Document JNMLjwLD1OQ7ow3o85pER7522

MONSANTO COMPANY ANNISTON, ALABAMA AROCtOR - MURIATIC ACID PROJECTS 1663 & 1772 START-UP OPERATIONS MANUAL APRIL 1965 AAAAAAAAAAAAAAAAAAAAAAAAA***AAA CONFIDENTIAL MUNS 092976 ARPC1DR-MURIATIC ACID START-UP OPERATIONS MANUAL DISTRIBUTION LIST COPY TO: 1. 2. 3. 4. 5. 6. 7. 8. 9. .10 U. 12. 13. 14. 13. 16. 19. 20. 21. Through 23. H. L. Mlnckler D. B. Hosmer J. A. Mullendore R. P. Stevens L. L. Fellinger R. S. Yates R. E. Howard H. L. Hubbard R. W. Bucknell J. R. McClain R. G. Moody W. F. Taffee, Jr. L. C. Fuhrmeister P. H. Sturman J. H. Aldridge J. M. Willette J. W. Molloy M. J. Willlama T. E. Lackey V. R. Haupt Extra* G.O. - St Lou la G.O. - St Lout* G.O. - St Loul* O.E. - St Louis O.E. - St Loul* O.E. - St Loul* O.E. - St Loul* O.R. - St Louis O.R. - St Louis Anniston Anniston Anniston Anniston Anniston Anniston Anniston Anniston Anniston Anniston Anniston COPY NO. MONS 092977 AROCLOR-MURIATIC ACID AT ANNISTON PROJECTS 1663 & 1772 START-UP OPERATIONS MANUAL - (ARO SOM) TABLE OF CONTESTS Demonstration Plan & Schadule...................................... Tima Tabl....................................... I 1.000 Organization.......................... I - 2.000 Conmunlcatlons......................... I - 3.000 Start-Up Expanaa................................................................... Code of Accounts....................... II - 1.000 Budget Sunmary........................... II - 2.000 Tentative Operating Instructions................................ Synopsis......................................... Ill - 1.000 Detailed Instructions............ HI - 2.000 Therminol Heater....................... III - 2.010 Weigh Tank. Ho. 9 Chlorinetor, & Ho. 2 Blow Tank......... III - 2.020 Ho. 4 Still System.................. III - 2.030 Batch and Continuous Liquid Chlorlnators................................ III - 2.040 Liquid Axoclor Still System............................................. III - 2.050 HC1 Clean-Up Facilities..,. III - 2.060 Muriatic Acid System.............. III - 2.070 Section I Section II Section III ia 29 Tabla of Contents Continued Training Flan.......................................................................... Overall Plan & Outline....'. IV - 1.000 Sample Lesson.......................... . IV - 2.000 All Operators (By Days).... IV - 3.000 Shift Leaders................... IV - 4.000 Section IV Objectives................................................................................. Overall........................................... V - 1.000 Process Simulation.................. V - 2.000 Initial Operations.................. V - 3.000 Project Demonstration........... V - 4.000 Section V Operations Plan....................................................................... Process Simulation..,........... VI 1.000 Initial Operatlona.................. VI - 2.000 Project Deronetratlon............ VI 3.000 Section VI Miscellaneous....................................................................................... Acceptance Criteria......... 1.000 Analytical Methods............, Calibration Charts............ Equipment Check-Out Procedure................................ , - 2.000 - 3.000 . 4.000 Data Sheet*.............. Performance Criteria.... - 5.000 - 6.000 Test Records......................... 7.000 Work Schedule* VII 8.000 Section VII 092979 TIME TABLE AROCLOR-MURIATIC ACID START-UP ARO SOM I - 1.000 Page 1 of 3 Rev. 0 Date: 3/23/65 This time table for start-up Is scheduled in three sections, with some overlap of completion due to the nature of this rehabilita tion program. These sections ere: PHASE I - AROCLOR SOLIDS SYSTEM PHASE II - RENOVATED LIQUID AROCLOR SYSTEM PHASE III - MURIATIC ACID SYSTEM PHASE I: AROCLOR SOLIDS SYSTEM Begin New Operator Training March 16 Begin All Operator Training March 29 Department Directors' Review: PHASE I, II, and 111 April 20 ( Start Equipment Check-Out (Produc tion) and Start-Up Thenninol System April 28 Start Process Simulation April 28 Complete All Mechanics Training April 30 Complete All Operator Training PH. I May 4 Charge Chemicals May 5 First Batch Finished May 8 Demonstrate Ability to Safely Process Quality Material May 12 Achieve 507. Design Rate May 19 Achieve 607. Design Rate May 26 Start Up HCl Clean-Up Facilities September 1 Demonstrate HCl Clean-Up Facilities September 15 Achieve 1007. Design Rate October 30 Time Table ARO SOM I - ..000 Page 2 of 3 Rev. 0 DaCe : 3/23/65 PHASE II: RENOVATED LIQUID AROCLOR SYSTEM Instrumentation Check-Out EDC May 10 Begin All Operator Training May 24 Release Equipment for Construction May 26 Start Up New Pumps at Chlorinators 1, 2, and 3 June 7-IB Complete All Operator Training PH.II June 15 Start Up Continuous Chlorlnator Blow Tank and New Biphenyl Feed System June 18 Start Up Altered No. 3 Still Receiver June 18 Complete Installation of Brink Demisters on Chlorinators 1-9 June 18 Start Up HC1 Clean-Up Facilities September 1 Demonstrate HC1 Clean-Up Facilities September 15 Achieve 1007. Design Rate October 1 PHASE III: MURIATIC ACID SYSTEM Release Equipment for Alterations to Allow Construction April 19 Begin All Operator Training June 28 Complete All Operator Training PH.Ill July 10 Start Equipment Check-Out (Production) July 12 Start Procesa Simulation July 12 MUNS 09^98^ Time Table ARO SOM I - 1.000 Page 3 of 3 Rev. 0 Date: 3/23/65 PHASE XII: (Continued) Charge Chemicals and Start Up HCl Clean-Up Facilities Pemonstrate Ability to Safely Process Quality Material Achieve 50% Design Rate Achieve 60% Design Rate and Efficiency Start Up HCl Clean-Up Facilities Demonstrate HCl Clean-Up Facilities Achieve 100% Design Rate July 15 July 17 July 25 September 1 September 1 September 15 October 1 These dates are targets - every effort will be made to beat them if at all possible and to accomplish the job In less time and at a lower cost than now scheduled. Guiding principles will be the best long range return for Monsanto. MONS 092933 ORGANIZATION Liaison & Start-Up Superintendent for Aroclor Aroclor Department Supervisor Aroclor Department Foreman Shift Leader Shift Leader Shift Leader 15 Operators 5 Chief Operators for Aroclor-Biphenyl Dept Support Groups: Maintenance Laboratory T.S.D. Organic Engineering Organic Research ARO SOM X - 2.000 Page 1 of 1 Rev. 0 Date: 3/21/65 w. F. Taffee J. W. Molloy T. E. Lackey M. J. Williams M. J. Williams N. K. Madison V. R. Haupt J. M. Willette 0. E. Dolln V. R. Haupt N. K. Madison R. S. Yates R. N. Harris R. W, Bucknefl MGNS 092904 COEttflJWICATIOHS 1. Operations Manual Demonstration Plan & Schedule Expense - Code of Account Operating Instructions Training Plan Objectives Operations Plan 2. Budgets, Cost Standards, Variance Predictions 3. Start-Up Progress Reports 4. Daily Production Suimary 5. Engineering Changes 6. Process Changes 7. Project Completion Report Manufacturins TPM, MPC TPM TIM DM, TPM TPM RPM TPM, MPC DM, TPM, MPC TPM TPM DM, TPM Eneineerine ER ER ER ER, DE ER ER ER ER ER ER Research RR RR RR RR, DR RR RR RR RR RR RR Plant (CC, PM, MR (SM, PE SM, PA, MR SM, MR SM, CC, PS MR PM, SM, MR PM, SM, MR PM, SM, MR PM, SM, MR PM, SM, MR PM, SM, MR PM, SM, MR PM, SM, MR Date: 3/21/65 MONS 0 9 2 9 8 5 COmUNICATIONS ARO SOM I - 3.000 Page 2 ol '2 Rv. 0 Date: 3/21/65 D1STRICUTI0N CODE Manufacturing Technical Production Manager - TPM Manager, Production Planning & Control - MPC Director of Manufacturing - DM Research - Research Representative Director of Research Research Group Leader _ RR . DR - RGL Engineering - Engineering Representative Director of Engineering _ ER - DE Plant - Plant Manager Manufacturing Representative Superintendent of Manufacturing Plant Engineer Chief Chemist Personnel Superintendent Plant Accountant _ PM MR - SM - PE _ CC - PS - PA MUNS 0989S6 ARO SOM II - 1.000 Pag* 1 of 2 Rav. 0 Data: 3/31/65 CODE OP ACCOUNTS Charg* for atart-up expenses will be collected agalnat 02-09-916.51, using appropriate code from the following Hat: 520 505 526 530 533 539 542 545 570 575 578 590 610 614 621 635 641 Interplent Raw Material Raw Material Purchased Raw Material Handling Steam Electricity Hater - Purchased Hater - Plant Gas Hages Salaries Payroll 0/H Factory Supplies Laboratory Clothing & Laundry Technical Service Experimental Expense Rentals Equipment MOMS 09^qaa Cod* of Account* 644 651 661 694 698 715 760 780 790 798 804 824 855 864 867 878 880 883 ARO SOM II - 1.000 Fag* 2 of Z Rv. 0 Date: 3/31/65 Start-Up Expense Production Process Research Waste Disposal Mechanical Expense Depreciation Consultant Fees Factory Indirect Expense (from Service Budgets) Insurance tunches Served Guests Meetings & Conferences Outside Contract Work Plant Trucks Sundries Office - Stationery, Printing, A Supplies Switching Expense Taxes Coonunlcation* Travel HONS 092989 ForAROCLORProj. Ho. 1663 6 1772 Capital $ 910.000 Approx. Start-Up Date April Thru June Project Title Solids Line - April, HCl System - May Liquids - June MONTH & TEAR Jan. 1965 b Feb. 1965 D i Mar. 1965 H at Apr. 1965 < H May 1965 w June 1965 -- RAH MATERIALS --3,500 2,100 - SAIA8IES & O.H. 1,430 3,710 5,080 2,770 1,855 1,625 WAGES & O.H. 1,140 3,420 5,275 11,435 7,165 1,920 MECHANICAL EXPENSE SUPPLIES 500 200 1,000 600 5,000 600 5,000 1,000 5,000 1,000 5,000 1,000 ALL OTHER 1,070 1,670 5,405 5,490 3,990 600 TOTAL 4,340 10,400 23,360 39,195 21,110 10,145 Start-Up Sub-Total 5,600 16,470 30,355 21,500 4,400 18,225 ' 96,550 MONTH A YEAR Apr. 1965 # PROD. 2,750,000 ss May 1965 3,250,000 o M June 1965 3,500,000 H Xc z O July 1965 at Aug. 1965 3,750,000 4,000,000 o O Sept.1965 4,000,000 rw u Correction Sub-Tocal O GRAND START-UP & 10,000 10,000 14,000 7,000 6,000 3,000 50,000 55,600 1,500 1,500 1,500 1,000 1,000 1,000 7,500 23,970 2,880 2,880 2,880 2,880 2,880 2,880 17,280 47,635 15,000 15,000 10,000 5,000 5,000 5,000 55,000 76,500 1,500 1,000 750 500 250 100 4,100 8,500 4,000 3,500 2,700 2,000 1,200 500 13,900 32,125 39,880 36,880 32,830 21,380 16,330 12,480 147,780 244,330 (M A O AKO SOM A I I ISECTION r -Vl'i'P... mqns 09^991 STOOPSIS OF PROCESS AR0CL08-HURIATIC ACID DEPARTMENTS ABO SOU III - 1.000 Page 1 of 4 Rev. 0 Data: 4/20/65 I. GENERAL Aroclors are the reaction products formed by chlorination of Biphenyl and/or Terphenyl using Ferric Chloride Catalyst. Crude Aroclora are produced In the chlorlnators, air-blown, distilled, and loaded for shipment. Liquid Aroclora are also earth-treated, filtered, and then loaded for shipment. The by-product EC1 gas produced la absorbed In water to produce Muriatic Acid. It Is carbon treated, filtered, and then loaded for shipment. II. CHL0EINAI0R AREA There are four batch liquid operated chlorlnators, one continuous operated chlorlnator system, and one batch solid chlorlnator. The batch liquid chlorlnators are charged with 3,000 pounds of Biphenyl with 1-1/2 pounds of Ferric Chloride catalyst. Chlorine gas added through a distributor plate reacts with the raw material to release NCI gas and heat. The NCI gas goes to the Muriatic Acid Department. Heat Is taken away by circulation through an external air-cooled heat exchanger. The specific gravity of the crude Aroclor Is checked to determine the level of chlorination. The continuous chlorlnator system consists of four batch chlorlnators cascaded with overflow from one unit to the next. In the continuous chlorination system, Biphenyl Is fed to the first stage and chlorinated. Crude Aroclor overflows Into the second stage, etc., - until the final product overflowa from the last stage, flows to a catch tank, through a continuous air blow tank, and then Is transferred to a crude holding tank prior to distillation. Each chlorlnator la held at different levels of chlorination with the last stage being the final crude Aroclor desired. Normally, Aroclor 1142 Is produced In this system. The system has been demonstrated on Aroclors 1148, 1154, and 1160. Crude Aroclors from the batch chlorlnators and the continuous chlorlnator system are transferred to a blowing tank to be air-blown for one hour minimum before distillation. III. STILL ABEA A. Liquid Aroclors Aerated Aroclor from a blow tank or feed tank Is charged to a still, hydrated lime la added, a vacuum of 720 am Eg (40 nn Eg absolute) Is applied, the still furnace Is fired, and the Aroclor distilled to a M0NS 092992 Synopsis of Process AEO SOM III - 1.000 Poge 2 of 4 Rev. 0 Date: 4/20/65 receiver. The distillation Is seml-continuous since ten receivers are distilled prior to drawing bottoms or residue from the still. Every two receivers are treated with 40 pounds of earth for two hours and then filtered. The finished product Is transferred to storage tanka prior to loading into drums or tank cars. B. Solid Aroclors Solid Aroclors are distilled In a similar manner to liquid Aroclors except for 1168. Aroclor 1168 Is not air-blown and It Is charged directly to the still from the chlorinator. A vacuum of 4 mm Ig absolute Is applied to the receiver (10 mm Hg absolute to the still) for distillation. One receiver of solid Aroclors Is distilled prior to drawing bottoms In the still. Solid Aroclors are not earth-treated or filtered. They are drummed directly from the receiver or ere flaked (Aroclor 1268 and 5460). Aroclor 2565 Is one exception to this rule since It Is an undlstllled product. C. Aroclor Nomenclature Aroclor is a trade name used to designate chlorination products of Biphenyl, terphenyls, or mixtures of the two. The physical properties vary from a light, free-flowing liquids to crystalline and non-crystal line solids. A numerical system of nomenclature, consisting of four digits, has been developed for Identifying the Aroclors. The "thousands" digit denotes the raw material used In the chlorination. The figure "1--" Indicates 100% technical grade Biphenyl. The hundreds digit denotes whether or not the product Is distilled. The "1--" indicates undlstllled and the figure "2--" Indicates distilled. The tens and units digit denotes the approximate percentage of chlorine contained in the finished product. For example, 1260 ie a distilled chlorinated Biphenyl containing 60% chlorine. Deviations from the above nomenclature for solid Aroclors are as followsi 1. Aroclors 4065 and 4465 Aroclor 4065 Is the crude end 4465 la obtained by distillation. The starting raw material contains 40% Santowax k and 60% technical Biphenyl. This Is chlorinated to 65%. 2. Aroclors 5060 end 5460 Aroclor 5060 Is the crude from which Aroclor 5460 Is distilled. The starting raw material Is 100% Santowax R which Is chlorinated to 60%. HONS 092993 Synopsis of Process ARO SOM III - 1.000 Page 3 of 4 Rev. 0 Sate: 4/20/63 3. Aroclor 5042 and 5442 Aroelor 5042 Is the crude from which Aroclor 5442 la distilled. The starting raw material Is 100% Santowax S which Is chlorinated to 42J. . 4. Aroclor 2565 This Is an undlstllled product. The starting raw material consists of 25% Santowax C and 75% technical Biphenyl. This Is chlorlnatsd to 65%. IV. MURIATIC ACID A. Absorption Muriatic Acid 31-36% (20-22 84) solutions are produced by the absorp tion In water of hydrogen chloride gas (HC1), a by-product from the Aroclor chlorination. The gaseous IC1 Is passed through a cooling tower system to remove vapor-entrained Aroclors or Biphenyl and Santowax. The HC1 gat then enters the primary stage of the absorber system at the top and flows co-currently down the tubes being absorbed In the weak acid from the tails scrubber stage. The lean gas existing from the bottom of the primary stage Is directed Into the bottom of the tails toiler. The feed water (city water) enters the top section of the tells tower and countercurrently absorbs the MCI from the weak gas stream. The gas stream depleted of IC1 Is exhausted from the tails tower through a Schutte-Koertlng fume scrubber jet to the atmosphere. Feed water Introduced Into the tells tower Is controlled by a differential pressure ratio recording controller sensing the gas flow to the primary absorber to produce add, varying from 20 to 23 b4. Acid from the primary absorber drains Into a catch tank and Is then pumped to commercial (regular) acid storage tanks. Regular acid Is loaded Into tank cars or trucks for shipment to customers. The absorption unit can be shut down by directing the HC1 gas flow through the Schutte-Koertlng fume scrubber jet. The HC1 gas stream Is absorbed by this unit In water and directed to the sewer. Sewered acid flows to a limestone pit where It Is neutralized to reduce the MCI to a maximum of 0.2% at a pH of 4.5 to 5.0 In the effluent from the plant. B. Carbon Treatment and Filtration Vatar-whlte Muriatic Acid Is produced by directing the add from the bottom of the absorber through activated carbon towers to remove odors, MQNS 092994 Synopsis of Process ASO SOM III - 1.000 Page 4 of 4 Rev. 0 Date: 4/20/65 organic Impurities, free chlorine, and improve color. The acid is then passed through a poroatone filter and to storage tanka. The acid is then loaded into tank cars or trucks for shipment to customers. MONS 092995 ARO SOM III - 2.000 Page 1 of 1 Rev. 0 Date: 4/20/65 DETAILED INSTRUCTIONS AROCLOR - MURIATIC ACID START-UP Detailed operating Instructions for the Aroclor-Murlatlc Acid rehabili tation program at Anniston have been written in the form of Process Function Outlines (PFO's). The Process Function Outlines have been divided Into seven major areas as follows: 1. Thermlnol Heater 2. Heigh Tank, No. 9 Chlorinator, and No. 2 Blow Tank 3. No. 4 Still System, Solid Aroclors 4. Batch and Continuous Liquid Chlorinators 5. Liquid Aroclor Still System 6. HC1 Clean-Up Facilities 7. Muriatic Acid System The flrstfour sections have been completed and are Included In this Start-Up Operations Manual. The liquid Aroclor still system has not been written since it will be a duplicate of our present operating instructions. Sections 6 and 7, the NCI Clean-Up Facilities and Muriatic Acid System, have not been written since the final details have not been established for these systems. They will be completed prior to training and start-up. *0N S PROCESS FUNCTION OUTLINE AROCLOR DEPARTMENT ARO SOM III - 2.010 Pag* 1 Rev. 0 Date: 3/24/63 I. THERMIHOL HEATER Thla cover* the charging, etart-up, shutdown, normal operation, and emergency altuatlon* Involving the Thermlnol heater In the Aroclor Department. 1.2 Description of Proce** Thermlnol PR-2(Aroclor 1248) 1* circulated through a pipe ayatem In the Aroclor Department at flow rates of 0 - 300 OPM at 60 p*l. The normal operating temperature la 250*C. onthe discharge of the heater at 300_GPM. Thla heating ayatem 1* used to heat up tanka, transfer lines, pumps, and material Involved In producing solid Aroclor*. II. PROCESS DIAGRAM Attached. III. OPERATOR OF PROCESS 3.1 Charae System With Thermlnol PR-2 (Aroclor 12481. A. Use temporarily relocated Pyranol pump to charge Thermlnol surge tank. B. Position 35 gallon drum next to pump. Remove drum bung end vent cap. C. Connect flexible hose to pump suction and the stain less steel pipe to be Inserted Into the drum. D. Position discharge line from the pump Into tha tank. E. Open valve on pump suction. Insert pipe Into drum and start pump. MOWS 092997 Proceee Function Outline Aroclor Department ARO SOM III - 2.010 Page 2 Rev. 1 Date: 4/13/65 7. Adjuat the auction valve on the pump until flow la eteady. G. Continue to fill the tank until 25 druma or approximately 1,200 gallone total are In the aurge tank (Item 627). 3.2 Start-Dn A. Initial Start-Up 1. Check to be aura Thermlnol la In the eurge tank. . Temperature ahould be 100*C. minimum. 2. Open natural gap valvee In line to furnace. 3. Open blower air valvee in pilot and main air llnee. 4. Turn on circuit No. 5 at aelll panel and awltch at the field control box. 5. Actuate red lnaet eafety lever lnalda the Honey well Protectoglo unit (lower right cover of caee). You muet wait 10 aeconda between aettlnga of thla lever In caee It haa to be redone. 6. Set the control point on Honeywell coll outlet temperature Indicator at 325*C. (617*F.). 7. Align valvee In the Thermlnol eyetem llnee to circulate main llnee only. 8. Place TRCA-629.12 In "manual" with the output preeaura at 15 pa la. Blower air control valve la air to open. Set FIC-628.01 at 300 CPM in "auto" poaltion. 9. Start Thermlnol circulating pump (Item 628). 10. Start air blower. Uee puahbutton at aide of field panel. Red llaht on Protectoglo unit ehould light up. Air preaaure at the blower diecharge ahould be above 1 palg. 11. Check preaaure gauge et main air Inlet to burner. It muet be above 15 o.a.l. MUNS 092998 Proceaa Function Outline Arocloc Department ARO SOM III - 2.010 Page 3 Rev. 1 Date: 4/13/65 12. Walt 3 mlnuteo. Craen light on Protectoglo unit light! up Indicating purge period la over, 13. Adjuat manual'valve In air line to burner until preeaure la below 1-1/2 o.a.l. 14. Preea Ignition "atart" puahbutton on aide of control box end hold In until white light on Protectoglo unit light! up. Red and green llghta ahould go out. 15. Adjuat manual valve In air line to burner until preeaure la between 15 and 22 o.a.l. It muat be above 15 o.a.l. 16. Reaet the two North American aafety valvea In the main gaa line. 17. Adjuat TRCA-629.12 to temperature at outlet of coll and tranafar lnatrument to "auto". Thla la for low fire etart-up. Uae care to make thla change aa you can cauae ahutdown of the furnace. 18. The furnace muat be dried out prior to Step 19. Detalla will be provided. 19. Obaerve the furnace temperature at the coll outlet. Do not exceed 30*C. lncreaae for flrat 2 houra. Set TRCA-629.12 In automatic and raiae the tempera ture 50*C. per hour until you reach 220*C. Open the manual air valve alowly to raiae the temperature. Place TRCA-629.12 in "auto" poaltlon and put aet point at 2S0*C. Syatem will circulate until needed. 20. Pill Thermlnol eyatem in all branch llnea. Open each branch valve at feed and dlacharge to drive out air. Pill llnea one at a time. Process Function Outllno Aroclor Department ABO SOM HI - 2.010 Page 4 Rev. 1 Date: 4/13/65 B. Start-Up Following Temporary Shutdown Assume' circulating, pump la running and tha pilot light la burning. 1. Check to be aure Therminol la In the aurga tank (Item 627), 6" above coll. 2. Check temperature In surge tank (Item 627), TI-627.03. It should be 100*C. Turn on steam to tank coll If necaesary. 3. Check valves In Therminol system lines to be sure where the heating system Is being circulated. 4. Adjust set point on FIC-628.01 at 300 CPM controller In "auto" position. 5. Adjuat set point TRCA-629.12 at 125*-150*C. and ' controller in "auto" position. 6. White light on tha Honeywell Protactoglo unit will ba on Indicating the pilot Is on. 7. Reset the two North American safety valves In the main gas line. 8. Start heat to burner by throttling 6" manual valve In the main air line. The main burner will light up, heating Therminol to the desired tempereture. Gradually raise the temperature set point to 250*C. 9. Open valves In branch Therminol system lines as needed. Open discharge and feed line at each feeder. 3.3 Routine Operations When the Therminol heater system Is operating normally, tha following conditions will exist In the process. A. FIC-628.01 pump flow set at 300 GPM. B. PI-628,02 pump discharge pressure 80-85 Psla. MONS 093000 Proceee Function Outline Aroclor Department ARO SOM III - 2.010 Page 5 Rev. 1 Data: 4/13/65 C. PI-629.16 heater coll outlet preaaure 62 pain. D. PI-628.03 Thermlno'l line preaaure 45 pain. E. TRCA-629.12 heater coil outlet temperature aet at 250*C. F. Honeywell coll outlet temperature Indicator at 250*C. Shutdown alarm aet at 325*C. G. TI-627.03 aurge tank temperature 245`C. H. Air blower reduced diacharge preaaure - above 15 o.a.l.. leaa than 22 o.p.l. I. Main natural gaa preaaure 40 pel. J. Natural gaa reduced preaaure 3-5 o.a.l. K. Natural gaa feed to burner atmoapherlc preaaure. 3.4 Safety Featuraa A. Honeywell Protectoglo unit haa the following aafety featurea: 1. Ignition period 10 aecond delay between actuation perloda for warp awltch to cool. 2. Blower reduced air preaaure muat be above 15 o.a.l. and leaa than 22 o.a.l. 3. Heater coll high temperature outlet ahutdown aet at 325*C. (617*F,). 4. Main natural gaa low preaaure ahutdown aet at 20 pale, and at 10 oala. 5. Natural gaa high reduced preaaure ahutdown aet at 5-0 <>* 6. Circulating pump low flow rate ahutdown aet at 200 GPM. 7. Air blower atart-up aeta up automatic 3 minute timed purge before neat atep of atart-up can pro ceed. 8. Minimum 15 o.a.l. air preaaure la neceaaary at the main burner for the purge period. 093001 mons Proceaa Function Outline Aroclor Department ASO SOM III - 2.010 Page 6 Rev. 1 Date: V13/65 9. A low air pTeaaure Ignition for lighting pilot light 1* neceaaary. Set for air preaaure to ba below 1-1/2 o.a.l. to main burner. 10. pilot flame muat ba burning to atart up unit. Indicated by 1-1/2 to 2 microamperea on current meter. B. Check aurge tank. Item 627, to be aure Thermlnol level la at leaat 6 lnchea above coll level. 3.5 Shutdown A. Temporary Shutdown Main gaa burner off with pilot light on and circulating pump running. 1. Adjuet TRCA-629.12 aec point to aero (lnatrumant In "auto"), or 2. If lnatrumant la In "manual", adjuat controller for output preaaure to aero, or 3. Cloae the 6" manual valve In the main air line to the furnace burner. In caae it la neceaaary to cool the furnace quickly, leave the air valve open. 6, Normally, the circulating pump la left on to cool the heater coll and prevent overheating. B. Complete Shutdown Main gaa burner pilot light and circulating pump off. 1. Puah Ignition "atop" button on aide of field control panel. 2. Puah "atop" button for air blower. 3. Cloae manual valve In the main air line. A. Cloae manual valvea in main gaa aupply line. HONS 09300/ Process Function Outline Aroclor Deportment ARO SOM III - 2.010 Pegs 7 Rev. 1 Date: 4/13/65 5. Allow circulating pump to continue pumping until furnace coll outlet has cooled to 100*0, Then shut off the circulating pump. 6. Check surge tank level to be sure the tank does not overflow. 7. If temperature of 100*C, la to be maintained In surge tank, It may be necessary to open the valve In the steam line to the tank coll. 8. Set points on TRCA-629.12, heater coll outlet, FIC-628.01, pump flow rate, and the Honeywell Protectoglo unit set point can be left In position whan shut off. 9. Shut off circuit No. 5 behind the still panel if the shutdown Is to be an extended one. C. Emergency Shutdown In case It becomes necessary to shut down fast, the following methods can normally be used. 1. From the Field a. Push Ignition "stop" button on side of field control panel to shut off pilot and main burner. b. Turn temperature shutdown set point on Honeywell Protectoglo unit below the furnace coll outlet temperature. c. Close manual valve In air blower discharge line or stop the air blower. d. Push "stop" button for the circulating pump located at side of field control panel. Mein and pilot gas burner will be shut off, vhlle air Is being blown through the furnace. Item d. Is the least preferred of the above methods. Normally, the circulating pump will continue to be operated. ! HONS 093003 Froceia Function Outline Aroclor Department ( ARO SOM III - 2.010 Page 8 Rev. 1 Date: 4/13/65 2. At the Still Panel a. Move PIC-628.01 below 200 PPM. Total uae of Therminol In department mutt be below 200 GPM for thla to cauea ehutdown of main and pilot gaa burner*. b. Turn off circuit Ho. 5 behind atlll panel. 3. At Motor Control Center a. Shut off circulating pump circuit breaker. b. Shut off blower circuit breaker. D. Emergency Shutdown with Alarm. Pilot and main gaa burner off. Circulating pump (till on. 1* High coil outlet temperature - above 323*C. (617*F.) 2. Low natural gas supply pressure - below 20 pale 3. Low blower outlet pressure - below 1 P*lg 4. High reduced natural gas pressure 5. Low coll flow - above 1-Eii - below 200 CPM 6. Failure of circuit 5 behind still panel. 7. Failure of "on-off" switch at side of field control panel or blowing 115 volt fuse in panel. 3.6 Control Loops. Interlocks, and Alarms A. Control Loops There are three major control loops in this system. MONS 0930Q4 Proceae Function Outline Aroclor Dapartnant ARO SOM III - 2.010 Page 9 Rev. 1 Date: 4/13/65 1. Circulating Pump Plow Control - FIC-628.01 The function of thle loop la to maintain the flow through the Thermlnol eyatam at 300 CPM. Thle la accompliehad by meaaurement of flow through an orifice connection and throttling a control valve at the extremity of the loop aa la needed. Low circulation rate (below 200 GPM) will ahut off natural gaa to the furnace and aound an alarm horn. 2. Thermlnol Heater Outlet Coll Temperature Control TRCA-629.12 Function of thle loop la to maintain a conatant temperature of 250*C.at the furnace coll outlet. Thle le accompliahed by meaaurement of the tempera ture with a thermocouple and controlling the haat Input to the furnace with a control valve in the main combuetlon air line. A low temperature alarm at 220*C. and a high temperature alarm at 300*C, will be actuated at too low or too high a tempera ture . . 3. Thermlnol Heater Furnace Controla - 629A The function of thle loop le to provide a aource of heat for the Thermlnol FR-2 (Aroclor 1248) circulating eyetem. Thle la obtained with a North American burner and air blower which le ueed to heat the Thermlnol circulating through a direct fired coll. Control of thle heating eyatam la obtained by FIC-628.01 and TRCA-629.12. There are four eafety featurea In the furnace controla to ehut the eyetem down. a. High coil outlet temperature - above 325*C. b. Low natural gaa eupply preaaure- below 20 oele or below'TOpITR c. Low blower outlet preaeure - below 1 peig d. High reduced natural gae preaaure - above 5 pain MONS 093005 Process Function Outline Aroclor Department ARO SOM III - 2.010 Page 10 Rev. 1 Date: 4/13/65 B. Interlocks Interlocks in this system are as follows. Each, except Items l.a. and b., have alarms. 1. Start-Up of Furnace a. Actuation of pilot ignition lever on Honeywell Protectoglo unit has a 10 second delay before second try can be made. b. Ignition "start" button at the.Protectoglo unit has a 3 minute purge delay after the air blower has been started before the furnace will light up. c. During purge period a minimum of 15 o.s.l. air pressure is necessary prior to completion of purge. d. To light the pilot the air discharge pressure to the main burner must be below 1-1/2 o.s.i. 2. Automatic Furnace Shutdown with Alarms (Pilot and Main Caa Burner Off) a. High coil outlet temperature - above 325*C. (617*F.) b. Low natural gas supply pressure- below 20 psia or below 10 osla c. Low blower outlet pressure - below 1 pslg d. High reduced natural gas pres sure - above 5 osla e. Low coll flow - below 200 CPM f. Failure of circuit No, 5 behind still panel. g. Failure of switch at side of field control panel or blowing 115 volt fuse in panel. C. Alarms 1. All shutdown items under Interlocks B2 above. 2. Therminol heater coll outlet low temperature below 220*C. 3. Therminol heater coll outlet high temperature above 300*C. MONS 093006 Proceee Punctlon Outline Aroelor Department ARO SOH III - 2.010 Page 11 of Rev. 0 Date: 3/24/65 3.7 Abnormal Condition! A. Unueuel high or low temperature readings can occur if the thermocouple extenelon wire for the Honeywell Protectoglo unit and TRCA-629.12 are mixed up. See note, Section IV-C. HONS 093007 Pros*** Function Outline Aroclor Department ARO SOM III - 2.010 Page 12 Rev. 0 Date: 3/24/65 IV. COMMENTS ON PROCESS A. It la very Important to be aure the coll In the eurge tank (Item 627) la covered when the ayatem la In operation. Thla aaaurea the circulating pump haa a poaltlve auction and preventa aurglng In the heater coll. Surgea In flow can cauae coll hot apota and ahorten tha coll life. B. Uae of FIC-628.01 flow control to ahut the ayatem down at the control panel can only be uaed whan uae of Aroclor In the department la leaa than 200 CPM; otherwlae, adjuatlng the controller will not throttle the control valve enough to ceuae automatic ehutdovn of the main and pilot burnera. C. At TRCA-629.12. be aure the Iron conatantan thermocouple extenalon lead wlra (type J) la uaed to tranamlt to the control room and the lnatrument. The conduit run alao contalna a type K extenalon lead wire which la chromal aluma1. If the type i wire la uaed, the Indicator will read correctly. If the type K wire la uaed by mlatake, the Thermlnol will overheat by about 100*C. The high temperature awltch ahould ahut the furnace down at 325*C. If the type J wlra la connected by mlatake to the temperature Indicator, It will cauae it to read too high. o*o. on o D. The Thermlnol furnace la rated at-B,000,000 Btu/hour heat Input. Thla correaponda to 22 o.a.l. air preaaure at the air Inlet of the burner. The manual valve In the air line ahould be aet for 22 o.a.l. when the auto matic valve la wide open. Thla will aaaure the heat input will not exceed the deaign rate If the automatic valve ahould open wide. E. Care muat be taken not to fill the aurge tank (Item 627) too full during normal operation. Thla can cauaa tha tank to run over when the circulating pump la atopped. Normal laval will be about 12" above tha tank colla. The level In the tank will vary, dependent on the operating temperature of the ayatem. MQNS 093006 Procat* Function Outline Aroclor Department ___________ APPENDIX I ARO SOM III - 2.010 Pag* 13 Rev. 0 Date-. 3/24/65 ITEM 627: THERMINOL HEATER SURGE TANK CALIBRATION SHEET Tank Innaae Reading No. Aroclor Drum* Added Stick Meaaurement* _______ Inchee_______ Level Gauge* Meaaurement - Inchae .1. 2 3. 4. .5. 6 7. a. 9. .10 .11 .12 13. 14. 15. 16. 17. 18. .19. .20 .21 22 23. 24. 25. 26. 27. 28. 29. 30. Total Drum Weight After Empty Lee* Tarelb*. * NOTE: . All atick meaaurement* are to be made from the top face of the nozzle uaed for thl* purpoae. MEASURE the tank lnnage on the level gauge from the bottom flange of the gauge. Make a epaclal not* when the dlah la full and th* tank le filled half way. M0NS 093009 PROCESS FUNCTION OUTLINE AROCLOR DEPARTMENT ARO SOM III - 2.020 Page 1 Rev. 0 Date: 3/25/65 I. WEIGH 1AHK. HO. 9 CHLORINATOR AND NO. 2 BLOW TANK 1.1 Scope Thlp cover* the charging, tart-up, ahutdown, normal operation, end emergency iltuatlon* Involving the velgh (charge) tank. No. 9 chlorinetor, and the No. 2 blow tank for production of aolld Aroclora. 1.2 Deacrlptlon of Proceaa Crude aolld Aroclora are produced by batch chlorination when a weighed quantity of Biphenyl, Santowax, or a mixture of the two la chlorinated In a vertical reaction veaael with Ferric Chloride aa a catalyat. Chlorine gaa la added at the bottom of the veaael. By-product HC1 gaa ventad at the top of the chlorlnator la recovered In the Muriatic Acid Department. Crude aolld Aroclora produced In batch chlorination are tranaferred to the blowing tank operation when the chlorination la completed. Chlorine gaa can be fed to the chlorlnator from the Chlorine Plant or from tank cara. II. PROCESS DIAGRAM Attached. III. DESCRIPTION OF PROCESS 3.1 Start-Up A. Chargee and Operating Temperature* for Varloua Crude Solid Aroclora Depending on the product to be produced, different quantltlea of the raw material* are needed. See Table I. MONS 093010 Procaae Function Outlln* Aroclor Department TABLE I ARO SOM III - 2.020 Fag* 2 Rev. 1 Date: 4/14/65 BATCH CHLORINATOR OPERATING CONDITIONS - SOLID AROCLORS 1168 2565 4065 5042 5060 Chlorlnator Charge: Biphenyl (lbg.) Santowax C 9,350 7,550 2,560 5,850 e>too 10,750 Total Charge (lbg.) Approximate Pound* 1001 Chlorine Re quired to Produce 9,350 10,110 9,770 Mr5r 10,750 3 too 37,250 37,750 34,620 Totaliaar Chlorine Setting* (BOX Cl*, Attuning 10X Air) lb*. Cl*: 33,100 33,500 30,700 a1/7 AA 27,200 Chlorlnator Tamp.: Beginning 130*C. 140*C. 140*C. 160*C. 160*C. Ending 265*C. 180"C. 210*C. 240*C. 250*C. Hold Point 155175*C. Softening Point 6672'C. 6672C. 50- 10556*C. 115C. Walght of Crude Batch 27,300 27,000 26.600> 25,215 Z?O0U 16 ooo NOTE; ADD 5 POUNDS OF FERRIC CHLORIDE TO EACH BATCH CHLORINATOR CHARGE 7 5n MONS 093011 Proceaa Function Outline Aroclor Department ARO SOM III - 2.020 Png* 3 Rev. 1 Date: 4/14/65 B. Chnrna Thermlnol Cooling Svatem for Mo. 9 Chlorlnator Chnrgo Thermlnol (1232 Aroclor) Into the eurge tank (Item 333) bp the following procedure; 1. Uee temporarily relocated Pyranol pump to charge the tank. 2. Poeltlon 55 gallon drum next to the pump. Remove drum bung and vent cap. 3. Connect flexible hoea to pump auction and the atalnleea ataal pipe to be placed In the drum. 4. Poeltlon dlacharge line from the pump Into the urge tank (Itam 533). 5. Open valve on pump auction. Inaert pipe Into the drum and etkrt pump. 6. Adjuat the auction valve on the pump until flow la ateady. 7. Continue to fill the tank until 5 druma or 250 aallona are In the aurge tank. C. Start Pp Thermlnol Coollna Svatem for Ho. 9 Chlorlnator 1. Set valvea In the ayatom to flow through the No. 9 chlorlnator heat exchanger (Item 538) and through the tube aide of the Aroclor cooler (Item 507). 2. Cloae aample valve on the auction of tha circulating pump (Itam 534) and at the dlacharge of tha He. 9 chlorlnator heat axchangar. 3. Cloae valvea to put Thermlnol FK-2 (Aroclor 1246) from the furnace ayetem on the No. 9 Aroclor chlorinetor heat axchangar (Itam 538). Blank llnee. 4. Open ataam valve to coll on the eurge tank (Item 533). Controller ehould be aet to control temperature In thla tank to 45 *C. HONS 093012 Procats Function Outline Aroclor Department ARO SOM XIX - 2.020 Paga 4 Rev. 1 Data: 4/14/65 5. Check level In the surge tank (Item 533). Should have 40" In th.a tank. 6. Set TRCA-338.01 In "auto" with set point at 190*C. Low temperature alarm aet at 120*C. - high tempera ture alarm sat at 275*C. 7. Set FICA-534.02 in "auto" with aet point at 300 0PM. Low flow alarm should sound at 250 GPM. 8. Whan the material In the surge tank la at 45*C.. start the circulating pump (Item 534). 9. Check flow through the Thermlnol cooling syatem by obeervlng the following Items: a. Pump dlecharge pressure, PI-534.01, should be 53 pals. b. Plow through Thermlnol system should be 300 CPM. Check FICA-534.02. c. Check action of control valve to the No. 9 Aroclor heat exchanger. See TRCA-538.01. Valve should be closed on lew temperature. 10. Check the following temperature points In the Thermlnol cooling system: a. Pump discharge temperature, No. 9 chlorlnator heat exchanger outlet temperature, and the temperature at the head of the water-cooled heat exchanger for the Thermlnol system. 11. If there are no problems with the ayatem, let it continue to circulate until needed. D. Initial Equipment Check for Start-llo 1. Set temperature controller In weigh tank, TIC-335.01, at 150*C. Controller to be In "auto". MQNS 093013 Proceaa Function Outline Aroclor Department ARO SOM III - 2.020 Page 5 Rav. 1 Data: 4/14/65 2. Check Thermlnol cooling ayatam. a.' Surge tank temperature controller TICA-533.01 In "auto" with the aet point at 50*C. b. Flow controller FICA-534.02 in "auto" with the aet point at 300 CPM. 3. The Thermlnol heater ayatam ahould ba circulating at 250*C. Control point ahould ba aa followa: a. FIC-628.01 In "auto". Sat at 300 CPM. low flow ahutdown will alarm at 200 OPM. b. TRCA-629.12 In "auto". Sat at 250*C. Low temparatura alarm at 220"C. - high temparatura alarm at 300*C. 4. No. 2 blow tank temperature controller TIC-541.01 In "auto" with the aet point at 240*0. 5. Open valvea on ataam line* to the Biphenyl and Santowax aupply to the weigh tank (Item 535). Open valvea In the ataam linea to the coil on the weigh tank. 6. Opan Thermlnol feeder linea to heat the following equipment: a. Transfer line* from weigh tank (Item 535) to the tranafar pump and to No. 9 chlorlnator (Item 505). b. Circulating line at No. 9 chlorlnator through the heat exchanger (Item 538) and back to the chlorlna tor. c. Sample line at No. 9 chlorlnator. d. Tranafar line at No. 9 chlorlnator to the No. 2 blow tank (Item 541). a. Coll In No. 2 blow tank (Item 541). f. Tranafar line from No. 2 blow tank to the pump (Item 539). Obaerve temperature to ba aura the Thermlnol ayatam ataya at 250*C.. or raturna to thla temparatura after the varloua feed line* have been atartad up. 7. Open water valve to S&K Jet (Item 531). 8. Start the air blower (Item 530). MOMS 093014 Troeaa* Function Outline Aroclor Department ARO SOM III 2.020 Page 6 Rev. 1 Date: 4/14/65 9. Check the auction on the No, 2 blow tank (Item 541) to be sure It Is adequate for operation. 10, Open the manual valves In the water system to the Aroclor cooler (Item 507). E. Charge Weigh Tank (Charge Tankl 1. Refer to SecClon 3.1-A. for the actual quantities of raw materials needed for the particular solid Aroclor to be produced. a. Sat the valves to receive the charge from the Biphenyl or Santowax Departments. Notify the operator you are ready for a charge. Biphenyl la obtained from the No. 1 or No. 2 Biphenyl catch tanks or the Biphenyl storage tanks. Santowax R or Santowax C Is obtained from the Santowax storage tanka. b. If Biphenyl la required, charge It Into the weigh tank first to the desired weight. Close the manual valve In the charge line. c. If Santowax R Is needed also, adjust the scale weight eat point to the correct charge desired; for example, In 4065, 5,850 lbs. of Biphenyl are added and then 3,920 lbs. of Santowax R are re* qulred. Place the scale set point at 9.970 lbs. d. Open the manual valve in the Santowax R line. e. Depress the pushbutton near the scale to open the automatic valve. This will put the annunciator window light out which Is marked "No. 9 Chlorlnator Heigh Tank Charge Complete." f. Rave the Santowax operator start the pump to charge the weigh tank. Santowax R Is now entering the weigh tank. HONS 09301b Process Function Outline Aroclor Deportment ARO SOM III - 2.020 Pege 7 Rev. 1 Date: 4/14/65 g. When the oeaeured weight approaches the set point, the automatic Santowax R control valve will close and the snnuncletor window narked ' "Mo. 9 Chlorlnator Weigh Tank Charge Complete" will be ectueted. h. Close the hand valve In the Santowax R line. 1. Start the agitator In the weigh tank. Allow agitation to take place for a minimum of one hour. Stop the agitator just before meterlel In the weigh tank la to be charged to the chlorlnator. j. Open manual valve on top of the weigh tank (Item 535) and add 6 pounds of Ferric Chloride. Cloea the manual valve after adding the Ferric Chloride. k. The material la now ready for the next chlorine* tor charge when needed. F. Chares Ho. 9 Chlorlnator and Start Chlorination 1. Manual Operation a. Cloee manual chlorine valves at dietrlbutore on Mo. 9 chlorlnator (Item 505). b. Close vent on Mo. 9 chlorlnator to the atmosphere. c. Open MCI vent valve to muriatic add area. d. TRCA-538.01 sat In "auto" and "eat". Control point sat at 160*C. Low temperature alarm 120*C. high temperature alarm 275*C. e. FRCS-505.01 in "auto" and "eat". Set point at 800 pounds per hour. f. Set valves to allow transfer of charge from weigh tank to the No. 9 chlorlnator. Be sure to stop the agitator before starting the transfer pump. MQN5 093016 Proceaa Function Outllnn Aroclor Department ABO SOM III - 2.020 Page 8 Rev. 1 Date: 4/14/65 g. Start tranafar pump (Item 536). Stop pump whan the weigh tank la empty. h. ' Set valvep to circulate chlorlnator through the Ho. 9 chlorlnator heat exchanger (Item 538) and back to the chlorlnator. 1. Start circulating pump (Item 506). ]. Open manual chlorine valvea at the dlatrlbutora on the No. 9 chlorlnator (Item 505). Chlorine header preaaura control PIC-500.07 will control tha preaaura to 20-25 gala. A low preaaura alarm la aet at 15 gala - high preaaura alarm at 35 oala. k. After one hour, lncreaaa chlorine rate to 1.500 lba./hour of chlorine feed. l. Shut off Therminol beat circulating In tha Jacketed llnea at the chlorlnator. m. Check the following ltama after tha atart of the . chlorination: (1) Temperature on TRCA-538.01. (2) Therminol cooling ayatem flow on 7ICA-S34.02 (Aroclor 1232 ayatem). (3) Chlorine flow on FRCS-505.01. (4) Circulating pump dlacharge preaaura on No. 9 chlorlnator, PI-506.01. n. Check temperature polnta In the ayatem aa foilowe: Ho. 9 chlorlnator temperature, TR-505.02. Tempera ture polnta In the circulating Therminol ayatem for the Ho. 9 chlorlnator (Aroclor 1232 ayatem). o. Check pump dlacharge preaaura on the Aroclor circulating ayatem, PI-534.01. MONS 093017 Proceaa Function Outline Aroclor Department ARO SOK III - 2.020 Page 9 Rev. 1 Date: 4/14/65 p. Increaaa temperature let polnte through the . chlorination aa la neceaaary to maintain the material'liquid and fluid. End temperature point will be approximately 255*C. Ralae tat point on TRCA-538.01 aa neceaaary to achieve dealred temperature. q. Sample* are taken at the diacharge line of the circulating pump (Item 506) at the aacond level. Depending on the material being produced, the apeciflc gravity, aoftenlng point, or hold point are run on thia batch chlorination. At the atart of the chlorination, a aample ahould be taken after two houra of operation on odd numberad houra (7, 9, 11, etc.). Samplaa will be taken every two houra through the chlorina tion. On tome of the higher chlorinated product*, example 1168, aamplea are not taken until the chlorinator haa bean on for four houra. r. When the chlorination la near completion, It may be neceaaary to run the aoftenlng point or hold point every tan to fifteen mlnutaa. g. When the chlorination haa bean completed (tea Table I), ahut off the chlorine feed valve* at the dlatrlbutor on the chlorinator. t. Note the chlorine preaaure on the main header. If It la above 30 pale, notify the Chlorine Plant that you have removed a chlorinator from opera tion. Tell them when you can atart It back up. If thla chlorinator la to be off for a long period of time, notify the Chlorine Plant prior to ahuttlng off the chlorinator. * 2. Programmed Chlorinator Operation a. Cloae manual chlorine valve* at dlatrlbutor* on No. 9 chlorinator. b. Cloae vent valve on chlorinator to the atmoaphere. c. Open HC1 vent valve to muriatic acid area. * Preaaure controller alarm PIC-500.07 will Indicate low preaaure at 15 pala and high preaaure at 35 palg. MONS 093018 Process Function Outline Aroclor Department ARO SOM III - 2.020 Fege 10 Rev. 1 Date: 4/14/65 d. Set TRCA-538.01 in "auto-caecade". Set point 190*C. Low temperature alarm 120*C. - high temperature alarm 275C. e. Set TRCS-505.01 In "euto-ceecade". Set point at 1,000 lbe./hour Chlorine. f. Adjust green set point knob on the chlorine totallaer per the Table on Peee 2 for meaeurlng the chlorine flow. Sat up flow-temp, program per Appendix I attached, g. Check the following control Instruments: (1) Weigh tank temperatura - TIC-535.01 at 150*C. Controller In "auto". (2) Thermlnol cooling temperature - TICA-533.01 at 50*C. Controller In "auto". (3) Thermlnol Cooling flow - FICA-534.02 at 300 CPM. Controller In "auto". (4) No. 2 blow tank temperatura - TIC-541.01 at 240*C. Controller in "auto". h. Sat valvae to transfer charge from weigh tank to the No. 9 chlorinetor. Start transfer eumo (Item 536). Stop pump when the weigh tank la empty. Close valves. 1. Set valves to circulate the No. 9 chlorinetor through the No. 9 chlorlnator heat exchanger (Item 538) and back to the chlorlnator. j. Start circulating pump (Item 506). MONS 093019 Process Function Outllna Aroclor Department AltO SOM III - 2.020 Faga 11 Rav. 1 Data: 4/14/65 k. Push tha groan reset pushbutton on ths chlorinator psnel for No. 9 chlorlnator, ' (Item 505). This resets the chlorine Integrator and programmer and la tha initiating signal for tha start of a new batch. The Flaxlpulse timer will begin to time the betch as indicated by cascade flow. The batch chlorine flow and tamperature will be controlled according to a pre-set program. At 80T of tha chlorine flow as sat by the chlorine integrator, an alarm ball will ring to Indicate 80X of tha chlorine feed has been taken into tha chlorlna tor. l. Open manual chlorine valves at the distributors on chlorlnator No. 9. This should be dons lasmdlately after pushing the reset button so the tlamr will control the batch correctly.* m. After two hours, take a sample of tha Aroclor and check for apedflc gravity, softening point, or hold point as necessary, depending on tha . Aroclor being produced. This sample is a check to be aura a short charge was not transferred into the chlorlnator. The next sample after that will be taken when tha 802 alarm ball rings. n. Check the following items during operation: (1) Temperature on TRCA-538.01. (2) Chlorine flow on FRCS-505.01. (3) Therminol cooling system flow through tha Thermlnol cooling (Aroclor 1232) system on PICA-535.02. (4) Temperature points through the system on tha No. 9 chlorlnator and tha Thermlnol cooling system (Aroclor 1232). * Chlorine header pressure control FIC-500.07 will control tha pressure to 20-25 pala. A low prassure alarm is set at 15 psia - high pressure alarm at 35 osix. HONS 093020 Proceaa Function Outline Aroclor Department ARO SOM HI - 2.020 Page 12 Rev, 1 Date: 4/14/05 o. The alarm bell vill ring when 80T of the chlorine hae been fed to the chlorlnator. Inroadlately take a (ample of the circulation line to determine the point which the chlorination level haa reached. p. Continue the chlorination until complete. It may be neceeeary to run the aoftening point or hold point more often during the laat one to two houre of the chlorination. q. At completion of the chlorination (See Table I), ouah the ereen react ouehbutton on the chlorlnator panel for the No. 9 chlorlnator. This raducea the chlorine flow to 300 lba./hr. and atopa the timer. Shut off the chlorine feed valvea to the dlatrlbucor at the chlorlnator. r. Note the chlorine praaaure on the main header ac in "Manual Operation." Notify the Chlorine Plant if the chlorlnator la to be off for any length of time, or if the praaaure la above 30 pale. Praaaure controller alarm PIC-500.07 will indicate low praaaure at 15 oaie - high praaaure at 35 Bait. a. If the chlorination la complete, prepare to pump to the No. 2 blow tank. See next aectlon of Operating Inatructlone. O. Ttanefer to No. 2 Blow Tank and Air Blow 1. Sat tranafer ltnea to pump to the No. 2 blow tank (Item 541). Be cure Thermlnol heat ia on jacketed linea. The chlorlnator ia vented to the HC1 line. 2. Check the level indication lnatrument, LI-541.02, to ba aura there le enough room to tranafer into the blow tank. 3. Change final valve In the tranafer line and allow material to pump from the No. 9 chlorlnator to the No. 2 blow tank. Obaerve tranafer and note level lncreaae In the No. 2 blow tank by LI-541.02. At the completion of the tranefar, cloaa valvea in the circulating ayatem and ahut off the circulating pump (Item 506) on the No. 9 chlorlnator. Q930Z1 HONS Proceee Punetion Outline Araclor Department ARO SOM III - 2.020 Pag* 13 Rav. 0 Data: 3/23/65 4. Tha chlorinator la now ready to charge back for tha next chlorination. 5. Record tranafer Information on tha chlorinator data ahaat and In tha log book. Normal blow tank lnaagaa aftar a glngla tranafer for tha following Aroclore are: Crude Aroclor ________________ 2565 5060 4065 5042 1168 Blow Tank Innagaa l 3.2 Routlna Onaratlona During normal operatlone of tha weigh tank, No. 9 chlorina tor, and No. 2 blow tank ayatem, tha following condltlona will axlat in tha procaaa. A. Tharmlnol Heater 1. Flow through the Tharmlnol heater ayatem will ba Indicated on PIC-628.01, 300 CPM normal. Low circulation ahut down aat at 200 6PM. Thla will alarm at tha annunciator. 2. TRCA-629.12 controla tha temperature of the Tharmlnol heating ayatem. Sat point normally at 250*C. Low temperature alarm aet at 220*C. high temperature alarm aet at 300*C. HONS 093022 Process Function Outline Aroclor Department B. Weigh Tank AKO SOM III - 2.020 Page 14 Rev. 1 Date: 4/14/65 1. Assuming a batch la charged Into the valgh tank ready for the chlorlnator, the following conditions will exist In the control room. The annunciator panel will Indicate "Ho. 9 Chlorlnator Weigh Tank Charge Complete." 2. The control valve In the Santowax R charge line will be closed. 3. TIC-535.01 will be controlling the temperature In the weigh tank at 150'C. 4. Temperature on the Multipoint Recorder, TW-535.02, will lndicete 150*C. 5. The agitator will be running to keep the Ferric Chloride In suspension. 6. The transfer pump will be shut off. C, No. 9 Chlorlnator 1. Chlorine flow will be Indicated on FRCS-505.01. If In "cascade-auto" control, the Taylor Flexlpulae Timer will be controlling the flow by progTem system. 2. Temperature will be controlled by TRCA-538.02. With the system In "cascede-suto", the tempersture will be controlled by s pre-set program. Initial starting temperature of 160*C. completion temperature 233*C. 3. No. 9 chlorlnator circulating pump will be In opera tion. The discharge pressure on this pump will be Indicated by PI-506.01. Normal pressure 30 PSla. 4. The Thermlnol cooling system (Aroclor 1232) should have the following checks: a. Flow will be Indicated by FICA-534.02. Normal sat point 300 GPM. Low flow alarm set at 230 OFM. b. Temperature in the circulating system Is indica ted by TIC-333.01. Normal Indication la 50*C. Low temperature alarm sat at 40*C. - high temperature alarm set at 60*C. Procaee Function Outline Aroclor Department ARO SOM III 2.020 Page IS Rev. 0 Data: 3/25/65 c. Surge tank Thermlnol level (Item 533) ahould ba above the ateam colla. d. The Thermlnol cooling ayatem pump dlacharga praaaura ahould be 40 oala. 5. Temperature of the No. 9 chlorinetor can alao ba obaerved on the Multipoint temperature recorder. D. Mo. 2 Blow Tank 1. Temperature will be Indicated by TIC-341.01. Normal aat point 240*C. 2. level In the No. 2 blow tank will ba Indicated by LI-541.02. Normal level with a full charge la 131. 3. Hater valve ahould ba open to the S&K jat providing auction on the No. 2 blow tank. 4. The air blower (Item 530) ahould ba operating with a dlacharga preaaure of 10 oala. E. Data Shaata A aolld Aroclor ayatem data aheet la available for the weigh tank. Ho. 9 chlorinetor, and the blow tank. Filling out thla aheet la a normal portion of tha opera tor' a dutiea during the ahlft. 3.3 Safety featurea A. The weigh tank (Item 535) haa an Interlock ayatem which will not allow atartlng the tranefer pump (Item 536) whan Santowax R la being charged Into the weigh tank. Thla interlock la to aaaura that an overcharge of Santowax can not ba made to the No. 9 chlorlnator. A high weight alarm aet at 15.000 oounde will eound for an overcharge. MUNS 093024 Process Function Outline Aroclor Department ARO SON III - 2.020 Fag* 16 Rev. 0 Date: 3/25/65 B. A high temperature elarm Is set at 275*C. on the No. 9 chlorlnator (Item 505) to prevent exceeelve carryover of trappings Into the HC1 offgas haadar. Temperatures above this should cause excessive carryover of Santovax and/or crude Aroclor. A low temperature elarm la aleo provided at 120*C. to prevent production of unetable Aroclore. C. Chlorine flow atopa will be placed on the chlorine flew control valve to the No. 9 chlorlnator set at 300 pounds oar hour to prevent shutting off the chlorine feed In caaes of air failure to the control valve. The conerol valve normally closes on air fallura. This Is for protection of the Chlorine Plant. D. If Biphenyl Is required for the chlorlnator charge. It ehould be charged Into the weigh tank first to the de sired weight. The Santowax R or Santowax C should be charged on top of the Biphenyl since the scale weight sat point will close the control valve In the Santowax R line only. This will allow more accurate weight control to the chlorlnator batches. E. The Thermlnol heating circulation system has several safety features which can be fouud In the P.F.0. for this heater system. F. Check the level In the Thermlnol cooling system surge tank (Item 533) to be sure the Thermlnol level le 6" above the coll level In the tank. 0. The valves to the coll In the No. 9 chlorlnator (Item 505) will normally be tagged out. These valves will not be opened unless there le a specific need for heat on the coll. It may be necessary to leave the discharge valve on the coll open sllahtlv to allow for expansion of the Aroclor In the coll during the chlorination process. This will be determined at a later date. H. The valves In the Thermlnol heating system to put heat on the No. 9 chlorlnator heat exchanger (Item 538) will normally be tagged out since this heat exchanger la used for cooling. The Thermlnol heating syetem le available only for cases of unplugging the heat exchanger. 0930i5 Process Function Out Lino Aroclor Department ARO SOM III - 2.020 Page 17 Rev. 1 Date: 4/14/65 I. A eight glaea haa bean placed in the RC1 offgas line of the No, 9 chlorinator to allow observation of the flow for possible entrainment. In case entrainment droplets are noticed being carried out in the HC1 gas, the chlorine flow should be decreased slightly to re duce this entrainment. Excessive entrainment carry over will cause plugging of the HC1 offgas line. J. In case the chlorine flow control valve cannot ba mads to work, a U-tube manometer containing 60" Baums' sulfuric acid (98X) has been placed on the chlorine header. The pressure in this manometer should be noted during normal operations. This will provide a reference to let the operator know what the chlorine flow is in cases of failure of the flow meter. A chart of chlorine flow va. pressure will be in the Operating Manual. A solid chlorinator batch could be completed using this pressure manometer if the need should arise. K. Whan the chlorine and temperature programed control system is in operation, the preset program should not be disturbed since this can cause excessive chlorine flow or temperature problems to result. L. Normally, when the progremed flow control system is in operetlon, a sample of the material being chlorinated will ba taken after two to four hours of operation. This sample is taken to assure a short charga has not baan made to the No. 9 chlorinator. The sample should be checked for specific gravity, softening point, or harden ing point, depending on the material being produced. If this sample indicates a normal batch, tha next sample would be taken when the BOX bell rings as preset by the chlorine flow integrator. This sample is to assure a batch is not over-chlorinated and sets up in the chlorinator preventing its transfer to the blow tank and/or to the still. 3.4 Shutdown Operations of Che weigh tank, the No. 9 chlorinator, and the No. 2 blow tank can occur which will cause temporary or prolonged shutdowns. The following detailed information concerns individual shutdowns of each of the above items. If the entire system la to be shut down, the various sections can be combined to achieve this objective. Dependent on the MGNS 093026 Process Function Outline Aroclor Department ARO SOM III - 2.020 Faga 18 Rev. 0 Data: 3/25/65 reaaon (or tha shutdown, It may ba nacaaaary to ihut down the Thermlnol heating syatem to make tha eyetea aafa. This siuat be considered, depending on the situation. A. Walsh Tank litem 5351 1. Temporary Shutdown a. Close tha manual valves In tha Biphenyl end Santovax supply lines to tha weigh tank. b. Close tha valve at the bottom of tha weigh tank and at tha discharge of the tranafar pump. c. Leave TIC-535.01 In "auto" with sat point at 150*C. d. Leave Thermlnol heat on the transfer lines to the No. 9 chlorinetor. e. The agitator and pump will normally be shut down unless In use. 2. Prolonged Shutdown a. Close the manual valve In tha Biphenyl and Santovax supply lines to the weigh tank. b. Close the valve at the bottom of the weigh tank and at the discharge of the transfer pump (Item 536). c. Move the weigh tank temperature control TIC-535.01 set point to 0*C. Close tha manual valve In the steam supply line. d. The agitator and transfer pump will be shut off. Close the valves In the Thermlnol heating system lines for tha charge tank transfer lines. Close valves In steam supply to Biphenyl and Santovax lines. f. Tha tank may or may not be empty, dependent on the work to be done or the cause for shutdown. g. Note shutdown Information on data sheet. MQNS 093021 ProcM Function Outline Aroclor Department ARO SOM III - 2.020 Page 19 Rev. 1 Date: 4/14/65 f. Drain the charge tank If neceaeary for repair work. g. Leave the ayttem In this condition until needed. h. Note ahutdown Information on data ahaat. B. No. 9 Chlotlnator (Item 5051 Operatlona can occur which will require a chlorlnator to ba cut back or temporarily ahut down. Soma of theta ltema are failure of chlorine feed, a tank car emptying, or a cut back of the Chlorine Plant, Normally, If a partial reduction In the chlorine feed occurs, the batch liquid chlorlnators will be ahut off and the No, 9 chlorlnator will continue to be operAtad. 1. Temporary Shutdown a. The circulating pump (Itam 506) will normally be left In operation. b. Close the chlorine valves at the distributor on the No, 9 chlorlnator. c. Check the chlorine header pressure and rotameter feed eo the other chlorlnators. It ahould be 20-25 oala. d. Check to aee that liquid chlorine Is baled fad to tha vaporleer and that steam la on the vaporiser. Steam pressure should be 10 oala. Discharge pressure on the vaporiser ahould be 1-2 oala greater than the pressure on tha chlorine header (normally 20-25 oala). a. Notify the Chlorine Plant of the problem and see If they have shut down or cut back. f. If the shutdown Is to ba longer than two hours, It may be necessary to put Thermlnol heat on the No. 9 chlorlnator circulating lines to keep the temperature at 120*C. minimum. Normally, tha cir culating pump will continue to run. Use Thermlnol heat on the coll of the chlorlnator as a last resort. *ONS 0 9 3 0 1 0 Proceea Function Outline l Aroclor Dapartnant ARO SON III - 2.020 Page 20 Rev. 0 Data: 3/25/65 g. Shutdown* ahould be mlnlmleed. If the cauea ' of the cut back can eaally be remedied, atart the chlorlnator back lanedlately, h. Leave the Thenslnol cooling eyetem circulating. I. Leave the Thermlnol heating ayeten circulating on the jacketed line*. J. Notify your chief operator or departmant eupervlalon irradiate ly in caaa of a problem. k. Note ahutdovn Information on data ahaat. 2. Prolonaed Shutdown a. Normally, whan a chlorlnator will be left down for a period longer than a few hour*, the chlorination will be completed and the batch pumped out prior to ahutdovn. If Maintenance pereonnel are to work on the chlorlnator, It may be necaaaary to vent the vaeeel and purge the chlorine line* and the chlorlnator tank with COg NOTE: In caaa of a complete ahutdovn for maintenance work, the chlorine valvee on the mein header to the chlorlnator will be tagged, the tranefer line* Into the vaeeel, and the Thermlnol heating ayeten valvea to the chlorlnator coil, the circulating pump circuit breaker box awltch will alao be tagged out. b. Bapty chlorlnator by pumping It out. Then abut off the circulating pump. Drain the chlorlnator c. Cloee chlorine valvea at dlatrlbutor on No. 9 chlorlnator. d. Check chlorine header preaeure at In Item lc above. a. Cloee the HC1 vent valve on the chlorlnator to the HC1 header. ( HONS 093029 Process Funetlcm Outline Aroclor Department ARO SOM III - 2.020 Page 21 Rev. 0 Data: 3/25/65 (. Notify tha Chlorine Plant of the problem If ' thla la to be a prolonged shutdown and It cauata an lncreaaa In tha chlorine header prasaura. g. Notify your chief operator or department aupervltlon the vaaaal la ahut down. h. Shut down tha Thermlnol cooling ayatea by: (1) Shut off circulating pump (Itaa 534). (2) Leave PICA 534.02 In "auto" with aet point at 300 GPM. (3) TICA-533.01 will be In "auto" with tha aet point at 50*C. (4) Leave tha ateaa on tha aurga tank (Itaa 533). Thla will kaap tha ayatea ready for uaa. (5) In case tha Theralnol cooling ayatea aust ba worked on, It aay ba nacaaaary to drain tha ayatea. If thla should occur: (a) ahut off the ataam to tha aurga tank; (b) watar to tha cooler (Itaa 507); (c) tag out tha circulating pump (Itaa 534) circuit breaker; and (d) tag out the Theralnol heating valves to tha No. 9 chlorlnator heat exchanger system. 1, Note shutdown Information on tha data sheet. C. Mo. 2 Blow Tank (Item 541) 1. Temporary Shutdown a. Cloaa the valve at the bottom of tha No. 2 blow tank (Item 541), b. Cloaa tha discharge valve on tha transfer pump (Item 539). MONS 093030 Proeeea Function Outline Aroclor Department ARO SOM III - 2.020 Page 22 Rev. 0 Date: 3/23/63 c. Tranafar pump will be ahut off. d. Adjuat TIC-341.01 let point at 230*C. Leave In "auto". e. The air blower will continue to run. f. Hater will remain on the S&K jet (Item 331). g. The ayatem will be left In thla condition until need to atart back up. 2. Prolonned Shutdown a. Normally, If thla veaael la to be ahut down for any length of time, the material In the tank will be emptied. b. Cloae the valve at the bottom of the weigh tank and at the dlacharge of the tranafar pump (Item 339). c. Shut off the tramfer pump (Item 539). d. Adjuat TIC-341.01 controller to 0*C. Cloae the manual valve In the Tharmlnol heating ayatem to the colli on the No. 2 blow tank and tag out valvea. e. Shut off the air blower (Item 330). f. Shut off water to the S&K Jet (Item 531). g. Leave the ayatem In thla condition until neceaaary to atart back up. D. Emergency Shutdown Normally, an emergency ahutdown doea not occur concerning the weigh tank (Item 535) or the No. 2 blow tank (Item 541). However, emargenclae can occur which make It neceaaary to ahut down the No. 9 chlorlnator aa faat aa poealble. The following methoda can normally be uaed. MOHS 093031 Process Junction Outline Aroclor Department ARO SOM III - 2.020 Page 23 Rev. 0 Date: 3/25/65 1. Proa the Field a. Cloee the manual chlorine velve* to the distributor, or the manual valve from the chlorine heeder feeding the Ho. 9 chlorlnator. b. Shut valve in HC1 pipe line to the Muriatic Acid Department. c. Stop circulating pump (Item 506), if neceasary. d. Dependent on the emergency situation which has occurrad, continue to shut this system down systematically by normal procedura. . 2, At the Panel a. Stop chlorine feed to the No. 9 chlorlnator. This will be done as follows, depandsnt on operation: (1) Manual Operation Controller FRCS-505.01 in "auto". Move chlorine flow controller sat point to earo. This will reduce chlorine flow to 300 lbs./hour to the No, 9 chlorlnator. Ismcdlately go into the field and shut off manual valves feeding this chlorlnator. (2) Programmed Operation Move controller FRCS-505.01 set points from "cascade" to tat. Next, adjust set point on chlorine feed to sero. Proceed at in Item (1) above. b. Shut valve in RC1 pipe line to the Muriatic Acid Department. HONS 093032 Process Function Outline Aroclor Department ADO SOM III - 2.020 Page 24 Rev. 0 Dete: 3/25/65 . Stop the circulating pump (Item 506) if neesrssary. d. Continue shutdown of this unit ss is necesaary to handle the emergency which has occurred. 3. Emergency Shutdown Therainol Cooling System for Mo. 9 Chlorinetor a. Stop circulating pump (Item 534). b. Close manual valves as necessary in the eyatam. . The pump can be shut off in Item a. above at the pump Itself or at the motor control center circuit breaker. 3.5 Control Loops. Interlocks, end Alarma A. Control Loons Thera are 9 major control loops in this system. 1. Welah Tank Scale loop - 544 The function of this loop is to allow setting the scale by the adjustable sat point for Santowax R charges. When the material reaches the desired weight, it automatically cloaca the control valve in the feed line to the weigh tank and rings an alarm bell indicating "No. 9 Chlorinetor Heigh Tank, Charge Complete." During charging of the weigh tank, the transfer pump (Item 536) cannot be started. In case the weigh tank is overcharged, an alarm horn will sound at 15.000 lba. This should allow approxi mately 5 minutea before the tank will overflow. 2. Weieh Tank Temperature Control - TIC-535.01 The function of this loop is to maintain a constant temperature of 150*C. in the weigh tank. This la accomplished by measurement of the temperature and controlling the heat input by throttling a control valve in the steam line to the coll on the weigh tank. M0NS 093033 Procats Function Outllnt Aroclor Department ARO SOM III - 2.020 Page 25 Rev. 1 Date: 4/14/65 3. Mo. 9 Chlorlnator Chlorine Flow Control FRCS-505.01 The function of this loop Is to control the chlorine flow to the No. 9 chlorlnator to regulate the chlorination rate. This la accomplished by measure ment of the chlorine flow with an orifice and controlling this flow with a control valve in the chlorine feed line. This system can be operated manually, automatically on chlorine feed control, or by a preset programmed chlorine feed control. a. Manual Control The chlorine flow controller FRCS-505.01 la positioned In "manual-set". The aet point la regulated to give the desired chlorine flow to the No. 9 chlorlnator. b. Automatic Flow Control The No. 9 chlorlnator chlorine flow controller FRCS-505.01 la positioned In "auto-set". The chlorine feed desired Is set on the controller which will maintain this chlorine feed by adjusting the control valve as required. c. Programmed Flow Control The chlorine flow controller has the set points in "auto-cascade". The chlorine Integrator set point Is adjusted for the desired chlorine alarm level dependent on the product being pro duced. The dial reads 0-375 and has a multi plier of 100. The range represents 0-37.500 lbs. of chlorine. When the desired quantity of chlorine has sntered the chlorlnator, an alarm bell will ring and an annunciator light will flash Indicating "No. 9 Chlorlnator, 80" Chlorinated." The totalizer settings ss listed can be used with the automatic flow control above if the controller Is not In "cascade". It must be reset by pushing the green set button. When the controller Is In "cascade", the Taylor Plaxlpulee Timer will, by a predetermined program, (See Appen dix I), change the chlorine flow rate to the No.9 chlorlnator. The chlorine flow program la set by MQNS 093034 Process Function Outline Aroclor Department ARO SCM III - 2.020 Page 26 Rev. 1 Date: 4/14/65 turning the knob on each flow profile eet point. Thla program, once eet up, should not be disturbed without consulting supervision. 4. Ho. 9 Chlorlnetor Temperature Control - TRCA-53B.Q1 The function of this loop Is to provide temperature control of the chlorination batch In the No. 9 chlorlnetor. Thla la accomplished bp measurement of che temperature In the crude Aroclor circulating line at the hast exchanger and controlling the Therminol cooling system to the shell of this heat exchanger (Item 538). The temperature controls can be operated manually, automatically, or by a pre determined program temperature profile. The tempera ture ayatam haa a low temperature alarm at 120*C. a high temperature alarm at 275*C. Range of the Instrument la 0-300*C. a. Manual Control The temperature controller TRCA-538.01 will be In "manual-set". Circulating of the Thermlnol cooling system across the Ho. 9 chlorlnetor heat exchanger can ba controlled manually by adjusting the control valve with TRCA-538.01 set point. Adjust until the desired temperature la acquired. b. Automatic Control The temperature controller TRCA-538.01 is In "auto-sat". The controller set point la adjusted to the desired temperature. It will automatically adjust the control velve to maintain the tempera ture as sat. c. Programmed Temperature Control The temperature controller la placed in "auto-cascade". The chlorination temperature time profile la adjusted to the desired tempera ture by turning the knob on each temperature profile set point. A predetermined program la MONS 093035 frecau Function Outline Aroclor Department ARO SOM III - 2.020 Page 27 Rev. 0 Date: 3/25/65 act up on the Taylor Plexlpulse Timer. After atart of the progrem, the Flexlpulee Timer will automatically advance through the temperature profile as sat up by the program. These aet points will be directed to the prograaner only If TRCA-538.01 la In "auto cascade". 5. Chlorine Beader Pressure Control - PIC-500.07 The function of this loop la to maintain the chlorine header pressure to the Aroclor chlorlnators within a range of 20-25 osla. This is accomplished by measuring the chlorine header pressure and throttling a control valve In the discharge from the chlorine vaporiser to maintain the chlorine header pressure within + 1 psig of the set point. A low pressure alarm la set at 15 pels and a high pressure alarm at 35 Pels. 6. Thermlnol Cooling System Flow Control - P1CA-53A.02 The function of this loop Is to maintain a conseent flow of 300 GPM In the Thermlnol cooling system. This Is accomplished by measurement of the flow with an orifice flow meter and adjusting a control valve to automatically bypass the No. 9 chlorlnator heat exchanger (Item 538). Flow through the No. 9 heat exchanger Is regulated by the tempereture control TRCA-538.01. Normal operation of the system Is with the controller In "auto" and the set point at 300 6PM. A low flow alarm will sound at 250 CPM. 7. Thermlnol Coollnc System Temperature Control TICA-533.01 The function of this loop la to control the Thermlnol cooling system (Aroclor 1232) In the surge tank (Item 533) at 50*C. This la accomplished by measurement of the discharge temperature from the Thermlnol water cooler (Item 507) and automatically throttling the water flow on the shell side of the cooler (Item 507). The low temperature alarm on this system Is set at 40*C. - the high tempereture elerm Is set et 60"C. HONS 093036 Process Function Outline Aroclor Department ARO SOM III - 2.020 Faga 28 Rev. 0 Data: 3/25/65 .0 8. Thannlnol Suras Tank Temperature Control - TC-533.0r Thla la accomplished by measurement of the tamparatura and throttling a control valve In the ataaa line to the coll on the aurge tank. Sat point of thla controller la 45*C. 9. Mo. 2 Blow Tank Temperature Control - TIC-541.01 Tha function of thla loop la to maintain a conatant temperature of 240*C. In the No. 2 blow tank. Thla la accompllahad by aaaaurlng tha temperature In the blow tank and throttling tha control valve In tha Thermlnol heating ayetem (Aroclor 1248) to tha colla In tha No. 2 blow tank. Thera ara no alarma In thla eyatem. 10. No. 2 Blow Tank Level Indication - LI-541.02 Thla loop maaeuree tha level of crude Aroclor In tha No. 2 blow tank. Thla la accompllahad by uaa of a bubbler differential preaaure level Indication lnatrumant. A 0-100% dial indicates tha tank level. B. Interlocks There la one Interlock In this system. 1. Welch Tank System The Santewax transfer pump (Item 536) cannot be started while Santowax R la being filled Into tha weigh tank. Thla Interlock la energised whan the control valve In tha feed line is open. C. Alarma The following alarma exlat through thla system. MQNS 093037 I ProcaM Function Outline Aroclor Dapartnent ARO SOM III - 2.020 Paga 29 Rev. 0 Dete: 3/25/65 1. Waiah Tank (Item 5351 a. When the maaaured or preeec weight epproechea tha aat point on tha acalaa, an alara ball will aound Indicating "No. 9 Chlorlnator Weigh Tank, Charga Complete." Thie alara la on tha chlorlnator annunciator panal. b. A high walght horn alara will aound If tha walgh tank la filled above 13.000 lba. Thla horn Indicator there la approximately 3 alnutaa before tha tank will overflow. 2. Ho. 9 Chlorlnator Svataa (Item 505) a. Chlorine Flow Alara (1) If the chlorine Integrator la being uaad, an alarm ball will ring whan tha batch la 801 chlorinated. The chlorine aat point for tha Integrator dependa on tha crude Aroclor being produced. b. Temperature Alaraa Abnormal temperature alarma are aat for a low chlorination temperature of 120*C. and a high tamperatura of 275*C. c. Chlorine Header Preaeure Alarm The chlorine header praaaura will aound an alarm at a low praaaura of 15 pala and a high praaaura of 35 pelt. Thla will actuate an annunciator on tha chlorlnator panal Indicating "High/Low Chlorine Header Praaaura." d. tow Flow Alarm A low flow alarm will aound In tha Thermlnol cooling ayatam (Aroclor 1232) If tha flow falla below 250 CPM. Thla alarm le on tha chlorlna tor annunciator panel. mqns 093038 Proceaa Function Outline Aroclor Department AKO SOM III 2.020 Paga 30 Rev. 0 Data: 3/25/65 a. Abnormal exit temperaturea on the Tharmlnol (Aroclor 1232) cooling system from the cooler (Item 507) will aound an alarm. The low tamperatura alarm la aet at 40*C. and the high temperature alarm at 60*C. f. An annunciator will aound In caaa the lnatrument air compreaaor motor ahould atop. Thla will Indicate air failure In tha department and will nacaaaltata a shutdown of tha equipment. IV. COMMENTS OH PROCESS A. Special flexible piping Jolnta have been made to tha weigh tank (Item 535) alnce thla tank la placed on acalea. Actuation of tha acala ayatam will require movement of thla tank approximately 1/4". Theaa flexible piping Jolnta ahould ba carefully lnapected to be aure there are no leaka alnce the material contained In them la extremely hot. During weighing of the raw material charge, tha operator ahould ba careful to eliminate problema with exceaalve movement of the acala. B. Steam la provided on tha tranafar llnaa and tha coll to tha weigh tank. From tha bottom piping on tha weigh tank, all tha tranafar llnea and colla In proceaa veaeala have Tharmlnol heat until the end of tha proceaa at the flaker hold tank. C. The tranafar pump (Item 536) for the weigh tank haa ataam on tha Tharmon-tracad and inaulatad aectlon of the caalng of the pump. . D. The Tharmlnol heating ayatem haa bean provided for thla aolid Aroclor facility to eliminate uae of gaa torchee on veaaalt and pipe llnea. Problem areaa ahould ba noted lamndlately ao that alteratlone can ba made to achieve thla goal. B. Care muat be taken not to fill the Tharmlnol cooling ayatem aurge tank (Itam 533) too full during normal operation. Thla can cauae the tank to run over when the circulating pump la atoppad. Tha normal level will be 6" to 12" above the tank colla. Tha level In thla tank will vary, dependent on the operating temperature of the ayatem. MOWS 093039 Froceia Function Outline Aroclor Department ARO SOM III - 2.020 Faga 31 Ray. 0 Data: 3/23/63 F. A change In the operating process haa been nada for the Mo. 9 chlorlnator. It does not hare a basket of Iron turning. Due to thle change. It la absolutely necessary that 15 Xba. of Ferric Chloride be added to each chlorlnator chares In the welch tank. *ONS 0930** Process Function Outline Aroclor Department ____________ APPENDIX 1 ARO SON III - 2.020 Page 32 Rev. 1 Date: 4/14/65 PROPOSED TEMPERATURE AND CHLORINE FLOW PROFILES FOR PROGRAMMED AROCLOR 5060 CHLORINATION 1 CHLORINE INPUT - FLOW RECORDER CONTROLLER (FRCS-505.011 First 6 Minutes 300 Lbs./Hr. of Chlorine One Hour 0 1.000 Lbs./Hr. Second Hour 0 1.500 Lbs. /Hr. Third and Subsequent Hour* Until End of Batch 9 2.000 Lbs./Hr. 2 TEMPERATURE CONTROL - TEMPERATURE RECORDER CONTROLLER (TRCA-538.01) ( First Hour 0 160*C. Second 2 Hours 0 190C. Third 2 Hours 0 200C. Fourth 2 Hours 0 210*C. Fifth 2 Hours 0 230*C. Slsth 2 Hours 0 240*C. Seventh 2 Hours 0 250"C. Eighth 2 Hours 0 255*C. 3 CHLORINE INTEGRATOR SETTINGS FOR SOI OF CALCULATED INPUT BASED ON 1001 CHLORINE AND 901 CHLORINE Aroclor Product 1002 Chlorine 901 Chlorlna 1168 29,800 33,100 2565 30,200 33,500 4065 27,700 30,700 5042 14,250 15,800 5060 24,500 27,200 MQNS 0 9 3 0 4 1 Proceee Function Outllna Arcelor Department _____________ APPENDIX II ARO SOM III - 2.020 Page 33 Rav. 0 Dace: 3/24/63 ITEM 622: THKRMIHOL CIRCULATING TASK FOR NO. 4 AROCLOR STILL C0HDEM8ER COOLING SYSTEM Reading Aroclor Mo. Drum* Added 1. _____________ 2. ______ 3. ______________ 4. ______________ 5. ______________ 6. ______ 7. ______________ Tank Innate Stick Meaiurament* Inchee level Gauge* Maaiuragent - Inchaa Total ______ Drug Weight After Empty Leaa Tara. lbe. * MOTE: All (tick aaaaurenenta are to be made from the top face of the noaala ueed for thl* purpoae. MEASURE the tank lnnage on tha level gauge from the bottom flange of the gauge. Make a apeelal note when the dleh 1* full and tha tank le filled half way. 093042 muns Process Junction Out1in* Aroclor Department APPENDIX III ARO SOM III - 2.020 Peg* 34 Rev. 0 Date: 3/24/63 ITEM 533; THBBMXHOL CIRCULATING TANK TOR MO. 9 CHLORINATOR COOLING 8TSTEM ` Reeding Mo. 1. 2. 3. 4. 5. 6. 7. Aroclor nrnme edited _____________ ______ _____________ ______________ _____________ ____ _ ______________ Tank Innas* Stick Measurement* Inchee Level Oeuge* Meaeurement Inchee Total _____________ Drua Haight After Eapty. Lee* Tare lba. * NOTE: All stick measurements ara to be made from the top face of the noasl* used for this purpose. MEASURE the tank lnnage on the level gauge from the bottom flange of the gauge. Make a special not* when the dish 1* full and the tank Is filled half way. 093043 MONS APPENDIX IV ARO SOM III - 2.020 Page 35 Rev. 0 Date: 4/21/65 METHOD OP RUNNING SPECIFIC GRAVITIES 1. Catch representative sample of material In metal cylinder provided for thle purpose. On the chlorlnatora. the sample point la at the discharge of the circulating pump. Excess material la returned to the suction of the pump through a special pipeline. 2, Take sample to the control room. 3. Allow water to run down outside of the cylinder while stir ring sample vigorously until the sample la 10*C. above the temperature at which the sample la run. See Table I, Page 2. 4. Cut off the water when the sample la ICC, above the desired temperature. Keep stirring until the sample la 1*C. above the temperature which the sample Is to be run. Stop stirring. Allow the hydrometer which has been thoroughly cleaned to sink Into the sample until It reaches equilibrium. 5. Observe reading on the hydrometer. Record hydrometer reading on the operating data sheet, along with the time the sample was taken. 6. In case the temperature was off 1* or 2* whan the reading was taken, a correction can be applied. It Is 0.001 specific gravity units per *C. If the sample was 2*C. hlah. add 0.002 specific gravity units to the reading. If the sample was 2*C. low, subtract 0.002 specific gravity units from the reading. 7. Carefully clean the hydrometer and thermometer. Place them In the rack provided for this purpose. Dump sample In the return Una to the chlorinetor pump. MONS 093044 APPENDIX V ARO SOM III - 2.020 Page 36 Rev. 0 Data: 4/21/65 METHOD OF RUNNING HOLDING POINTS 1. Obtain representative tampla of matarlal from aampla Una at pump dlaeharga Una. Catch aampla In a pint can. 2. The racaptacla for running the aampla la 1" x 4-1/2" Pyrex tuba, sealed at one and. The tuba la Inserted In a equate 8-os. bottle which la Insulated In the bottom by a layer of 1" aabeatoa fibre. The tube la held In place by a large cork. Insulation la usad In an effort to keep tha Aroclor from cooling too rapidly. 3. Pour the material Into the tube until It la filled within 1-1/2" of the top. 4. Material will probably crystallise In the cold tube and will have to be melted again. 5. When the matarlal la malted. Insert a suitable thermometer (0-360*C.1 which la flttsd with a cork to hold It In place. The bulb of the thermometer should be fitted In the center of the sample, care being taken that It la not too close to the side of the tube. 6. Heat the tube to 200*C. place It In the aabestoa Jacket, then put It In the bottle. 7. Take readings on tha thermometer every 30 seconds. At first the temperature will drop rapidly (4-6*C. between reedlngs). Thle drop will decrease and finally come to a stop and stay constant for several readings, or will start to go back up several degrees. 8. Record the point at which the temperature remains constant, or In case of a rise, the highest point of the rise Is tha hold point of the material. MCJNS 093045 I APPENDIX VI ARO SCW III - 2.020 Page 37 Rev. 0 Dace: 4/21/65 METHOD OP RUNNING SOFTENING POINTS 1. Obtain representative sample of material from sample line at dlacharge of circulating pump. Catch the sample In can lid or Pyrex beaker. 2. Heat ring and sample. 3, Place ring on can lid or metal plate and fill with sample until material stands slightly higher than edge of ring. Pill the ring from the large diameter side. A. Cool the ring and lid from bottom of the side until sample sets up, being careful not to get any watar on top of the sample. 3. Finish cooling by running water on top of the sample efter It sets up. 6. Remove filled ring from lid and trim off any material that Is on the outside. 7. Maks slight Indentation on top of the sample In the canter of the ring with a heated wire to hold the ball In place. 8. Fill beaker with water or glycerin. a. Use watar whan expected softening point Is under 80*C. b. Use glycerin when expected softening point Is over 80*C. 9. Place the ring In tha sample holder, place ball on sample, and put holder In the beaker. 10. Adjuat the thermometer in the holder so that the tip of bulb protrudes 1/4" through the hold In the crossbar that holds sample. 11. Place the beaker on a stand with screen under It and set burner under the stand. 093046 kons Week of June 28 & July 5. 1965 SECOND DAY Tima Topic 7:00 - 8:00 a Review of Prevloue Day's Training 8:00 - 9:00 Detailed Operator Review of Operating Instructions 9:00 - 9:15 Break 9:15 - 11:00 Field Tour Detailed Operator Review of Operating Instructions 11:00 - 11:30 Lunch 11:30 - 12:30 p.m. Review HC1 Facilities Instrumentation & Setting of Flow Control System 12:30 - 1:30 Detailed Operator Review of Operating Instructions & Instruments 1:30 - 1:45 Break 1:45 - 2:30 Field Tour Review Afternoon Training In Detail 2:30 - 3:00 Question & Answer Period Check-Out Procedures Review ARO SOM IV - 3.000 Page 2 of 2 Rev. 0 Date: 3/25/65 Instructor Williams Molloy Molloy & Williams Molloy Haupt Haupt & Williams Haupt t MONS 093145 MURIATIC ACID START-UP TRAINING PROGRAM WEEK OF JULY 12. 1965 MONDAY - TUESDAY lias Topic 7:00 a.m.?.3:00 p. m. Start Equipment Check-Out New Abeorber Carbon Towers Surge Tanka Filter Location Storage Tanka Pumps Instrument Panel Water Batch Equipment ARO SOM IV - 3.000 Page 1 of 1 Rev. 0 Date: 3/26/65 Inatructor Haupt Molloy Williama Madison WEDNESDAY 7:00 i,ni - 7lOO p.i . Department shut down for Change-over to start up witt; Chemicals. Continue Check-Out Program THURSDAY 7:00 - 10:00 a.i . Charge System with Chemicals. Take readings op start-up of new System. Check Muriatic Acid pro duction at tower. Sewer Acid until quality material la being produced. Malloy 10:00 11;30 Have Tower Production Analyzed by Lab. 11:30 - 12:00 Start flow to Carbon Towers & Filter. If material la a quality product, start collecting in a storage tank. Continue operations & development of operetor knowledge of in strument system for Muriatic Acid Tower operation. Shift coverage will lest two days during this time. "UNS 09314b AROCLOR-MURIATIC ACID START-UP TRAIHIHG PROGRAM WEEK OF AUGUST 23. 1965 Typical 4 Hour Training Program Four ShifC Creva Co bo Trained Time Tonic 12:00 - 1:00 p.m. Proceai Flaw Review & Detailed Operating Inatructlone for HC1 Clean-Up Facllltlea 1:00 - 1:30 Queatlon 0 Anavar Period 1:30 - 1:45 Break 1 :45 - 3:00 Plaid Tour Detailed Inatructlone k Plaid Instrumentation Review by Operatore 3:00 - 4:00 Review Safety Featurea Queatlon 4 Anavar Period ARO SOM XV - 3.000 Page 1 of 1 Rev. 0 Date: 3/26/65 Inatructor Williams Haupt Haupt & Williams Molloy MONS 093142 ARO SOM IV - 3.000 Page 1 of 1 Rev. 0 Date: 3/26/65 AROCLOR-MURIAIXC ACID START-UP TRAINING PROGRAM WEEK OF AUGUST 30, 1965 MONDAY & TUESDAY Time 7:00 e.m. - 3:00 p.m. Topic Instructor Start Equipment Check-Out Condensers Transfer Pump Tank Piping System Instrumentation Haupt Molloy Williams Water Batch Equipment WEDNESDAY 7:00 a.m. - 3:00 p.m. Department shut down for tle-ln of New Equipment Start up as soon as HC1 gas Is available. 0931.46 MON* SHIFT LEADERS TRAINING ARO SOM IV - 4.000 Page 1 of 3 Rev. 0 Date: 3/30/6S Tueeday, March 30 7:00 r 3:00 Attend Second Shift of Operator Training Widneeday,. March 31 8:00 - 10:00 10:00 11:30 11:30 - 12:00 12:00 - 3:00 3:00 4:00 4;00 3:00 Proceaa nd Equipment Overview R. S. Tatea Field Trip Covering Same Areee At Claaaroom Discussion Lunch Process, Equipment, and R. S. Yates and Instrument Overview R. H. Harris Field Trip Recap and Diacuaalon of Day'a Diacuaalon R. S. Tatea R. N. Harrla J. W. Kolloy Vmtinj, JglU 8:00 - 10:00 Inatructora R. S. Tatea and R. N. Harrla Proceaa ( Equipment Speciflea: a. Thermlnol Heater Furnace b. Thermlnol Heater Furnace Controla c. Thermlnol Circulating Systea Above to cover equipment dealgn. aafety feature#, Initial atart>up, normal atarfup, emergency ehutdown, normal ehutdown, and normal opera ting proceduraa, aa well aa check polnta. MQNS 093149 Shift Leader* Training ARO SOM IV - 4.OOO Faga 2 of 3 Rev. 0 Data: 3/30/63 10(00 - 10:13 10:15 - 11:30 11:30 - 12:00 12:00 2:00 2:00 - 2:15 2:15 - 3:30 3:30 - 4:30 6:00 - 9:30 Break continue 8*10 a.m. Dlicuaalon with Field Trip Lunch Solid Aroclor Sy*tem Specific*: a. Charge Tank b. Chlorlnator and Chlorlnator Cooling Syatem c. Blow Tank Bretk Field Trip (Alternate: Continue Dlacuwlon of 12:00>2:00 p.a.) Recap of Day'* Dlecuealon and Introduction of Friday'* Lenon Dinner Meeting Friday. April 2 6:00 - 10:00 10:00 10:15 Inatructor* R. S. Tate* and R. N. Harrl* Proceaa 6 Equipment Specific*: a. Blow Tank Scrubber 4 Air Supply b. Still c. Still Furnace Break MONS 093150 Shift Leader* Training ARO SOM IV 4.OOO Paga 3 of 3 Rav. 0 Datai 3/30/63 10il5 - 11:30 11:30 12:00 12:00 1:00 1:00 - 3:00 3:00 - 4:00 4:00 - 4:30 c. Still Furnaca (Contlnuad) d. Still Condanaar and Cooling Syataa Lunch Still Jat Syatam Field Trip Covering Day'a Dlacuialon and Still Receiver Saaap of Day'a Dlacuialon Including Still Receiver and Uhere Material Goaa Dlacuaelon Period for Ravlev of Overall Solid* Syataa, In* eluding Tharalnol Haater and ALL Control* on Inatruaaent Panel Saturday. April 3 8:00 - 4:30 Inatructlon for Oroup on Inatrunant Panel. Primary Eaphaala on Field Inatructlon MONS 093151 ARO SCM I IV - 4.000 Page 1 of I Rav. 0 Data: 3/31/63 SHIFT LEADERS TRAIHIHC Waak of April 5 Shift laadara to participate In training hourly crawa Monday through Saturday. Shift laadara Mating 4:30 p.a. aaeh day. Waak of April 12 Shift laadara partlelpata In training hourly crawa Monday through Saturday. Shift laadara Meting 4:30 p.a. aach day. Waak of April 19 Partlelpata In hourly training for four ahlfte. Shift laadar review awatlng Friday, April 23 - all day - to dlacuaa prograaa and problaaa to data. Shift laadara aaatlng aaeh day at 4:30 p.a. mu, ef April ff Shift coverage to atart for atart-up of Tharalnol eyaten. Start-up - procaaa alaulatlon of aollda ayatea - will occur lata In tha waak. MQhS 09315^ SHIFT LEADER TRAINING ARO SOM IV 4.000 Page 1 of 1 Rev. 0 Datet 3/31/65 Waak of May 3 1. Solid Aroclor i]rit demonstration 2. Each shift ladar to hava one ihlft of training on liquid Aroclor system during thla waak. S4jL.2..,y.,k9 1. Solid Aroclor ayataai demonstration 2. Shift laadars to participate in hourly shift training one shift this weak. Waak of Hay 17 1, Solid Aroclor system demonstration 2. Each shift leader to hava one shift training on continuous blew tank and naw No. 3 racelvar this waak. ywfc 9tt m ? 1. Solid Aroclor system demonstration 2. Conclude shift work this weak, 3. Bach shift laadeT to hava one ahift training in HC1 system. Waak of May 31 1. Three shifts of training on HC1 absorber. 2. Wrap up demonstration reports on solids system. O'*3 V*3 SHIFT LEADER TRAINING ARO SOM IV 4.000 Paia 1 of 1 Rev. 0 Date: 3/31/65 Meek of June 7 1. Participate in hourly training for HC1 abeorber 2. Participate in hourly review training for eollda ayatarn, contlnuoua blow tank, air-cooled heat exchangers on liquid chlorlnatora Weak of June 14 Shift supervisors return to regular Jobs for this week. Weak of June 21 Participate in hourly HC1 training Weak of June 23 HC1 tie-in and process simulation MONS 093154 - SHIFT LBADKB IRAINIMC ARO SOM IV - 4.000 Paga 1 of 1 Bov. 0 Data: 3/31/63 Waak of July 3 HC1 ayataa itarc-up Waak of July 12 Partlclpata la hourly ravlaw training covarlng aolld and liquid ayatam and Cl abaorbar MONS 093155 ARO SOM IV - A.010 Pag* 1 of 1 ( Rav. 0 Data: 4/20/65 SHIFT LEADERS TRAINING SCHEDULE FOR ALL DAT 3BSSI0H ' April 23. 1965 8:00 - 9:00 a.m. Group dlacuaalon (In TSD trailer) lad by Vince Haupt covering Thermlnol Heater 9:00 10:00 Group dlacuaalon lad by Jack Molloy covering eolld Aroclor ayatem, Including aaapllng and other In procaaa controla 10:00 10:15 Break 10:15 10:45 Demonatratlon of field teat for free chlorine In chlorlnator off-gaa by Horman Madlaon 10:45 11:30 Group dlacuaalon of lnetrument ayataia capabilltlaa, limitations, and dlagnoatlc methoda led by Dick Harrle I 11:30 - 12:00 Lunch 12:00 - 12:30 p.a. Summary of changaa being mada to liquid Aroclor ayatan by Bob Yatta 12:30 - 2:00 Dlacuaalon of procaaa chamlatry, raaaarch hlatory, and quaatlona rotating to raaaarch lad by Rogar Bucknall 2:00 4:00 Field review of procaaa by entire group 4:00 - 4:30 (In trailer) Thoee Attending: J. W. Molloy J. G. Bryant Nandell Ellle H. K. Madlaon M. J. Wllllama V. R. Haupt R. S. Yatea R. W. Bucknall Dick Harrla 093l3fa j *ON3 i m um OVERALL OBJECTIVES ARO SQM V- 1.000 Page 1 of 1 Rev. 0 Data: 4/19/65 I. OBJECTIVE A. Thle project la Intended to successfully complete, ataff, atart-up, and demonetrate a plant which will conalatantly produca 10 million pounda per year of aolid Aroclora, 36 million pounda per year of liquid Aroclora, and racovary of 901 of avallabla HC1 offgaa aa Muriatic Acid, which maeta or aurpaaaea our preaent apeclflcatlon for Salaa. The fore going la to be accompllahed within tha praacrlbed time and money budgeta and In auch a manner that the normal manufactur ing coat ahall meet eatabllahed coat atandarda. B. Start up In eequance of graateat need which now appeara to be: (1) Solid Aroclora (2) Liquid Aroclora (3) Muriatic Acid. C. Every effort ahall be guide to better the existing achedule economically, but not eacrlflclng aafety or quality. II. ACTIVITIES A. Carry out Manufacturing Repraaantatlve reaponalbllltlea out lined In Bulletin 0-11 and "Guide for Plant Start-Up". B. Provide adequate llaiaon with Engineering and Reaaerch during dealgn to Inaure benefit of all applicable Monaanto operating experience. C. Provide edequate number of trained etarc-up shift leaders prior to water batching. 0. Provide adequately trained department operating eupervleor and foreman prior to water batching. 1. Provide adequately trained operating force prior to water batching. P. Provide for adequate maintenance capability for start-up. In cluding spare parts, trained supervision, and personnel. 0. Provide for adequate laboratory support, both control and analytical, prior to chemicals processing. MONs 093158 PROCESS SIMULATION OBJECTIVE ARO SOM V - 2.000 Pag* 1 of 1 Rev. 0 Data: 4/19/65 I. OBJECTIVE ' To demonetrata, utilizing flulda other than the uaual raw notarial*, that all eyatea* in the Department have been lnatallad according to the daalgn intent, aafaly and adequate ly perform thalr Intended function*, Individually and collec tively. Our Intent la to locate and correct aa many problem* aa poeelble prior to charging raw material*. II. ACTIVITIES A. Review each proceae atap for applicability of fluid* other than proceae fluid for proceae alaulatlon and arrange to uae procaa* material* only in caaee where uae of other izateriala la impractical. B. Check out auxiliary facllltlea for operation of the eolld Aroclor facllltlea. C. Check out each procaa* atep, and all control* aeaoclated, almulatlng procaea conditlona aa cloaely aa poaalbla. D. Operate the entire department on water, almulatlng normal operation aa cloaely aa poaaible. B. Simulate probable "aaMrgency" altuatlona for operator and eupervlaory training under field conditlona. F. Complete water batching each unit In aequenca one week after conatructlon completion. 0. Field teat all control*, alarm*, Interlock*, timer*, and other aafaty and aequanclng device* during water batching. MONS 093159 INITIAL OPERATIOH OBJECTIVES ARO SOM V - 3.000 Pag* 1 of 2 R*v. 0 Date: 4/19/65 I. OBJECTIVES . A. Demonstrate ability to produce Aroclor and Muriatic Acid in a aaf* manner. B. Demon*trata ability to produce Aroclor and Muriatic Acid which meet* praaent quality opacification for Sale*. C. Damonatrat* following rataa: 1. 10 M pound* per year aolld Aroclora. 2. 36 M pound* par year liquid Aroclora. 3. 90X recovery of available HC1 gaa a* Muriatic Add. D. Demon*trace manufacturing co*t estimate uiage* for all coat clement* a* specified In Appropriation Requeat. E. Ho declalona are to b* made favoring rate over quality or aafaty. 11. ACTIVITIES A. Upon aueceiaful completion of all proca** ilmulatlon, and not before, Introduce chemical* Into aystem and proceed with chemical proceeding In "Blocked" operation for two batch** on aolld Aroclora. B. Establish ability to safely process chamlcals one weak after completion of proca** simulation. C. Damonatrat* ability to produce goods of specification quality on consistent basis two weeks after completion of process simulation. Quality Is to take precedence over rat*. D. Reach dealgn rates as follow*: 1. Solid Aroclora a. 501 of design rata three weeks after completion of process simulation. s o^vb *0t*b Initial Operation Objectives l ARO SOM V - 3.000 Page 2 of 2 Rev. 0 Data: 4/19/63 b. 701 of daalgn rata four weeks after completion of process simulation. e. 1002 of design rata four weeks after completion of HC1 offgas clsan-up facilities. 2. Liquid Aroclors a. Maintain department at present 3 M lbs./mo. rate through construction phase. b. 802 of daalgn rate four weeks after completion of equipment alterations. c. 1002 of design rate four weeks after completion of BC1 offgas clean-up facilities. 3. Muriatic Acid a. 302 of design rate two weeks efter completion of process simulation. b. 602 of daalgn rate four weeks after completion of process simulation. c. 1002 of design rate four weeks after completion of HC1 offgas clean-up facilities. ( MQNS 093161 ARO SOM V - 4.000 Fag* 1 of 1 t R*v. 0 Data: 4/19/65 PROJECT DEMONSTRATION I. 08JBCTIVB Th* objactlva of th* damonatratlon parlod la to auccaaafully ahow that th* plant ean aonalatantly b* oparatad to produce apaclflcatlon-grada matarlal at daalgn rat* within th* eoat alanant uaagaa apaelflad In th* coat atandarda. ii. m,irvm A. Oparata at 1001 of daalgn rat* for on* or two aucciaalva weak*. B. During thla parlod, produc* notarial which laaata or axcaada quality raqulraaanta aatabllahad for Salaa. C. During thla parlod, daaonatrata raw notarial ylalda aqulvalant to th* coat atandarda. D. Acecnpllah A through C utlllalng th* coat atandarda allowad amount* of labor, utllltlaa, and aupplla*. I. Danonatrat* that th* allowanca for aachanlcal axpanaa can ha aat. T. Acecnpllah thaa* actlTltlaa by Hovaalbar 1, 1965: 1. Solid Aroolora 2. Liquid Arodors 3. Muriatic Acid ( HONS 093162 ARO SON I VI - 1.000 Pag* 1 of 3 Rev. 0 Data: 4/19/65 AROCLOR START-UP BRpoggg gpwwnw WBBK OF APRIL 26.1965 FOUR-DAY PROGRAM Typical 1 Day Program Pour Shift Crawa to ba Trained Tima Topic 7:00 8:00 a.m. Squlpmant Check-Out Re view A Procaaa Simulation 8:00 - 9:00 Plant Tour Detailed Individual Operator Training Operator Review of 8tart-up and Normal Operation* - Use Hater .In Vessel* - Solid Aroclor Equipment 9:00- 9: IS Break 9:15 - 11:00 Continue plant tour and water processing In aach vessel a* for 8:00 > 9:00 11:00 - 11:30 Lunch 11:30 4:00 p.a. Start-Up Tharmlnol Heater A Check-Out Safety Feature* Start-Up Circulating Tharmlnol System* for No. 9 Chlorlnator and No. 4 Still Condenser System* Start Equipment Check-Out: Tharmlnol Heater System Heigh Tank No. 9 Chlorlnator No. 2 Blow Tank No. 4 Still A Receiver Instructor Molloy Haupt A William* Madison, Williams, Haupt, and Molloy MONS 093164 Process Simulation MURIATIC ACID START-OP PROCESS SIMULATION WEEK OF JULY 12. 1965 Mwtfwr-lwtar Pltt Pay - Typical Has 2Ei 7lOO - 8:00 a.m. Equipment Check-Out Re view & Process Simulation 8:00 - 9:00 Plant Tour Detailed Individual Operator Training. Operator Review of Start-up U Normal Opera tions Us* Hater in Vessels 9:00 9:15 9:15 - 11:00 11:00 11:30 11:30 - 1:00 p.m. 1:00 - 3:00 Break Continue Plant Tour & Hater Processing in Each Vessel *s for 8:00 - 9:00 a.m. Lunch Complete Hater Trensfer In Vessels Possible Review Inetrumentetlon Detail* It Operation AltO SOM VI - 1.000 Pag* 2 of 3 Rev. 0 Data: 4/19/65 Instructor Molloy Taylor & Williams Madison It Williams 093lb5 Proceu Simulation AR0CL0R-MUR1ATIC ACID PROCESS SIMULATION WEEK OF AUGUST 30. 1965 Monday & Tuaaday tint Day - Typical Time Topic 7:00 - 8:00 a.m. Equipment Check-Out Review & Proceaa Simulation 8:00 9:00 Plant Tour Detailed Individual Operator Training. Operator Review of Start-up and Normal Operation - Uae Water In Veeeela 9:00 - 9: IS Break 9:IS 11:00 Continue Plant Tour and Water Proceaalng In Each Veaael aa for 8:00-9:00 a.m. 11:00 - 11:30 Lunch 11:30 - 1:00 p.m. Complete Morning Seaalon Drain System < Dry Out. Prepara for Start-Up Next Day. 1:00 - 3:00 Review Instrumentation Detalla & Operation ARO SOM VI - 1.000 Page 3 of 3 Rev. 0 Date: 4/19/65 Instructor Molloy TaylorCi Williams Madison & Molloy MOWS 93166 AR0CL0R START-UP INITIAL OPERATIONS ARO SOM VI - 2.000 Page 1 of 7 Rev. 0 Data: 4/19/65 WEEK OT MAt 5.1965 mmsm, Has 7:00 - 9:00 e-m . 9:00 - 10:00 10:00 > 11:00 Topic Final Check-Out of Equipmane Syatana aa Follow*: Thermlnol Heatar Ralae Temparatura Continua Chack-Ouc of: Halgh Tank No. 9 Chlorlnator & Aux. No. 2 Blow Tank No. 4 Still Syatam & Aux. Control Panel Instrument* Start-Up Tharmlnol Syatam: No. 9 Chlorlnator No. 4 Still Shift Supervision Laekay, Haupt, Mo Hoy, Williams, Madison Schedule to be determined later. Start-Up SUC Drowning Jet Syatam for No. 2 Blow Tank 11:00 - 1:00 p.a. Charge Weigh Tank with 1/2 Slxe Santowax Batch for 5060 1:00 - 2:00 Tranafar Santowax to No. 9 Chlorlnator - Start Chlorina tion Batch No. AE-1 - Taka Offgaa Samplaa - Fill Out Data 8heat 2;00 11:00 Complete Chlorination Complete Data Sheet 11:00 - 12:00 ldni(ht Tranafar to Blow Tank 12:00 - 1:00 a.m, Air Blow crude 5060 1:00 2:00 Charge No. 4 Still with Lot AE- 2:00 - 7:00 Start-Up No. 4 Still and Bagln Dletlllatlon Lot AE-1 Fill Out Data Sheet MQNS 093167 Initial Operation# Wf*K 9( Mty f, l?6f (continued) wmm lias 7:00 - 12:00 noon - Topic Complete Dlatlllatlon Ho. 4 Still Lot Ag-1 Coaplate Data Sheet 12:00 2:00 p.a. Lab Analyse First Distilla tion Quality 2:00 - 3:00 Transfer to Flaker Hold Tank 3:00 - 4:00 Start-Up Flaker and Sample to Check Quality 4:00 - 5:00 Charge Heigh Tank with Full Slae Santowax Charge for Hast Chlorination Batch Fill Out Data Sheet 3:00 - 6:00 Charge Ho. 9 Chlorlnator and Start Chlorination Batch AE-2 Take Offgaa Sample Fill Out Data Sheet 6:00 - 7:00 Continue Chlorination Batch AE-2 ARO SOM VI - 2.000 Page 2 of 7 Rev. 0 Date: 4/19/63 Shift Supervision Schedule to be determined later. I HONS 093168 Initial Operations Weak of May 5. 1965 (continued) ARO SOM VI - 2.000 Paga 3 of 7 Rev. 0 Data: 4/19/63 FRIDAY Tina Topic 7:00 - 12:00 noon Conplata Chlorination Batch AK-2 12:00 - 1:00 p.m* Transfer Batch to No. 2 Blow Tank Shift Supervision Schedule to bo determined later. 1:00 - 2:00 Air Blow Batch No. AE-2 2:00 3:00 Charge No. 4 Still With Lot AB-3 Begin Distillation Fill Out Data Shaat 3:00 - 1:00 a.n. Conplata Distillation Lot AB-1 Conplata Data Sheat 1:00 3:00 Lab Analyse Second Distilla tion Quality 3:00 4:00 Transfer to Flaker Hold Tank 4:00 5:00 Start-Up Flaker and Sanple to Cheek Quality 3:00 - 6:00 Charga Heigh Tank with Full Slae Santowax Charge for Next Chlorination Batch 6:00 - 7:00 a.n. Charga No. 9 Chlorlnator and Bold for Start-Up at 7:30 a.m. PIONS 093169 Initial Operations Waalt of May S. 1965 (continued) mvmz jUaj Tonic 7:00 - 1:00 a.m. Start Chlorination Batch Ho. AE-3 Begin Programed Batch Operation Take Offgas Sample! Fill Out Data Sheet Continue Operatlona as Before. Start Continued Operation aa soon as One Batch Is Complete. Start Next Batch for Chlorination & Distillation. ABO SCM VI 2.000 Page 4 of 7 Rev. 0 Date: 4/19/63 Shift Supervision Schedule to be determined later. SUMDAT-MOHDAT- TUIBDAT Continue Shift Coverage on Operation as Hotad Before. If Operation is Acceptable at This Stage, Shift Coverage Hill be 8topped on May 24, 1965. HUNS 093170 Initial Operations AROCLOR START-UP INITIAL OPERATIQMS WEEK OF MAY 24. 1965 ARO SOM VI - 2.000 Faga 5 of 7 Rev. 0 Data: A/19/65 Has Topic Shift Supervision 7:00 a.a. - 7:00 a.a. Start Operation of Control Instruments on Chlorlnetors No. 1 through 8. Start Programed Batch Chlorine* If Operator* Developed to This Stage. If Necessary, Delay Until After Review Training Week of June 7, 1965. Lackey Haupt Madison Molloy William Schedule to be determined later. ( Cover Operation for All Shifts Until Each Operator Has Demonstrated Operation of These Instruments. mqns 093171 Initial Operation* MURIATIC ACID START-UP INITIAL OFERATIOHS JULY IS. 196S vmm yi-- 7:00 - 9:00 a.m. Topic Final Check-Out of Equipment New Abaorber Carbon Tower* Surge Tank* Filter Storage Tank* Pump* Instrument* 9:00- 1:00p.m. ' Charge Syiten with Chemical*. Take Read ing* on Start-Up of New System. Check Muriatic Acid Production at Tower. Sewer Acid Until Quality Material 1* Being Produced. 1:00 2:00 Have Tower Production Analyced by Lab. 2:00 - Start Flow to Carbon Tower* and Filter. Analyie Product. If Material 1* a Quality Product, Start Collecting in a Storage Tank. Continue Operation* and Development of Operator Knowledge of Instrument Syatem for Muriatic Acid Tower Operation. Shift Coverage will La*t Two Day* During This Time. It will be Extended If Pro blem* Aria*. ARO SOM VI - 2.000 Pag* 6 of 7 Rev. 0 Date: 4/19/65 Shift Suparvltlon Lackey Madlion William* Molloy Schedule* to be determined later. HONS 09317^ Initial Operation* I AKO SOM VI - 2.000 Pag* 7 of 7 Rav. 0 Data: 4/19/65 AROCLOR-MURIATIC ACIP IMIUAL OPKRATICMS WEEK OF SEPTEMBER 1. 1965 Tina 7i00 - 9:00 a.n. 9:00 - 11:00 Toole Final Equipment Check-Out: Condenaeri Tranafer Pump Tank Piping System Instrumentation Start HC1 Gaa Fran Chlorlnator* Through the Syaten Shift Supervision Lackey, Taylor, Madison, HillIans, Molloy Schedule to be determined later. Evaluate Preaaure Drop i Through the Syaten. Sample Gaa Sy*terns and Analyse for Effective- nee* of Clean-Up System It may be necessary to sewer Muriatic Acid during Initial start-up due to possibility of new pipe causing off-color acid (high Iron). Continue Operations & Development of Operator Knowledge of Instrument Systen for HC1 Clean-Up Facilities. 8hlft Coverage Hill Last Two Days During This Tima. It Hill Be Extended If Problems Arise. MOWS 093173 ARO SOM VI - 3.000 (. Pag* 1 of 6 Rev. 0 Date: 4/21/63 AROCLOR START-UP PROJECT DEMONSTRATION I. SOLID AROCLOR SYSTEM A. Baaln Project Demonstration WEDNESDAY (5/26/633 (S-U + 14) 1. Contlnuoue proceeiing of acceptable quality eolld Aroclor*. a. Proceaa batch** at rate which will Insure good quality solid Aroclor*. Rate will not be favored over quality. b. Continue sampling at all key points to build analytical background data. Demonstrate SOS Daalan Rata on Instantaneous Baslp WEDNESDAY (6/2/631 (S-U + 211 1. Schedule continuous processing to produce solid Aroclors at 420,000 lbs./mo. Instantaneous rata. a. Demonstrate estimated usages for all cost elements a* specified In Appropriation Request for SOS rats. b. Continue to Improve product quality upward from acceptable level. c. Increase emphasis on: (1) Safe operation (2) Proper functioning of equipment d. Continue maximum eampllng echedule. I MOMS 093174 AKO SOH VI - 3.000 Fag* 2 of 6 Rev. 0 Data: 4/21/65 C. Pemonatrate 70% Paalan Rate on Inatantanaoua Baala WBPSESPAY (6/9/651 (S-U + 281 1. Schedule contlnuoue proceeclng to produce aolld Aroclors at 585,000 lb*./n. rate, a. Demonstrate eatlnated usage* for all coat elementa aa specified in Appropriation Request for 7OX rat*. b. Improve product quality. c. Continue emphasis on: (1) Safe operation (2) Proper functioning of equipment d. Consietent with requirement* of process, begin reduction of sampling program to routine re quirements , D. Pemonatrate 100X Paalan Rat* on Instantaneous Baals FRIDAY (10/1/651 (S-U HC1 Clean-uo + 301 1. Schedule continuous processing to produce solid Aroclore at 833,000 lbs./mo. rate. 2. Operate plant as Integral department of Anniston Plant with the following considerations: a. Maximum production b. Excellent quality c. Lowest possible production cost d. Good labor relations e. Full cooperation with other plant group* f. No lost-time accidents g. High level of housekeeping MOWS 093175 AX0 SOM VI - 3.000 Page 3 of 6 Rev. 0 Date: 4/21/65 II. LIOPIP AROCLOR SYSTEM A. Basin Project Demonstration MOMDAY (6/21/65) (S-P + 18) I. Continuous processing of accaptable quality liquid Aroclora. a. Process batch and continuous matsrial at rata which will lnaura good quality liquid Aroclora. Rata will not ba favorad ovar quality. b. Continue sampling at all key points to build analytical background data. B. Demonstrate 80% Design Rata on Inatantaneoua Baala TUESDAY 0/19/65) (S-U + 391 1. Schedule continuous processing to produce liquid Aroclora at 2,370,000 lbs./mo. rata. a. Demonstrate estimated usages for all cost elements aa specified In Appropriation Request for BOY rate. b. Improve product quality. c. Continue emphasis on: a. Safe operation b. Proper functioning of equipment d. Consistent with requirements of process, begin reduction of sampling program to routine re quirements. C. Demonstrate 1001 Design Rate on Instantaneous Baals FRIDAY (10/1/65) (3-0 HC1 Clean-Up -I- 301 1. Schedule continuous processing to produce liquid Aroclora at 3,217,000 lbe./mo. rate. I MOMS 093176 ARO SOM VI - 3.000 Fag* 4 of 6 Rev. 0 Data: 4/21/63 2. Operate plant a* an lntagral department of the Anniston Plant with the following conalderatlona: a. Maximum production b. Excellent quality c. Lowest poaalble production coat d. Good labor relation* a. Full cooperation with other plant group* f. No lost-time accident* g. High level of housekeeping III. MURIATIC ACID SYSTEM A. Botin Project Pemonatratlon TUESDAY (7/20/653 (8-0 + 61 1. Continuous processing of acceptable quality Muriatic Acid. a. Froceaa at rata which will Insure good quality. Rat* will not be favored over quality. b. Continue templing et all key points to build analytical background data. B. Demonstrate 501 Dealan Rate on Instantaneous Baals MONDAY (7/26/651 (8-0 -6 121 1. Schedule continuous processing to produce Muriatic Acid at 50Z recovery of available HC1 gas as Muriatic Acid on Instantaneous rat*. a. Demonstrate estimated usages for all cost elements at specified In Appropriation Request for 501 rate. ( M0NS 093177 ARO SOM VI - 3.000 I Page 3 of 6 Rev. 0 Data: 4/21/65 b. Continua to Improve product quality upward from accaptabla lavel. c. Incraaaa amphaala on: (1) Safa oparatlon (2) Propar function of equipment d. Continua maximum sampling achadula. C. Damonatrata 701 Design Rata on Instantaneous Basis THURSDAY (8/12/63) (S-U + 291 1. Schedule continuous processing to produce 701 recovery of available HC1 gas as Muriatic Acid on Instantaneous rate. a. Damonatrata estimated usages for all coat elements as specified In Appropriation Re quest for 70X rate. b. Improve product quality. c. Continua emphasis on: (1) Safe operation (2) Proper functioning of equipment d. Consistent with requirements of process, begin reduction of sampling program to routine re quirements. D. Demonstrate 1001 Destan Rate on Instantaneous Basis FRIDAY (10/1/65) (S-U HC1 Clean-Up + 301 1. Schedule continuous processing to produce muriatic acid at 90S recovery of available HC1. ( q931?8 mons ARO SOM VI - 3.000 Paga 6 of 6 Rav. 0 Data: A/21/63 2. Oparata plant aa lntagral department of Analaton Plant with tha following conaldaratlonai a. Maximum production b. Excallant quality c. Lowaat poaalbla production coat d. Good labor ralatlona a. Pull cooperation with othar plant groupa f. No loat'tlma accldanta g. High laval of houaakaaplng Saginning waak of Octobar 1, 1965, damonatrata ability to ccnelatantly product at: 10,000,000| lba./yr. Solid Aroclor 38,600,000 lba./yr. Liquid Aroclor 90X Recovery of available HC1 aa Muriatic Add Period from October 1, 1963, through Octobar 18, 1965, to ba uaad aa damonatratlon parlod. ( 0931^9 mons AKO SOM VII - 2.000 Page 1 of 1 tor. 0 Datej 4/20/65 ANALYTICAL METHODS Analytical method* for ciiacklng operation of the Aroclor and Muriatic Acid fadlltlaa operation *111 not differ from preaent laboratory practical. Preaent lab method* and technique* are being reviewed and revlaed. Upon completion of thli review, they will become a permanent part of thla aectlon of the Start-Up Manual. q931B1 HONS ABO BOM VII - 3.000 Pag* 1 of 1 Bay. 0 DataI 4/20/65 CALIBRATION CHARTS Calibration eharta for all tanka In' thla ayataa hava baan mada and lneludad at part of th* Proeaaa Function Outlln* lnatructlona. Aftar atart-up, th* flald calibration chart* will bacoma th* paraanant chart* for thla aactlon of th* Start-Op Manual. MONS 093182 EQUIPMENT CHECK-OUT PROCEDURE ARO SOM VII - 4.000 Pag* I of 6 Rev. 0 Data) 3/26/65 I. THERMINOL (AROCLOR) ITEMS 627. 628. 629. 629-A Objective: Teat Thermlflol heater piping system for leak*, heater, Circulating pump 6 instrumentation for control end In dication. Check List: 1, Check circuit breakers start-stop buttons on following motors: [Comp. Mv4adJ Date Remarks a. ICam 628-Tharmlnol Hester Circula ting pump motor Circuit No. 10-2. b. Item 628-Start-stop button st side of furnace field control box. c. Item 629-Thermlnol Heater Controls - Circuit No. 2. Air pressure test gas pipe lines st 20 pale for one hour - If no leaks continue test. Soap flanges. Open valve In gas line to furnace controls (40 pslg min.) 3. Open valve In steam lines to coll on Item 627 - Thermlnol Heater Surge Tank. Pressure should be 90 pslf minimum. 4. Open valve In Instrument air supply to control Instruments on heater system cabinet (90 pels min.), TRAC-629.12, & FIC-628.01. Check Instrument systems. 5. Connect water mater to hose and'fill surge tank (Item 627). Record level & meter readings per sheet attached until tank Is full. Empty tank whan callbratlon Is complete. 6. Blank off pump discharge & return line from the department. Close all valves on branch lines off the main 4" supply & 6" return line. Place e 20 pslg air pressure test on pipe system. Soap all flanges and valve packing And be sure there are no leaks. Check Individual branch lines one at a time. Allow 30 mins. min. check on each line. HONS 093183 Equipment Check-Out Procedure - Thermlnol Ch*ck List: .6 (Continued) Chack following pressure gauge* In pipe aystem: a. PI-628.02 Pump' discharge b. PI-629.16 Heater coll discharge c. PI-628.03 Automatic Valve AJ 1c When tests complete, vent main pipe system and then each branch line indivi dually. 7. Charge Thermlnol FR-2 Into Burge tank (Item 627) by following procedure: a. Use temporarily relocated Pyranol pump to charge tank. b. Position 55 gal. drum next to pump. Remove drum bung and vent cap. c. Connect flexible hoae to pump suction & stainless steel pipe to be Inserted Into drum. d. Position discharge line from pump Into tank. e. Open valve on pump auction - Insert pipe Into drum and start pump. f. Adjust suction valve on pump until flow Is steady. g. Continue to fill tank until_25 drums or 1.200 gala, are In reservoir tank .6 Cheek out furace control circuit & start up as follow*: a. Open furnace flue damper. b. Chack that Thermlnol la in surge tank (Item 627). c. Open manual natural gas valves In line to furnace. d. Open blower air valve* In pilot & main air lines. Date: Remark* ABO SOM VII - A.000 Pag* 2 of 6 Rv. 0 Date: 3/26/65 HONS 09318A Eoulpmnt Check-Out Procedure - Thermlnol ASO SOM Vir - 4.000 Pig* 3 of 6 Riv. 0 Data: 3/26/45 Chick Llt: 8. (Continued) jconp. 4J Cate Ma Remarks i. Turn on circuit No. 5 at atill panel and awltch at field control box. f. Actuate rad lnaat lever lnalde the Honeywell protectoglo unit (lower right corner of caae). Wait .10 aec. between aattinga of this lever In case it has to be redone. g. Set control point on Honeywell coil outlet temperature indicator at 325C. h. Align valves in Thermlnol system line* to circulate main lines only. Throttle pump discharge valve to allow system to fill slowly. I 1. Place TRCA-629.12 in manual with output pressure at 15 psla. Set FIC-628.01 at 300 GPM in "auto" position. j. Start pump (Item 628). Check lines throughout the department for leaks. Fill system slowly, then open dis charge valve of pump wide open. k. Start air blower. Use push button at side of field panel. Red light on Protectoglo unit should light up. l. Check pressure gauge at main air inlet to burner. It must read above 15 o.a.l. m. Wait 3 minutes - green light on protectoglo unit lights up in dicating purge period is over. n. Press ignition "start" push button on sld* of control box & hold in until white light on protectoglo I unit lights up. Red 6 green lights should go out. MQNS 093185 Equipment Check-Out Procedure - Tharmlnol ARO SOM VII - 4.000 Fag* 4 of 6 Rev. 0 Date: 3/26/65 Check Liat: 8* (Continued) a MQ Date Remark* Note one meter on front of field control cabinet Indicate* pilot flame 1* burn ing aa long aa the currant exceeds 1-1/2 to 2 microamperes. o. Reduce output pressure of TRCA-629.12 to zero while In manual position. This Is for low fire start-up. p. Throttle the manual air valve In main air line to furnace to control the heat. Observe the furnece temperature at multipoint recorder. Do not exceed 50C Increase for first two hours. Set TRCA-629.12 In "auto" and raise \ the temperature 50C per hour until you reach 220C. Open the manual air valve slowly to raise the temperature. q. The following Items will shut down the furnace automatically (pilot & main gas burner "off" and actuate alarm at still panel). (1) High coll outlet temperature above 325C. (2) Low natural gas supply pressurebelow 20 pslg. (3) Low blower outlet pressure below 1 palg. (4) High reduced natural gas press.above 5 pslg. (5) Low coll flow - below 200 gpm. (6) Failure of circuit #5 at still ( panel. (7) Failure of switch at side of field control panel. M0NS 093186 Equipment Check-Out Procedure - Thermlnol Chack List: a Check out furnace shutdown by the follow U8 ing methods: each method should shut the furnace down identically. Have furnace coil outlet temoeratur* at 100C for checks. (See Item 10 for start-up) Note: All items below will shut off the main and pilot gas to furnace. Air will continue to be blown through the furnace and the circulating pump will continue to pump. . Push "stop button for circulating pump. Main and pilot gas to fur nace will be shut off. Air will continue to-be blown through the furnace. a. Push furnace ignition "stop" button. b. Put TRCA-629.12 in manual and adjust output pressure to zero. c. Close 6" manual valve in main air line. d. Adjust FIC-628.01 sat point below 200 gpm. For this to work, the use of Thermlnol In the Department must be below 200 gpm. e. Cut off circuit #5 at still panel. f. Cut off switch at side of field control panel. Use following procedure for start-up after furnace has been In operation: a. Open furnace flue damper. b. Check that Therminol is in surge tank (Item 627) (1/2 full minimum). c. Check temperature in surge tank (Item 627) TI-627.03. Should be 100 d. Set valves in Therminaol system lines to circulate main lines only. In it. ARO SOM VII 4.000 Pag* 5 of 6 Rav. 0 Data: 3/26/65 Date Remerka M0NS 093187 Eoulpmant Chack-Out Procedure - Thermlnol Chack List: (Continued) a 8 O e. Adjust set point on FIC-628.01 at 300 aom controller In "auto" position f. Adjuat aet point TRCA-629.12 at 300C and controller in "auto" poaltion. Be aure 6" manual valve In main air line la closed. g. Start circulating pump. h. Start heat to burner by opening 6" manual valve in main air line. The main burner will light up heating Thermlnol to 250C. Fill Thermlnol system in all branch lines a. When Thermlnol is 250C open each branch kalve at feed and discharge to drive out air. Fill lines one at a time. Throttle valves to fill each line end allow line to fill slowly. b. Check Thermlnol when it reaches 250C. Inspect level in gauge glass to be sure an adequate level is main tained to cover steam colls and pump suction. Do not add additional Thermlnol un less you check drainage of lines & level in tank after the circulating pump has been shut off. c* Aftsr complete check-out, set T^CA629.12 at 100C and allow system to circulate until needed. In tt. ARO SOM VII - 4.000 Pag* 6 of 6 Rav. 0 Data: 3/26/65 Date Remarks MQNS 093188 EQUIPMENT CHECK-OUT PROCEDURE Items 535-536-544 - Charge Tank, Agitator, Charge Tank Pump, & Scale Syatem Items 505 - 506 - Chlorinetor and Circulating -Pump _ Items 538-533-534 - Chlorlnator Cooling Facilities 507 Items 530-531-539 Air Blower, Scrubber Jet, 541 Transfer Pump, Air Blow Tank Items 615-618-619 Still Heater, Condenser, Receiver, 620-621 & Transfer Pump Items 622-623-624 Still Cooling Facilities Item* 625-626-632 Still Jet Syatem ARO SOM VII - 4.000 Pag* 1 of 11 Rv. 0 Date: 3/26/65 Oblectlve: Test i circulating pumps, and Instrumentation for control and Indication. ( Check List: . Data jln it Check circuit breakers & start-stop buttons on following motors; 1 V Remarks a* Item 535-A - Agitator on charge tank Cltcult No. 11-1. b. Item 536 - Charge tank pump motor Circuit No. 12-1. c. Item 544 - Scale electrical circuit. d. Item 506 - No. 9 chlorlnator cir culating pump motor-Clrcuit No. 7-2. - a. Itam 334 - No. 9 chlorlnator Aroclor circulating pump motor-Clrcuit No.3-1 f. Itam 330 - Air Blower motor Circuit No. 7-5. Item 530 - No. 2 Blow lank pump motor I Circuit No. 6-3. ^ h. Item 616 - No. 4 Still circulating pump motor - Circuit No. 1-5 MQNS 093189 I II. Equipment Check-Out: Procedure ARO SOM VII - 4.000 Fege 2 of n Rev. 0 Dete: 3/26/65 Coop. In it. Check Llet: Date l. (Continued) I. Item 6I8-A - No. 4 Still Heeter electric circuit eyetem - light panel - Circuit No. C 9e. Remarks J, Item 623 - No. 2 Surge Tank pump motor - Circuit No. 5-2. k. Item ,621 - No. 4 Vacuum Receiver Tranafer Pump motor-Circult No. 4-5. l. Item 624 - No. 2 Surge lank Cooler Fan Motor - Circuit No. 5-3. .2 Check gaa preeaure to No.4 Aroclor Still Heater Control System - 40 pala minimum. I 3. Check steam supply to the following: a. Coll In charge tank, Item 535. b. Piping In and around charge tank. Item 535. c. Tracing on pump casing & stuffing box, Item 536. d. Coll In No. 1 Thermlnol Surge Tank, Item 533. e. Tracing on pump casing and stuffing box. Item 534. f. Pipe tracing'for the chlorlnator cooling system. g. Coll In No. 2 Thermlnol Surge Tank, Item 622. h. Treeing on pump casing & stuffing box, Item 623. t 1. Steam supply to No. 4 Still Jet, Item No. 626. Pressure should be 90 - 110 palg. MONS 093190 II. Equipment Check-Out Procedure Check List: 4. Check tower water supply to No. -9 Chlorlnator heat exchanger cooling system. Item 507. Open manual valves slowly and fill water system. Break flange on tube discharge line and check for leaks. 5. Check city water to following Items: a. Safety showers & eye baths In blow tank and Solid Aroclor areas. b. HC1 Scrubber Jets for Blow Tanks: 1) New Jet for No. 2 Blow Tank, Item 531 2) Existing Jet for No. 1, 3, 4, & continuous blow tanks, Item 532. ( c. Barometric sump on No. 4 Still Jet, Item 626. .6 Check out Thermlnol (Aro. 1232) System for leaks on No. 9 Chlorlnator heat exchanger system. a. Blank discharge & suction line at pump (Item 534) and the vent line on surge tank (Item 533). b. Place 20 pa la air pressure on the system. Soap the flanges, gauge connections, valve packing, and welds to be aura there are no leaka. Break head flanga connactlon on Crude Aroclor circulating line to heat exchanger (Item 538) to be sure there are no tube leaks. c. During pressure teat, check circulat ing pump discharge pressure gauge PI-534.01. i d. At the completion of the test, break flange In syatem and slowly vent off air pressure. Leave system empty and dry. ARO SOM VII - 4.000 Page 3 of 11 Rev. 0 Data: 3/27/63 II. Equipment Check-Out Procedure ARO SOM VII - 4.000 Page 4 of XI Rev. 0 Date: 3/27/65 Check List: 7. Charge Therminol (Aro. 1232) system and check tank calibration as follows: i . In it `Date Remarks a. Use temporarily relocated Pyranol pump to charge Therminol surge tank. be Position 55 Gal. drum next to pump. Remove drum bung and vent cap. .c Connect flexible hose to pump auction and stainless steel pipe to be In serted into drum. d. Position discharge line from pump Into tank. a. Open valve on pump suction. Insert pipe into drum and start pump. * .f Adjust suction valve on pump until flow is ateady. ' g- Continue to fill tank until 5 drums or approximately 250 gallons total are in aurge tank (Item 533). Use calibration sheet attached. 8. Start up Therminol System and check to be aura circulation and instruments operate. a. Set manual valves In system to cir culate from aurge tank through heat 1 exchanger (Item 538), the water cooled heat exchanger, & back to surge tank. b. Open valves on pressure taps for PICA-534.02. c. Close valve at sample point on pump auction and at heat axchangar (Item 538). d. Chack and close valves to put Thermi nol PR-2 (Aro. 1248) on heat exchanger ( (Item 538). e. Set TC-533.03 to control the tempera ture in aurge tank, Item 533 at 45C (113F). Open steam valve to coll in aurge tank. Therminol should be warm before starting pump. MONS 093192 / XX. Equipment Check-Out Procedure Check List: (Continued) -. f. Set FICAc536;02 in "auto" with set point at 300 gpm. Set TRCA-538.01 in "auto" with act point at 190C. Set TICA-533.01 in "auto" with the aet point at 50C. g. Start circulating pump (item 534) Diacharge pump preaaure ahould be 40 palg (See preaaure gauge PI-534.01) h. Check flow through ayetem and the following temperature polnta: 1) Pump diacharge - TE-534.03 2) No. 9 Heat Exchanger diacharge TE-538.03. 3) Temperature in heat exchanger 538 TRCA-538.01 4) Temperature in heat exchanger 507 discharge - TICA-533.01. 5) Heat exchanger cooler head TW-507.02. 6) Heat exchanger cooler - TW-507.03 IV- 507.06 1. Check preaaure at water feed and diacharge llnee to heat exchanger cooler, PI-507.04 & PI-507.05 ). Cheek level in 533 on L.G.-533.02. Be aure Thermlnol la 12 inchea above colle. k. Laava system circulating if there are no problems. [Comp. 4J Ma ARO SOM VII - 4.000 Page 5 of H Rav. 0 Date: 3/27/63 Date Remarks 2 MONS 093193 ( II. Equipment Check-Out Ptocadura ARO SOM VII - 4.000 Pag* 6 of 11 R.v. 0 Data; 3/27/65 Check Llat: Check out Thamlnol FR-2 (Aro, 1248) ayatem for leak* on No. 4 Still Condenser o In il Date Remarks a. Blank discharge 4 suction line at pump (Item 623) and the vent line on surge tank (Item 622). b. Place a 20 pals air pressure on the system. Soap flanges, gauge connactlons, valve packing, and velds to b* sura thar* are no leaks. Break flanga connection on shell aide of No. 4 still condenser (Item 619) to b* sura there are no leak*. c* During pressure test, oheck circulat ing pump discharge pressure gauge PI-623.03. d. At completion of the test, break ' flanga In ayatem and alovly vent off tha air pressure. Leave system empty and dry. Charge Therminol FR-2 (Aro. 1248) system and cheek tank calibrations as fpllows: a a Use temporarily relocated Pyranol pump to charge Therminol Surge Tank. b. Poeition 55 gal. drum next to pump. Remove drum bung and vent cep. c. Connect flexible hoae to pump auction and atainleee eteel pipe to be ineerted into drum. d. Poeition discharge line from pump intc tank. e. Open valve on pump auction. Insert pipe into drum and start pump. f. Adjust auction valve on pump until flow is steady. g- Continue to fill tank until 4 drums or approximately 200 gallons total are in the surge tank (Item 622). Use calibration sheet attached. MONS 093194 II. Equipment Check-Out Procedure Check Llet: 11. Start-up Thermlnol system and check to be sure circulation and Instruments operate. a. Set manual valvaa In syatam to cir culate from surge tank through No. 4 still condenser (Item 619), the sir cooled heat exchanger (Item 624), & back to the surge tank. _ b. Cloae valve In system to by-pass the air cooled hast exchanger. _ c. Cloae valve on sample point at cir culating pump suction. _ d. Set IICA-622.01 in "auto" with the set point at 120C. Sat point changea dependent on Aroclor being produced (see Details of Operating Inetructlons I. a. Open block valves in Thermlnol Heater System to the coll in the aurge tank (Item 622). Be sure material in surge tank is 100oC. __ f. Start circulating pump (Item 623). Discharge pump pressure should be 100 gpm at 26 pslg. Sea pressure gauge Pi-623.03. Check flow through the system and the following tempera ture points: _ 1) Pump discharge - TIA-623.02 & TE -623.01 2) No. 4 Still condenser temperature TW-619.02 3) Temperature of aurge tank TICA-622.01 g. Check level in 622 on L.G.-622.02. Be sure thermlnol is 12 inches above coll. h. Leave system circulating if there are no problems. ARO SOM VII - 3.000 Pege 7 of 11 Rev. 0 Dete: 3/27/65 Data_____ Remarks HONS 093195 II. Equipment Check-Out Procedure Check Llat: 12 Calibrate tank capacltlea for (Items 505,. 535, 541, 615, and 620. Uea a water meter and stick measurement for a check. (See attached calibration sheets. 13 Check out use of Solid Aroclor equipment using water: a. Check Thermlnol System and close all valves to jacketed lines and colls, In the Ho. 9 chlorlnator. Ho. 2 blow tank, No. 4 still and receiver. NOTE: This la Important during water test ing to be sure over-heating doaa not occur. b. Be aura blanks axe In Biphenyl and Santowax linea to the weigh tank,tba HC1 & Chlorine lines to No. 9 Chlori ne tor, and Ho.4 Still Racalver lines to the flaker hold tank. c. Close valve at bottom of Heigh Tank (Itam 535). d. Turn steam off feed lines, colls, A transfer lines to the weigh tank and pump. a. Adjust scale sat point at 5.000 lbs. f. Adjust TIC-535.01 sat point at 30C. g. Start water feed Into the tank. h. Hhen the scale reaches 5.000 lbs, tha annunciator alarm will ring a bell. Check the control valve In Santowax line. It should close when the alarm ball sounds. Reset the scale point and fill the tank to 15,1)00 lbs. At 15.000 lbs, a high weight alarm horn will sound. 1. Hhen full, check the following items: 1) TIC-533.01 - Weigh Tank temp, control 2) TW-533.02 - Weigh Tank temp. ARO SOM VII - 4.000 Pag* 8 of II Rev. 0 Date: 3/27/65 Date Remarks MONS 093196 II. Equipment Check-Out Procedure Check List: 13|. (Continued) j. Turn on agitator In the weigh tank. Rotation ahould be clockwlee. j , k. Set valve* to tranefer to the No. 9 chlorlnator (Item 505). J l. Start pump (Item 536) and tranefer the water to the chlorlnator. ; m. Set valve* to allow clrculatin the No. 9 chlorlnator to the heat ex changer (Item 538) and back to the chlorlnator. During circulation, try operation of the aample valve. Checlf the tempera ture element TE-505.02 and preaaure gauge PI-506.01. n. Set valve* to tranefer to the No. 2 Blow Tank (Item 541). . Check the.level gauge Indication dur ing thla tranefer and the temperature TIC-541.01. . o. Start the SMC Fume Jet bjr opening the valve In the water line to the jet. . p. Start the air blower (Item 530) and cheek the dlacharge preaaure gauge. . Check operation of the fume auction ayatem and the leval indication In the No. 2 Blow Tank (LI-541.02). . q. Set valve* to tranafer to the No. 4 Still (Item 615). Open water valve to atufflng box on No. 4 Still Pump (Item 616). . Start tranafer pump 539. Obaarve the level gauge In the No. 2 Blow Tank aa material 1* tranaferred. ARO SOM VII - 4.000 Fag* 9 of 11 Rav. 0 Data: 3/27/65 Date Reiaerka M0NS 093197 I I II. Equipment Check-Out Procedure Check Llet: 13. (Continued) ' eL -a r. Set valves to circulate through the ' furnace coll and back Into the still tank. During circulation, check the follbw: 1) Flow through coll FRA-618.01 2) Discharge pressure of the coll PI-618.05. 3) Temperature of No. 4 Still Tank TIC-615.03. 4) Temperature coil Inlet TE-618.02 5) Temperature coll outlet TE-618.04 6) Temperature coll outlet on Honey well high temperature shutdown alarm Instrument TIA-. a. Break flanges In all system and allow all water to drain out of the tanka and lines. System should drain for one day prior to connecting up for etart-up. 14. Check vacuum on the No. 4 Still furnace, still tank, condenaer, still receiver, and piping syatem. a. Close all valves which will allow venting the syetem. b. Open valves to manometers on the No. 4 still tank (615), No. 4 Still receiver (620), and Catch Tank (625). c. Sat PRC-615.04 In "autp" with set point at IQ am Hg. In it. ARO SOM VII - 4.000 Page 10 of 11 Rev. 0 Date: 3/27/65 Dat* Remarks HONS 093198 II. Equipment Check-Out Procedure Check Llat: 14. (Continued) Q< 3 3Me ' d. Open velvet In ateam lines to the Ho. 4 still Jet (Item 626). Check steam pleasure - It should he 90 pelg minimum. Time jet pull-down on the still system. Record this time. Observe pressure Indication at each manometer. Record data on attached data sheet. a. Should problems occur In the vacuum system, It may be necessary to blank off the system and presaura test with HCl gas to determine the leaks. f. Shut the steam off the Jets and vent the aystam when test Is complete. Leave system vented. ARO SON VII - A.000 Pag* 11 of 11 Rev. 0 Data: 3/27/65 Date Remarks MONS 093199 MO SOM VII 8.000 page 1 of 1 Rev. 0 Date: 4/20/65 rare scflKWMs Personnel for start-up of tho Aroclor-Murlatlc Acid rehabilitation facilities will come from the Aroclor-Blphanyl Department. A special a tart-tip craw consisting of flftaan oparators and tha flwa chief oparators for tha Aroclor-Blphanyl Department will be trained for operation of tha facilities. Training will be handled on a ala work day basis at tlaa-and-a-half for each parson to ba trained. Bach parson being trained for operation of this facility will rsealva between 4B and 56 hours training on tba now facilities. Pus to tha problan of training during nornal oporatlone of tha existing department, this program will .extend over a five weak period of time. During start-up of tha facilities, an- operator. In addition to normal department requirements, will ba scheduled on an overtime basis to cover any unusual problems encountered during initial operations. After start-up, whan tha facilities have bean proven out, normal oparatlona will ba taken over by present Aroclor Department pereonaal. Work schedules for training, process simulation, start-up, and project demonstration will ba a part of tha normal Aroclor-Blphanyl Department schedules. These schedules are not Included In this manual. HONS 093200 APPENDIX VI ARO SON I METHOD OF RUNNING SOFTENING POINTS (CONTINUED) III - 2.020 Pag* 38 Rev. 0 Data; 4/21/6} 12. Light burner and adjust to give a temperature rlee ae shown on the tharmomatar of 5*C. par minute. 13. Bring temperature up 5*C. par minute until ball falli through tha sample. 14. Record temperature at time ball falls to lower crossbar as tha softening point. ( MOMS 09304 7 PROCESS FUNCTION OUTLINE AROCLOR DEPARTMENT ARO SCM III - 2.030 Pag* 1 Rev. 0 Data: 3/28/65 I. HO. 4 STILL SYSTEM 1.1 Scoca Thla eovara the charging, start-up, shutdown, nomal operation, and emergency aituatlona Involving tha No. 4 Aroclor still system. 1.2 Description of Process Aaratad crude Aroclor from a blowing tank or a roof tank la fad to tha atlll tank. Hydrated lima la addad to tha crude Aroclor. Vacuum la applied to tha still and tha Aroclor la clrculatad through tha furnace coll and hasted to the vaporisation temperature. Vapors pas* up an opan column to tha condenser. Distilled Aroclor la collected In a racalvar. Quality of tha distilled solid Axoclois Is analysed by tha lab, and If in specification. It la drawn directly from tha racalvar Into suitable containers or transferred to tha flakar operation. 8tlll residua or bottoms from each distillation ara drawn Into containers and sold as Montar*, or It la discarded In trash drums. ii. rwcis? diawm Attached. III. OPERATION OF PROCESS 3.1 8tart-Pp A. Initial Start-Up 1. Tharmlnol Cooling System for No. 4 Still Condenser a. Charge system with Tharmlnol PR-2 (Aroclor 1248). MONS q93048 Proceae Punetion Out1In* Aroclor Department ARO SOM III - 2.030 Page 2 Rev, 0 Data: 3/28/65 (1) Usa temporarily relocated Pyranol pump to charga Therminol aurga tank (Itaai 622). (2) Poaltlon 55 gallon drum next to tha puap. Remove drum bung and vent cap. (3) Connect flexible hoaa to pump auction and the atalnlaaa ataal pipe to be lneerted Into tha drum. (4) Poaltlon dlacharge line from tha pua^ Into the tank. (5) Open valva on pump auction; lnaert pipe Into drum and atart pump. (6) Adjuat the auction valve on the puap until the flow la ateady. (7) Continue to fill the aurga tank until 4 drama or approxlmataly 200 tallona total are In the aurge tank (Itaa 622). 2. Still and furnace Start-Op a. Charaea to the No. 4 Still for the Varlouo Crude Aroclora: Vndar normal condltlona, crude Aroclore will be charged to the No. 4 etlll and the charge aeaaured by tha level Indication (LI-541.02) on the No. 2 blow tank. The chargea for all crude Aroclore for chlorination In the No. 9 chlorlnetor are baaed on an output from the chlorlnator of 2.100 eallona. Thla quantity of Aroclor will ba able to be charged to the atlll without any problem. The atlll tank alsa la 2.500 aallona. Aroclor 1168 la normally charged directly from the chlorlnator to the No. 4 atlll. Thla Aroclor la not air-blown. HONS 093049 ( Process Function Outline Aroclor Department ARO SOM III - 2.030 Page 3 Rev. 1 Date: 4/13/63 b. Prepare Ho. 2 blow tank (Item 541) for tranefer of charge. (1) Check to be sure the Therralnol heating system Is on the transfer pump (Item 339) and the charging Unas. Material to be pumped must be hot or It will damage the mechanical seals on the transfer pumps. Cold lines can also cause plug-ups and failure to transfer material. (2) Check temperature of material In blowing tank to be eure It la hot enough to transfer (240*C. minimum). Sea TIC-541.01. (3) Check with the chlorlnator operator to be sure crude Aroclor has been alr-blown for one hour. ( c. . Prepare still to receive charge. (1) Cloae valve at the bottom line under the still (Item 615). (2) Open vent valve on the still. (3) Open valve on vent line of the etlll. (4) Sat valves from the Ho. 2 blow tank to tha Ho. 4 still. Be sure the Thermlnol heating system Is on all transfer lines. (5) Close the main valve Intha vacuum 11ns to the still just above the receiver. Set the vacuum controller PIC-613.04 In "auto" with the set point at 10 ima Ha. Start steam to the vacuum Jets. Put steam on stage 3, stage 2, and stage 1, In that order. Stage 1 Is the closest to the receiver. Adjust water to the Intercondenser on the middle stage. The Jet on the No. 4 still should pull down to 4-5 mm Ha absolute on the receiver (Item 620). The steam to the Jet on tha Ho. 4 still should have a minimum of 90 pslg supply pressure. ( MUNS 093050 Frocass Function Outline Aroelor Department AIO SOM III - 2.030 Page A Rev. 1 Date: 4/13/63 d. Start up tha Tharalnol cooling ijritn for the Ho. 4 atlll condanaor (Itaa 619). (1) Sat TICA-622.01 at 120*C. with tha control* lor In "auto". (2) Adjust tha sat point for tha Tharalnol low taaparaturo alarm Instrument TXA-623.02 approximately 20*C. balow tha control point for TICA-622.01. Ea: 100*C. (3) Open the block walwoa In this Tharalnol hooting system linos to tha coll on tha aurga taak (Itaa 622). Sat tha valwas In tha Tharalnol cooling system for the Ho, 4 atlll coadamsar (Itaa 619) to allow circulation from tha aurga tank through the condenser through tha Themlaol cooler (Item 624) and back Into tha aurga taak. (4) Halt until tha temperature of tha Tharalnol cooling system Is 100*C.. than start tha circulating pump (Itaa 623). (5) Chock tha level la tha surge tank (Itaa 622) to ba sura the Tharalnol level covers tha hasting colls In tha surge tank, normally, this will ba j^l22 above tha coll level. (6) Do not permit distillation to start until tha daslTad set point of 120*C. has boon rasehad In the Tharalnol cooling system. Settings for tha taaparaturo controller TICA-622.01 for tha Aroclors are as follows! AotfilSE-B&k 0*L ML im Sat Feint, *C. 120* 120* 120' 170* The fan on tha Tharalnol cooler (Itaa 624) can ba started whan necessary to hasp tha taaparatura at the sat point during distilla tion. It Is operated manually. (7) Check tha following ltaas on tha Tharalnol cooling systaa circulation! MQNS 093031 Procttt Function Outline Aroclor Department AHO SOM III - 2.030 Page 5 Rev. 1 Date: 4/15/63 () 'Thermlnol cooling eystem circulating pump (Item 623) discharge pressure should be 37 pslg. (b) Circulating pump discharge temperature TIA-623.02 should read 120*C. with the low temperature alarm point set at 100*C. (c) Surge tank temperature TICA-622.01 should read 120C, . Charging the Ho. 4 still and atart-un: (1) Set valvee in transfer line from No. 2 blow tank to the still. (2) Start the blowing tank pump and transfer a full charge Into the still tank. (3) The still furnace coll can ba preheatad by using the pushbutton on the still control panel. This will allow bypassing the furnace Interlocks f to start gas Into the furnace without etartlng the still pump. The pilot and main gas burner will be started as usual. This la to prevent plugging the still coll during start~up. Flace gas flow controller FRC-618.06 In "manual" with the output pressure at 3-1/2 pals. Observe the furnace stack temperature on the multipoint recorder and do not exceed 200 *C. (4) Note the level of material leaving tha No. 2 blow tank (Item 541) on the level Indication gauge. As soon as 15X of the material has been transferred to the still, start the still circulating pump (Item 616). (5) Set valvee In the No. 4 still circulating line through the heater coil (Item 618) and back Into the still tank. (6) Stop the No. 2 blow tank transfer pump when the charge la complete as noted on the No. 2 blow tank level gauge. Allow lines to drain and then close the charging llnee to tha atlll. (7) Close the valve under the No. 2 blow tank. ( (8) Add hydrated lime through the funnel provided for this purpose on the No. 4 still. Add 200_ound of lime for each still batch. (9) Close the valve on the lime addition line. MONS 093052 Process Function Outline Aroclor Department ARO SOH III - 2.030 Page 6 Rev. 1 Date: 4/15/65 (10) Set So. 4 still condenser condensate temperature alarm TIA-619.03 at 100*C. (11) Start up the No. 4 still furnace (Item 618). f. Furnace Start-Up for the first time; (1) Open manual valves In the natural gas line to the furnace main and pilot gas lines. (2) Open damper on the furnace stack. (3) Turn on circuit No. 6 at the still panel and the switch on the outside of the field . control box to "on". The "red" light at the Honeywell Protectoglo unit will light up. (4) Set the control point on the Honeywell coll outlet temperature Indicator locatad In the box at 400*C. (5) Gas teat the atmosphere Inside the heater. Dee a 3 foot length of copper tubing on the end of a rubber hose. If the test shows dangerous, atop and correct the eauee of trouble before lighting up the burner. When the heater la cold, there la no natural draft to carry away gas or fumes. After the unit gets hot, there will always be a natural draft provided the flue damper la open. (6) Actuate the red reset lever Inside the Honeywell Protectoglo unit in the field control box. Open the door of the fleam unit. This exposes the small red lever in the lower right-hand corner of the case. Tou must wait 10 seconds between settings of this lever In case it has to be redone. (7) The "green" light on the Protectoglo unit should come on within 3 minutes. NONS 093053 Process Function Outline Aroclor Department ARO SOM III - 2.030 Page 7 Rev. 1 Date: 4/15/65 ' (8) Depreaa the Ignition atart button on the aide of tha field control box to actuate tha pilot flame. Hold the button depreeeed for no more than 10 eeconde. If all la wall, the "white" light on the Protectoglo unit will come on and the "xreen" light will go out. When this occurs, pull your finger away. The pilot Is now properly lit. (9) Put the set point on the natural gas flow controller FRC-618.06 to the solid still heater et 0. The switch will be In "auto". (10) Manually open the two reset safety valvas In the main gas line. The heater la now ready for normal operation. (11) Start up the solid still circulating pump. Tha Aroclor circulating flow mater FRA-618.01 will now record a flow above 150_0j1J. Low ( flow below 100 CPM through the coll will cause the main burner to be shut off. (12) Gradually raise the set point of the natural gas flow controller FRC-218.06 to the de sired set point. The furnace refractory must be dried out prior to starting heat-up to 400*C. Special In structions will be made at start-up. Tempera ture Of the furnace will be controlled by the stack high temperature point on tha multipoint recorder. Observe the coll outlet temperature on the multipoint temperature recorder. Do not exceed 50*C. Increase for the first two hours. Raise FRC-618.06 sat point for the natural gas flow as required to lncraass the temperature 50*C. per hour until you reach 400*C. The natural gas flow controller should be In "auto". The distillation or "boiling" la considered to be started when the vapor temperature makes a sudden Increase. Watch for this Increase during Initial heat-up of the furnace for the first time. MOWS 093054 Process Function Outline Aroclor Department ARO SOM III - 2.030 Page 8 Rev. 1 Date: 4/13/63 (13) Check the following Items In the ayatam to be aure operations are normal. (a) Natural gaa flow to the furnace on FRC-618.06. (b) Ho. 4 still circulating pump flew FRC-618.01 (c) Thermlnol cooling system temperature on TICA-622.01 (d) Check the coll temperature differential on tha Inlet and outlet of tha furnace (Item 618). g. Start-up of Furnace after Temporary Shutdown (1) Sat tha still temparature controller TIC-613.03 In "auto" with the set point at 240*C. Prior to atart-up, the still coll can ba pre heated before starting tha circulating pump. If necessary. See Section e.(3). Page 5. (2) Adjust natural gas flow controller to "auto" with the set point at 0. This Is FRC-618.06. ~ (3) Start up the aolld still circulating pump (Item 616). The Aroclor circulating flow mater FRA-618.01 should now Indicate a flow In excess of 150 CPM. Shutdown will occur at a flow below 125 CPM. (4) Open the main valve In the vacuum line to the vacuum Jets above the receiver. Vacuum at the still receiver should ba approximately 5 am He. PRC-615.04 should Indicate the exact vacuum on the still, which should bo *0-Sji Hgc (5) Gradually raise the set point of the natural gas flow controller FRC-618.06 to the desired set point. MCNS 093055 I Procaaa Function Out lino Aroclor Department ARO SOM III - 2.030 Page 9 Rev. 1 Data: 4/15/65 (6) Chack tha Multipoint temperatura record ing lnatrunant for tha tamparatura rlaa acroaa the coll In tha haatar furnace. In caae thla tamparatura chart la not Indicating correctly, chack for plugged llnaa or lnatrunant problem. Check to be aura tha pump flow la being meaaured correctly. If naceaaary, ahut off tha pump while at a low tamparatura to ba aura tha ayatam la operating. Have tha electrician chack the temperatura inetrumanta If you do not gat a rlaa. (7) Adjuat the atlll furnace natural gaa food with FRC-618.06 to give tha maximum rate of tamparatura rlaa without overheating. A apraad of 4 - 6*C. between tha coll inlet and outlet la normal.The gaa aupply preaaura will normally be approximately 4-1/2 pain. (8) Be aura tha Thermlnol heating ayatam la off the vacuum line to the Jeta during operation. (9) Check tha Thermlnol cooling ayatam on tha No. 4 atlll condanaar (Item 619) to ba aura the condanaar doea not plug up. If plugging begina to occur, ralae the tempera ture In tha Thermlnol cooling circulation ayatam. Uee TICA-622.01 to accompllah thla. The temperature Indicating alarm TIA-619.03 aat at 100*C. will Indicate plugging of tha condanaar. If the ayatam la too hot, tha fan on tha Thermlnol cooling ayatam cooler (Item 624) can ba atartad. mqns 0930&6 Process Function Outllnu Aroclor Department ASO SOM III - 2.030 Page 10 Rev. 0 Date: 3/28/65 (10) Vacuum problema on tha atllla are usually due to flashing of product over plugged vacuum lines, laaka In tha still system, leaks at pump packing, or Tharmlnol flow problems on tha condenser, vatar adjust ment on the Inter-condenser, on tha Jet, changes In tha stsam pressure to tha Jets. or problems In the nozzles for tha Jet. Flashing can ba stopped by lowering tha temperature of tha Tharmlnol cooling aystem for tha No. 4 still condenser. Vacuum trouble must ba traced systematical ly from tha Jat to tha receiver and than to the still. To accomplish this, manomster pressure Indicators have bean placed In tha system as follows: (a) On top of tha trap In front of tha Jet (Item 625); (b) On tha still receiver (Item 620); (c) On tha still (Item 615). (11) During normal operation, tha manual valves to the coll on the racalvar (Item 620) era open. Tha still racalvar temperature Indicating controller TIC-620.02 la sat at 152^. with tha controller In "auto". (12) A level Indication gauge has bean Installed in tha still receiver (Item 620) to allow Indication of tha level of suiterlal being distilled over. Tha level Instrument la LI-620.04. This level Indication can ba used to determine when tha distillation Is near completion. This will aid tha still operator along with his normal observation of coll temperature spread across tha fur nace. (13) Batch data sheets are filled out during each distillation. Information Includes the still lot number, aiaterlals being distilled, start time, finish tlma, the temperature spread on the still colls, tha vacuum, the end tlma for tha distillation, etc. Sea distillation table details which follow on Page 11. HONS 0 9 3 0 5 1 Procot Function Out Una Aroclor Department TABU II ARO SOM III 2.030 Page U Rav. I Date: A/13/63 DISTILLATION OPERATING CONDITIONS - SOLID AR0CL0RS 1 1268 4463 5442 5460 Approximate Temperatures at which Varloua Aroclor* Start Distilling 9 3-5 m Vac. At Racalvan , Column Coll Inlat Coll Outlat 225*C. 220*C. 215*C. 260*C. 240*C. 235*C. 240*C. 280*C. 243 *C. 24Q*C. 245 *C. 283 *C. Approximate Finishing. Temperature When Bottome Are Rot to be Drawn! ColuBB CollXnlet Coll'Outlat 310*C. 330*C. 375*C. Approximate Finishing Temperature After Which Bottome Are to be Drawn! Column Coll.Inlat Coll'Outlet Finishing Hold Point Finishing Softening Point 283*C. 350*C. 315*C. 353*C. 293*C. 360*C. 340*C. 373*C. 3j0*C. 400*C. 380*C. 400*C. 130170*C. 60- 46- 9866'C. 52*C. 105.5*C. HONS 093058 Procett Function Outline Aroclor Dtprtmt ARO SOM III - 2.030 Pegs 12 Rev. 1 Date: 4/15/65 (16) At the dlttillatlon neart completion, temperature In the atlll pot will rite. Flow through the coll will remain attady. When the flow dropt btlow 125 GPM. an alarm will tound. The main gat burner to the furnace will ihut off If flow dropt below 100 0PM. An additional aid It the level lndlcttor In the etlll receiver (Item 620). (15) At the end of the dlttillatlon, the batch la checked for color and aoftaning point or hold point, depending on tha material being produced. Before trantfer, check that apace It available In the fleker held tank and that the hot Tharmlnol ayttam la on the trantfer llnet from the etlll receiver to tha flaker hold tank. (16) At the end of the dlttillatlon, thut off tha furnace If It hat not already bean thut down automatically. (17) (18) Clcae the main valve in the vacuum line on top of the receiver (Item 620). Thla It to laolate tha Jet from the etlll ayttam and eliminate plugging of the Jet. Vent the furnace coll and allow It to tuck dry alowly to prevent carryover to the atlll condanaer. (19) Shut off the fan on the Tharmlnol cooling lyatem cooler (Item 624). Thlt can ba done at the control panel. 3. Operation of the Still Purina Dlttillatlon a. Regulate the gat pretture at the burnert by ute of PRC-618.06 to give the maximum dlttillatlon rata with conelatent good color of tha product. b. Tha lower tha vacuum, tha fatter tha dlatlllatlon rate, normally. (See table "Dlttillatlon Operating Condition* " Solid Aroclora".) MONS 093059 Proceea Function Outline Aroclor Department . ARO SOM III - 2.030 Pag* 13 Roy. 0 Data: 3/28/63 c. Coll temperature apraad: (1) Coll Inlet and outlet tanparatura nuat be watched cloaely at the end of the dlatlllatlon. Still bottoaa are vary vlseoua; therefore. If the circulating punp la In poor condition, or tha dlatlllatlon la carried too far, circulation nay atop and the coll will becona plugged or be burned. Haat from tha furnace actually buna tha Aroclor to carbon whan over heatad. If the coll outlet tanparatura jumpa auddenly and tha lnlat tanparatura etaya the aana or falla, circulation la nearly atopped. In thla caaa, ahut off the furnace gaa eupply FRC-618.06 quickly and auck tha coll. Normally, tha low flow rata FRA-618.01 will alarm with a flow below 125 GPM. If tha coll cannot be aucked, It la plugged and will have to be replaced. *. Punp Out Still Receiver a. Tranafer material iron tha atlll receiver (Itan 620) to the flaker hold tank or drum out, dependent on material being produced. b. Obaerva level of material in the atlll receiver by uae of LI-620.04. c. Check to be aura Thermlnol heating ayatem la on tha Jacketa of the tranafer llnea. d. Set valvea In tha line to drum out material or tranafer to the flaker hold tank. a. If material la to be tranaferred to the flaker hold tank, atart tranafer pump (Item 621) under the receiver. Allow material to pump until the receiver la ampty. f. Cloae the valvea and atop the tranafer punp whan tha receiver la empty. Thla can be obaervad by checking level gauge LI-620.04. HONS 093060 Process Function Outline Aroclor Department ARO SOM III - 2.030 Pag* 14 Rav. 0 Data: 3/28/65 B. Start-On Following Tamnorarv Shutdown This start-up phaaa would normally b* a altuatlon whara a pravloua distillation la complat* and tha still has baan shut down for charging with a naw batch. 1. Prepare Ho. 2 Blow Tank for Transfer Chars* a. Check to be sura that the Tharmlnol heating syatam Is on th* transfer lines from tha blow tank to tha still pot. b. Check the temperatur* of tha material In tha blow tank. It should ba 1S0*C. minimum. c. Check with tha chlorlnator operator to b* sura that tha crude Aroclor has baan air-blown on* hour. d. Tha Ho. 4 still vacuum syatam should b* opera ting with th* valve just above tha No. 4 still receiver closed. Water should b* on tha lntarcondansar and steam on th* Jat stages. Vacuum on th* trap (Item 625) In tha vacuum pip* line should ba Indicating 4-5 mm Ha. 2. Set tha vacuum control PRC-615.04 in "auto" with tha sat point at 10 me Ha. 3. Tha No. 4 still receiver tamparatura still controller TIC-620.02 should b* In "auto" with th* sat point at ISOM. 4. Tha Tharmlnol cooling syatam should ba circulating through tha No. 4 still condanaar and back to tha surge tank. Th* tamparatura controller TICA-622.01 should ba In "auto" with tha sat point at 120*C. Th* fan for the Tharmlnol cooler (Item 624) should b* running, If necessary, to cool Tharmlnol. Tha No. 4 atlll tamparatura control TIC-615.03 will b* In "auto" with th* sat point at 150*C, MONS 093061 Frocaaa Function Out1In* Aroclor Dapartaant ARO SOK III - 2.030 Fat* IS lav. 1 Data: 4/13/63 3. Tha natural |a* flow controllar FKC-618.06 will ba In "auto" with tha aat point at . 6, Tha Ho. 4 atlll furaaca (Itaa 618) will ba on aa Indicated bp tha Honapwall Protactoglo unit In tha (laid panol. Tha "whlta" light on tha Protactoglo wait will bo on. 7, Sat valvaa In tha tranafar Una from tha Ho. 2 blow tank to tha Ho. 4 atlll. 8, Opan tha want valvo on tha Ho. 4 atlll. Cloao tha valva at tha bottoai of tha atlll. f, 8tart tha Ho. 2 blow tank tranafar puap and ohorga tha Ho. 4 atlll. Obaorva loval Indication gauge la tha Ho. 2 blow tank to aaaaura tha atlll charge. 10. Start up tha aolld atlll circulating puap. Tha . Aroelor circulating flow aatar PRA-618.01 will now record a flow In aseaaa of 1?0 0PM. U, Tha atlll circulating puap will ba atartod aa aooa aa 131 of tha notarial froa tha Ho. 2 blow tank haa boon charged to tha atlll. 12. Stop tha Ho. 2 blew tank tranafar puap aa aooa aa tha blow tank la eapty. Cloaa tha valvaa at tha bottaa of tha blow tank and at tha dlacharga of tha tranafar puap. 13. Add 200 lba. of Uaa to tha atlll charga. 14. Cloao tha vant valva on tha Ho. 4 atlll. Open tha vacuua valva on tha Ho. 4 atlll racalvar and atart tha vacuua on tha apataa. 13. Gradually ralaa tha aat point of tha natural gaa flow controllar PRC-618.06 to tha doalrod aat point. Hatch tha taaparaturo rlaa acroaa tha furaaca oall tniot and outlat aa tha taaparaturo la reload. Horaallp, a * -_8*C. aproad will ba ebtalnod acroaa tha furnace coll. MONS 093062 Process Function Outline Aroclor Department ARO SOM III - 2.030 Page 16 Rev. 1 Date: 4/15/65 16. During normal operation of the still system, the following Items will be observed. a. Tamparature spread across tha still furnaca. : b. Flow of tha Aroclor through tha furnace coll. See FSA-618.01. . c. Level Indication In the No. 4 still receiver See Ll-620.04. d. Natural gas flow control to the No. 4 still furnace. SEE FRC-618.06. a. Temperature In the Tharmlnol circulating system. See TICA-622.01. f. Temperature control In the No. 4 still. See TIC-615.03. g. Temperature control In the No. 4 still racelver. Sea TIC-620.02. 17. At the end of the distillation the batch Is checked for color, softening point or hold point, depending on tha material being produced. As the distillation continues, tha temparatura In the still pot will rise; flow through tha coll will remain steady. When the flow drops to 125 0PM. an alarm will sound. Shut-off of the main gas to the still furnace will occur If flow drops below 100 GPM. An additional aid to finishing the batch la tha lavel Indication In the Mo. 4 still receiver LI-620.04. 18. Shut off the natural gas If It has not alarmad. Clear the coll by doing the following: a. Close the vacuum valve on top of tha No. 4 still receiver In the line to the jet. b. Vent tha still heater coll and suck tha coll dry. c. Shut off the fan at the Aroclor cooler (Item 624). M0NS 093063 Process Function Outline Arcelor Department ARO SOM m - 2.030 Pago 17 Rev. 1 Data: 4/15/65 19. Sat llnaa to either drum material or tranafer to the flatter hold tank, dependent on the material being produced. In caee the material la to be tranaferred to the flaker hold tank, be eura the Thermlnol heating eyatem la on the pump auction and dlacharga linea. Set the valvea in the tranafer line and start tranafer pump to the flatter hold tank. When the Ho. 4 still receiver la empty, atop the circulating pump and close the valvea In the transfer llnaa. 3.2 Routine Ooaratlona When the Ho. 4 still system la operating normally, the following conditions will exist In the process. A. Ho. 4 still pressure control PRC-615.04 set at 10 ma Ha. B. Ho. 4 still circulating pump flow recorded on FRA-618.01 with flow above 123 GPM. C. Ho. 4 still temperature control TRC-615.03 set at 150*C. D. Hatural gas feed to the still furnace controller FRC-618.06 set to give desired coll outlet temperature (about 500 cfh). B. Furnace high temperature alarm Instrument sat at 400*C. F. Thermlnol cooling system circulating temperature control ler nCA-622.01 set at 120C. G. Ho. 4 still racelver temperature control TIC-620.02 set at 150*C. H. Ho. 4 still lsvel Indication gauge LI-620.04 will Indicate level In jthe receiver. I. Main natural gas pressure 40 psla. J. natural gas reduced pressure 2-1/2 to 4 psla. MUN5 093064 I I Procats Function Outline Aroclor Department ARO 30H III - 2.030 Page 18 Rev. X Data: 4/1J/65 3.4 Safety Features A. The Honeywell Protactoglo unit haa the following aafsty faaturaa for tha No. 4 still furnace (Item 618): 1. Ignition period 10 second delay between actuation periods for the warp switch to cool. 2. Heater coll high temperature outlet shutdown eat at 400*C. 3. Natural gee high reduced pressure shutdown tat at 5-0 ! 4. Circulating pump low flow rate shutdown alarm sat at 123 CPM. 3. Pilot flams must be burning to start up tha unit. This la Indicated by 1-1/2 to 2 microamperes on tha field control panel. B. Thennlnol cooling system tamparatura control alarm sat for low alarm at 100*C. and high alarm at 175*C. C. Check surge tank (Item 622) to be aura Tharminol level is at least 6"-12" above the coll level. 3.5 Shutdown A. Temporary Shutdown Main gaa burner on the furnace off with tha pilot light on. The No. 4 still circulating pump running and tha vacuum eystem on. 1. Adjust FRC-618.06. Sat point to 0. Inatrument In "auto". ~ 2. Close tha manual valve In the natural gas faad supply line to the main burner. MONS 093065 Proceea Function Outline Aroclor Department ARO SOM III - 2.030 Page 19 Rev. 0 Date: 3/28/65 3. The vacuum may be cut off by cloclng the manual valve above the No. 4 atlll receiver. The etlll would than be vented and chut down eyetaaatlcally. If necaeeary. B. Complete Shutdown Main gae burner and pilot light ehut off in the furnace. Still circulating pump off. The vacuum ehut down and the Thermlnol cooling eyatem shut off. 1. Push Ignition atop button on aide of the field control panel for the furnace control eyetam. 2. After the furnace has cooled slightly, push the atop button for the No. 4 atlll circulating pump (Item tit). 3. Close manual valve above the No. 4 atlll recalver In the vacuum line. 4. Shut off steam to the vacuum jet by closing main valve In the steam supply line. 5. Close valve In the water line to the Intar-condansar on the No. 4 still jet. 6. Shut off Aroclor to the colls on the still tank and the receiver by adjusting the temperature controller set points to 0 for each tank. 7. Stop the Thermlnol cooling system circulating pump (Item 623). 8. Check the surge tank level to be aura the tank doaa not overflow after this pump Is shut off. 9. Adjust TICA-622.01 controller set point to 0. Thla will stop the Thermlnol heating system flow to the colls on the surge tank (Item 622). 10. Stop the fan on the Thermlnol cooling system cooler (Item 624). MUNS 093066 Frocata Function Outline Aroclor Department ARO SOM III - 2.030 Faga 20 Rav. 1 Data: A/15/63 3.6 Control Loopa. Intarlocks. and Alarna A. Control Loopa Thara ara 9 major control loopa In thla ayatam. 1. Vacuum Control for tha Mo. 4 Still - PRC-615.04 Tha function of thla loop la to maintain a conatant vacuum on the No. 6 atlll tank. Thla la accomplished by meaauramant of tha vacuum on tha atlll and throttling a control valva at tha auction of tha No. 4 atlll jet. Normal aattlng of thla InstrusMnt la 10 nm Ha. 2. No. 4 Still Circulating Pump Flow Recorder FRA-618.01 The function of thla loop la to meaaure and record the flow through the furnace heater coll on the No. 4 atlll. Thla la accompliahad by maaaureamt with a aegmantal orifice which Indlcatea tha flow to a panel recorder with alarm. Thla la a apaclal flanged jacketed orifice assembly ualng a Taylor volumetric d/p cell to meaaure flow. Normal flow will be above 150 GPM. A low flow alarm shutdown for tha furnace (Item 618) main gaa ayatam will ba actuated If the flow dropa below 123 GFM. Shutdown occura if flow drops below 100 GPM....... 3. No. 4 Still Temperature Control - IIC-615.03 Tha function of this loop le to maintain a minimum temperatura In tha No. 4 atlll, dependant on the material being produced (See Page 8 of thla P.F.O.). This la accompliahad by measurement of tha tempera ture and throttling a control valve on the discharge of the Thermlnol heating system from the colle in the Mo. 4 atlll (Item 615). M0NS 093067 Procaee Function Outline Aroclor Department AXO SON III 2.030 Page 21 Rev. 0 Date: 3/28/65 4. Furnace Mature! Oaa Plow Control - FRC-618.06 The function of thla loop la to control the gat Input to the No. 4 etlll furnace. Thla la acconpllahed by maaeurament of the natural gaa through an orifice flow mater and throttling the control valve In tha reduced gaa line. 3. No. 4 Still Furnace Controla - 618A The function of thla control eyatea la to control the natural gae feed preaaure to tha etlll furnace and aaaure a pilot light la alweya burning when natural gaa la being fed to tha furnace. Thla la accoapllahed with a tUnneapolla-Honeywell Protactoglo pilot light control aachanlea. There are ala eafety featurea In the furnace controla to ahut the eyatea down: a. High furnace coll outlet temperature will ahut down the furnace above 400*C. b. Low reduced natural gaa preaaure 2-1/2 Bale. c. High reduced natural gaa preaaure 10 pale. d. Failure of circuit No. 6 at the rear of the atlll panelboard, or electrical failure. e. Failure of any componant In tha Honeywell pilot flane nechanlam. f. Failure of the pilot eyetea la lndlcatad by the "red" light on the Protectoglo unit lighting up. 6. Theralnol Coollna Svetea Temperature Control PICA-622.01 The function of thla loop la to aeaeura tha tempera ture In the Theralnol cooling ayataa eurge tank and control thla taaparature to 120*C. Thla la accoapllahed by aaaeurlng tha taaparature In the aurga tank and throttling a control valve In tha dlecharge of the coll In the eurge tank. The louvere in the Theralnol cooling eyatea heat exchanger (Itea 624) are alao throttlad to allow more or leaa air to paaa acroaa the colla. A low temperature alarm aounda at 100*C. and a high temperature alarm at 175*C. MOMS 0 9 3 0 6 8 Frocaa* Function Outline Aroclor Dtpirtmt ARO 8OH III - 2.030 Page 22 Rav. 1 Data: 4/13/65 7. No. 4 Still Receiver T.'croerature Control TIC-620.02 The function of thl* loop la to control the tamper*tura In the No. 4 atlll racalver to 130C. Thl* la accompllahad by meaeuring the tamparatura In the racalvar and throttling a control valve In tha Tharninol heating ayatam dlacharge line on tha coll from the No. 4 atlll receiver. 8. No. 4 Still Receiver Level Indication - LI-620.04 Tha function of thla loop la to Indicate tha level of dlatllled product In the No. 4 atlll racalvar. Thla la accompllahad by a float level lnatrumant which Indicate* tha Aroclor level on a 0-8 ft. dial gauge. 9. Ho. 4 Still Condanaate Temperature - TIA-619.03 Tha function of thla loop 1* to lndlcat* tha tampara tura of tha condanaate from tha No. 4 atlll condanaar and aound an alarm If thla tamparatura ahould become too low. Normally, a tamparatura of 20-30*C. below the product tamparatura Indicate* the condanaar la plugging up, will aound an alarm. B. Interlock* Interlock* In thl* ayatam are aa follow*: 1. Start-Uo of No. 4 Still Furnace (Item 6181 a. Actuation of tha pilot Ignition lever on tha Honeywell Protactoglo unit haa a 10 aacond delay before a aacond try can be made. b. The Ignition "atart" button at the Protactoglo unit haa a 3 minute purge delay after the "atart" button haa bean puahad. Thla la to allow air purging of the furnace before It light* up. *QNs G9^069 I Procaaa Function Outline Aroclor Department AXO SOM III - 2.030 Fngc 23 Rev. 1 Date: 4/15/65 2. Automatic No. 4 Still Furnace Shutdown With Alarm* (Pilot and Main Oae Burner Offl a. High furnace coll outlet temperature above 400*C. b. Low reduced natural gae preeaure 2-1/2 oala. c. High reduced natural gaa preaaure 10 pala. d. Low coll flow below 100 CPM. e. Failure of circuit Ho. 6 at the rear of the till panel. f. Failure of the awltch at the aide of the field control panel, or blowing tha 115 volt fuaa ( In the panel. C. Alarm* 1. All ahutdown ltama under "Interlock*" (B-2 above) have alarma. 2. Ho. 4 atlll circulating pump low flow alarm below 125 OFM. 3. Thanainol cooling ayatam TXCA-622.01 haa a low temperature alarm at 100*C. and a high temperature alarm at 175*C. 4. Condanaata temperature alarm on low tamparatura for tha diatllled product coming out of the Ho. 4 atlll condanaar (Item 619). Thla controller TIA-619.03 la aat to alarm at approximately 20-30*C. below the condanaer product outlet temperature. IV. C0MMEHTS OH THE PROCESS A. It la vary Important to be aura the coll In tha Tharmlnol cooling ayatam aurga tank (Item 622) la covered when tha ayatam la In operation. Thla aaaurad tha circulating pump haa a positive auction and pravanta aurglng In tha 1 haater coll. Thl* will allow more uniform control of the tamparatura In tha Tharmlnol cooling ayatam. MONS 093070 Proceea Function Outline Aroclor Department ARO SOM III - 2.030 Page 24 Rv. 0 Data: 3/28/63 B. Cara nuat ba taken not to fill tha aurga tank (Itaa 622) too full during normal operation. Thle can cauaa tha tank to run over when tha circulating pump la etopped. A normal level will ba about 6" to 12" above the tank colla. Tha level In the tank will vary, dependent on tha operating taaparatura of tha ayatem. Normally, thla will ba 120*C. C. Ba aura that chromel-alumal thermocouple axtanalon lead wire la uaad to connect up the furnace natural gaa high temperature coll outlet alarm. Type K wire la In tha aame conduit aa Type J wire. If Type J[ wire la uaad by mletaka, the Indicator will read too high and cauaa furnace ahutdowna. D. After the flrat two or three atlll batchaa have bean run ao the natural gaa heat Input rata la known, adjuat tha linkage on tha reduced gaa praaaura control valvw ao a 3-13 pala lnetrument algnal will fully etroka tha valve. Make the adjuetment ao that only 10-131 above tha maxi mum needed gaa praaaura can ba obtained. Thla will reduce charring of tha colla In tha atlll furnace (Item 618). In netting thla lnetrument, a manometer la furnlahed with tha furnace controle for adjuating tha control valve. The nanometer readlnge acroaa tha orifice will ba: 0.595" t 400,000 Btu/hour Input 0.74 " at 500,000 Btu/hour Input 0.89 " at 600,000 Btu/hour Input 1.04 " at 700,000 Btu/hour Input 1.19 " at 800,000 Btu/hour Input E. Tha flow meaaurament recording lnetrument for tha atlll heater ayatem FBA-61B.01 la an extremely Important portion of tha controla for tha new No. 4 atlll ayatem. A eegnantal orifice la uaad for obtaining differential praaaura readlnge to Indicate flow. Thla orifice ayatem la In a epeclally daalgnad Therminol jacketed pipe aactlon. A epeclally daalgnad d/p call racorda tha praaaura readlnga and indlcataa flow. The orifice la daalgnad to allow aucklng the coll completely empty whan MONS 093071 Process Function Outllno Aroclor Department ARO SOM III - 2.030 Pago 25 Rev. 0 Data: 3/28/65 a dlitlllatlon la complete. Tha hola in tha orlflca plata la flush with tha bottom of tha plpa Una. This flow recorder should lndlcata low flow rataa at tha and of a distillation which will aid tha oparator In completing a normal distillation. F. A restricting orifice haa baan Installed in tha furnace circulating Una on the No. 4 still as tha plpa Una re enters the still tank. This orlflca la designed to main tain a prassuraof 6 pals through tha still furnace coll. This lncrsasad prassure at the coll outlet will suppress any boiling or vaporisation within tha coll. Actual vaporisation and distillation should taka place In tha still tank (Itam 615). 6. During distillation of solid Aroclors, vacuum problems occur in the pipe Una to the Jet system and plugging of tha jat nosslas occur dua to flashing and normal vapor pressure carryover. Tha vacuum Una from the No. 4 still racalvar (Item 620) has Thermlnol hast on tha Jacket of tha pipe Una up to tha suction Una on tha Jat (Item 626). The trap tank (Item 625) In tha vacuum Una has Thermlnol heat on tha coils In tha tank. It la vary Important that tha Thermlnol heating system be cut off tha lackatad Unas and the colls In tha trap tank during normal oparatlon. If those lines are kept hot during normal oparatlon. It will cause carryover Into the Jet nosslaa and causa more rapid plugging than In tha past. When using tha Thermlnol heating system to clean out the Unas or drain the trap tank, the Jat should ba Isolated from the No. 4 still system. This can ba done by either shutting tha steam off to the Jets or closing tha block valve In the plpa Una at tha auction of tha Jet. 8. In the existing No. 1 Aroclor still system, leaks occur in tha still condenser where the tubes are welded to the tuba sheet at tha ends of the condenser, Tha new con denser for tha No. 4 still haa a specially designed flexible expansion Joint In tha shall of tha condenser. It la felt that this expansion Joint will eliminate our present leakage problems In tha new No. 4 still system. It la extremely Important that we watch for potential leaka ainca tha material leaking into tha distilled product will ba Thermlnol FR-2 (Aroclor 1248). MOHS 09 30 22 PR0CK88 FUHCTIOH OUTLINE . AROCLOR DEPARTMENT ARO SOM III - 2.OAO Page 1 Rev. 0 Data: 4/20/85 I. TAME. BATCH AND OOHTIWUOUS LIQUID CHLORIHATORS. AMD BLOW TAR88 1.1 Scopa Thla covara tha charging. tart-up, ahutdovn, normal operation, and emergency situations Involving tha charge (malt) tank, tha batch and continuous liquid chlorlnatora, and tha blow tanks (or production of liquid Aroclors. 1.2 Description of Process Crude liquid Aroclora are produced by batch or continuous chlorination whan a measured quantity of Biphenyl la chlorina ted In a vertical reaction vassal with Ferric Chloride as a catalyst. Chlorine gas Is added at the bottom of the vssael. The reaction Is cooled by circulating tha reaction mass through an external air-cooled heat exchanger. By-product KC1 gas vented at the top of the chlorlnator is recovered In tha Muriatic Acid Department. Crude liquid Aroclors produced In tha batch chlorination are tranafarred to the blow tank operation whan tha chlorination la complete. A continuous blow tank la Installed In the continuous chlorination system so aerated material Is tranafarred directly to still feed tanks (or roof tanks). Chlorine gaa can be fed to the chlorlnatora from tha Chlorine Plant or from tank ears. U. PR0CE88 DIAGRAM Attached. XXX. DESCRIPTION OF PROCKSB 3.1 Start-Up A. Charges and Qparatlna Temperatures for Various Crude Liquid Aroclors - Batch Chlorlnatora Depending on the product to be produced, different quantities of raw materials are needed. See Table I on Page 2. HONS 093073 TABLE I ARO SON III - 2.040 2 Rev. 0 Deter 4/20/65 BATCH LIQUID CHLORINATOR OPERATING CONDITIONS 1121 A R 0 C LOR 1142 1148 1154 1160 1162 Chlorlnator Charge Biphenyl (U>e.) 3,000 3,000 3,000 3,000 3,000 3,000 Approximate Pounds 100X Chlorine Required to Produce Batch 1,600 3,330 5,560 7,040 9,030 9,480 Totallier Chlorine 8etting (80* Cl*, Aeeualng 101 Air) Lbe. Cl* 1,420 3,000 4,940 6,250 8,020 8,420 I Chlorlnetor Temp. Beginning - *C. Ending - *C. 130 130 130 130 130 130 140 150 155 155 160 160 Pinal Specific Gravity 1.150 1.344 1,410 1,500 1.558 1.582 Range 1.160 1.357 1.420 1.510 1.572 1.586 9 65 *C. 65 *C. 65 *C. 65*C. 90*C. 90'C Haight of Crude Batch Lba. 3,750 5,080 5,550 6,350 7,160 7,545 Gallons 390 450 470 505 550 570 MOMS 0930 74 ARO SOM III - 2.060 Page 3 Rev. 0 Data: 4/20/65 B. Filling Charaa (Malt) Tank for Batch Chlorlnatera 1. Rafar to Sactlon 3.1-A for the actual quantltlaa of raw materiel* needed for the particular Aroclor to be produced (Table I, Page 2). 2. Set the valvaa to receive the charge froa the Biphenyl Department. Notify the operator you are ready for a charge. Biphenyl la obtained froa the No. 1 or No. 2 Biphenyl catch tanka or the Biphenyl atorage tanka. A normal 3,000 pound Biphenyl charge la 35" lnnage In the charge tank for Biphenyl. 3. Be aura eteam le on tranafer llnee and the coll for the Biphenyl charge tank. One and one-half (1-1/21 pounds of Ferric Chloride are elurrled in Aroclor and dumped Into the charge tank with each chlorlnator charge. When the cor rect charge of Biphenyl la In the charge tank, cloaa the manual valva In tha line to the tank. Notify the operator who atarted the charge that it la complete. 4. Start tha agitator In the charge tank and let It run for one hour minimum prior to charging the chlorlnator. Thla la after tha Ferric Chloride haa been added. 5. Material In the charge tank ahould be a minimum 100*C. when charging tha chlorlnator. 6. Tha material la now ready for the next chlorlnator charge when needed. C. Charge the Batch Chlorlnator and Start-Up 1. Manual Operation a. Cloaa manual chlorine valve at tha dlatrlbutor on the chlorlnator to be charged. b. Cloaa vant on tha chlorlnator to tha atneaphere. c. Open HC1 vent valve to muriatic add area. MQNS 093075 ARO SOM III - 2.040 Fag* 4 Rev. 0 Date: 4/20/65 Sat temperature recorder controller In "auto" with the eat point at 150*C. Low temperature alarm 120*C. - high temperature alarm 190*C. Place aelector awltch for chlorinator fan in "auto". Place chlorine flow control inatrument in "auto" and aet. The chlorine aet point will be 400 lba./hour. Set the valve* to transfer charge from charge tank to the chlorinator. Be sure to atop tha agitator before starting the transfer pump. Start chlorinator charge pump. Stop pump whan tha charge tank 1* empty and cloaa tha valve* St the charge tank. Sat the chlorinator valvea to circulate the chlorinator through the asternal heat euchangar and back to the chlorinator. Start the circulating pump. Open manual chlorine valve at the dlatrlbutor on the chlorinator. Chlorine header praasure control PIC-500.07 will control the preaaure to 20-25 pais. A low prasaure alarm is sat at 15 oala - high praasure alarm at 35 pals. After one hour, lncreaaa tha chlorine rate to 600 lba./hour chlorine feed. After two hours, increase the chlorine feed rate to 800 lbs./hour. Check the following item* after eh* start of the chlorination. . (1) Temperature at tha temperature controller. (2) The chlorine flow at tha flow controller. MO hi 0930 76 AKO SOM III - 2.040 Pag* 5 Rev. 0 Dae*: 4/20/65 (3) Circulating pump diacharga praaaura. (4) Temperature of the chlorlnator batch " on the Multipoint Recorder. n. Samplee are taken at the dlecharge line of the circulating pump at the aecond level. The specific gravity la run on the batch chlorination. At the etart of the chlorine* tlon, a sample is taken after two hours of operation on odd numbered hours (7, 9, 11, etc.). Samples will be taken every two hours through the chlorination. o. When the chlorination is near completion, it may be necessary to run the specific gravity more often to determine the enact end point. p. When the chlorination ha* been completed (see Table I), shut off the chlorine feed valve et the dletrlbutor on the chlorlnator. q. Hot* the chlorine pressure on the main header. If it la above 30 pale, notify the Chlorine Plant that you have removed tha chlorlnator from operation. Tell them when you can start it back up. If this chlorlnator is to be off for a long period of time, notify the Chlorine Plant prior to shutting off tha chlorlnator. Pressure controller alarm PIC-500.07 will indicate a high preasure in case it should occur at 35 P*i. r. The chlorlnator is now ready to ba pumped out when the operator la ready. 2. Programed Chlorlnator Operation a. Close the manual chlorine valve at tha distributor on the chlorlnator. b. Close the vent valve on the chlorlnator to the atmosphere. c. Open the HC1 vent valve to the muriatic acid area. MONS 093077 ARO SOM III 2.040 Fag* 6 Rev. 0 Data: 4/20/65 d. Sat tha temperature recorder controller In "auto" with the sat point at 130*C. a. Sat the'chlorin* floe recorder controller In "auto-cascade". Have the set point at 400 lb*./hour. f. Adjust the green set point knob on tha chlorine totallier per Table I on Page 2 for measuring chlorine flow. Set up the chlorine flow pro gram per Appendix I, attached. g. Set the valvea to transfer the charge from the charge tank to the chlorlnator. Start tha transfar pump. Stop tha pump when tha charge tank la empty. Cloae the valvea In the charge line. h. Set the valvea to clrculat* tha chlorlnator to the external air-cooled heat axchangar and back to the chlorlnator. 1. Start tha circulating pump. j. Push the green reset button on the chlorlnator panal for the chlorlnator to ba atartad up. This ressts the chlorine totallser and la tha Initiating signal for the start of a new batch. The Flaxlpulse Timer will begin to time the batch as Indicated by cascade flow. Tha batch chlorine flow will b* controlled according to a preset program. At 801 of tha chlorine flow a* sat by the chlorine totallser, an alarm ball will ring to Indicate 801 of tha chlorine feed has been taken Into the chlorlnator. k. Open the manual chlorine valve at tha distribu tor on tha chlorlnator. This should ba done Immediately after pushing the raaet button so tha timer will control tha batch correctly. Steps j. and k. can be re versed If desired, dependent on where the opera tor Is whan starting tha batch. I MONS 093078 I AXO SON in - 2.040 Pag* 7 Rev. 0 Date: 4/20/6S Tha chlorln* header pressure control PIC-300.07 will control the preaaura to 20-23 pala. It - will Indicate a low preaaur* alarm at 13 Bale and a high preesure alarm at 35 pel*. l. Alter two hour*, take a sample of the crude Aroclor and check for apeclflc gravity. Thla aaapl* la a check to be tur* a ahort charge waa not tranafarred Into the chlorlnator. The next eampl* after that will be taken when eh* 801 alarm bell ring*. m. Check the following ltema during operation. (1) Temperature at the temperature recorder controller. (2) Chlorine flow et the chlorine recorder controller. (3) Circulating pump diacharga preaaura. (4) Temperature of the chlorination batch on the Multipoint recorder controller. (5) Not* program time and approximate time until coeipletlon of batch. n. The alarm bell will ring when 801 of the chlorine haa been fed to tha chlorlnator. Immediately take a eampl* at the circulation line to determine the point which tha chlorina tion level ha* reached. o. Continue the chlorination until complete. It may be naceaaary to run the apeclflc gravity more often during the laat on* to two hours of chlorination. p. At completion of the chlorination (a** Table I), ouah the ereen reaet pushbutton on the chlorlna tor panel for the chlorlnator. Thla reduce* the chlorine flow to 300 lb*./hour, and atop* the timer. Shut off the chlorln* feed valve* to the distributor at the chlorlnator. MOWS 093079 ARO 3OH III - 2.040 Page 8 Rev. 0 Date: 4/20/65 q. Note the chlorine preaaure on tha main header aa in "Manual Operation". Notify tha Chlorine Plant If tha chlorlnator la to be off for any length of time, or If the preaaure la above 30 oala. The chlorine header preaaure controller alarm will Indicate an abnormal low or high preaaure. r. If the chlorination la complete, prepare to pump to the blow tank aa dealred, depending on the product being produced. See next aectlon of Operating Inetructlona. D. Tranafar to Blow Tank 1. Sat tranafar llnae to pump to tha blow tank, dependant on tha material being produced. Ba aura etaam heat la on tha tranafar line. Hie chlorlna tor la ventad to the HC1 line during tranafar. 2. Check tha leval Indication lnatrumant on tha blow tank to ba aura there lx enough room to tranafar Into tha tank. 3. Change the final valve In the tranafar line and allow material to pump from tha chlorlnator to tha blow tank. Obaerva tranafar and nota laval lncreaae on tha blow tank level Indicator. At tha completion of tha tranafar, cloae tha valvea In tha circulating ayatem and ahut off tha circulating pump on tha chlorlnator. 4. The chlorlnator la now ready to charge back for the next chlorination. 5. Record tranafar Information on tha chlorlnator data cheat and In tha log book. Normal blow tank lnnagac after a single tranafar are aa followe: Aroclor Blow Tank Innaae Blow Tank Laval lnatrumant 1121 14 Inchea 1142,1148 1154 16-17 Inches 1160,1162 18 Inchea MOMS 093080 ARO SOM III - 2.040 Fag* 9 Rev. 0 Data: 4/20/65 6. If th* chlorlnator which la to b* ahut down had 1160 or 1162 la It, It ahould ba waahad oat with approximately 100 aallon* of 1142 prior to coaiplat* ahutdown. K. Fill Blohanvl Mix and Feed Tank for th* Contlnuou* Chlorlnator Sv*tn 1. Chock th* laval In tha mix tank. Th* tank low laval alarm ahould hav* aoundad (aat for 2511 full 1 Silane* th* alarm by puahlng th* acknowledge button on tha control panel. 2. S*C tha valves to receive th* charge of Biphenyl. Notify th* Biphenyl atlll operator to pump a charge to th* mix tank. Fill tha tank to 751 full laval. Cloa* th* valve In th* charge line whan thla laval la obtained. 3. Start tha agitator In th* mix tank. 4. Add 3-1/2 pound* of Ferric Chloride to tha mix tank. Allow tha Blphanyl and Ferric Chloride to mix until th* food tank require* filling. 5. Th* faed tank low level alarm eound* th* annuncia tor ayatam at 251 full In th* faad tank. Tha mix tank batch can b* dropped Into th* faod tank any time after th* alarm round*. The low alarm In th* f**d tank sound* approximately 30 rnlnut** prior to th* tank running empty. 6. Stop th* agitator In th* mix tank. 7. Open th* valv* under th* mix tank and allow tha Blphanyl-Farrlc Chloride mix to drop Into th* f*d tank. Th* level Indicator In tha f**d tank should Indiesta approximately 851 full. 8. Start th* Blphanyl feed tank agitator. 9. Cloa* th* valv* undar th* mix tank when th* tank la empty. 10, Prepare another mix for th* Blphanyl mix tank a* noted above. Th* low lv*l alarm In th* mix tank ahould hav* sounded and b**n acknowledged. ARO SOM III - 2.040 Pag* 10 Rev. 0 Data: 4/20/65 F. Contlnuoua Chlorlnator Operation The contlnuoua chlorlnator oparatlon constate of four cascade flow chlorlnator* In series where specific levels of chlorination occur. Biphenyl la fad Into the first chlorlnator where the material la chlorinated and overflows to the second unit. This continues until the finished product coons off the final unit, flows to tha catch tank, and through the continuous, blow tank. This chlorination ayatem can be reduced to three ( 3) chlorlnator* In aariea In caaa problem* occur with on* unit. Normally, 1142 1* tha only liquid Aroclor produced on the continuous ayatem; however, 1148, 1134, and 1160 can also be produced with the chlorlnator* aat for different levels of chlorination. 1. Four Staae Contlnuoua Chlorlnator Oparatlon a. Set the temperature controllers for chlorine* tor No. 5, 6, 7, and 8 at 130*C. b. Set the chlorine flow controllers In "auto" with the sat points at 600 lb*./hour for chlorlnator* No. S, 6, 7, and 8. c. Set the specific gravity recorder controller for No. 8 chlorlnator In "auto" with the set point at 1.350. The Accuray controller will adjust the chlorine feed automatically to No. 8 chlorlnator to maintain the indicated specific gravity. d. Sat the Biphenyl feed controller In "auto" with the set point for 2 CFM (Instrument reading 4). e. Charge each of tha four chlorlnator* (No. 3, 6, 7, and 8) with Biphenyl as for a regular batch chlorination. Start the circulating pumps on the chlorlnator*. f. Follow normal procedure to chlorinate the material to the following levels; MOMS 093082 AKO SON III - 2.040 Pag* 11 Rev. 0 Data: 4/20/65 Stag* Chlorlnator Specific Cravltv Flrat 5 1.078 - 1.104 Second 6 1.170 - 1.196 Third 7 1.254 1.280 Fourth 8 1.336 - 1.362 g. Cloaa tha valve on tha chlorine dlatrlbutor on each chlorlnator whan the correct epedflc gravity level ha* been reached. Hold thla chlorlnator until all four are ready. It may be necessary to put Steen on the chlorlnator to keep the teuperature at 120*C. h. Check the Biphenyl feed tank to be sure nix ha* bean charged and the agitator la running. I. Set the valves on the Biphenyl feed line to tha Ho. 5 chlorlnator and allow circulation back to the feed tank. J. Start the Biphenyl feed punp. k. Set the valve* on the overflow lines at tha chlorlnators as follows: Crude fron No. 5 chlorlnator to overflow to No. 6 chlorlnator; No. 6 chlorlnator to No. 7; No. 7 overflows to No. 8; No. 8 overflows to the crude Aroclor catch tank and than to the continuous air blow tank. l. Whan all four chlorlnator* have reached the correct specific gravity level, start the chlorine feed to each of the chlorlnators (600 lb*./hour on each) and open tha valve to start Biphenyl feed to the No. 5 chlorlnator. Open manual valves at each chlorlnator dlatrlbu tor. Chlorine feed Is adjusted at the auto matic flow controller* in the control room to maintain tha required specific gravity level. Normally, No. 5 chlorlnator chlorine feed la lower than the other three chlorlnator*. Thla la to decrease Biphenyl carryover Into the HC1 header line. HONS 093083 ARO SOM III - 2.040 Pag* 12 Rav. 0 Data: 4/20/6S Be aura and cloaa the manual valve In the Biphenyl feed line to No. 5 chlorlnator. m. Sample* will be caught and specific gravity run on chlorlnator* No. 5, 6, and 7 ovary other hour on even hours (8, 10, 12, etc.). A sample will be run on No. 8 chlorlnator avery four hour* (8, 12, 4, 8, ate.). n. Check the following Items during operation. (1) Temperature of tha Individual ch lortu tors on th* automatic temperature controllers. (2) Chlorine flow on th* chlorine flow controller*. (3) Discharge pressure of the circulating pumps for each chlorlnator. (4) Temperature on the Multipoint temperature recorder for the chlorlnator batch tempera ture for each unit. (5) Specific gravity of No. 8 chlorlnator. o. Tha continuous blow tank lavel controller UCA-529.01 has a set point at SOI. Th* controller Is always in automatic. p. Th* crude Aroclor catch cank level Indicating controller LICA-545.01 Is set at SOI. Tha controller Is always In automatic. q. When tha level In the crude Aroclor catch tank reach** th* 501 set point, set th* valves to allow transfer from the crude Aroclor catch tank to th* continuous blow tank. Start the crude Aroclor catch tank pump. r. Sat tha valves to allow transfer from th* continuous blow tank to the No. 4 blow tank. When th* level In the continuous blow tank has reached 501. start th* transfer pump which will allow pumping to th* No. 4 blow tank or the No. 1 roof tank. HONS 093084 ARO SOM III - 2.040 Paga 13 Ray. 0 Data: 4/20/63 a. Tha lavala In tha two tanka will ba malntalnad automatically. Parlodlcally tha No. 4 blow tank muat ba tranafarrad to tha ' No. 1 roof tank to faad tha No. 3 atlll. Whan tha contlnuoua blow tank ayatam haa baan provan to aatlafactorlly air blow tha cruda Aroclor, valvaa can ba aat to allow pumping dlractly to tha roof tank. 2. Thraa Chlorlnator Svatam a. Routlna rapalra to tha chlorlnatora raqulraa ramoval of ona of tha four contlnuoua chlorlnatora from tha ayatam. In thla caaa, tha following procadura would ba followad to run thraa chlorlnatora contlnuoualy. b. Switch valvaa on the overflow linea from ona chlorlnator to another to allow bypaaalng a particular chlorlnator. c. Shut off the Biphenyl faad to tha flrat stage chlorlnator and chlorlnata the material to the following levela: Stage Chlorlnator* Specific Cravltv Plrat 3 1.108 - 1.124 Second 6 1.224 1.240 Third 8 1.343 - 1.353 *Note: Indlcatea No. 7 chlorlnator out of ayatam; however, any ona of tha four can ba bypaaaad. d. Start tha chlorine and Blphanyl feed again In tha cams manner aa for tha four ataga contlnuoua operation. a. Continue operation of the ayatam aa a thraa ataga unit, merely omitting tha one ataga which haa baan bypaaaad. AKO SOM III 2.MO Tags 14 Rev. 0 Dete: 4/20/65 f. The chlorinetor renoved from service should be chlorlnsted to e finished Aroclor end pumped out. The chlorlnstor will be ehut ' down in-e routine feehlon. See details in "Shutdown" section. 6. Chlorine Vaporiser Liquid chlorine from tank care la vaporised in e shell and tube heat exchanger, using steam for heat. Vaporised chlorine at 25 pels enters the chlorine header to the Aroclor chlorlnators. 1. Open manual valve on the steam line to the vaporises. 2. Set the vaporiser temperature control at 65^3^ to allow the steam control valve to open. 3. Check to be sure steam pressure to the vaporiser is t? Pflfi or lower. 4. Sat the chlorine header pressure conerol valve In "auto" with the set point at 0. The chlorine valve feeding liquid chlorlne~lnto the header will be closed. 5. Hook up the take-off lines to the chlorine car. Hear a gat mask while making this connection. Open the valve on the car to take on chlorine when the car la connected. This valve must be opened slowly or the check valve ball will jump up in the valve and make It impossible to take chlorine out of the car. 6. Open the valve in the liquid chlorine line to the vaporiser located at the tank car. 7. Open the block valves on each side of the automatic liquid chlorine take-on valve. Cloaa the bypass valve at the control valve. 8. Check the vaporiser level control to bs sure it closes the liquid chlorine control valve when the vaporiser is approximately one-half full. 09doa6 ARO SOM III - 2.060 Page 15 Rev. 0 Date: 4/20/65 9. Set the chlorine preaaure control lnetrument PIC-500.07 at 25 palg with controllar In "auto". 10. Open the chl'orlne vapor valve slowly to eliminate surgas In the chlorine header system. 11. Observe operation to be aura tha chlorine header pressure does not exceed 25 psla and the etaam pressure to the vaporiser remains below 12 pale. High chlorine pressure can cause extreme problems In the Chlorine Plant and result In chlorine re leased to the atmosphere In that department. In case a high pressure alarm (presently set at 35 palg) should occur, contact tha Chlorine Plant lmaadlately and try to eliminate their pressure problem If possible. Tha pressure Indicating controller indicates a low pressure alarm at 15 Bale. 3.2 Routine Operations During normal operations of tha batch and continuous chlorlnators, tha following conditions will exist In tha process. A. Batch Chlorlnators 1. Chlorine flow will ba Indicated on tha flow controller. If In "cascada-auto" control, tha Taylor Plexlpulae Timer will be controlling tha flow by prograasaed system. 2. Temperature will ba controlled by tha temperature recorder controller with tha system In "auto". Normal temperature la 150C. 3. The chlorlnator circulating pump will ba In opera tion. Discharge pressure on the pump will be 35 pale. Normal flow of tha pump will be 200 CPM. 4. Temperature of the chlorlnator can also be observed on tha Multipoint temperature recorder. 5. The chlorine pressure on the main header can be observed on PIC-500.07, tha pressura indicator controllar from the chlorine vaporiser. Normal pressure will be 20-25 psla. M0NS 093067 ARO SOM III - 2.040 Pago 16 Rev. 0 Data: 4/20/65 B. Continuous Chlorlnatore 1. Chlorine flow will be In "auto" control with the 'flow Indicated on the flow recorder controller for the Individual chlorlnatore, Mo. 5, 6, 7, and 8. 2. Temperature will be controlled by the temperature recorder controller for the Individual chlorlnatora. Normally, the controller will be In "auto" with the eat point at 150C. 3. The chlorlnator circulating pumpe will be In operation with the discharge pressure at 35 pels. Normal flow of the pumps la 200 GFM. 4. The temperature of the Individual chlorlnatore ean be observed on the Multipoint temperature recorder. 5. Biphenyl feed to the first stage of the continuous chlorlnatore, (normally No. 5 chlorlnator), can be observed on the Biphenyl feed control Instrument. Nonsally, this Instrument la In "auto" with the sat point at 3.0 CM. 6. The Accuray specific gravity lnstruawnt for the No. 8 chlorlnator will be Indicating the specific gravity for the material In the No. 8 chlorlnator. The controller will be sat In "auto" with the control point at 1.350 specific gravity unite. 7. The level In the Biphenyl mis and feed tanks will be indicated by the level Indicators on the control panel. Normally, the mix tank will have a charge In It Indicating 751 full. The feed tank level will vary from 25-851 full. 8. The level In the crude Aroclor catch tank will normally be 501. 9. The level In the continuous blow tank will normal ly be 501. 10. Air pressure to the continuous air blow tank will normally be 5.0 to 10 oala. 11. The HC1 header off-gas pressure will normally be 1.5 to 3.0 PSia. MOMS 093088 c. Chlorine Vporlr ARO SOM III - 2.040 Fag* 17 Rev. 0 Date: 4/20/65 1. Chlorine level In Che vaporlter will be approximate ly 12S- ' 2. Steam to the chlorine vaporlxar eteam cheat will be 10-12 Pl. 3. Chlorine preeaur* from the tank car will normally be 60 Pile. 4. The chlorine vaporlter temperature controller will be eet at 65C. Normally, the liquid chlorine will be wall below thl* temperature which open* the tteam control valve. 5. The chlorine preteure Indicating controller PIC-300.07 will be eet In "auto" with the control ler at 20-25 Pil. D. Blow Tank 1. On* of the air blowara will be operating with the dlacharg* preeaur* at 5-7.5 palx. 2. Water at a preeaur* of 40 pelt will be on the S6K acrubber jet; drowning the HC1 fumea from the blow tank. 3.3 Safety Feature* A. A level Indication lnatrument la on the chlorlnator control panel to Indicate when e new charge la needed In the mix tank. A low level alarm la Indicated at 251. B. A level Indication lnatrument la located on the chlorlna tor control panel for the feed tank. A low level alarm will aound at 251 full to Indicate a new charge 1* needed for the feed tank. Approximately 30 minute* operation time la available before the tank will be empty. C. A level Indicating controller la located In the crude Aroclor catch tank to control the level to 501. A high alarm will aound at 601 level. Thla allow* approximate ly lb hour* prior to the tank being completely full. moms 093089 ARO SOM III - 2.040 Pag* 18 Rav. 0 Dace: 4/20/65 D. A high temperature alarm la act at 190C. on the Individual chlorlnator* to prevent excaaelve carry over of trapplnga Into the HC1 offgaa header. Temperature* above thla will caua* exceaalve carry over of Biphenyl or crude Aroclor. A low temperature alarm la alao provided at 120C. to prevent production of unatable Aroclora. B. Chlorine flow atop* will be placed on the chlorine flow control valvea to the chlorlnator eat at 300 lb*./hour to prevent ahuttlng off the chlorine feed In caaee of air failure to the control valve. The control valve normally cloeea on air failure. This 1* for protection of Chlorine Plant peraonnel. P. A alght glaa* haa bean placed In the HC1 offgaa line of each chlorlnator to allow obaarvatlon of the flow for poaelble entrainment. In caa* entrainment droplet* are noticed being carried out of the HC1 gas, the chlorine flow ihould be decreaaed (lightly to raduc* thla entrainment. Exceaalve entrainment carryover will cauaa plugging of the HC1 offga* line. C. Normally, when the programed flow control tyitam 1* In operation on a batch chlorlnator, a sample of the material being chlorinated will be taken after four hour* of operation. This sample 1* taken to assure a short charge haa not been med* to the chlorlnator. The sample ahould be checked for specific gravity. If the sample Indicates a normal batch, the next sample should be taken when the 801 bell rings as preset by the chlorine flow totallser. Thle sample la to assure e batch Is not over-chlorinated and sets up In the chlorlna tor, preventing Its transfer to the blow tank. H. In ease tha chlorine flow control valve cannot be made to work, a rotameter Is Installed In each of tha chlorlna fead lines to the batch and continuous chlorlnator*. This rotameter will provide a reference to let the opera tor know what the chlorlna flow la In case* of failure of the flow meter. I. A chlorine pressure Indicating controller haa bean Installed to regulate the chlorine pressure to the main header. Chlorine pressure is regulated by feeding liquid chlorine from a tank car and vaporising It Into tha haadar. PIC-500.07 will be set for a normal chlorine header pressure of 20-25 oslx. with a high alarm point at 35 oslx and a low alarm point at 15 pain. M0NS 093090 AXO SCM III - 2.040 Pag* 19 R*v. 0 Data: 4/20/65 J. Tha chlorln* vaporlcar haa aavaral safety faaturea and equipment Items built Into lta design. They ara: 1. A high level alarm shut-off in cats the level should exceed 50% In the vaporiser shell. This shut-off stops liquid chlorine feed to the vaporiser by closing a control valve. 2. Steam pressure to the chlorine vaporiser is regula ted to 10-15 pels. A pressure relief valve la Installed In tha system to relieve any pressure abova 15 pels. 3. Steam supply pressure to the chlorine vaporiser is regulated by the temperature of the liquid chlorine feeding tha vaporiser. Normally, the temperature Indicator set point Is above 40C. Liquid chlorine from a tank car Is normally 0C. at 35 pals. 4. The chlorine header pressure la regulated to 20-25 pals by a pressure Indicating controller vhlch regulates a control valve on the discharge aide of the chlorine vaporiser. 5. A rupture disc Is Installed on the chlorine vaporiser to relieve the pressure at 275 pals and a relief valve la Installed on the discharge of the rupture disc to relieve at 300 pels. 3.4 Shutdown Operation* of the charge tank, the batch chlorlnators, the continuous chlorlnator system, and the blow tanks can occur which cause temporary or prolonged shutdowns. The following detailed Information concerns Individual shutdowns of each of the ebove items. If tha entire system Is to be shut down, the various Items can be combined to achieve this objective. A. Charge Tank 1. Temporary Shutdown a. Close the manual valve In the Biphenyl feed llna to the charge tank. HONS 093091 ARO SOM III 2.040 Page 20 Rav. 0 Data: 4/20/65 b. Cloaa the valve at the bottoei of the charge ' tank an4 at the dlecharge of the chlorlnater charge pump. c. Leave etean heat on the tranafer llnaa to the charge tank. d. Leave eteaai heat on the coll to the charge tank. e. The agitator and charge tank pump will normal ly be (hut down unleae In uae. 2. Prolonged Shutdown a. Normally, tha tank will have been emptied prior to a prolonged ehutdown. b. Cloae the manual valve on the Biphenyl feed line Into tha charge tank. c. Drain the charge tank, If neceaaary, for re pair work. d. Close the valve at the bottom of the charge tank and at tha discharge of tha chlorlnator charge tank pump. a. Shut off the steam to the transfer Unas to and from the charge tank. f. The agitator and charge tank pump will be shut off. g. Shut off tha steam supply to tha discharge line from the charge tank pump. h. Leave the system In this condition until needed. 1. Note shutdown Information on data sheet. B. Batch Chlorlnator Operations can occur which will require a batch chlorinetor to ba cut back or temporarily shut down. Soma of these Items are failure of chlorine feed, a tank car ( emptying, or a cutback of the Chlorine Plant. Normally, MONS 093092 ARO SOM III - 2.040 Pag* 21 Rav. 0 Data: 4/20/65 If a partial raductlon of tha chlorina faad oceura, tha batch liquid chlorlnatora will ba abut off and tha contlnuoua chlorlnator ay*tan and tha Ho. 9 chlorlnator will contlnua to ba oparatad. 1. Temporary Shutdown a. Tha circulating pump will normally ba laft In oparatlon. b. Cloaa tha chlorina valva at tha dlatrlbutor of aach chlorlnator. c. Chock tha chlorina haader praaaura and rotanatar faad and chlorina faad to tha othar chlorlnator*. Tha praaaura ahould ba 20-25 pal*. d. Chock to aaa that liquid chlorina 1* balng fad to tha vaporlzar and that ataan la on tha vaporlaar. Steam praaaura ahould ba 10-15 pala. Dlacharga praaaura* on tha vaporlaar ahould ba 1-2 pala graatar than tha praaaura on tha chlorina haador (normally 20-25 oalal. a. Notify tha Chlorina Plant of tha problaa and aaa If thay hava ahut down or cut back. f. If tha ahutdown 1* to ba longar than two houra, It nay ba nacaaaary to put ataan haat on tha coll of tha chlorlnator to kaap tha tanparatura at 120C. minimal. Normally, tha circulating pump will ba In oparatlon. g. Shutdown* ahould ba minimized. If tha cauae of tha cut back can eaally ba remedied, atart the chlorlnator back lamadlataly. h. Notify your chief operator or departmant tuparvlalon lmaadlately in caaa of a problem. 1. Note ahutdown Information on data ahaat. M0NS 093093 ARO SON III - 2.040 Page 22 Rev. 0 Dace: 4/20/63 2. Prolonged Shutdown a. Normally, when a chlorlnaCor la to be left down for a period longer chan a few houra, Che chlorination will be completed and the batch pumped out prior to ehutdovn. If maintenance pereonnel are to work on the chlorlnator. It may be nacaeaary to vent the veeael and purge the chlorine linaa and the chlorlnator tank with COj* NOTE: In caae of a complete ehutdovn for maintenance work, the chlorine valvee on the main header to the chlorlnator will be tagged, the tranafar linaa Into the veeael, and the ateam valvea to the chlorlnator colle. The pump motor circuit breaker box awltch will be tagged out. b. Cloea chlorine valvea at dletrlbutor on tha chlorlnator. c. Empty chlorlnator by pumping out, than ahut off the circulating pump and drain tha chlorlnator. d. Check chlorine header preaaure aa In Item 1-c above. a. Cloaa the HC1 vent valve on the chlorlnator to tha RC1 header. f. Notify tha Chlorine Plant of tha problem If thla la to ba a prolonged ehutdovn and It cauaee an Increaae In the chlorine header preaaure. g. Leave tha chlorine flow controller In "auto" with tha aet point at 0. h. Leave the temperature recorder controller In "auto" with the eat point at 150C. MONS 093094 ARO SOM III - 2.040 ( Fag* 23 Rev. 0 Date: 4/20/65 i. Notify your chief operator or department aupervlalon the vaaeel la ahut down. J Nota ahutdovn Information on tha data aheat. C. Contlnuoua Chlorlnator Svatam 1. Taanoratv Shutdown a. Tha circulating pump* will normally ba left in oparatlon. b. Cloaa tha valve* to the chlorine dlatrlbutor on chlorlnator* No. 5, 6, 7, and 8. Adjuat the chlorine feed control valve* to 0 with the lnetrument etlll In "auto". c. Cloaa tha automatic Biphenyl faad valve to tha No. 5 chlorlnator ualng tha automatic controller; than ahut the manual valva In thla llna to aaaura faad atop* to tha No. 5 chlorlnator. Sat valve* to allow circulation back Into the feed tank. d. Proceed to check out tha ayatam to determine the reaeon for the cut back If you have not bean Informed. a. Check tha chlorine header praaaur* and chlorlna faad to the other chlorlnatore. The header praaaur* ahould ba 20-25 oala. f. Notify the Chlorlna Plant of tha problem and aaa If they have ahut down or cut back. g. If the ahutdovn la to b* longer than two hour*, it may be nacaaaary to put ataam on tha circulating line* or tha coil of the chlorinator to maintain 120C. minimum tamparatur*. h. Shutdown* ahould be mlnimlced. If the caua* of the cut back can caally b* remedied, atart the contlnuoua chlorination ayatam up laaadlataly. < *0NS 093095 ARO SOM III - 2.040 Pag* 24 Rev. 0 Date: 4/20/6S I. Notify your chief operator or department aupervlalon Immediately In caee of a problem. J. Note ahutdomn Information on data eheete. 2. Prolonged Shutdown a. Normally, when the contlnuoue chlorlnator yatam li to be shut down for a period longer than a fav youre, the eystam le handled In the name manner aa for a temporary ahutdomn except that ataam may be cut off of come of the aupply llnae. For a prolonged ahutdomn, thlc ayatam mould not be emptied except when the ahutdomn becomaa greater than 48 houra. In that caaa, the chlorlnatora might be flnlahed batchmlae and then emptied. Notify the Chlorine Plant if the ahutdomn mill be prolonged and will cauaa an increaae in the chlorine header preeaure. Normally, the chlorine vaporlrer muat be ahut domn nhen the contlnuoue chlorlnatora are ahut off. b. Shut off the automatic Biphenyl feed valve to the No. S chlorlnator uelng the automatic controller. c. Shut off the chlorine feed to chlorlnatora No. S, 6, 7, and 8, uelng the chlorine flom controllere In the control room. d. Cloae the manual valvaa at the chlorine dlatrlbutora on chlorlnatora No. S. 6, 7, and 8. a. Cloae the manual block valve at the automatic Biphenyl feed valve to acaure no laakaga occura. Direct Biphenyl feed back into the feed tank. MUNS 093096 AKO SOM III - 2.040 Pag* 25 Rav. 0 Data: 4/20/65 f. Th# Blphanyl feed tank pump can b* abut down If necessary. Cloaa tk* discharge valve In the line from the pump to No. 5 chlorlnator. Stop the pump. Close the suction valve to the piasp on th* bottom of the Biphenyl faad tank. g. Stop th* agitator In the Biphenyl feed tank If necessary; otherwise, leave th* agitator operating. h. Stop th* agitator In th* Biphenyl mix tank If necessary; otherwise, leave this agitator operating. I. Vhen the crude Aroclor catch tank level Is at 50%. stop th* transfer pump. Cloe* the valve In th* discharge line to th* continuous air blow tank. J, Stop th* continuous air blow tank transfer pump. Close th* discharge valve In th* line from this pump to th* blow tank or th* roof tank. k. Shut off th* air to th* continuous air blow tank If necessary. There are four valves in th* air header to th* continuous air blow tank. l. Check th* chlorine header pressure as In Item 1-c. above. m. Close th* HC1 vent valves on the chlorlnator* to th* RC1 header. n. Steam mist be placed on the coll or th* circulating lines of the chlorlnator* If th* material Is not pumped out. A minimum temperature of 120C. must be maintained. MONS 093097 ARO SCH III - 2.040 Page 26 Rav. 0 Data: 4/20/6S o. Notify your chlaf oparator or department - auparvlalon tha contlnuoua chlorlnator ayataa la ahut'down. p. Nota tha ahutdown information on tha data ahaat. D. Chlorlna Vanoriiar 1. Tamoorarv Shutdown a. Cloaa block valva on aach alda of liquid chlorlna control valva. b. Allow ataam to vaporlza liquid chlorlna in tha vaporlcar. c. Shut off block valva in ataam llna into tha vaporlcar or cloaa tha ataam control valva by adjuatlng tha aat point on tha vaporlcar taaparatura controller. d. Cloaa tha automatic chlorlna faad valva to tha chlorlna haadar by adjuatlng tha chlorlna praacura controllar PIC-500.07 to 0. Laava tha lnatruaant In "auto". Cloaa tha block valva In tha llna to tha chlorlna haadar. a. If thara la a particular problaa with tha vaporlcar, notify your chlaf oparator or dapartmant auparvlalon tha vaaaal la ehut down. f. Nota ahutdown Information on tha data ahaat. 2. Prolonged Shutdown a. In eaaa tha chlorlna vaporlaar la to bo ahut down for a period greater than three daya, tha ayatam ahould be completely empty of chlorlna. MQNS 093098 ARO SOM III - 2.040 Fag* 27 Rev. 0 Date: 4/20/65 b. Dleconnect the liquid chlorine car frod the chlorine fend line to th* vaporlaar. (1) Put on gaa mask for ua* In connecting and dlaconnactlng car. (2) Cloa* manual valve In 1" liquid chlorlna line to vaporlaar. (3) Cloa* angle valve on top of tha chlorlna tank car. (4) Break the union on th* pip* connection line. Slowly lat th* chlorlna preaaure bl**d off. When tha praaaur* la r*laaa*d, remove th* piping. c. Connect a CO2 cylinder to tha chlorine feed Una to th* vaporiser. Oa* praaaur* from th* CO. cylinder to puah th* liquid chlorine to the vaporiser. Normally, 80-90 pals la all that will be required. d. When the liquid chlorine ha* been pushed through tha tranafer line to th* tank ear to the vaporiser, cloa* th* block valve on each side of th* liquid chlorine control valve to th* vaporiser. a. Allow staam to vaporise th* liquid chlorine In the vaporiser. f. Shut off block valve In steam line to th* vaporiser. g. Connect CO. to tha vaporiser at th* pressure gauge on the line to the vessel. Purge tha chlorine vaporiser with C02- Do not exceed 40 pels. HONS 093099 AKO SCM XXI - 2.040 Pag* 28 R*v. 0 Data: 4/20/6S h. Cloa* the automatic chlorln* faad valv* to tha chlorln* haadar. Adjuat th* chlorln* . praaaur* controller PIC-500.07 to 0 with tha controller In "auto". Cloa* th* block valv* in th* line to th* haadar. I. Notify your chlaf operator or department upervialon th* chlorln* vaporlaar haa bean hut down. J. Not* ahutdovn Information on th* data ahaat. B. Blow Tanka and HC1 Drowning Facllltlaa 1. Temporary shutdown Thia temporary ahutdown applies to a alngla blow tank. It can apply to all blow tanka. a. Cloa* the valve at th* bottom of th* blow tank. b. Cloa* th* dlacharg* valve on th* blow tank tranafer pump. c. Shut off th* tranafer pump. d. Laava th* air blowar running. *. Hatar will remain on th* S&K Jet. f. Th* eyatam can b* left In thl* condition until n**d*d. Actually, th* blow tank* ar* atlll being air blown. 2. Prolonged Shutdown Thia procedure appllea to a alngla blow tank; however, It can apply to all blow tanka by merely extending th* work to tha other v*aa*la. HONS 093100 ARO SON III - 2*040 Page 29 Rev. 0 Data: 4/20/65 a. Normally, if tha vaaaal la to ba shut down fox any length of tine, tha material In tha . tank will ba emptied. b. Shut off tha blow tank pump. c. Drain tha blow tank. Cloaa tha valve at tha bottom of tha blow tank and at tha dlacharga of tha tranafar pump. d. Cloaa tha ataam aupply valva to tha coll on tha blow tank. a. Shut off tha ataam on tha tranafar llnaa to tha blow tank and from tha blow tank. f. Shut off tha air blowar or blowara. g. Shut off watar to tha S&K Jat. h. Whan air la ahut off tha air blowara If tha contlnuoua chlorlnator ayatam la to contlnua to ba oparatad, tha cruda Aroclor balng producad nuat ba re>dlrected from tha roof tank to an Individual blow tank (No. 1, 3, or 4). 1. Leave tha ayatam In thla condition until naadad. 1 Notify your chlaf oparator or daparcnant auparvlalon tha ayatam la ahut down. k. Nota ahutdown Information on tha dapartmant data ahaata- F. Contlnuoua Chlorlnator Air Blow Tank 1. Tamoorarv Shutdown a. In caaa tha contlnuoua air blow tank la to ba ahut down for a lack of air on a temporary baala, cruda Aroclor from tha Aroclor catch tank nuat bo directed from the roof tank to an Individual blow tank. MOWS 093101 ARO SOM III - 2.040 Fag* 30 Rev. 0 Date: 4/20/65 b. Cloie air valve* to diatrlbutor header on th* continuou* air blow tank. Crude Aroclor can . (till b* allowed to flow through the tank and it will not b* used as an air blow tank. e. Notify your chief operator or department aupervlalon this tank is temporarily shut down. d. Determine the nature of the problem. If poaalbla, start th* system back up. e. Not* th* downtime for this veaeel on th* department data aheat. 2. Prolonged Shutdown a. In case the continuous sir blow tank la to be shut down for a long period of time, this vassal may be bypassed by directing flow from the catch tank to blow tank No. 1, 3, or 4. b. Close tha air valvas to ths distributor on the continuous sir blow tank. c. Start th* circulating pump on tha continuous air blow tank. d. Close the discharge velve from th* continuous air blow tank pump to the roof tank. a. Close th* valve in tha line from th* crude Aroclor catch tank to the continuous air blow tank. f. Notify dapartaunt supervision th* vasael has basn shut down. g. If necessary, th* tank can ba drained through a bottom outlet. Normally, ths tank cannot be pumped empty due to the baffles in the tank. h. The system can be left in thla condition until needed. 1. Note shutdown information on department date sheet. MGNS 093102 C. Bmeraencv Shutdown ARO SOM III - 2.040 Pag* 31 Rev. 0 Date: 4/20/65 Normally, an emergency ahutdovn doee not occur concern ing tha charge tank or the blow tanka; however, emergenclea can occur which make it neceaaary to ahut down the batch chlorinatore and the contlnuoua chlorinatora aa faat aa poeelble. Hie following methoda can normally be uaed: 1. From the Field a. Cloae tha manual chlorine valve* to the diatributor* on the individual chlorinatore. b. Cloae the manual valve in the Biphenyl feed line to the contlnuoua chlorlnator ayatan. c. Shut off the chlorine vaporizer. Stop liquid chlorine feed. d. Stop the circulating pumpa if neceaaary. Normally, theae pumpa would be left operating. e. Shut the valvea in tha HC1 pipeline to the Muriatic Acid Department if neceaaary. f. Stop the flow of crude Aroclor from Che catch tank to the contlnuoua air blow tank to the roof tank if naceaaary. g. Dependent on the emergency altuatlon which ha* occurred, continue to ahut the ayatom down ayatematlcally by normal procedure* for both the batch and contlnuoua chlorlnator ayatema. Notify the Chlorine Plant if they have not already been Informed. 2. At the Panel a. Stop chlorine feed to the chlorlnator* aa follow*, dependent on operation: I mons 093103 ARO SOM III - 2.040 I Page 32 Rev. 0 Date: 4/20/6} (l) Cloae chlorine automatic valvaa by adjuatlng flow controllera to 0. - This reduces chlorine flow to 300 lbe/hour on each of theae chlorlnatore. Immediately go Into the field and shut off manual valvaa feadlng thaaa chlorlnatora. b. Stop Biphenyl feed to the continuous chlorine* tor system using the automatic Biphenyl feed control Instrument. Adjust sat point to 0. lamadlataly go Into the field and shut off tha block valve to the No. S chlorlnator. c. Continue shutdown of this unit at la necessary to handle the emergency which has occurred. Normally, the remainder of the shutdown will have to ba carried out from the field. Notify tha Chlorine Plant If they have not already bean Informed. 3.5 Control Loops. Interlocks, and Alarms A. Control Loops There are 14 major control loops In this ayatam. 1. Chlorlnator Temperature Controls - TRCA-508.01 Tha function of this loop Is to provide temperature control for the chlorination batch In tha chlorlna tor. This la accomplished by measurement of tha temperature In tha crude Aroclor circulating Una at tha discharge of tha external heat exchanger and controlling the position of tha dampers at tha cooler and automatically turning tha fan for the cooler on and off by temperature. Tha temperature controls for tha fans can be operated manually. Tha control Instruments can be operated manually or automatically. Tha temperature system has a low temperature alarm at 120C. and a high alarm at 190C. Each chlorlnator has the same control system. MOWS 093104 *. Manual Control ARO SON III - 2.040 Pag* 33 R*v. 0 Data: 4/20/45 - The temperature controller will be In "manual". Adjustment of the louvera on the air cooler can be controlled manually by adjusting the control valve with the TRCA Instrument set point. The fan can either be In "auto" or "manual". Adjust until the desired tempera ture Is acquired. The fan can be stopped or started as desired. b. Automatic Control The temperature controller Is in "auto" with the set point at 150C The cooler fan will be In "auto". The controller will autosMtleal- ly adjust the louvers on the cooler and the fan to maintain the temperature of the set point. 2. Chlorine Header Pressure Control - PIC-300.07 The function of this loop Is to maintain the chlorine header pressure within a narrow rang*. This is accomplished by measuring the chlorine heeder pres sure and throttling a control valve at the discharge of the chlorine vaporiser. This system will only control the pressure assuming you are uslns more chlorine than the Chlorine Plant Is producing. Normal operation of the system Is with the control ler In "auto" and the set point at 20-25 osln. A low pressure alarm will sound at IS nsia and a high alarm at 35 oaln. 3. Batch Chlorlnator Chlorine Flow Control - FRCS-551.01 The function of this loop is to control the chlorine flow to the batch chlorinators and regulate the chlorine chlorination rate. This is accomplished by measurement of the chlorine flow with an orifice and controlling this flow with a control valve in the chlorine feed line. This system can be operated manually, automatically, on chlorine feed control, or by a preset programmed chlorine feed control. Each batch chlorlnator has this same system. HONS 093105 ARO SOM III - 2.040 Page 34 Rev. 0 Date: 4/20/6S Manual Control The chlorine flow controller 1* positioned In "manual-set". The set point Is regulated to give the desired chlorine flow to the chlorinetor. b. Automatic Flow Control The chlorlnator chlorine flow controller le positioned In "auto-set". The chlorine feed dealred le set on the controller which will maintain this chlorine feed by adjusting the control valve as requlrsd. c. VI ml Control The chlorine flow controller has the set points In "auto-cascade". The chlorine Integrator set point Is adjusted for the de sired chlorine alarm level, dependent on the product being produced. The dial reada 0-225 and hae a multiplier of 100. The range repreaenta 0 - 22.500 lbe. of chlorine. When che desired quantity of chlorine hae entered the chlorlnator, an alarm bell will ring and an annunciator light will flash Indicating "Chlorlnator, 80% Chlorinated". The totallaer can be ueed with automatic flow control above If the controller Is not In "cascade". It muet be reaet by puahlng the ereen set button. When the controller Is In "cascade", the Taylor Flexlpulse Timer will, by predetermined program . (See Appendix I), change the chlorine flow rate to the chlorlnator. The chlorine flow program le set by turning the knob on each flow profile set point. This program, once aet up, should not be disturbed without consulting supervision. 4. Continuous Chlorlnator Chlorine Flow Control FRCS-558.01 The function of this loop Is to control the chlorine flow to the contlnuoue chlorlnator system chlorinetors and regulate the chlorination rate. This le accomplished by measurement of the chlorine flow with an orifice and controlling this flow with a control 093106 mons AKO SON III - 2.040 Paga 35 Rev. 0 Data: 4/20/65 valva In tha chlorine fend Una. Thla system can ba operated manually or automatically on .chlorine food control. Each of the chlorlnatora In tha contlnuoua eyataa haa tha eama controla. a. Manual Control The chlorine flow controller la poeltloned In "manual". The aet point la regulated to give the dealred chlorine flow to the chlorlnator. The output praaaure of the controller can be obaervad by looking at the top of the control lnatrument. b. Automatic Flow Control The chlorlnator chlorine flow controller la In "auto". The chlorine feed dealred la cat on the feed controller which will maintain thla chlorine fead by adjusting the control valve aa required. 5. Biphenyl Mix Tank Level Indication - LIA-520.01 Thla loop maaaurea the level of Biphenyl In tha mis tank. Thla la accompllehed by a bubblar differential prasaura level Indication lnatrument. A 0-1001 dial lndlcatea tha tank level In the field and on the control panel. A low level alarm la aet at 2SI and a high level alarm at 751. 6. Biphenyl Feed Tank Level Indication - F1A-520.01 Thla loop maaaurea the level of Biphenyl In the feed tank for the contlnuoua chlorlnator ayatem. Thla la accomplished by uae of a bubbler differential preasura level Indication instrument. A 0-1001 dial Indicates tha tank level In the field and on the control panel. A low level alarm will sound at 231 and a high level alarm at 801. HONS 093107 ARO SOK III - 2.040 Page 36 Rev. 0 Date: 4/20/6S 7. Crude Aroclor Catch Tank Level Control - LICA-S43.01 Thla loop measures the level of crude Aroclor In the catch tank for the contlnuoua Aroclor chlorlnator ayatem and maintains a constant level of 301 la the tank. This la accomplished by measurement of the level In the tank by a bubbler differential pressure level Indication Instrument and throttling a control valve In the discharge of the crude Aroclor catch tank pump line. A high alarm will sound If the tank reaches 60% level. 8. Continuous Blow Tank level Control - LICA-329.01 Function of this loop la to maintain a constant level In the continuous air blow tank. This la accomplished by measuring the level with a bubbler differential pressure level Indication Instrument and throttling a control valve in the discharge line from the contlnuoua blow tank pump to the roof tank or a blow tank. The level in the system is normally 501. A low level alarm is set at 401 and a high level alarm at 601. 9. HC1 Pressure Alarm - FRA-702.02 The purpose of this loop Is to measure the HC1 header pressure to the HC1 absorber, record this pressure and give an alarm In case of excessive high pressure. This Is accomplished by measure ment of the pressure with a pressure transmitter and sounding an alarm at a high pressure of 8 pels. 10. Continuous Chlorlnator Biphenyl Feed Control The function of this loop Is to control the Biphenyl feed to the continuous chlorlnator system. This Is accomplished by swasuremant of the Biphenyl flow with an orifice and throttling a control valve In the Biphenyl line. This system can be operated by a controller on manual or automatic operation. A flow range from 0-5 GFM of Biphenyl la possible with this controller. A low flow alarm Is set at 1 CFK and a high flow alarm at 4 OFM. The recorder read-out hat a multiplier of 2. MONS 093108 ARO SOM III - 2.040 Fag* 37 Rav. 0 Data: 4/20/65 11. Mo. 1. 3. and 4 Blow lank Laval Indication Theta loop* maaaura tha laval of cruda Aroelox In tha No. 1, 3, and 4 blow tanka. Thla It accompllahad by uaa of a bubblar differential praaaura laval Indication lnatrumant. A 0-1001 dial Indicate* tha tank laval In tha field. 12. Biphenyl Chara* Tank Laval Indication Thla loop aaaauraa the laval of Biphenyl In the charge tank for the chlorlnatora. Thla la accompliahed by uaa of a bubblar differential praaaura level indication lnatrumant. A 0-1001 dial indicate* the tank level in tha field. 13. Mo. 1 and 2 Aroclor Roof Tank Laval Indication Thla loop mature* tha level of cruda Aroclor in the No. 1 and 2 Aroclor roof tanka. Thla la ac conpllahad by uaa of a bubblar differential praaaura level indication lnatrunant. A 0-1001 dial indicate* tha tank level In the field. 14. Chlorine Vapotiter Control Loop* Thar* are aavaral control loop* on the chlorine vaporlxer ayatam to lnaur* aafa operation. Tha control loop* conaiat of a ateam praaaura regula tion valve, high liquid level control, and ataaa aupply temperature control. Thaae control* are acconpllahad by tha following: a. Steam Control A temperature indicating controller aenaea tha liquid chlorine feed to tha vaporlaar and throttle* a a team valve In tha main atam feed line to the vaporizer. b. Liquid Laval Control The liquid level control In the vaporlaar la maaaurad by a ball float level lnatrumant which la actuated on high laval and cloaaa a control valve In the liquid chlorine feed line to the vaporleer. Thla high laval alao Bound* an alarm in the control room. KQNS 093109 ARO SOM III - 2.040 Pag* 38 Raw. 0 Data: 4/20/65 c. Steam Supply Tempwratur* Alarm Tha temperature of tha ataam supply to tha vaporlcar la measured by a Fanwall taapara tur* alamant and aounda an alarm whan tha ataam tamparature drop* balow 100c. Thla fallur* lndlcataa tha vaporlaar may fill with liquid chlorlna. Normally, thla lndlcataa ataam failure. d. Chlorlna Pressure Control A praaaure control loop PIC-500.07 la Installed for controlling the discharge pressure from the vaporlaar. It la described under 3.5-A-2 above. B. Interlocks Thar* are no interlocks In this system. C. Alarms The following alarm* exist through the system: 1. Biphenyl Mix Tank A low level alarm sounds at 251 full and a high level alarm sounds at 751 full. Theaa alarms are on the chlorlnator annunciator panel. Tha high alarm horn Indicates there la approximately 5 minutes before the tank will overflow. 2. Biphenyl Feed Tank A low level alarm will sound whan tha tank Is m full and a high level alarm when the tank 1* 801 full. The low level alarm indicates there la ap proximately 30 minute* time before the tank will run empty. 3. Batch Chlorlnator* a. Chlorlna Flow Alarm If tha chlorine totallser la being used, an alarm bell will ring when the batch Is 801 MUMS 093110 ARO SOM III - 2.040 Fag* 39 R*v. 0 Data: 4/20/63 chlorinated. The chlorine cat point for the totalizer depend* on the crude Aroclor . being produced. b. Temperature Alena Abnormal temperature alarm* are eat for a low chlorination temperature of 120C. and a high temperature of 190C. 4. Continuous Chlorlnatora Abnormal temperature alarms are set for a low chlorination temperature of 120C. and a high temperature of 190C. 5. Chlorine Header Pressure Alarm The chlorine header pressure will sound an alarm at a low preaaura of 15 pala end a high presaure of 33 osl. This will actuate an annunciator on the chlorlnator panel Indicating "hlgh/low" chlorine header pressure. 6. Instrument Air Low Pressure Alarm An annunciator will sound In case the Instrument air pressure drops to 70 psl. 7. Continuous Chlorlnator Biphenyl Feed Alarm Biphenyl feed alarms are provided for a low flow of 1.0 GPM and a high flow of 4.0 GB1. 8. Chlorine Vaporizer High Level A high level above 501 will sound an alarm for the chlorine vaporizer. IV. CtBMMTS OH PROCESS 1. Problems with the chlorine vaporizer can occur which would allow liquid ehlorlna to be fed to the chlorlnator*. In case this should happen, slugs of liquid chlorine would be fed Into the chlorlnator possibly causing excessive reaction or exces sive loss and venting of chlorine to the atmosphere. Chlorine MQNS 093111 ARO sat III - 2.040 Pag* 40 Rav. 0 Data: 4/20/65 In the HCX offgas pipe Unas could cause excresia reactions which would generate exceasive heat. This raactlon can causa a pip* lln* to become red hot and melt the pip* line In two. Thla would rasult In chlorine gas escaping to tha atmospher*. Every effort possible should be made to operate the vaporiser with the control eystem provided. 2. Entrainment of Biphenyl or crude Aroclor into the HC1 lines can occur When excessive chlorine rates occur. This same situation can occur In case the Chlorine Plant la blowing too much air. This can be checked by observing the offgas from the chlorlnators in the sight glasses on top of tha Brink Demister on each chlorlnator. Normal operation of the chlorlnator should ba to minimise thla carryover. Abnormally high or low chlorine header preaaurea can cauaa operating problems. High chlorine header pressure causes problems within the Chlorine Plant to the department operating personnel. Chlorine fumes are forced back into tha Chlorine Department, and at tlmas aulfurlc acid can b* blown from tha Nash compressor system. Since this presents a safety hasard to the department person nel, every effort should be made to eliminate high pressure problems. Low chlorine pressure can causa operating problmns within tha Aroclor Department. In cases of extreme low pressure, tho crude Aroclor could back up In the chlorine lln* and begin flow-back Into tha chlorine header. In small pipe lines where there Is no heat removal from tha reaction, problems can occur as stated In Item 1 above. 3. Free chlorine In the offgas from an Individual chlorlnator or from the vent at the HC1 absorber sewer box indicates problem operation la the Aroclor Department. It can be caused by In adequate reaction of the Biphenyl and might Indicate formation of unstable Aroclor. If this situation occurs. It should ba corrected Immediately. Catch samples from the Individual chlorlnator offgas and have them analysed for free chlorine by the lab. Check grab samples from each chlorlnator of the crude Aroclor balng produced and observe It for unusual appearances. Inadequate amounts of catalyst present as Ferric Chloride or Iron turnings can cause free chlorine In the offgas 11ns. In case this situation occurs and cannot be resolved, remove tho chlorlnator from operation. Contact department supervision lamedlately. HONS 093112 ARO SOM III - 2.040 Pag* 41 Rev. 0 Data: 4/20/65 4. An agitator ha* baan lnatallad in th* Blphanyl load tank to koap Farriq Chlorlda In auapanalon. It la axtraaaly Important that th* natarlal b* kapt In auapanalon to allow production of atabla Aroclora aa wall a* eliminate production problaaa Involving plugged line* with Farrlc Chloride. 5. In tha FFO outline for the batch chlorlnatora, It la auggaatad that th* batch chlorlnatora will be charged and pumped out whll* vantlng to th* HC1 haadar. Thla la to try and a1Ininat* ftuaea In th* chlorlnator ayatan which preaantly cauaa axcaaalva corroalon around tha upper level of tha chlorlnatora. Thla operation will ba triad whan th* new ayatan la lnatallad and It la no longer nacaaaary to blow out tha Blphanyl charge line to th* individual chlorlnator*. Blowing of thla line will b* eliminated dua to tha fact Santowax la not being charged to th* batch chlorlnatora. 6. Th* contlnuoua chlorlnator catch tank haa a high level alarm at 601. Thla alarm Indicate* there la approximately 30 minute* before material will begin to back up In th* contlnuoua chlorlnator ayatam. Hold-up of material In th* chlorlnatora can cauaa production of off-grad* apeclflcatlon material. In cae* a high level alarm occur*, th* problem ahould be aolved immediately or the ayatem shut down rather than produce offgrad* material. 7. A low praaaura inetrument air alarm aounda at 70 Dale. Thla alarm Indicate* the large Instrument air compressor did not com back on at Its normal 85 osla. In this caa* th* small InatruMnt air compraaaor will start up at 68 nalx. Tha large compraasor ahould b* checked Immediately to detarmlna tha problem since the (mall compressor will not nonally handle th* entire air requirements for this dapartMnt. M0NS 093113 ARO SOM III - 2.040 I Fag* 42 Rev. 0 Data: 4/20/65 APPENDIX I PROPOSED CHLORINE FLOW PROFILE FOR PROGRAMMED BATCH CHLORINATION I. CHLORINE INPUT FLOW RECORDER CONTROLLER Flrat Hour 400 LBS./HOUR Second Hour 600 LBS./HOPE Third Hour 800 IBS./HOUR Fourth Hour To End Of Batch 1.000 LBS./HOUR End of Batch (Control Valve Closed) 300 LBS./HOUR ( II. TEMPERATURE CONTROL RECORDER CONTROLLER Entire Batch 150*C. III. CHLORINE INTEGRATOR SETTINGS FOR 801 OF CALCULATED INPUT BASED ON 100X CHLORINE AND 9OX CHLORINE Aroclor Product 1001 Chlorine 90S Chlorine 1121 1142 1148 1154 1160 1162 1280 2660 4450 5630 7220 7580 1420 3000 4940 6250 8020 8420 IV. CHLORINE INTEGRATOR SETTINGS FOR SOX OF CALCULATED INPUT BASED OH USING 1142 TO CHARGE CHLORINATOR Aroclor Product 1001 Chlorine 901 Chlorine 1148 1154 1160 1162 1790 2970 4560 4920 1990 3300 5070 5470 ( MONS 093114 APPENDIX II ARO SOM III - 2.040 Pag* 43 Rev. 0 Data: 4/20/6S CONTINUOUS CHLORINATOR SPECIFIC GRAVITY LEVELS FOR 1142 PRODUCTION I. POUR STACK PRODUCTION STAGE 1 2 3 4 CHLORINATOR 5 6 7 8 SPECIFIC CRAVITY 1.078 - 1.104 1.170 - 1.196 1.254 1.280 1.336 - 1.362 II. THREE STAGE PRODUCTION STAGE 1 2 3 CHLORINATOR* 5 6 8 SPECIFIC GRAVITY 1.108 - 1.124 1.224 1.240 1.345 - 1.355 NOTE: THIS INDICATES MO. 7 CHLORINATOR OUT OP SYSTEM. ANY ONE (V THE POUR CAN BE BYPASSED. MONS 093115 APPENDIX III ARO SOM III 2.040 Page 44 Rv. 0 Data: 4/20/65 POUR CHLORINATOR BIPHENYL-CHLORINE FEED RATE CHART: BIPHENYL FEED PPM 2.1 2.4 2.7 3.0 3.3 3.6 3.9 4.2 4.5 4.8 5.1 CHLORINE RATE AT EACH CHLORINATOR 100X CHLORINE 9 OX CHLORINE Total Each Total Each Chlorlnatorai Chlor. Chlor. Chlor. Lbs./Hr. Lbf,/Hr, Lba./Hr. Lba./Hr 1,400 1,600 350 1,560 400 1,760 390 440 1,800 450 2,000 500 2,000 500 2,200 550 2,200 550 2,440 610 2,400 600 2,680 670 2,600 650 2,880 720 2,800 700 3,120 780 3,000 750 3,320 830 3,200 800 3,560 890 3,400 850 3,760 940 093llb APPENDIX IV ARO SOM III - 2.040 Pag* 45 Rev. 0 Date: 4/20/65 OPERATION OP AUTOMATIC CONTROLLERS 1. Automatic Control Thla procedure atarta with the controller aet at manual and glvea eet-vlae changeI to eutomatic and back to manual. Thla aaaumaa a flow recorder controller (PRC) ia uaad. Example: Chlorine Plow Control Operation Manual to Automatic 1. PRC on manual. Set point moved to give daelred flow aa Indicated on recording aheet. Flow Indicated by recording pen. .2 Tranafer PRC to seal. Place set pointer (Red) opposite flow recording pen (Red). 3. Tranafer PRC from seal to automatic. Adjust PRC aet pointer until flow levela out If any fluctuations occur. Leave Instrument In thla position for automatic control as the aet point la adjusted. Return system to manual. 4. Note PRC output air signal. Transfer from automatic to seal. Adjust PRC aat pointer (Red) to the same output air. 5. Tranafer from seal to manual. Adjust aet point If fluctua tions occur. M0NS 093ll7 APPENDIX IV (CONTINUEDt ARO SOM III - 2.040 Page 46 Rev. 0 Data: 4/20/65 2. Caacada Control - For a controller to operate In caacada. It muat flrat be In autonatic. The manual eat poeltlon la overriding and will not lat caacada elgnala control. Uea the same procedure ae above to tranefer from manual to automatic. Operation "Automatic-Sat" to "Automatlc-Caacade" Switching PRC Manual Seal [Automatic I Set C<ced| 1. PRC on automatic. Sat point (Red) moved for deelred flow. XX 2. Adjuat external aat point (Oranaal to line up with the (Radi eat point. XX 3. Move the controller from "aet" poeltlon to "Caacada". Adjuat the PRC aet pointer until flow levele out If fluctuatlona occur. XX Leave lnetrument In thle poeltlon for "automatlc- caecada" control from the external act point. | Return eyatem to "Automatic-Set". l 4. Adjuat the (Red) eat point to line up with the (Orange) aet point. | X 5. Tranafar from "Caacada" to eat. Adjuat (Rad) aet pointer If fluctuatlona occur. I XX MONS 093118 APPENDIX V ARO SOM III - 2.040 Page 47 Rav. 0 Date: 4/20/65 METHOD OF RUNNING SPECIFIC GRAVITIES 1. Catch representative sample of material In metal cylinder provided for thla purpoae. On the chlorlnatora, the ample point la at the discharge of the circulating pump. Excess material la returned to the auction of the pump through a apodal pipeline. 2. Taka sample to tha control room. 3. Allow water to run down outside of tha cylinder while stir ring sample vigorously until tha sample la 10*C. above tha temperature at which tha sample la run. Sae Table I, Page 2. 4. Cut off tha water when tha sample Is 10*C. above tha desired temperature. Xaap stirring until tha sample Is 1*C. above the temperature which tha sample Is to be run. Stop stirring. Allow the hydromater which has bean thoroughly cleaned to sink Into the sample until It reachee equilibrium. 5. Observe reading on tha hydrometer. Record hydrometer reading on the operating data sheet, along with tha time the sample was taken. 6. In case tha temperature waa off 1* or 2* whan the reading wae taken, a correction can be applied. It la 0.001 specific gravity units per *C. If tha sample was 2*C. hlah. add 0,002 specific gravity units to tha reading. If tha aampla was 2*C. lSH> subtract 0.002 specific gravity units from tha reading. 7. Carefully clean the hydrometer and thermometer. Place them In tha rack provided for this purpose. Dump sample In tha return line to tha chlorlnator pump. \ 9*il 9 MONi 0931i0 OVERALL PUN AND OUTLINE ARO SOM IV - 1.000 Page 1 of 6 Rev. 0 Date: 3/21/65 AROCLOR TRAINING SCHEDULE Training will be organized by shift groups from the existing Aroclor operating personnel. The training sessions will cover areas of interest for the combined shift and also smaller functioning groups covering the areas of particular interest for one or two operators. Classroom sessions consisting of lecture and discussion, field trips, personal study, problem solving or utilizing classroom problems and field problems will be involved in all training sessions. Discussion periods and demonstrations led by manu facturers' representatives and trained technicians will also be utilized in the case of new and unfamiliar types of equipment. Charts, flow diagrams, drawings, slides, models and other vlsusl aids will be utilized wherever applicable. Each participant will be provided with an outline of the material covered. Copies of applicable visual aids and material for taking notes in a binder or binders will also be available to aid in organization and retention of the material by the operating personnel. Instructors will include, but not be limited. to the following personnel: W. F. Taffee V. R. Haupt R. S. Yates J. W. Molloy N. K. Madison M. J. Williams R. N. Harris Areas to be covered during these training sessions will include the following general topics: a. Chemical process. b. Process control and general instrumentation. c. Instrument panel and hardware trouble-shooting and maintenance. d. Physical processing item by item. e. Operating and maintenance of auxiliary equipment. f. Electrical supply, substation and motor control center. MUNS 093121 Ovarall Plan and Outline ABO SOM IV - 1.000 Page 2 of 6 Rev. 0 Data: 3/21/65 Department personnel will be trained on a scheduled besia normally for an eight hour period of time. The training will follow the pattern putllned below: Time Descrlption 8:00 - 9:00 AM Review of previous day's material. 9:00 - 10:00 New material, classroom presentation. 10:00 - 10:15 Break 10:15 - 11:30 New material, classroom discussion. 11:30 - 12:00 Noon Lunch 12:00 - 2:00 FM Field work or demonstration with class participation related to new material covered in morning session. 2:00 - 4:00 Group discussion, question and answer period in small groups. 4:00 - 4:30 Group leader summary of day's activities and general Introduction to topic for next dey. The techniques and time distributions above will be varied to fit the subject matter In groups, but In no case will a solid eight hours of classroom lecture be employed. The following is a general outline of the training for all personnel involved In the start-up of Aroclor-Murlatlc Acid operations. A detailed daily training program will be Issued imnedlataly. Personnel to be trained: Chief Operators Operators Foreman Supervisor Shift Supervisors Overall Plan and Outline ARO SOM IV - 1.000 Page 3 of 6 Rev. 0 Data: 3/21/65 Trailing Instructors: Plant- Division Engineering & Research Start-up Superintendent Department Supervisor Department Foreman Shift Supervisor Project Engineer Instrument Technician Research Group Leader Each training session will be repeated four times to cover four separate shifts of operating personnel consisting of 3-4 men per shift. This is necessary to allow continued operation of the department during the training program. Program Outline by Topics: Week Beginning: March 29, 1965 - (Train 4 shift crews - 8 hours) Indoctrination - Training Schedule Process Flow - Equipment for: Thermlnol Heater Weigh Tank No. 9 Chlorinator No. 2 Blow Tank No. 4 Still & Receiver Safety - Operating Procedures - Thermlnol Heater Weigh Tank No. 9 Chlorinator No. 2 Blow Tank No, 4 Still & Receiver Plant Tours - Solid Aroclor Facilities Motor Control Center Control Panel Air Compressor April 5. 1965 - (Train 3 shift crews - 16 hours) Review Process Flow from Week of March 29, 1965 MONS 093123 Ovrll Plan and Outline ARO SOM IV - 1.000 Pag* A of 6 Rev. 0 Date: 3/21/65 April 5. 1965 (Continued) Operating Procedures - Thermlnol Heater Weigh Tank No. 9 Chlorlnator No. 2 Blow Tank No. A Still & Receiver Control Room Panel Review changing from temporary control rooms to new control room. April 12. 1965 - (Train A shift crews - 16 hours) Complete April 5th Training Schedule - (Train A shift crews - 8 hours) Review April 5th Trelning - Control Room Panel - Review changing from temporary control rooms to new control room. Tower Water System Alterations - Review Alterations to HC1 Drowning Facilities - April 19. 1965 - (Train A shift crews - 8 hours) Review Operating Procedures for: Thermlnol Heater Weigh Tank No. 9 Chlorlnator No. 2 Blow Tank No. A Still & Receiver Operating Procedures for Instrumentation Changes on: Existing Chlorlnators Chlorine Flow Control Temperature Control Programmed Chlorination Step April 23, 1965 - (Train A shift crews - 8 hours) Review Operating Procedures for: Thermlnol Heater Weigh Tank No. 9 Chlorlnator No. 2 Blow Tank MONS 093124 Overall Plan and Outline ARO SOM IV - 1.000 Page 5 of 6 Rev. 0 Data: 3/21/65 April 23. 1965 (Continued) Review Opereting Procedures for: - No. 4 Still & Receiver ' Instrumentation Changes on Existing Chlorlnators April 28. 1965 - (Train 4 shift craws - 8 hours) Equipment Check-Out and Testing - Process Simulation - Review Operating Procedures for: Solid Aroclor Equipment Instrumentation Changes on Existing Chlorlnators Emergency Training - Process Simulation and Equipment Check-Out in field - Start-up Thermlnol Heater - Begin 'start-up of instrumentation for chlorlnators No. 1 through No. 8 - M*y S. 1965 Charge Solid Aroclor Facilities and carry first batch through stepwise. May 24. 1965 - (Train 4 shift crews - 8 hours) Continue start-up of new instrumentation facilities for Chlorlnatore No. 1 through No. 8. June 7. 1965 - (Train 4 shift crews - 8 hours) Review instrumentation alterations to chlorlnators No. 1 through No. 8. Start programmed batch chlorlnator train ing. Chlorine flow control and totalizing temperature control. Process flow. Equipment, and Operating Procedures for Continuous Chlorlnator feed and continuous blow tank systems. Review alterations to chlorlnators No. 1, 2, & 3. MONS 093125 Overall Plan and Outline ARO SOM IV - 1.000 Page 6 of 6 Rev. 0 Data: 3/21/65 Weak Beginning: June 14. 1965 - (Train 4 Shift CrewB - 4 houra) Review batch chlorlnator training for prograaaned batch control. Review alteratlona to No. 3 Aroclor Still. June 28. 1963 - (Train 2 Shift Crews - 16 houra) Process Flow - Equipment for: Muriatic Acid Facilities Operating Procedures - Control Panel Instruments Safety - Field Tours - July 5. 1965 - (Train 2 Shift Crews - 16 hours) Identical to training weak of June 28, 1965. July 12. 1965 Start Muriatic Acid Process Simulation or Field Check-out Charge system with chemicals July 15. 1965. August 23, 1965 -(Train 4 Shift Crews - 4 hours) Process Flow, Equipment, and Operating Instructions for: HC1 Clean-up Facilities Safety - Plant Field Toura - Instrumentation Controls - August 30. 1965 Equipment field check-out by production. Charge system with chemicals September 1. 1965. 093^b Ak0 SOM W - 2.000 Pag# 1 of 2 Rav. 0 Datai 4/20/65 SAMPLE LESSON OUTLINE OF TYPICAL TRAINING PROGRAM TOE WEEK OF APRIL 5. 1065 FIBfll AMD 8EC0HD DAT I. Proeaaa Plow Ravlaw A. Tharalnol Eaaear B. Walgh Tank C. No. 9 Chlorlnator D. No. 2 Blow Tank E. No, 4 Still, Still Haatar, and No. 4 Still Eaealvat P. Tharalnol Cooling Syataa Auxlllarlat for No. 9 Chlorlnator and No. 4 Still II. Datallad Poorating In*traction* A. Tharalnol Haatar 8vatan 1. Ganaral Flow 2. Haatar Start-Up 3. Inatruaantatlon Datalli and Control* 4. Safaty Paaturaa for.Haatar Syataa B. Haith Tank. No. 9 Chlorlnator. and Mo. 2 Blow Tank 1. Ganaral Plow and Start-Up 2. Noraal Operation* In Autoaatie Control 3. Noraal Oparatlona In Prograaaad Plow Control for Chlorlnator Syataa 4. Shutdown 3. Inatruaantatlon Datalla and Control* * 6, Spaclal Coaaanta on Oparatlon Datalla and Changa* froa Praaant Syataa HONS 093127 Sample Lesson ARO SOM IV - 2.000 Pag* 2 of 2 Rev. 0 DataI 4/20/63 C. Mo. 4 Still and gaealvar System 1. Ganacal Plow and Start-Up 2. Normal Oparatlona 3. Shutdown 4. Instrumentation Datalla and Controls 3. Consents on Spaclal Changes from Present System III. Plant Tour* During the Day A. Detailed tharmlnol Master Review for Start-Up and Shutdown 1, Detailed Weigh tank. Mo. 9 Chlorlnator. and Ho. 2 Blow Tank System Review C. No. 4 Still System Review D. Control Room Instrument Review IV. Group Discussion with Question and Answer Period MUNS 09312B aroclor start-up TRAINING PROGRAM - WEEK OF MARCH 29. 1965 Typical 1 Day Training Program Four Shift Crews to be Trained Time Topic 7:00 - 7:30 a.m. General Information a. Training Schedule b. Reason for Plant c. Capacity Expected 7:30 - 9:00 Procesa Flow a. Flow Sheets in Detail b. General Instrumenta tion c. Safety d. Motor Control Center e* Air Compressor f. Control Panel 9:00 - 9:15 Break 9:15 - 9:30 Introduction 9:30 - 11:00 Plant Tour Flow & New Motor Control Center Control Room 11:00 - 11:30 Lunch 11:30 - 12:00 Reactions 12:00 - M:15 p.m. Operating Procedures Thermlnol Heater Safety Features 1:15 - 1:30 Break ARO SOM IV - 3.000 Pag* 1 of 2 Rev. 0 Date: 3/27/65 Instructor Taffee Molloy or Haupt McClain Williams & Haupt Haupt or Molloy Molloy HONS 093129 Heek of March 29. 1965 Time 1:30 - 2:30 2:30 - 3:30 Topic Operating Procedures Heigh Tank No. 9 Chlorinator No. 2 Blow Tank Plant Tour Thermlnol Heater ARO SOM XV - 3.000 Page 2 of 2 Rev. 0 Date: 3/27/65 Instructor Molloy Molloy & Hllllama MONS 093130 AROCLOR START-UP TRAINING PROGRAM ' WEEK OF APRIL 5. 1965 Typical 2 Day Training Program Three Shift Craws to be Trained FIRST DAY; Time Toole 7:00 - 8:00 a.m. Procasa Flow Review 8:00 - 9:00 Operating Procedures: . Thermlnol Heater Safety Features 9:00 - 9:15 Bxeak 9:15 - 11:00 Operating Procedures: Weigh Tank Ho. 9 Chlorlnator No. 2 Blow Tank 11:00 - 11:30 Lunch 11:30 - 12:30 Operating Procedures: No. 4 Still & Receiver 12:30 - 1:30 p.m. Plant Tour For Items covered ! above 1:30 - 1:45 Break 1:45 - 2;45 Plant Tour Detailed Instructions 2:45 - 3:30 Group Discussion & Questions ARO SCM IV - 3.000 Page 1 of 2 Rav. 0 Date: 3/25/65 Instructor Williams Haupt Holloy Molloy Williams & Haupt Williams & Haupt Molloy MQNS 093131 Weak of April 5 1965 SECOND DAY: Tima Topic 7:00 - 8:00 a.m. Raviaw of Previous day1a training 8:00 - 9;00 Oparating Instructions: Weigh Tank No. 9 Chlorlnator & Auxiliaries No. 2 Blow Tank Safety Features 9:00 - 9:15 Break 9:15 - liioo Continue Instructions It1000- 11:30 Lunch 11:30 - 12:30 p.m. Plant Tour Emphasis on Operating Instructions for morning session 12:30 - 1:30 Operating Instructions: No. 4 Still, Reciver, & Auxiliaries Safety Features 1:30 - 1:45 Break 1:45 - 3:00 Plant Tour Emphasis on Operating Instructions for No. 4 Still & Receiver *: 00 - 4:00 Classroom Review & Questions - Changes to New Control Room AKO SOM IV - 3.000 Page 2 of 2 Rav. 0 Data: 3/25/65 Instructor Molloy Haupt Haupt Molloy & Williams Molloy Molloy & Williams Molloy t HUNS 093132 ABOCLOR STMT-OP TRAINING PROGRAM WEEK OF APRIL 12. 1965 COMPLETE TRAINING OF FOURTH SHIFT CREW OH OUTLINED PROGRAM FOR WEEK OF 4/5/65 Typical 1 Day Training Program Four Shift Craw* to ba Trained MO 80M IV - 3.000 Pag* 1 at 1 Rav. 1 Data: 4/13/65 Tima 7:00 - 8:00 a.m. 8:00 - 9:00 9:00 - 9:15 9:13 - 11:00 11:00 11:30 11:30 - 1:00 p.m. 1:00 - 1:45 1:45 2:00 2:00 - 2:30 2:30 - 4:00 Tonic Inatruetor Ravlaw Pravlou* Waek'a Training Chlorlnator Systam Madlaon - Haupc Haw Control Inatrumanta Braak Oparatlng Inatructlon*: No. 4 Still Syatam Raupt Lunch Plant Tour Chlorlnator 6 Still Syatama Molloy Ravlaw Watar 8yatam Chang** 6 NCI Drowning Facllitlaa No Hoy Braak Ravlaw Changing to Haw Control Room Molloy Plant Tour Ravlav Oparatlng Inatructlon* Chlorlnator & Still Syatama Molloy - Wllllama HONS 093133  AROCLOR START-UP TRAINING PROGRAM WEEK OF APRIL 19. 1965 FIRST FOUR PAYS Typical I Day Training Program Four Shift Crawa to ba Trained Tima Toole 7:00 9:45 a.m. Oanaral Raviaw Operator Individual Training on: Weigh Tank No. 9 Chlorlnator No. 2 Blow Tank No. 4 Still & Receiver 9:45 - 10:00 Break 10:00 11:00 Plant Tour Operatori Inetrueted on Datalla of Start-up and Operation Group Dlacuaalon 11:00 11:30 Lunch 11:30 - 1:30 p.m. Inetrumantation & Equip ment Change! on Existing Chlorlnatora 1:30 - 1:45 Break 1:45 - 2:45 Plant Tour Thermlnol Heater Operating Instruction* 2:45 3:30 Plant Tour Review Instruments In Field AR0 SOM IV - 3.000 Page 1 of 1 Rev. 1 Date: 4/16/45 Instructor Haupt Madison 6 Williams Molloy Williams & Madison Molloy & Williams MOWS 093134 AROCLOR START-UP TRAINING PROGRAM WEEK OF APRIL 26 1963 FOUR-DAY TRAINING PROGRAM Typical 1 Day Training Program Four Shift Crewe to ba Trained ARO SON IV - 3.000 Page 1 of 1 Rev. 2 Date: 4/19/63 Slaa. 7:00 - 8:00 a.m. Toole Equipment Check-Out Re view & Process Simulation Instructor Molloy 8:00 - 9:00 Plant Tour Detailed Individual Operator Training Operator Review of Start-Up and Normal Operations - Usa Water In Vessels - Solid Aroclor Equipment Haupt 4 Williams 9:00 - 9:15 Break 9:13 - 11:00 Continue Plant Tour and Water Processing In Each Vessel as for 8:00 - 9:00 a.m. 11:00 11:30 Lunch 11:30 - 4:00 p.n. Start-Up Thermlnol Heater & Check-Out Safety Features Madison, Williams Haupt, and Molloy Start-Up Circulating Thamlnol Systems for No. 9 Chlorlnator and No. 4 Still Condenaar Syetarns Start Equipment Check-Out: Tharmlnol Heater System Weigh Tank No. 9 Chlorlnator No. 2 Blew Tank No. 4 Still and Recelvar MONS 093135 AR0CL0R START-UP TRAINING PROGRAM Week of. April 28. i%5 FOUR DAY TRAINING PROGRAM Typical 1 Day Training Program ARO SOM IV - 3.000 Pag* 1 of 1 Rev. 0 Dat*: 3/23/65 Time 7:00 8:00 a.m. 8:00 - 9:00 9:00 - 9:15 9:15 - 11:00 11:00 - 11:30 11:30 - 12:30 p.m. 12:30 - A:00 Topic Instructor General Review Operating Instruction! Williams Equipment Check-Out Review & Process Simulation Molloy Break Plant Tour Detailed Individual Operator Training Operator Review of Start-Up & Normal Operations - Solid Aroclor Equipment Molloy & Williams Lunch Emergency Training Molloy Start-Up Tharmlnol Heater Molloy, Williams & Check-Out Safety Features & Heupt Start-Up Circulating Tharmlnol Syatama for No. 9 Chlorlnator, & No. A Still Condenser Syatama Start Equipment Check-Out: Tharmlnol Heater Syatem Weigh Tank No. 9 Chlorlnator No. 2 Blow Tank No. A Still & Receiver MONS 093136 ARO SOM IV - 3.000 I Fag* 1 of & Rav. 0 Data: 3/25/65 AROCLOR START-UP TRAINING PROGRAM WEEK OF MAY 5. 1965 WEDNESDAY Time Topic Shift Suparvlalon 7:00 r 9:00 a.in. Final Check-out of Equipment Syatama a* follow*: Tharmlnol Haatar Raiae Temperature Lackay - Haupt Molloy - Wllllaia* Madlaon 9:00 - 10:00 Cpntlnu* Check-out of: Weigh Tank No. 9 Chlorinator & Aux. No . 2; BlOw Tank No. A Still' System & Aux. Control Fanal Instrument* Schedule to ba determined latar I 10:00 - 11:00 Start-Up Thermlnol Syatama: No. 9 Chlorinator No. 4 Still Start-Up S&K Drowning Jet System for No. 2 Blow Tank 11:00 -: .1:00 p.m Charge Weigh Tank with 1/2 size Santowpx Batch for S060 1:00 - 2:00 Transfer Santowax to No. 9 Chlorlnator-Start Chlori nation Batch No. AE-1 Take off-gas samples Fill out Data Sheet 2:00 - 11:00 p.m. Complete Chlorination Complete Data Sheet 11:00 12:00 midnight Transfer to Blow Tank 12:00 1:00 a.m. Air Blow Crude 5060 1:00 2:00 Charge No.'4 Still with Lot AE-1 2:00 7:00 a.m. Start-Up No. 4 Still and begin t Distillation Lot AE-1 Fill out Data Sheet HONS 093137 Weak of May 5. 1965 THURSDAY Tima 7:00 - 12:00 noon 12:00 - 2:00 p.m. 2:00 - 3:00 3:00 - 4:00 4:00 - 5:00 5:00 - 6:00 6:00 - 7:00 ARO SOM IV - 3.000 Page 2 of 4 Rav. 0 Data: 3/23/63 Todlc Shift Supervision Complete Distillation No. 4 Still Lot AE-1 Complete Data Sheet Lab Analyze 1st Distillation Quality Tianafex to Flaker Hold Tank Start-up Flaker & Sample to check Quality Charge Weigh Tank with full size Santowax Charge for next Chlorination Batch Fill out Data Sheet Charge No. 9 Chlorlnator & Start Chlorination Batch AE-2 Take off-gaa Samples Fill out Data Sheet Continue Chlorination Batch AE-2 HONS 093138 ARO SOM IV - 3.000 Page 3 of 4 Rev. 0 Data: 3/25/65 Weak of May 5. 1965 FRIDAY lime 7:00 - 12:00 noon Topic Complete Chlorination Batch AE-2 Shift Supervision 12:00 - 1:00 p.m. Transfer Batch to No. 2 Blow Tank 1:00 - 2:00 Air Blow Batch No. AE-2 2:00 - 3:00 Charge No. 4 Still with Lot AE-2 Begin Distillation Fill out Data Sheet 3:00 - 1:00 a.m. Complete Distillation Lot AZ-1 Conplata Data Sheet 1:00 - 3:00 Lab Analyze 2nd Distillation Quality 3:0Q - 4:00 Transfer to Flaker Hold Tank 4:00 - 5:00 Start-up Flaker & Sample to Check Quality 5:00 - 6:00 Charge Heigh Tank with full size Santowax Charge for next Chlorination Batch 6:00 - 7:00 a.m, Charge No. 9 Chlorinator and Hold for Start-up at 7:30 a.m. HONS 093139 ARO SON IV - 3.000 Page 4 of 4 Rav. 0 Data: 3/23/65 Watk of May 5, 1965 SATURDAY Time . Topic Shift Supervlalon 7:00 - 1:00 a.n. Start Chlorination Batch Ho. AE-3 Begin programmed batch < operation Taka off-gas*aamplea Fill out Data Sheet Continue operatlona aa befort. Start continued operation aa aoon aa one batch la complata Start next batch for Chlori nation and distillation. SUKDAY-MOHDAY-TUESDAY Continue ahlft coverage on operation aa noted before. If operetlon la acceptable at this stage, shift coverage will be stopped on Hay 24, 1965. HONS 093140 AROCLOR SIAM-UP TRAINING PROGRAM WEEK OP MAY 24. 1965 MONDAY Time 7:00 a.an-- 3:00 p.m. . Topic Start operation of Control Instruments on Chlorlnatora No. 1 through 8. Start programmed hatch chlorination If operators developed to this stage. If neceaeary delay until after review training week of June 7, 1965. ARO SOM IV - 3.000 Page 1 of 1 Rev. 0 Date: 3/25/65 Shift Supervlaor Haupt Madison Molloy Williams MOMS 09314! ARQCLOR START-UP TRAINING PROGRAM WEEK OF JUNE 7, 1965 Time Typical 1 Day Training Program Four "S" hifti Cre"w a--to --b e Tre-ln--e--d- Topic 7:00 - 7:30 e.m. Review Alterations to Chlorinetors Nos. 1, 2, & 3, and Start-up 7:30 - 9:00 Review Instrumentetlon Alteretions to Chlorlnators No. 1 thru 8 Train on Batch Program System with Taylor Flexl-pulse Timer Chlorine Flow Control, Temperature Control 9:00 - 9:15 Break 9:15 - 11:30 Field Tour Review Training above Detailed Operator' Review & Discussion 11:30 - 12:00 Lunch 12:00 - 1:00 p.m Process Flow, Equipment & Operating Procedures for Continuous Chlorinator & Continuous Blow Tank System 1:00 - 2:00 Field Tour Review Continuous System Operation 2:00 - 2:15 Break 2:13 - 3:00 Group Discussion & Review ARO SOM IV - 3.000 Page 1 of 1 Rev. 0 Date: 3/25/65 Instructor Williams Holloy Molloy & Williams Haupt Haupt & Williams Williams HONS 0931^ AROCLOR START-UP TRAINING PROGRAM WEEK OF JUNE 14. 1965 Typical 4 Hour Training Program Four Shift Craws to be Trained ARO SOM IV - 3.000 Page 1 of 1 Rev. 0 Date: 3/25/65 Tima 12:00 - 1:00 p,m. 1:00 - 2:00 2:00 - 2:15 2:15 - 3:30 3:30 - 4:00 Topic Instructor Review Batch Chlorinetor Williams Programmed Control System Field Tour Detailed Operator Training Haupt 6 Williams Break Group Dlacuaalon of System Molloy Review Alterations to No. 3 Aroclor Still Molloy HONS Q93143 MURIATIC ACID START-UP TRAINING PROGRAM ARO SQM IV - 3.000 Page 1 of 2 Rav. 0 Data: 3/25/65 WEEK OF JUNE 28. & JULY 5, 1965 Typical 2 Day Training Program Four Shift Craya to be Trained FIRST DAY Time Topic Instructor 7:00 - 8:00 a.o. Process Flow Review New Absorber Carbon Towers Filter Storege Tanks Haupt 8:00 - 9:00 Questions & Answer Discussion Period Haupt 9:00 - 9:15 Break 9:15 - 11:00 Field Tour HCl Facilities Haupt & Williams 11:00 - 11:30 Lunch 11:30 - 12:30 p.m. Operating Procedures & Detailed Instrument Instructions Molloy 12:30 - 1:30 Questions - Group Discussion Williams 1:30 - 1:45 Break 1:45 - 2:45 Field Tour Detailed Operator Review of Operating Instructions Molloy & Williams 2:45 - 3:30 Group Review of Operating Details Williams 0931'*'*