3,253 - 3,420 - 3,590 - 3,762 - 3,937 - 4,113 - 4,292 - 4,472 - 4,655 - 4,839 - 5,025 - 5,213 - 5,403 - 5,594 - 5,787 - 5,981 - 6,177 - 6,374 - 6,573 Level Ft. In. 4 012- 345678910 11 5 012345678910 11 6 012345678910 11 7 0123- 45678- 910 - 11 - Volume Gcil s * - 6,772 - 6,973 - 7,175 - 7,379 - 7,583 - 7,788 - 7,994 - 8,201 - 8,409 - 8,617 - 8,827 - 9,037 - 9,247 - 9,458 - 9,670 - 9,882 - 10,094 - 10,307 - 10,520 - 10,734 - 10,948 - 11,161 - 11,375 - 11,589 - 11,794 - 12,008 - 12,221 - 12,435 - 12,649 - 12,862 - 13,075 - 13,288 - 13,500 - 13,712 - 13,924 - 14,134 - 14,345 - 14,554 - 14,763 - 14,972 - 15,179 - 15,386 - 15,592 - 15,796 - 16,000 - 16,203 - 16,405 - 16,605 Level Volume Ft. In. Gals. 8 0 - - 16,804 1 - - 17,002 2 - - 17,199 3 - - 17,394 4 - ** 17,588 5 - - 17,780 6 - - 17,971 7 - - 18,160 8 - - 18,347 9 - - 18,533 10 - - 18,716 11 -- - 18,898 9 0 - - 19,078 1 - - 19,256 2 - - 19,432 3 - - 19,605 4 - - 19,776 5 - - 19,945 6 - - 20,112 7 - - 20,276 8 - - 20,437 9 - - 20,596 10 - - 20,752 11 - - 20,905 10 0 - - 21,055 1 - - 21,202 2 - - 21,346 3 - - 21,487 4 - - 21,624 5 - - 21,758 6 - - 21,888 7 - - 22,014 8 - - 22,136 9 - - 22,254 10 - - 22,368 11 - - 22,478 11 0 - - 22,582 1 - - 22,682 2 - - 22,777 3 - - 22,866 4 - 22,949 5 - - 23,026 6 - - 23,095 7 - - 23,158 8 - - 23,211 9 - - 23,255 10 - - 23,286 10 5/8 - 23,297 SL 009957 Confidential; Subject to Protective Order of 14th Judicial District Court <fe>, 9t-U*5 VINYL CHIORIDE PLANT. Vessel - Heavies Still Reflux Tank (65A-60-708) Length - 24.0' Tangent to Tangent I.D. - 11' 10 3/4" SL 009958 Level Ft. In. 0i 2 3 - 45- 6- 7- 8- 910 - 11 1 0- 123- 45- 6- 789- 10 - 11 2 0- 12- 3- 45678- 910 - 11 - 3 0- 12- 3- 45- 6- .7 8- 9- 10 - 11 - Volume Gals. - 23 - 60 - 108 - 165 - 231 - 303 - 382 - 467 - 558 - 654 - 755 - 861 - 971 - 1,085 - 1,204 - 1,326 - 1,453 - 1,583 - 1,717 - 1,853 - 1,994 - 2,137 - 2,284 - 2,433 - 2,586 - 2,741 - 2,899 - 3,059 - 3,223 - 3,388 - 3,556 - 3,726 * 3,899 - 4,074 - 4,251 - 4,430 - 4,611 - 4,794 - 4,978 - 5,165 - 5,354 - 5,544 - 5,736 - 5,929 - 6,124 - 6,320 - 6,518 Level Ft. In. 4 012345678- 910 11 5 0- 12345678910 - 11 6 0- 12- 34- 56* 789- 10 11 7 0- 12- 3- 456789- 10 - 11 - Volume Gals. - 6,718 - 6,918 - 7,120 - 7,324 - 7,528 - 7,734 - 7,941 - 8,148 - 8,357 - 8,567 - 8,778 - 8,990 - 9,202 - 9,415 - 9,630 - 9,844 - 10,060 - 10,276 - 10,493 - 10,710 - 10,927 - 11,146 - 11,364 - 11,583 - 11,809 - 12,028 - 12,247 - 12,465 - 12,682 - 12,899 - 13,116 - 13,332 - 13,547 - 13,762 - 13,976 - 14,189 - 14,401 - 14,612 - 14,823 * 15,033 - 15,241 - 15,449 - 15,655 - 15,861 - 16,065 - 16,268 - 16,469 - 16,670 Level Volume Ft. "8" In. 01- Gals. - 16,869 - 17,066 2 - - 17,262 3 - - 17,457 4 - - 17,650 5 - - 17,842 6 - - 18,031 7 - - 18,219 8 - - 18,405 9 - - 18,590 10 - - 18,772 11 - - 18,953 9 0 - - 19,131 1 - - 19,308 2 - - 19,482 3 - - 19,654 4 - - 19,824 5 - - 19,991 6 - - 20,156 7 - - 20,319 8 - - 20,478 9 - - 20,636 10 - - 20,790 11 - - 20,942 10 0 - - 21,091 1 - - 21,236 2 - - 21,379 3 - - 21,519 4 - - 21,655 5 - - 21,787 6 - - 21,917 7 - - 22,042 8 - - 22,164 9 - - 22,281 10 - - 22,395 11 - - 22,504 11 0 - - 22,608 1 - - 22,708 2 - - 22,803 3 - - 22,892 4 - - 22,976 5 - - 23,053 6 - - 23,124 7 - - 23,187 8 - - 23,243 9 - - 23,288 10 - - 23,322 10 3/4 - 23,336