Document Jw46xyQ9p97OJvjzQwybgDKO
SOLV/EDC & CMP PLANT NOTIFICATION OF PROCESS CHANGE CHECKLIST
Type: LEVEL 1 (minor) LEVEL 2 (moderate) M LEVEL 3 (major)
Originator; R. Rolke___________________
Date of Origination: 12/20/97__________ Plant: Methanes
Actual Date of Change:
Area:
Thermal_______________ Equipment: R-1300
P rmanent D Ye* Temporary H Yes From: 12/18/97__ To:
12/19/97
Description and Location of Change (Scope): Change the minimum lightofftemp., AP(1913) & AP(1914), from 250 & 240 to a minimum of 200 for both.
Technical Basis for Change: This is the minimum lightoff temperature in the reactor for the reaction to start. If the average bed temperature is less than 200 C, the starup will be aborted.
Impact on: 0Safety El Loss Prevention Environment Health Quality Production Other: ____________________
Type of Change:
Alarm ^Shutdown Point instrument
^Process Computer Control Addition/Removal of Equip. Piping Modification
Equip./Material Modification Chemical Job Procedure No.
^Process Set Point Change CPiping Spec. Other:
Pre-modification Checklist: Applicable
Applicable Applicable Applicable Applicable ^Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Explicable ^Applicable ^Applicable BApplicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable
Written job scope and sketctvofproposed change; POD# Project economics; attached. Consult piping and equipment specifications; Spec. # Comply with Engineering Practices. Consult Technology Center or comply with Tech. Ctr. guidelines. Equipment access/congestion considered. Consult Environmental function Environmental project checklist complete. Chemicals listed in the (TSCA) inventory before use. Perform Reactive Chemicals testing or review. Consult Safety function for compliance with S&LP and Block requirements Consult Process Safety for impact on PHA(F&EI, CEI, & Fire protection). State Fire Marshall notified. Consult Industrial Hygiene function Consult maintenance/Reliability Eng. Consult Instrument function. Consult Electrical function. Consult Analyzer function Consult/Inform Computer/Programming Support. Consult Area Engineer. Consult Operations. Consult Area Technologist Consult Inventory Management Consult Process Engineering. Evaluate and modify relief system. Work Order written. (List them) Consult Construction/Small Projects Consult Site Logistics Consult Quality (Customer Notification ?) Other (Name them)
Follow-up Signature
Date
Yes Yes Yes
Yes Yes
________________ ________________ ________________
^ \
________ ________ ________
________ /lJZ.fr
Yes Yes ________________ Yes ________________ Yes Yes Yes ________________ Yes
________ ________ ________
________
Yes Yes Yes Yes
Page 1 of 4 RR4/96
DOW CONFIDENTIAL INFORMATION
Document 1
DO A 0P5866 CONFIDENTIAL
APPROVALS: Originator: First Reviewer:
Preliminary Reviewer(Lvl 2 & 3
Date: Date: /2'
Date: _/
__________ "97
I Applicable Applicable Applicable Applicable Applicable
Applicable Applicable KlApplicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable
i6liChecktist:tBEFORESTART4JP)
Perform prestartup audit: major equipment addition/mod. Ivl 3;attach.
PSM files updated(such as piping circuits).
Project list updated.
Documented in Operating Discipline Library
Completed Job Procedures reviewed by:
Emergency Procedures
Operations Safety Envir.
Training Aids (IPT, etc.)
_________ Controlled copies of Critical Oper. Procedures updated
_________ Safety/Environmental (cleaning, vessel entry, red tag)
_________ Update plant Roundsheets, forms
Plant equipment files updated.
P&ID's, process flow sheets, and plot plans updated.
Personnel trained on the change. Method:j
Critical instrument checklist updated.
Updated HAZCOM Manual & equip. List.
Pressure vessels, PVRV's, & PRD registered.
Instrument loops checked and documented.
Field switches, equipment, & MCC starters checked & labeled.
Log sheets/controlled forms updated.
GPI flow diagram & history/EDAS updated.
GEMTS, PPM, & MSMS updated.
Mod V program change checklist completed.
Fugitive emission tags added to valves.
Follow-up Signature
Date
Yes _______________
Yes _______________
Yes _______________
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes _______________
Yes _______________
Yes
Yes _______________
Yes _______________
Yes
Yes
Yes _______________
Yes _______________
Yes _______________
Yes _______________
Yes _______________
Yes _______________
Yes _______________
Yes _______________
___________
APPROVAL: Final Approver:
Date:
\
Page 2 of 4 RR 4/96
DOW CONFIDENTIAL INFORMATION
Document 1
DO A 025867 confidential
Co
19-1*0fa?
SOLV/EDC & CMP PLANT NOTIFICATION OF PROCESS CHANGE CHECKLIST
Type: LEVEL 1 (minor) LEVEL 2 (moderate)
LEVEL 3 (major)
Originator: g 'fcklkfc.
Data of Origination: 12/15/97
Plant: Methanes
Actual Date of Change: i a.- 1U - 9 7__________ Area:
Permanent Yes Temporary
From:
Descriptiosnn and Location of Change (Scope): Itse. aatoM.
fro/=->S~IS' -V
WA-t> "R-i3oo-
Equipment:
7/3/75
To:
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Technical Basis for Change: of Too*c\
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Impact on: ^Safety 0Loss Prevention ^Environment Health GQuality QProduction QOther: ____________
Type of Change:
OAlarm GShutdown Point ^Instrument
QProcess Computer Control 0Addition/Removal of Equip. Doping Modification
Equip./Material Modification QChemical QJob Procedure No.
nprocess Set Point Change
KjPiping Spec.
QOther:
____
| Pre-modification Checklist? Applicable
^Applicable Applicable ^Applicable Applicable IS Applicable 21 Applicable 0 Applicable Applicable Applicable Applicable ^Applicable Applicable Applicable Applicable SI Applicable 0Applicable Applicable Applicable Applicable Applicable EH Applicable 0Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable
Written job scope and sketch of proposed change; POD# Project economics; attached. Consult piping and equipment specifications; Spec. # ** Comply with Engineering Practices.
comply with Tech. Ctr. guidelines. quipmeni access/congestion considered. Consult Environmental function Environmental project checklist complete. Chemicals listed in the (TSCA) inventory before use. Perform Reactive Chemicals testing or review. Consult Safety function for compliance with S&LP and Block requirements Consult Process Safety for impact on PHA(F&EI, CEI, & Fire protection). State Fire Marshall notified. Consult Industrial Hygiene function Consult maintenance/Reliability Eng. Consult Instrument function. Consult Electrical function. Consult Analyzer function. Consult/Inform ComputQr/Programming Support. Consult Area Engineer. Consult Operations. Consult Area Technologist Consult Inventory Management Consult Process Engineering. Evaluate and modify relief system. Work Order written. (List them) Consult Construction/Small Projects Consult Site Logistics Consult Quality (Customer Notification ?) Other (Name them)
If Sect wtc/ F'P*- for fce/fre^r
Page 1 of 4
RR 4/96
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DOW CONFIDENTIAL INFORMATION
Follow- up Signature
Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
:
Date jkUzf*
7
Yes Yes Yes Yes Yes
/<tJr* ?
MOCChecldist
DO A 025868 CONFIDENTIAL
APPROVALS: Originator: First Reviewer: Preliminary ReviewedLvl 2 & 3):
Date: JZL-jU-Q'Z
Date: Date: (1%^ ~J
[ Poat-modificatlon Checklist: (BEFORE START-UP) Applicable
/applicable Applicable Applicable ^Applicable
Applicable Applicable ^Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable
Perform prestartup audit: major equipment addition/mod. tvl 3;attach. PSM files updated(such as piping circuits). Project list updated. Documented in Operating Discipline Library
/! .0. Completed Job Procedures reviewed by: Operations SafetyEnvir._ Emergency Procedures Training Aids (IPT, etc.) Controlled copies of Critical Oper. Procedures updated Safety/Environmental (cleaning, vessel entry, red tag)
'______ Update plant RoundsheetSj forms Plant equipment files updated.
P&ID's, process flow sheets, and plot plans updated.
Personnel trained on the change. Method: Critical instrument checklist updated.
5
Updated HAZCOM Manual & equip. List.
Pressure vessels, PVRVs, & PRD registered. Instrument loops checked and documented.
Field switches, equipment, & MCC starters checked & labeled.
Log sheets/controlled forms updated. GPI flow diagram & history/EDAS updated.
GEMTS, PPM, & MSMS updated.
Mod V program change checklist completed.
Fugitive emission tags added to valves^_____ Equipment RTO Checklist completed.
/'
Follow-up action pjdn completed prior to Ferial Appfoval(attached).
FqKow-up
0Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes E-Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes
Signature
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Date 11.^7
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APPROVAL: Final Approver:
Date: iz
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Page 2 of 4 RR 4/96
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DOW CONFIDENTIAL INFORMATION
woe.
MOCChccklist
D0 A 025869 CONFIDENTIAL
Methanes MOC Training Signoff Sheet
MOCTITLE: ftfio.wvL
J3QQ
DATE: )*-!{*-<}?
Mark the box next to the appropriate individual that the communication/training is intended to reach.
Engineering Staff Master#
Signature
Date
1 SOS
Master# /n Signature
Date
Taylor, D. Haney, J. Young, Barry. Storm, C. Hunt, L.C. Rolke, R.W. Stallcup, J.S.
434501 091506 433620 249497 088600 097946 240558
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Breaux, R.
Beieler, B.
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Bickham, Cook, F.
C.J.
Cavalier, N.
Giant, W.C.
1 Gravouilla, D. C.
433793 281334 432411 431977
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434499
I Jackson, R. t Metrejean, D.J.
t Harrison, D. L
433457
241773 * 096480 ar
Day Personnel Michel, A. Cook, J. Dugas, D. Brown, M.S. Rizzo, G. Johnson, J. Donatto, B. Carrier, B.P. Witt, J. Vavasseur, T. Landry, C.P.
Master#
Signature
J JI432203 A........ .* f
uj433658
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432407
433928
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241996
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434292
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i Ronald Skinner
Master# ` Signature " Date5
432751 i `iCh&Ck^
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Site Logistics Clebert, J. Mathis, J. Armond, N.L. Doucet,'K
Master# 432385 432997 098664 432056
Signature
Date
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Page 4 of 4 RR 4/96
DOW CONFIDENTIAL INFORMATION
MOCChecklist
DO A 025870 CONFIDENTIAL
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DO A 0 2 5 8 7 4 c o n fid en tial
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Equipment Cora*Mssioniing Plans Complete: Pressure Testing Dry Jtuo/Siiinulatiom
k.Fail Safe Interlocks Verified
Completed ? Yes No N/A
J
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Instnanaonts CaGbrated
Instruments Loop Checked
Pump Rotation checked
System Leak Free
Other (specify):
Monitoring Plans in place for during and after startup (sampling, emissions or leak testing, etc.)
Mechanical Integrity Programs updated: Pressure Vessel
Relief Device
&In Block Piping Registration Inspection
/
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V
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Critical Instruments Rotating Equipment (Vibration, Lubrication, etc.) Other Preventative Maintenance Programs updated List of Glass Devices Updated SEOLD's Updated Compliance Checklists Updated (Safety, IH, Env., etc.) SPC/SPCC Plans Updated Necessary Spare Parts Obtained
I 1 1 1 1 1 1 1
Equipment inspected for Compliance with Design Specifications and Standards
Safety & Loss FTcveaboe Standard S-333, FTe-Sttrtop Safety Aodit
01/27/97 page 211
DO A 075876 CONFIDENTIAL
Attachment 1
Audit Checklist
To be completed prior to Pre-Startup meeting (Brother's Keeper Pre-Startup Audit form acceptable for RAD Projects) Project Name,Project Rep______________________________________ Date _
1 1 Item
Cmpfcted Yes N4 N/A |
Procedures are complete for: startup shutdown normal operations emergency operations line/equipment openings confined space entry lockout/tagout sampling filter changes spiD containment loading / unloading decontamination other emergency (freeze; power loss, etc.) Other (specify)
Consequences of deviation defined Training Modules/Tests Complete Training Conducted or Scheduled Plant IH Manual1 Updated:
New MSDS's Area Maps (noise, etc.) Programs (PPE, Hearing. Hazcom, etc.) Chemical A Physical Agent Inventory (CPAI) Other (specify)
Safety A Loss Prevention Standard S-333, Pre-Startup Safety Asdl
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1 -- r A 025877
CONFIDENTIAL 01/27/97 Pa*e276
Training & Development Procedures
Chlorinated Methanes
CMP/SOLVENTS PROCEDURE R-1300 Preheat with Methane Burner
PURPOSE
SCOPE
RELATED PROCEDURES DEFINITIONS
SAFETY CONCERNS & EQUIPMENT
To safely heat nitrogen to preheat R-1300 with an open flame methane burner before startup.
This procedure will outline all the necessary steps involved in the operation of the open flame preheater ...safety, setup, startup, running, and shutdown modes.
R-1300 Startup, R-1300 Long Heatup
Open Flame Preheater : The coiled preheater that heats up partially heated nitrogen flow into the R-1300 reactor utilizing fuel gas/air mixture to supply a flame for the heat. This job entails many hazards that could prove to be quite dangerous. Below is a listing of those hazards:
1) Fire from open flame of the preheater 2) Explosion - from a combustible mixture of methane/air
inside the vessel of the preheater 3) Temperature Exposure - from the temperature generated
from this type of preheating (>600 deg. C) on outlet piping. The inlet nitrogen piping will be 200 C. 4) Falls - the clutter of piping, hoses, etc. in congested area 5) Flammable Spills - Shutdown fuel gas to burner, shutdown
steam to E-1515, & apply deluge gun to burner to cool it off. 6) Burner Tube Failure - Shutdown fuel gas, shutoff N2 @ E-1515 & R-1300. To combat these various job hazards, it is necessary for personnel working with this system to have the following safety equipment available as outlined below: 1) Lighting/adjusting the Flame - Flashsuit with Safety hood. Asbestos Gloves, Torch rig, and normal safety equipment and clothing for this area. 2) Safety Observing the Preheater - Normal block safety equipment and clothing for this area along with an explosive ______ meter.______________ Due to die nature of this open flame Preheater, it is necessary for a safety observer to continuously monitor the preheater while it is being used to verify that no problems are evident. This round involves an explosive meter reading and visual inspection of the flame, preheater outlet line, and preheater coil for problems.
Dow Confidential This procedure is valid for 24 hours from the date viewed, 12/23/97 08:07 AM
DO A 025878 CONFIDENTIAL
Training & Development Procedures
Chlorinated Methanes
R-1300 Preheat with Methane Burner
ENVIRONMENTAL CONCERNS
SPECIAL CONCERNS
PROCEDURE RECOMMENDATIONS
The fuel gas flow to the preheater should be monitored every 2 hours and recorded in the logbook. This can be done by getting the difference between the block limit fuel gas flow and the Throx and C-650 feed flows. The outlet vents from R-1300 will be sent to the Throx through the dry vent header. If the Throx can not handle the entire flow, some of the flow can be sent to Vinyl II. The reportable spill amount for methane fuel gas is 100 lbs.
The R-1300 pressure should be monitored at all times. The D-1320 pressure will have to be used since the R-1300 pressure is disconnected for the hot nitrogen purge.
A small nitrogen purge will be maintained in the mixer to prevent the mixer from getting to hot while preheating the reactor. Try to maintain the mixer gun barrel temperature is than ISO C. The nitrogen can be purged through the organics inlet line on top of the reactor from S-1300 bottom valve.
If a procedure is currently active at relief, state in the relief notes the status off the job and the steps that have been completed up to this point.
Highlight the procedure steps as they are completed so operations personnel are aware of its status. This is especially important during shift relief when jobs are incomplete.
Avoid carryover of a job when possible. I.E. Starting a Job at 5:00 AM/PM, just prior to relief.
PROCEDURE
A. Setting the Preheater
Step 1
2
3 4
Action
Place the 10 ft tall Preheater on the West side of R-1300. Have fire blankets placed under the preheater, especially if it is placed over the ditch on the West side of R-1300. Run 1" screwed pipe from the fuel gas line by C-650 to the burner. A 300# to 75# pressure regulator will be placed in the line by C-650, Install an emergency shutoff valve approximately 20 feet from the preheater. 2" screwed pipe will be used to send hot nitrogen to the preheater coils. The 2" inlet spool to V-1515 from E-1515 will be dropped and used as the N2 feed source. This N2 piping will be wrapped with insulation up to the preheater. A bleed will be placed in the line. Pressure check the line with N2 from E-1515 using the gauge mounted in the line. Run %" tubing from the R-1300 tail line bleed to the dry vent header drop. Run Vt" tubing from the D-1320 drain manifold to the dry vent header drop. This will be used to vent the N2 to the Throx. Hook up two air hoses to the inlet mixer on the preheater. This is used to mix the fuel gas and force the flume through the heater.
DO A 025879 CONFIDENTIAL
Training & Development Procedures
Chlorinated Methanes
R-1300 Preheat with Methane Burner
5 Remove the R-1300 pressure transminer located on the PRD nozzle. Run welded pipe from the outlet of the preheater to the 1" valve on the reactor PRD
nozzle. Make sure the piping is supported properly along the West side of the
R-1300 structure. The piping spec will need to handle 600C nitrogen. Insulate
with foam glass.
6
Pressure check all the N2 and fuel gas piping. /
Starting Nitrogen Flow:
7 Open the nitrogen to E-1515. Line up the valves through the preheater coils and into R-1300. Note; Monitor the throx ventflow to make sure it does not over pressure the header. Begin sending some of the flow to Vinyl as needed.
8 Start heating up the nitrogen with 475# steam in E-1515. The outlet temperature should be around 200 C.
9 Monitor the R-1300 pressure. Try to control the reactor at less than 20 psig. The reactor pressure can be controlled by increasing the vent flow to the Throx, or varying the nitrogen feed with AOV-115. The N2 flow can be monitored with AI-120 or the Throx dry vent flowmeter. During this same time, adjust the nitrogen flow to its maximum capability as defined by the Throx load (should be around 2200 #/hr) and any excess vents can be sent to Vinyl's Throx.
10 The preheater is ready to be lit at this point.
Starting a Flame in the Preheater:
11 Round up the appropriate safety equipment for this job: flashsuit with safety hood, asbestos gloves, torch rig, and normal safety equipment and clothing for this area.
12 To ensure the burner is free of any restrictions, open air valves V* of a turn on both branches of the inlet air connections on the preheater. Allow it to blow at least a minute to clear the burner. Next, open fuel gas valve to the burner V* of a turn and allow it to blow for 10-20 seconds. Shut-off fuel gas valve and purge burner with air.
13 At this point, the safety observer for the lighting will sniff the area thoroughly with an explosion meter for combustibles. If combustibles are found, stop the lighting job at this point and notify operations team.
14 Once a good sniff is achieved, the person doing the lighting will don the safety equipment. During this time, the safety observer for the lighting will rope off the entire area of the steam heater and preheater with yellow caution tape.
15 With the appropriate safety gear on, the person doing the lighting will light the torch rig. Adjust the height of the flame to the appropriate length for lighting; approximately 12".
16 Now, adjust the air to the preheater by opening the valve to a 1/4 of turn in the open position on both branches of the inlet air connections.
17 Once air has been added, insert the flame into the burner and begin opening the fuel gas to the burner until the flame lights.
DO A 025880 CONFIDENTIAL
Training & Development Procedures
Chlorinated Methanes
R-1300 Preheat with Methane Burner
18 Once a flame has been lit, adjust the air and fuel gas flows to achieve the desired heatup temperature. The burner flame should be blue if the air-tofuel mixture is set properly. The outlet Une temperature is monitored in the field with 2 skin temperature probes. Control the outlet line temperature at 650 C. There will be one field mounted probe and one sent to the control room. After the flame has been lit, we must maintain a N2 flow through the coils to prevent excess heat buildup and a coil failure. Flame Failure - If the flame fails, shutoff the fuel gas flow. Purge the burner with air for 3 minutes. After purging, restart the burner at Step #15. Throx Shutdown - Swap the vents to Vinyl II. If Vinyl can not take the flow, shutoff the fuel gas flow. Block in some of the vents from R-1300 and take a pressure rise in the reactor. Reduce the flow N2 flow to the coils, but maintain a flow until the coils cool down, then block in the N2 at E-1515 & R-1300.
19 Begin recording the fuel gas flow.
20 Periodically monitor the operation of the preheater by looking at the temperature and nitrogen flow into R-1300. Adjust the fuel gas, air, and nitrogen flows as needed to obtain the optimum heat input. Note: If more vent flow is desired, we may be able to vent the atmosphere if the reactor is clear. Make sure the area has been roped off with red hazard tape. Consult with the Environmental contact first.
21 During the operation of this preheater, a Dow person must be present at all times to check for problems with the system such as combustible mixture sniff, visual inspection of outlet line, and heater coil mechanical conditions (leaks, cracks, sagging, etc.).
NOTE: Should any problems be found during these rounds, the outside operator will immediately shutdown the preheater and extinguish the open flame. 22 Monitor the R-1300 temperatures. If the mixer temperature gets to hot(>150 C), increase the nitrogen flow through the mixer. A Mod alarm will be setup in the control room for low and high temperatures. Continue heating until R-1300 light off conditions are met. Shutting Down the Preheater:
23 To shutdown the preheater, block in the fuel gas then the air. At this point the flame should be extinguished.
24 Notify the boardman that the preheater has been shutdown.
25 Shutdown the steam to E-1515. Block in the N2 to the preheater. Remove the N2 from the PRD nozzle. Extreme caution will be used because of the high heat. Use thick leather gloves. Reinstall the pressure transmitter.
26 Remove the temporary vent piping on the tail line.
27 Bleed the fuel gas pressure off the 1" line through the burner.
DO A 025881 CONFIDENTIAL
Training & Development Procedures
Chlorinated Methanes
R-1300 Preheat with Methane Burner
D0 A 025882 CONFIDENTIAL
Training & Development Procedures
Chlorinated Methanes
R-1300 Preheat with Methane Burner
Document Control and History
Note: To Automatically Update the following fields, Go to Edit menu and choose "Select All", Press F9
File Name Created By Creation Date Last Saved By Last Saved Date Last Print Date Location of Controlled Copies
R-1300 Methane Burner Heatup
Richard Rolke
12/15/97 9:47 AM
Jim Haney
12/15/97 8:07 PM
12/23/97 8:07 AM
This procedure will be located in the LANT51 Methproc/Procedures
NOTE TO AUTHOR: IF YOU DESIRE A HARD COPY OF THIS PROCEDURE PLACED IN THE PROCEDURE BOOK IN THE CONTROL ROOM, INDICATE THAT HERE AND SEND ME A MAIL MESSAGE.
DELETE THIS NOTE WHEN YOU ARE FILLING OUT THIS PROCEDURE
Copy
Location Procedure Book In Control Room
Revision History
Revision Date
Reviewer Name
12/15/97
Jim Haney
\
Description of Revision Procedure Updates
DO A 0P5883 CONFTDFNTTAt