Document KJpmjGpQJazO5b26Vm8VNX2or

CENTRAL ENGINEERING - RES 608.1 02 CONFIDENTIAL RELIABILITY STUDY VINYL CHLORIDE MONOMER EXPANSION EDC CRACKING FURNACES, DOWTHERM HEATER, AND VCM II SUMMARY by P. A. KELLEY, PETROCON, INC. REVIEWED BY: B. A. VIRNIG, PETROCON, INC. NOVEMBER, 1980 DISTRIBUTION B. E. BECK - WITHOUT APPENDIX L. W. CARTER - WITHOUT APPENDIX G. B. EDWARDS/C. R. WEST - WITH APPENDIX W. L. OGLESBY - WITH APPENDIX R. E. SANDERS - WITH APPENDIX KEY WORD RELIABILITY VCM II SL 012025 TABLE OF CONTENTS Page INTRODUCTION........................................................................................................ A.O ABSTRACT.................................................................................................................. B.O DISCUSSION AND RESULTS................................................................................. 1.0 RECOMMENDATION................................................................................................... 2.0 TEST REQUIREMENTS.......................................................................................... 3.0 CONCLUSIONS........................................................................................................ 4.0 APPENDIX I, FAULT TREES & SUPPORTDATA............................................. 5.0 APPENDIX II, CRACKING FURNACES AND DOWTHERM HEATER SHUTDOWN SYSTEM..................................................................................... 6.0 APPENDIX III, TOXIC GASDISPERSIONS.................................................. 7.0 APPENDIX IV, MISCELLANEOUS SUPPORT AND CORRESPONDENCE . . 8.0 CONFIDENTIAL! to Protective Order Of 14th Judicial District Court NO. 91-1145 SL 012026 INTRODUCTION Upon completion of the OHC Reactor Study on August 5. 1980, work began on the EDC cracking furnaces, Dowtherm heater, light and heavy stills, and the VCM shift storage tanks. Another area that was con sidered was the combined OHC reactor and the liquid phase reactor vent system. COH?' T ATi protective order Subject tc Ih District Court of li 5)1-1X45 1 r-.+ ***' m- I**- t... A.O SL 012027 Subject ^\rE:JTiA,: c -14th Judicialt'o?t,lvs Or<*or KK;o* -pIIa45triot Court ABSTRACT This report covers the EDC cracking furnaces, Dowtherm heater, light and heavy stills, and the VCM shift storage tanks. The combined vent system including OHC reactor and liquid phase EDC reactor was studied also. Years between explosions were determined using standard ICI fault tree analysis. Explosions were broken down between minor and major explosions. Minor explosions are those that cause little or no equipment damage but cause one or two days of equipment outage. Major explosions are those that cause up to one week or more equipment outage and danger to life of operating personnel. Examples of minor explosions in the Dowtherm heater or EDC cracking furnace include small gas leaks that upon ignition cause minor damage such as dislodging explosion doors, breakage of burner and/or pilot tips, and minor damage to refactory. Explosion pressures generated by these types of explosions or fires would be contained by the vessel walls and would not cause any significant hazard to operating personnel. Table 1 summarizes top events for the "Present" and "Proposed" crack ing furnaces and the Dowtherm heater. Criteria for toxic gas releases and explosions are also listed. The present furnaces and heaters exceed the major explosion criteria for the entire VCM II expansion. The number of minor and major explosions can be reduced significantly with minimal capital investments such as valve position switches, input modules to the programmable logic computer (PLC) and use of on-line gas chromato graphy to provide a back-up system for explosive mixtures of chlorine ethylene and other inerts in the combined vent of OHC reactor and liquid phase EDC reactor. B.O SL 012028 tro, ffOr '^4$ A; ** c/' 4 0} *. *J -KS %, fc TABLE I CRACKING FURNACE & DOWTHERM HEATER YEARS BETWEEN OCCURRENCES Events I. Toxic Releases Category III Category II Category I Category 0 II. Minor Explosion III. Major Explosion Present - --- 1.01 6.9 Proposed - 101 165 Criteria 15-30 2-5 0.5 0.0192 5-10 50-100 B.l SL 012029 of i4%**t^&s**. in.' s-<!2 - * --U v<5 J ot DISCUSSION AND RESULTS ep This level III study of the Vinyl Chloride Monomer Phase II Plant Expansion details frequency and severity of both toxic gas omissions and hydrocarbon releases that could lead to minor or major explosions. Table II summarizes Hazard Rates for the "As Built" and "Revised" furnaces and Dowtherm Heater. Cracking Furnaces, Fault Tree No. 1 Fault Tree No. 1 deals with shutdown and subsequent start up of the EDC Cracking Furnaces. The Furnace Shutdown System is detailed in the Appendix. As shown in the fault tree, all Factory Mutual cock valves, one tight shut off valve, and natural gas flow control valve are proved closed. Also pilot gas valve KV-3832 is proved closed. The status of 28 XV-A151-178 valves in the pilot gas line is unknown because the valves do not have position indicators. Upon subsequent start-up when one ig niter is pushed and a flame is perceived by the Fire Eye, the natural gas is held open by the Flame Management System. If one or more of the 28 "XV" valves have "hung" in the open position, a pocket of flammable gas builds in the furnace until it reaches an ignition source. As seen from the fault tree, this small explosion, as defined in the fault tree support information, happens in both furnaces every 1,1 years. Installation of position switches on the 28 "XV" pilot gas valves reduces the number of small explosions to once every 257 years for both furnaces. Explosion pressures of 1.1 PSIG (see support information with fault tree) should cause only minor damage at most to the furnace such as dislodging the explosion door, burner and/or pilot tips, dampers, and small parts of the 1.0 SL 012030 SL 012031 TABLE IT V//M7T X/JANE/x>ft FPACP/Nc7 F6'/'A/A'F X/'MU/7MWM PF/I TfrN HAZARDS s<t//s?M/}xy HA'YAPP tfATE, r/me/Year /v^T 7% x/% AIS 8L/LT YEI//S2TP ~TPR 2YXA/T Jt* /L/PXONFLS5TSATudAPS FT6 /NAZtm't' z APrFTrgpAeTtawNr:a,t>p. J LOSS OF Etov ' PAN uFE Of= 4 SMUfFfc'G S7m* EXCESS rj/)3 jfX J Fl/PfSACE. 0. 909 o. tss O. 00340.0052. 0.0034 0.OO38 9* 0.000/25 o,oo*>4 O. <>& 5 2. AY/ftftp E/XY/OS/&M ft/ftTO# EYYZpS/ofS F/FE /A) Fi/XftftXL Aft/ljP/? EX8L0S/Oft 5 ruse EAuuH o<*/ i rAti.ru P o.cn z o. OOO s o F/ftE /ft FUFftA C r<X& FAUNAE o.noooQi 1 ftANTie TAX o. 0 0/33 2 Less aF FiOW 0.0 0099 3 v#/o 4 Fft/FftEu/NfFtpi/A#/f#tCE O. OOO \ s OETECrt# SA S TE*aF. F.oaL E'N/CS F>NaJ 0.00001 O.OOIOZ4 O. OOOV^ l/fe /ft Plater. paw/fefm xftLgi/g/zArioft AfftSOA' LXftEL5/0ft OOft TMNNt naFSAF/FA r/Oft ^t:DC LRftUR/A/P} LftftA/ftPL5 - FAULT 7/3ELS ft- / Tftftl/ F 6 * -* DLv/rMLLA/) //latll - lllfs ft / rft/su ft-s cn itit-** cO' if* l-JJT Ct> O Cii rr .C o. c t- o n H3 t- H ef < i-- O -'j r!" ?3 - c ft) ^ J^ O M i tfi rf >* ^ (+!- tr1 hi < ** w- n> o hi a o-* o ft> CH *+ 70 m E r <3 M V WC? H *- --<- "k- * Subject to Protective Order of 14th Judicial District Court No. 91-U45 refractory. No structural damage is anticipated to the fire box or fur nace tubes. Expected duration of furnace outage is two days or less. Cracking Furnaces, Fault Tree No. 2 Fault Tree No. 2 deals with vapor detector initiated shut downs and the probability of a main gas valve failing open. Since the fuel gas vent valve is operator initiated, it is assumed that the majority of gas vent ing would be into the furnace prior to the operator's opening this valve. It would take an operator 10 to 15 seconds to analyze the cause of fur nace shut down and the opening of the vent valve after this short duration means that a flame continued in the furnace after a vapor detector ini tiated shut down has occurred as seen from the fault tree. This situa tion can occur once every 7.2 years for both furnaces. Installation of a solenoid dump valve on HV-3834 to make operation of this valve auto matic, instead of operator initiated, would reduce major explosions as a result of fires continuing in the furnace after vapor detector ini tiated shut downs from once every 7.2 years to once every 1380 years. Cracking Furnaces, Fault Tree No. 3 Fault Tree No. 3 examines loss of crude EDC flow to the furnace and the back up systems to prevent tube rupture from over firing. (Refer to fault tree support information for overall FDT of the loss of flow shut down system.) The system as designed with a crude EDC flow loss of 0 to 75 percent (which will result in tube failure if the gas firing rate is not cut accordingly) will not alarm or cast a vote for shut down. The low flow shut down as designed is only 15 GPM and the alarm condi tion is 25 GPM, It is recommended to alarm and cast a vote for fur nace shut down at design minus 20 and 33 percent respectively. These 1.2 SL 012032 Subject to Protective Order of 14th Judicial District Court No. 91-1145 values are based on a constant firing rate with the additional fuel gas used to increase product outlet temperatures. (See page 7 of 7 of Fault Tree Support Information for more details.) It is also recommended to cast a vote for shut down when Tube Metal Temperature exceeds 1500F; alarm TMT when temperature exceeds 1400F. (See page 6 of 7 for maximum allowable working pressure versus operating temperature). The temperature and pressure relationship on the furnace tubes is based on the American National Standard Code for Pressure Piping. This analysis is more conservative than the power piping or boiler code. There is an 80% safety factor in the pressure piping analysis; however, the dotted curve on page 6 of 7 of the Fault Tree Support Data removes this safety factor. This new operative line should represent an approximate relationship between maximum allowable working pressure and operating temperature of the furnace tubes. Cracking Furnaces, Fault Tree No, 4 Fault Tree No. 4 analyzes the failure of the snuffing steam when activated by a vapor detector shut down. Based on the fault tree analy sis, it is recommended that the snuffing steam valves be tested every three months. This frequency of testing is required to keep the failures of snuffing steam system to once very 192 years for both furnaces. Cracking Furnaces, Fault Tree No. 5 Fault Tree No. 5 considered failures of the snuffing steam system to an open position. Snuffing steam in an operating furnace causes an "all fires out" condition which places a demand on the shut down system. Overall FDT of the "all fires out" alarm, PLC I/O, and the 2 of 2 pilot 1.3 SL 012033 Subiect Of 14th J gas block valves is 0.0057 including bypass time. (See Fault Tree Sup port for details on FDT calculations.) Top event for this situation is excess gas in furnace without any fire which itself does not lead to an explosion; however, if an igniter were pushed in this situation, a significant explosion would result de pending on the quantity of gas built up in the furnace. As recommended in the Pec-Tri Dowtherra Heater Report, when snuffing steam valve position switches are sensed in the open position, a furnace shut down should be initiated to stop fuel gas flow. Once the shut down has been initiated, the accidental pushing of an igniter is not possible because of the start up sequence required by the flame management system. Cracking Furnaces, Fault Tree No. 6 Fault Tree No. 6 deals with cold furnace start up and rate changes. The system, as designed, requires the operator to establish crude EDC feed prior to increasing the furnace firing rate. Also significant rate changes of the feed requires operator interface to prevent tube rupture from over firing. During cold start ups a loss of flow as determined by the two out of three inputs of the two furnace feed flows and one tube metal temperature per pass cannot cause a shut down because the two flows are bypassed prior to their respective values being satisfied. As a re sult of startup bypass, the shut down system can only be armed by the tube metal temperature. As a result, tube rupture from over firing and a resultant fire in the furnace occurs every 13.9 years. It is recommended during startup that the shut down system for loss of flow condition be a one of three using tube metal temperature, high process outlet, and high bridgewall temperature. Revised hazard rates 1.4 SL 012034 Subject troo lPJrr' otective Order Of 14th Juddiicciiaal District Court No. 91-1145 for both furnaces during start up and rate changes are reduced from once every 13.9 years to once every 2000 years. This one of three shut down on loss of flow condition should apply during the decoking phase also, although hazard rates for this phase have not been determined this time. Dowtherm Heater, Fault Tree No. 1 Fault Tree No. 1 on the Dowtherm heater looks into the situation where the heater is double blocked, the low flow shut down fails to cause a shut down and the relief valve fails to relieve. As expected, the occurrance of tube ruptures or flange leaks is very low, once every 968 years. Number of occurrences of "seized closed" safety valves was taken from the IC1 Failure Rate Data Book; however, these values do take into account the pecularity of a frozen safety valve inlet, which is a characteris tic of the fluid to be relieved. Dowtheni^A and Thermino]VP fall into these classifications of fluids. The following recommendations are made on the relief valve installation system, whose most common reason for failing would be freezing: 1. Install a local "skin temperature" sensor beneath the insula tion on PSV-9-509 inlet flange. 2. On the steam trap that controls condensate removal on the PSV inlet piping, use a liquid crystal temperature sensor that visually signifies a working or plugged trap by changes in color. 3. It should be standard operating practice prior to start up to check the condition of the steam trap on safety valve inlet piping to insure proper operation. 4. An alternate to steps 1-3 would be to use a heat transfer 1.5 012035 media whose the Lake Charles area, preferably below 0F. Dowtherm Heater, Fault Tree No. 2 Fault Tree No. 2 deals with the loss of Dowtherm flow via pump or the blockage of a single valve. The primary devices that provide a backup system for these situations are a low flow switch, high tube metal temperature, and high stack temperature. The temperature loop TIC-9604 is not a backup system for a loss of flow condition since this primary device relies on flow to sense the bulk temperature of the process outlet of the heater. With a flow stop page the thermocouple controlling operation of firing rate is outside the heater and therefore fails to a dangerous situation. Only these thermocouples within the heater provide a backup system to a flow stop page demand. Overall FDT, including PLC I/O and the three gas block valves, is 0.00405. (Refer to Fault Tree Support Data for details on FDT calcula tions.) The number of occurrences of Dowtherm carburization from over firing are once every 1013 years which includes operating steam time of ten percent. It is recommended to alarm low Dowtherm flow at 750 GPM and to initiate a low flow shut down at 700 GPM. (Refer to Fault Tree Support information for details.) Dowtherm Heater, Fault Tree No. 3 This fault tree has been voided as these demands have been included in Fault Tree No. 4. SL 012036 1.6 t-ive OrS? Dowtherin Heater, Fault Tree No. 4 Fault Tree No. 4 considers a shut down situation initiated by a flammable vapor cloud. It is assumed that every vapor cloud reaches at least two of the six vapor detectors that surround the Dowtherm heater. As a result of 0.5 vapor clouds per year the number of major explosions is once every 6480 years. Dowtherm Heater, Fault Tree No. 5 Fault Tree No. 5 investigates the number of Dowtherm carburiza tion as a result of temperature loop TIC-9604 failing open. The backup systems for these demands are high tube metal temperature, high stack temperature, and high outlet temperature. The use of 0.001 as the frac tional dead time for the three of three temperature sensors is based on common mode, since all of the primary devices are identical and do not provide system diversity. Total number of Dowtherm carburizations as a result of excess gas firing is once every 13,720 years which includes the operating stream factor. Light and Heavy Stills, and Vinyl Storage Area A Level III investigation into these areas revealed no occurrences of major/minor explosions or significant toxic gas releases. However, a toxic gas dispersion program was run to simulate the relieving of a safety valve in the vinyl storage area. As seen from the computer output titled VC01 in Appendix III, the release is summarized as a 100% probability of a category zero. OHC Reactor and Liquid Phase Reactor Combined Vent System The combined vent of the OHC and the liquid phase EDC reactor can become an explosive mixture when excess chlorine is present. Refer to SL 012037 1.7 Cou the ternary diagram in Appendix IV. Normally this vent system contains ethylene, trace quantities of HCL chlorinated hydrocarbons, and inserts which are not an explosive mixture. From the liquid phase ethylene dichloride reactor section (Unit II) Level III Reliability Study, the occurrences of high chlorine in the vent system was determined to be .00893 times per year. (Refer to Fault Trees Nos. 11A and 15A for de tails.) Explosions once every 112 years as a result of high chlorine is anticipated for each excursion of excess chlorine because ethylene is always present in the vent. The gas chromatograph backup system as defined in the OHC-Rx study. Fault Tree No. 11 and my letter dated May 15, 1980, titled Gas Chromato graphic Analysis Backup Oxygen Analysis (Refer to Appendix IV), should be used to prevent explosions due to excess chlorine in the vent system. The fraction dead time of such a system is relatively high (0.05) but the low number of demands results in only one explosion every 2240 years due to excess chlorine in the combine 0HC and liquid phase reactor vent system. The following Table II summarizes the combined VCM II Expansion for toxic gas releases, minor explosions, and major explosions. When the Liquid Phase Reactor, Unit II, Report was completed, the excursions of excess chlorine were not included in the explosion category. Using the explosion diagram for ehtylene, chlorine, and inerts shown in Appendix IV, it was agreed that when sufficient amounts of chlorine were present in an over chlorinated liquid phase reactor, a major explosoin results which endangers the life of operating personnel and causes significant unit down time. Explosions resulting from excess chlorine are included in SL 012038 CONFIDENTIAL: Subject to Protective Ordar Of 14th Judicial District CoUPfe No. 91-1145 the VCM II Unit Summary. Only in Category 0 did the VCM II expansion meet the "as designed" criteria. All other categories of toxic gas releases, minor explosions, and major explosions exceeded the criteria. However, with the recommended proposals in this report as well as the OHC - Reactor Report, and the Liquid Phase EDC Reactor Report all criteria can be met. f 14th &G-. _ uJs 0r<**r CfrBJPfe SL 012039 1.9 msniSSION AND RESULTS (Continued) Events I. Toxic Realeases Category III Category II Category I Category 0 II. Minor Explosions III. Major Explosions TABLE II VCM II SUMMARY As Designed 0.8 0.39 0.4 0.4 1.01 3.0 Proposed 18.2 5.5 7.4 6.7 101 55.9 Criteria 15-30 2-5 0.5 0.0192 5-10 50-100 suDject to Protective OrdeS* of 14th Judicial District Cotxfc No. 91-1145 1.10 SL 012040 RECOMMENDATIONS EDC Cracking Furnaces 1. Install position switches on XV-A151 through A178. These new position switches must be proved closed prior to start up. 2. Install solenoid dump valve on HV-3834 to make venting of this valve automatic instead of operator dependent. 3. Alarm crude EDC cracking flow at design minus 20%. This would allow for turn down if the alarm condition was determined from the con trol set point and not a predetermined quality. The shut down value should be determined from the set point also. 4. Initiate a furnace shut down when the flow is 33% below set point. 5. Alarm radiant Tube Metal Temperature at 1400F. 6. Initiate a furnace shut down when TMT exceeds 1500F. 7. If snuffing steam valve position switches are sensed in the open position, a furnace shut down is initiated, 8. During start up bypass, the shut down of the furnace should be a one of three on: a. Tube metal temperature, 1500F b. Outlet temperature, 1200F c. Bridgewall temperature, 1750F. Once the flow shut down values have been satisfied for 30 seconds, the low flow shut down reverts to a two of three based on two flows and one TMT. 9. Prior to furnace start up, determine that each flame detector discriminates on its particular pilot or buner. In multiple burner systems each detector must be positioned so its line of sight does not intercept 2.0 SL 012041 flames from other burners. Flame discrimination can be adjusted by re ducing sensitivity until the flame relay only responds to its pilot or burner and not adjacent flames. to Protective Order ot 14th Judicial District Coui No. 91-1145 2.1 SL 012042 TEST REQUIREMENTS ective Order District Court EDC Cracking Furnaces 1. The protective shut down function for the furnaces should be proof tested once per month unless a scheduled shut down provides the proof test requirement for that shut down function. 2. Once per month compare furnace thermowells with dual thermocouples and note deviation, ANy thermocouple not meeting manufacturer specifica tion should be replaced. 3. Zero and span orifice run and vortex shedding meter on furnace feed twice per year. Verify alarm and shut down valves each month. Com pare vortex and orifice meter reading and note deviations. Deviations greater than five percent should be remedied. 4. Compare furnace inlet pressure readings once per month and not deviations. Significant deviations should mean differences in coking rates on the parallel furnace tube runs. Improper firing patterns should be suspected. 5. Test the snuffing steam system every three months. 6. Test all safety relief valves at least once per year. 7. Test vapor detectors prior to each scheduled start up but no less than twelve times per year. 8. Visually inspect and verify all position switches on all gas valves prior to each scheduled start up. Dowtherm Heater 1. Test relief valves prior to each scheduled start up (minimum, twice per year). 2. Test vapor detector with combustible gas prior to each scheduled 3.0 SL 012043 start up. Verify operation of gas and deluge valves. 3. The shut down functions controlled by the vapor detector should be tested prior to each scheduled start up. CONFIDENTIAL: Subject to Protective Order t 14th Judicial District Court: No. 91-1145 3.1 SL 012044 CONCLUSION If the aforementioned recommendations in this report and the OHC and Liquid Phase EDC Reactor reports are accepted and become standard operating practice, the toxic gas criteria as well as the explosion criteria can be met for the entire vinyl chloride monomer expansion. ?SS5KU order 4.0 SL 012045 A^AJA/ Ass# /2<zz>r A%s/7a3zl< - j}$ /?*&/jj?/} T&57~/aJ6 Os- A)5 SySTSAs? IA/POLO &CCC/& O// SWJE T\*S> SC*' DUCK'D 5-- &?-<&&?*//? S f 7~- . r Y&9/2S) . COS?\to^\t< tss<*'**A#^o-cc\- ^9\"vA** o< aV SL 012047 |pETRocon,inc| Client ** 77"- ENGINEERS 6 DESIGNERS P.O.Box 3971 Beaumont, Texe* 77704 713-842-2417 Job No. ^ ST7 Ref. Dote ___________________________________ CG/zl/sO_______ srv&S; 0EOE6. 7// xY ___/!4&El.Y ... 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Date ____________________________________ ?//9Jte___________ I- 9CMZT- /?U/)3/uTY S7V/Q-V. m SvbjKt !;ru0/A>4*s -- SHOTCOW* SI'STSM /^^fy____ * /?j4 t/ir?r//fc d/PS/S i I). 1/S *4 r&r/i L d>/=~ 6 ft: P ~YTA */s sr^n/^s ZPU/$JC>u$ 7* $Pu/<2l/s DYvrPcp-ws xgv s/y/7~/>/cuA/ syst&a# PP A 7 YsrPft ', 3, SHUTDDctJ// (or/pr/r J/M&&/S) <. Q.s /yr P/?/?Cr DAPpp. b. A <T/V A -/ c. 0-3 /yr lc`S ip spypp ppc plow a/. %Q /jr Y/r>dcPD ^/rpmjtJS 4*3 /y f J-7 Ay/ o /'//c' mm $ $>#& t-e&wws $/?c//Z/d>L/S $//&rc>\A//\/S /Pe^MY 7-or/u. ///imts) f TZ?P */^-//r 1., x? Fu^ WAC=_ -THMpEia&Vtfas. ' SOSOv^. <J?LC.~1>UZ.\') "Au_S , i" \ S possi-act TO iTAilT A "OOsl_o" ~oV>^CE. WiTHCiOT s M>NOTE TimE. 2 /4 pi/m? ^x/sr/MG /// rsfS Pt/P/s/te# p/1Pep. ///ap/P7ZP> P No. 9>l~iSi4t5ric^t SL 012049 IPETROCOnjnC. I EHGIMEER5 a desigpiers ------------- M p. 0. Box 3971 BMumont, Texas 77704 713-842-2417 Po8 - Of <? Job No. 7&* "7 client Ref. Txe&TD. 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(8$d -4roYF y/ teoc'r 26,9~OM60 . 077 ^/00O - 4T64 Fu72373 A W = -72.31S (\00s): QO.OA iooo 90 vJ - 2^S9>0.00<0 -- 4,/243 /i /)> R 11 OO r "V > ------------- - <<e71 0/aO -4$mo) A\N = CpIZ43 Qqq) = 4 7.7 7 moo A> <$0 4oo f 1, A LA KM CeuD/2 FOC FLoktj AT Jr 20% OBiAjATfM z. Sh/UTDOvJfiJ FuUMACS AT J 33.3 S/o tAF^/ATjoa^ GaJ C&lJOE. 0 6 <o U-V Fft/SW FLOW T& e<P7/i> FTFsAWAFt as 330 Aac/m/W Flow to a t/^z. <t /Ass = 330/4 * 32. t A/.AKM FlOtf = 0.%>(S2.S) - A. A SNurTiaw -a,47/3?,) - i'-r CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court ' No. 91-1145 [PETROCaijncl Subject to pro-cici. iv 'Jp, .-.^trLctXaiMS Of 14 Lb Sic. 1L-22-H EnGIHEERS6 DESIGHERS P.O.Box 3971 Beeumont Texee 77704 713-842-2417 Page Of Job No. 7,,g?(..C~2-- Client 00T? ~ Z.///SQ YSCA/PS^, ZA, R.f, Date job y&/t^z-/fecs4/&6s7>' Subject /^y^j^nzz By E A f/f itNV,______ Checked By StJUFf=/A/C) STAX) -- 3^/gS// /ocY PcM Pc/js/7~ TCTYiL AY// U*2j. (AX/OS. C.Ct*S>) SCoAmP/O Y-Y v, AY A/)y>//J XA/- US'. AH/ 0, 2 /g. 2 SL 012064 e^ o.4 /yy x 2/3 (cast/siocS) e = .?7/y# F/Y<L U/IO YATA OX Boss/ yA/. JA5 XX/ /-ss^ Cos SAY YCS/T/C/U !///Z\/ A YC/S/Ca/C* /S Y'ACAD yYS'S tab C/i/YC/A/tf 5rAA/S} /s T/SA Af0& TO 7W^ TOA" BX*S7~. Ycvxo-asYs a/TA 5/suCA/s/Y TOY 5 ss <Y, Y Zy/2 . AAcsx' /rsscr yAAcsL SJ / TAOS S s/XJ Y TAT7/AQ CSS A r^//(j/-os SSY SYSTYA TAB sYxsgA/Z/Q AjT /5 t / A/- ,-ABes g' ~ ^3 & A0SZ A z*a2 -tY) ZTsr/?*s) Y?/z/a/4 r - % (azT) = <?. ,8 // - -78 /. S') _ /32/Tr c-Z r?Sv T^ytr^iz /s * r 7&/s /s rea rf/ss// Cm. r-o.c 6- - Z7 > -. T )er*.,r A; 0-0 _ _ 12M At = .004 Zg/rr sc C/ZCA ,* 2 5 3 Ysars> A '/4 p= GC //= C.0Clf/yr SS c'S/YB /u 6 YSAAS CONFIDENTIAL: Subject to protective Order _ of 1144tthh JJuuddiicciiaall Doisisi trict Cour Page I PETROCOn P/p6 -Client I Jj.EriGinEERS P. O. Box 3971 Beaumont Texa* 77704 Ref. 713-842-2417 1 Date Job No. 9/3/fi<p - ,//? _ZT~ - A%TZMS/UtY ST-pt^y, /jVL JTT .y JP^ Of 79,57 Subject //J4n A-s//Q/S^Z - Smu 8A^ TtA ,~y?/c% OAFaJcv**By l/,r? N> (s. . Ss^/rszot. oez> P -- S S / o Pst7 P'\.T4r77TSd%7/0/4> P#LV , H Y Pano \/al\7> t /// &2 O.Z <...<> 0,4 ,-K ^3 OfS/S*/ &* P/S /P'tMZ ftQH-UgLe '=- t/NLJg 3&JO B^N '^/Y/ C/Z JVWm 7-0 7477 <>7?r^7tp7*777 & 7^4/t?77*9<L C^4yC4> C<?t9tQ to t477 t7 C - 'P/tCS^ ^47/~" Oast/42s 7~s Os-7 ~-r/4 SSTiiA/yOT/ ^PoTS -V 427*s?t}*7 0 -.i'^sT^ Scr4//d77'7ik' POuj/o" SYSTtsV //Si J/7t~ TA?7}T 77 TOsZ. 74-44./> &L77~4 V TK/PS T~h $TsFt4*77 y'spT-Us' fS 0>77 4.4 <Sye*ZY ZCyA7^S sk>ufp/ua steam -r&/> Sorrows /s P>7`c*r~'0 &y A OOVS& AjM/OM PJZE i/ss 7-S /^5T PtOO/ Gts 7>7 C 7-^7 PS. SL 012066 | FETROconjnc. H CUOil1 iUthi . Subject to Protective CroSist Of 14th Judicial District Court EMGIMEER5 Q DE5ldHEF&-1145 Pag. * ** of 7^r-^~ P. 0. Bo* 3871 BMumont T.xm 77704 713-842-2417 Cli.nl <%>.'ijr/jrz Z4. . R.f. -- Oat. , m. (WJ./s--fk^s&jjrY s?&0Y./EU3zr *, Sublet *** Ch.<k*d By &4t/lWtr EOT OE E4UHVAZS& <EOTOOUVE ZTSTE*/ Birr pass - Sotu vlouj me.'e. by passed po. OK>e NriCiofe OU STfttTuPS - 6/S7GO ^=0,000t,e5 # Trr C/Vr.jc/7VCs/ 7~> ^0 7" & Y S>r = FO&x Ji/r&wr/c. 3C0GK /*/ r/*s s/sr^^/Z^i rVr'5 6////^ /J Oa/c. V 6.8/ X/O /}y/& /^A-z SL 012067 s COHFiUp-- -- Order ' 1I .i Su' b. lett +to-n proteDclBt!tri. ;tj Court f i M'xMi 'Ac-TjMre* PfTftJi*. 0. vV/K* z/O /F/is TE Afl *& Ci !M, E>, 0.003 0tOQ!$/vsAX N rj-----x &F> F I'.HtVt' ' F4>- l SJM lU^fa a T Ai 0 OQZV/rf Fife /V Future j/s&4 '-'SAPS /NrftnTES MW UuO tAPLOfit* 0.00 H Soti*t PueNhOES 1 /1^2. 'TSAiCi //-- eT^-e *-) i fotOA* M//&/*7-/a*j s v t. Te^t cicszs&e or Born s.teaaa ; . 5/V^^V^ fALygS & S&Y TAEEEfs) M OAj> 7~/~i * . t-. SL 012068 TT.i1. : -i ';'I Il t St I ' i .; _ edc c'f/ifjs//s Yo&jafes X 4 F/tutr TEEE XQ : /~AtLa#E of Stwrjot&- STEAM SYAM W : /?/! tfSTUE Y t3/f/3& ;...... __ ________ : BA i/j)?cv(6' .c : SubieC* ot ith *' l i * r _:2mt-Wtiiv w T(*E toYsA> UfVfcifeO 2/VTt IS Vjiu SuoOtL ^os>\*\vJ<a *0>nrw A ,^wuPv*y<j. sj-C(V^;...U fir LV C _S?<?W) Du SiVP.lTC^, : P^U IS JJdt J*Vv^t*S.Y> u*Vv4 THt ;**-*viKL ; M4w^t^6itfT WitCM <5V^ /* 1MOT00MS /ifas i ;. ; i,,. " 3L 012069 -1 -- t-- I --. - tt ;i t 5 * i j/fc 1. jf SWO-pf'*W2, - - -.:................ ^IcP^M 0<v\mC ^ .^'rvO siovtciAG.^; Arc s>ewsUlo t*c> * tSL m 4k Ofe*sJ JojSfTltw A- ,SROT&6^#0 t?* ^iTrfVrEp. J I I j \....... - J. ,, . _.. &.. .4 W74/6. 5 ; /v44/4r Xi9 ; $/ri*f f/Ute d?4?At ft'Y'vZyO'DATS! J('LL'Y ........:.... L. .; *.:,..... ___ >-i/j&j_lLx ^/j/&C I IPETROConjnc. Subject tm fret0?M i of 14 th Judicial EhGinEER5 5 DESIGNED Y?J? P.O.Box 3971 BMumont Tmm 77704 713--842-2417 Pag* Job No. Of 7&r7 Clint job -.^5- <Z4(4*L& ^ ZJ. /V - fets/?/w<L/rY R,f. Dal* / 3uetzzr By /Z4Y&/6JTY Subject <604^/4/6 -Oxj? S&ZTV*? && &7? AM*6g Chkd By ^ ^ &r*/z ruP .5 ?. 4 - 5# ^ /?s97-^ G> /Ye. a K ^><^9 Action < v>''E.tCi T*a'-,c a^EgftroR, Trr CY//r.L, 3 V 7VCs/ 7~# /*> 7~ 3 Y /V- ra&x Ayr&sr.Yr/c- Sc&c*: /<v r&s s^s-ss; ///rr^/Zsrl :'W5 4///cf /J Oa/l-Y' 6,8/X/O /}s/Y> /7YK3 ^v-'JT //A~C^C73TYP. SL 012070 COHFXDBKTIAL: subject to P:!pf^:.hrict court IPETROCOn.inC.I o 14th Judicial Dis_^ B------------- ----------- B P. O. Box 3971 Beeumotrt, Texe* 77704 7713--842-2417 Pag* ______ Of ______ Job No. .ZS..f-F_ Client m. t&s-* jz-r ffet/sl^MsrY ,, Ref. ... Date . 9/zz/fa___ nsw' .ue '777T ^ s?s/ V Subject _ - PS1/ FlFL a Checked By A>A l/ltZ// /, z>t/ry -0,0 /-/fat OF c//Af4?/FA77 <>**/ &f O&s-' r'jt/FFyy? / (gP 'ZOO *F~ 92 SrO'/c# FeJ " <7-5 /A - Od>(3^ CHP&^ - 00 957 /6/A/s. S /= 7 FsSSSS S/ m /.) /S'f /fZi)l;JU 7 /?FSSUF. = 173.7 />s,A. A~ O ~ipr ~n), C K f -fPT - 00 9S? ~i Y~J- 3 "20* O, 970* //? S? 7j 92 ( 4 " 4.2 2. "n /Sfxr ZA6aZ &F/F/OS / s A/ &.>F/0 A4?' 54 v/v ZJ A7SOO/7BS Ft 4" /F/T AS/0 0 V OOFosr /?$ / 4S sFFrS/0///F<Q /S Aa/ '4 F^/F'/Og. 4// 77/ 203 /A/ 2. A/07" S/zazf/pl /j&aA 7~~ / / ........... I--................................. " -- - I -- ----------------- -- * 0 * / / C&MA00A/0 /A/ FAFF'a S/aS/Z / '/ ZfA/jA/T~>' ^_ ///'//> aV/ // f / / /a A % '* /7 SL 012072 I EnQinEER5 Q DE5IGMER5 P. O. Box 3971 BMumont Twm 77704 713--842-2417 Client AAA Z/t, R.f D -/> -AjA 4 YYYYZZT- ,xYy;/1&/c;TY ,?r^y /.EY&t 2ZZT By Pag* -- Job No. /AA/YecLEY **i- /3sy- -SJ/ur&VAJ ' Y>Ya//WYS rww By &/)/&: /. Ti&o c~*&>Ji.ea S/-s?s<zrts& STARTUPS gQO/&D 3^ P<ll/ s ZMtsT# <?*UaS S . 2. &< Y/ YA i//?As>/e C&/4> s*s/r;*r& j#or&s>*JAj. 2. A S~ /YY y&cYy &cdr&yy.y}d. E/9/. issues . 4. 2.4 / YA 6&S S eE &>;ttYE/cA* /=Z&uJ 5 0'6 / ^ SY^E/dX/s SAt&r-A&^sss (<A?z/**/ZizuY zsi. Q.O> / V -TcuTAL - iootf/ ^TKAM PfrJTO(Z Zr4As1 7-&E -- )*/ -/^EAdYcDA? , 3Z`/a -- Ii)uoT hrE^-M (t* \W\vai;mV) , Sj^/o fi?Fr/d'sS Ts/fc. -s; SrEFs/s* /YpdiTOE & E Fry/py oz^> s 7. 3 y. . y/J y,<s rp/3 SrdYY , / % > -- /_ dSStTtO, rsY YF Y C~//7~ YE r^S 7~ -' S 7Y~y/ T l"'y/<Lt_ .g^T -~F P sd.YJ ~Y s ~ 7~>P.~ <Y "~ -- Dy.'YYYjFY.s Y E/i /FY FYY/yYF /' -. YEYY. AYYYZrED Y2s?S/S YYY SyYEA^ /YPdEY/2. 1. 7~tf/d> SdYEVULEO SrFFFYY YEY YYAY YLY Sry?an/Y Y<F<?dJs*:<>> py ^/s/F -'rsv# s/J. 2. 6 Y/y'Y S/lPdF gi,#t- /Y/rs/irFF <#vr5 3. ^,'.r/w 4. . Zg/y'Y 5. Y- $ r/YY Yc. s-Y/yyP.F. Yrs: .: - DcuTYggY YddutS '* v yp>o /s /2 Y/m/jyy y Bsi. .-y/ajFst) 1\ SL 012073 I PETROConjnc.] ENGINEERS 5 DE5IGriER5 P.O.Box 3971 Beeumont, Texei 77704 713-842-2417 Page Job No. Client Job -s'sr'Aj? ________ Ref. A3rz^tf//TY' STZS&'y'. 3.-A Date /2<J By Subject At&erg'A?- y#ss y'y&L**/ Checked By Of '/!9/S'7 jCbi^r#/?M y/^Arz/y yf^^^/yr/y s?&cx/yews y/S-Mo/$/d>/ <?/&s/?/)0*/a/T A(5 /y'Y' // / , ' /- : y:-..J y^/uszss yy-//y^/s -s&sr/c&*o 2.1 &, / c. / * 'fe x y$ X -V? /t^v -/fexxt6 /ysr ycosey> = 344/y^e DU&/AJ<$ . V'y>r-j>e pa&Atei /vejewfic. &x>&ex>7y<o*s j^r/syr^s -y -9/W r/osj <** C. /0/Yk CONFIDENTlM** Subject to tco^feetive 0l"er of 14th Jlidici.il Oistiict court no* gl"li45 SL 012074 Pfr&AjjA/e >/z. &?> w** systxa* /r>7~=. 0*3 ( Sams Fen. tfj-U F/ouj Sutra**) ; W &?// ' ' ') r=0>r- 4/36- .60S <9 = -C r=yz rpr- ,oI) Per* .022. *07* ,00/ SL 012075 s,n ftw^ t f^t/cT 7^ee -2T/P, $/?/}&. F/r^k'c//^> _______ ^ MO /P/47JF. W.L S/fiKhY S2/&/74 i 'i * s i i \ J -i* t i * ' ; COfTFIDEITTinr ` - Subject. to Pr CTt>rP.y 0-;' - f- - CS 1 `i th I JuP:;:: i r-I r5 it 1 I'cu.'ur-f: i j No. S1-11-45. |pETROcon,inc.| Cllant COKTlt^Ti:X?iI.s Subject to iPrc.tert.ive Order ErtGIWIEEfSBli3Plgg|^rict CMrt P. O. Box 3871 BMumont &71 713-843-8417 Pag* of ------------- Job No. _ R*f, Oat* .____________________________________ fZ/pte -* ifmjr- X,rv/>/2/v7Y srt/OY. J2ZT______ * >JH_ J2x*/77Vjef //&trs& - ZM#reu/A/ n-^< - <&X*iL S=v?r t/r /buma&f Alstosa Swr/K>w SL 012078 CO^FIDE^TIAI.' "Mf^JEfSS;g&ctJiVefcOruCeoi urt ~- . . .............................Q 14th Judiocial14th I PETROCOnjncl.............. ............. M EMGinEEre5DE5idte&1' P, O. Box 3971 713-842-2417 Beaumont, Texas 77704 1 -/as yaaels Client Ref. Date SO Job y/C/sfJZT- S?e/.a4&/l/tY stody , LBS/21 2ZZT r Subject Heater- i/AP>& Derecrz> s&.Checked By Page Job No. Of /l/SL2 Ssr Sd>M^X j FA/L2 to cow TeAO/a/<$ - P/A/jcts /yr TAE POW7YEPM AEATER AAS s 1X A4A0/2 OETEGTDjeS 4/2CC///D the FEF/m222/2. YJsSua^t a Oca?c/2> 2GA/7TfO 7~s T\A/& z) >&`r-C7&*2 s FA&fiSi El/EAY >/&-<- 7*/. CSSE TWO fc) DEGREES OF /^EDOa/DAWCY . /V- A 7~/y- Sx^/-or/^iS)/ = 2 /YK y 7~= 4.TYZ FF# OPFFAT/SS6 YEAR S/A/CE AAA OpRJ? 4 T/W4 YeA/Z EGA. 7~A/<E DO\HTHEAA4 HEATE/Z /2 OWDY /O OE 4 S2>a2s*?/42- Y/=aaz SotA TS/E AA/LoRE AAA4 T2ST 42/2/OD /s 4DTOST2& TO JZE TIEGT AOTt/AL 0>A2AAlT/aS<$ t~sa#e:. = -2 /YEAR ; / =0.02 YEA/2 7~AE TWO 4CT//4L TESTS OT THE /AY#? ?T6r04 SPd/T'povUAA SYST/2/4 S//GU/C 02 AA/OA TZ> TA2 S^AEOULED S TA/2TU4S r // = a.Z (.oOJj-x/>&t>r(-=///&- //- /. 7 {//}) SL 012080 I FETRQCOnjne order t0 PrAl^triGt CU Page ___ 0f ,, Job No. 7*4. 7 Client t /*A Ref. Date Job J^Js?3F/feud&yrv tMFt, J7T_______ By sublet IhwrMZZM A/esinr# -/d/h* ^trst/z/? /<^//s/jfy_________ By >UjZ/)<ll r&r gp- //}/&/? Ysrstra# .z#Jt&d\a/aj W/lr SL 012081 IPETROCOhjncI EnQinEERS 6 DE5IGnER5 ......... -- ----B P. o. Box 3871 Beaumont, Texas 77704 713-- 842-2417 Page Job No, Of $7 Client PPP -1 i l .! r/ III- *I IN ! "II PIT v --c * ' T"R'e,#f. ...y<//?rr- ^k^ac/TY g^gv Job '' "-- /swttt: //.~.T^ - /'J/L/sSz . Date '/'/ft By - Checked ^ _B>MypjLU J.C2T /?/%r MP S9/2&// t&SY M>. $//vT0/r/ /jas/r //s SjCM/tS - (9 - <? ?2S ; Pf/rf#/*//*/<'? <z?Pa/ ^ \ o \ Z O f- K/kitT Tt 3k ^ NtO'Sf 0.V\ft--ri OtO $~C>\L Ow \)v9o?- bt-T tcroZ% , M^) ^ TCS T \ *0 ^ coru'iBOTiKt't , v i -.vLr-C hi "6 Order S^b^ncc to strict Court ai Hth JUa't t. j u \ f SL 012083 | PETRQCon,inc| EMOinEERS 6 DE5IGnER5 P. O. Box 3971 Beaumont Taxaa 77704 713--942-2417 Page _______of Job No. 1?- Cllent _______ Ref. Dole ------------------------------------------------------------------------------------------- uk y^JT-sr^Y, *i/L -Z2ZT~8y Subject 7Z&A*f // ~* MyrJ~/27T- Checked By lifft(Qt d/XML swr ^ /Jm-jr/2 Sfryrm'M/ ,<;yst&*s> COOTIDENTlMbt SL 012084 "" "---------------M IFETROCOdjnCi ------H EdGiriEEFS5DE5IGnER5 P.O.BOX 3871 Beaumont, Texae 77704 713-842-2417 Page Of ------------------ -ZZ.S7 Client FPF - ZS/dPlPS, /A. JBb /SMFT- /?<LM&/ury Ref. Dote . , /I/L JZT By ...FF AGILE'S Subject J?0i*/TS/#M //ZAT/Z/e - Tf C LOcP Pa/<-UL% Checked By .. &AY\dNtt^ Z/^rz/? dt/ri&r <F>s*? As/>/T 7" = 7~~r ~r/ c T~l/ {tail: <?6Z>cZ>) P^pp/ r/o sj<ta; FpssxeeL 7~/<z OAN6/Z - PAST* 3PN 0.2 X '/9 a. r A o. r" X &. z X '/9 0. z A '/* <S ~ O, />/ 'T/K Oa" T^/tsfs?2/?ATOP c~Gi&/2> /aJ 7W/T &p,j-r/ci*s /?<l4c P/^>a?*/os oas : 1. TU/5 asja<_L. 7as>p&jzatuge 2. A//4H Srst^K T^7 t?je4TJ/Z.j 3 A//6tf &3>iA/r#AZM ^rcer rs>*t/?ss/zjm/&iE Z/s /T/f/^O/eS P T#E T7VB. 5/?4Ar TE/s?PArup spajSo&s. {AeaM&ALY <Zpss?A*r&AS 2Tajstupas p/s7~ ra& p/?p/7p 7-/ A x<s /}PO Ppr^A/TSO^^?? ysrf TP Z`/2P/cT'' TPas? TUZSlj 0/- O.&Gt. CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 SL 012086 I PETROConjnc I En<3IMEER5 G DE5IGMER5 P. O. Bo* 3971 B**omont T*** 77704 713-842-2417 Client job Subject R*f. sr&#Y , ~lH~ZBy Dot* //7~&^ ~~ TIC* G&P fijJLU^S S cheeked By Pag* Of 7Job No. ^ Bd l/irZWUa- dtfXML M?r M/UWJ&/!/fe>?r&2 Swr/v--#/ Syst^as? SL 012087 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 3-4 Dow PMP Stop HS/HI-9953-A/B Subject to Protective Order of 14th Judicial District Co No. 91-1145 - This is a pushbutton/1 amp, unlit normal and steady red when both pumps are down. Momentary pushing of this pushbutton will trip either or both of No. 2 OHC Rx dowtherm circulation pumps. The pumps can only be started in the field. The switches and lights located on 0IP-6B associated with the dowtherm system are: DV-8/D Furn. Run/ Bypass i 6BB-8 - This is a key operated switch used to bypass the dowtherm heater shutdown and deluge valve No. 8 that is activated by vapor detectors 6B-8, 9 & 10. It does not bypass the remote manual trips or any other shutdwon feature. While in the by pass position, a red indicator light labeled "System Bypass" will flash. This light is located at the top of this panel. DV-12/SD Run/Bypass - This is a key operated switch used to bypass the dowtherm heater shutdwon and deluge valve No. 12 that is activated by vapor detectors 6B-13, 14 & 15. It does not bypass the remote manual trips or any other shutdown feature. While in the bypass position, the red indicator light labeled "System Bypass" will flash. DV-8/D Furn. Trip - This is a pushbutton switch. When momentarily HS 6BD-8 depressed, this switch will trip the dowhterm heater and cause the deluge valve No. 8 to open. DV-12/SD Trip - This is a pushbutton switch. When momentarily 6 BD-12 pressed, this switch will trip the dowtherm heater SL 012090 and cause the deluge valve No. 12 to open. f , . to protective Shutdown Dow Furn. Trip This is a red indicator lamp that flashes when any of the above vapor detector shutdown features initiates an intended dowtherm furnace shutdown to the "Flame Management System". The lamp is steady red when acknowledged and unlit in run. VII. Dowtherm Heater Start-up Sequence 1. The Dowtherm Furnace run-block switch on OIP-2 must be in the run position. 2. Place "Stop-Run" switch in the "Stop Alarm Reset" position, apply power to panel. "Power On" light should be on. 3. Close the 1 1/2" and 3/4" natural gas valves immediately upstream of the burners and pilots. Be sure that the factory mutual valve and the fuel supply solenoid valves are closed and the fuel vent solenoid valve is open. 4. Establish 1000 GPM dowtherm flow through each pass. 5. Open the secondary air registers wide open. 6. Place "Stop-Run" switch in run position. The "Limits Normal" light and "Purging" lights should come on: If the "Limits Normal" light does not come on, check the status lights on the first out annunicator to determine which limit is not satisfied. The limits which are not satisfied must be cleared. If theMPurging" light does not come on, check that the proof of closure switches on the factory mutual valve and the fuel supply solenoid valves are made. SL 012091 enh. UC0NF1DENTIAL: f 14th Judicfal^ist'' rdSr ";i-urict curt 7. At the end of the purge period, 5 minutes, the purge light will go out and the "Purge Complete" light will come on. Power is now avail able to the upstream fuel supply solenoid valve. The fuel vent valve should go closed at this time. Manually open the upstream fuel supply solenoid valve. The fuel supply pressure control valve should be set to maintain 30 PSIG downstream. 8. Check the atmosphere inside the furnace with an explosimeter to assure that no residual gases are left in the heater. 9. Open hand block valves on the pilot header. Pilot gas pressure should be set from 2 to 5 PSIG. 10. Push the "Push To Ignite Pilots" switch. The "Ignition On" light will come on and the run trip lamp on 01 P-2 will go out. If the ignition on light does not come on, verify that proof of open switch on the upstream solenoid valve is made. Hold the "Push To Ignite Pilots" switch until the "All Pilots On" light is on. If all pilots do not ignite, and the U/V scanners do not see a pilot flame within 10 seconds, the "Ignition Time Limit" light will come on. 11. To clear this alarm, push the "Ignition Time Limit Reset" button and hold until the "Ignition Time Limit Resetting" light comes on. After approximately 40 seconds the "Ignition Time Limit" and "Ignition Time Limit Resetting" lights will go out and a restart may be ignitiated with step 8. NOTE: During steps 4 through 10 the downstream solenoid and factory mutual valves must remain closed and be proven so. If at anytime during steps 4 through 10 either of these valves are opened, the system will trip and you must place the "Stop-Run" switch in "Stop Alarm Re set" position and return to step 4 to start again. SL 012092 Subject r.o Protective Order of 14th Judicial District Court No. 91-1145 12. Place the temperature control valve in manual and open it 25% open. Close the secondary air register to H open. Check to see that the primary air door is partially open. 13. After the pilots are on and so established by the U/V scanners, then power should become available to the downstream solenoid valve. Manually open the downstream solenoid valve. (Note: The factory mutual valve must remain closed and be proven so or the downstream solenoid valve will not open.) 14. Open hand block valves on the main burner headers. 15. The main burners are ignited by slowly opening the factory mutual valve. (It should be located so that the ignition of the main burners can be visually monitored.) If the flames become too large in the process of opening the factory mutual valve, then close back on the temperature control valve until the factory mutual valve is fully open and the temperature control valve is giving satisfactory flame size. Adjust the primary air door to give the minimum size stable flame. Adjust the secondary air register to give the desired excess air. 16. The main burners only can be turned off by pushing the "Main Burners Stop" switch. If this method of stopping main burners is used, the factory mutual valve must be closed and return to step 12 to relight the main burners. 17. The main burners and pilots can be shutdown by placing the "Stop-Run" switch in the "Stop Alarm Reset" position, by the remote manual trip switch on 01 P-2, and 0IP-6B. To relight return to step 3. SL 012093 . _ t_> \ 18. If any limit opens anytime after the "Limits Normal" light comes on, the malfunction will be annunciated by the first out annuncia tor and all burners (main and pilot) will be shutdown. The fires out lamp on QIP-2 will flash. The unit may be restarted by clearing the malfunction and returning to step 1. 19. If a flame failure occurs at anytime the "Flame Failure" light will come on and all burners (main and pilot) will shutdown. The fires out lamp on OIP-2 will flash. A restart can be initiated by returning to step 1. VIII. Typewritten alarm messages associated with the Dowtherm Furnace Shutdown System are provided by PLC I. the amber PLC I typewriter message indica tor alarms when the PLC I operates. These alarms are provided prior to shutdown and when shutdown occurs. They are also provided during start-up and anytime the shutdown system is bypassed. The typewritten messages for the dowtherm furnace provided by PLC I will state the time, seconds and tenths of a second, dowhterm furnace then a code number. The code number will indicate the following: 210 Dowtherm Furnace Deluge Valve Initiated Trip 217 Dowtherm Furnace Trip Flame Out 221 OHC Rx Area Dowtherm Furnace High Vapor Detector 8ypassed SL 012094 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 FURNACE SHUTDOWN SYSTEM I. The furnace shutdown system is provided to stop fuel gas firing of one or both furnaces in the event that undesirable conditions develop on the furnace or in the area. In addition to stopping the firing of the furnace, in the case of a vapor detector shutdown, snuffing steam is automatically started into the firebox and the deluge below the furnaces is started. The system also monitors the operation and start-up of fuel gas burners. The undesirable conditions to be protected against are: 1. Loss of flow to one or more passes on a furnace, while it is being fired, resulting*in tube rupture or damage, or refactory or structure damage. 2. Ignition of a vapor cloud by the furnaces, resulting in a fire or explosion. 3. Accumulation of fuel gas fn the furnaces, either during start-up ignition or during normal operation, which could result in an explo sion due to fuel gas vapor cloud within the furnace. II. The conditions that will cause a shutdown are: 1. High or low fuel gas pressure measured at downstream side of the flow control valve to each furnace. 2. Any damper, plenum or stack, going fully closed. 3. Total Flame Failure. 4. Manual pushbutton in the field. 5. Power failure to the Flame Management System or PLC III. 6. Loss of flow as determined by any two out of three inputs of the two furnace feed flows and one tube metal temperature per pass. 7. Any two vapor detectors designated to the furnace shutdown system sensing a LFL of 40%. SL 012095 Subject to ProtTI?L; of 14th JudiciffnCtiVe 0rder &sLu:?iGt 8. Manual pushbutton in the control room on the vapor detector panel, 0IP-6A. 9, Manual pushbutton in the control room on the furnace operators panel, 01P-4- III. The actual inputs are: #1 Furnace (To PLC III) FT-3011 #1 Furnace #1 Pass Feed Flow FT-3016 #1 Furnace #1 Pass Feed Flow FT-3012 #1 Furnace #2 Pass Feed Flow FT-3017 #1 Furnace #2 Pass Feed Flow TE-3616 #1 Furnace #1 Pass Radiant Section at Floor TMT TE-3618 #1 Furnace #2 Pass Radiant Section at Floor TMT TE-3621-B #1 Furnace Center Chamber Bridgewall Temperature HS-3809 Board Mounted Trip Switch #2 Furnace (To PLC III) FT-3061 #2 Furnace #1 Pass Feed Flow FT-3066 #2 Furnace #1 Pass Feed Flow FT-3062 #2 Furnace #2 Pass Feed Flow FT-3067 #2 Furnace #2 Pass Feed Flow TE-3666 #2 Furnace #1 Pass Radiant Section at Floor TMT TE-3668 #2 Furnace #2 Pass Radiant Section at Floor TMT TE-3671-B #2 Furnace Center Chamber Bridewall Temperature HS-3859 Board Mounted Trip Switch Vapor Detector System (To PLC III) 6A-1, 6A-2, 6A-3, 6A-4, 6A-5, 6A-6, 6A-7, 6A-8, 6A-9, 6A-10, 6A-11, 6A-12 HS-3800 Board Mounted Trip Initiated Switch (Manual) SL 012096 HS-3905 Field Mounted Trip Initiated HS-3801 Field Mounted Reset Switch 1A'1 ? i-i ft J UUrQ? ivC' c -l11.33 J'1"-t er-f- V Vg r, Wo' Co Ur < #1 Furnace Flame Management System (FMS) (KTI Package) ZSL-3803 #1 Furnace Natural Gas Double Block & Bleed Position Switch ZSL-3805 #1 Furnace Stack Damper Position Switch ZSH-3805 ZSL-3806 #1 Furnace South Chamber Plenum Damper Position Switch ZSH-3806 ZSL-3807 #1 Furnace Center Chamber (South) Plenum Damper Position Switch ZSH-3807 ZSL-3808 #1 Furnace Center Chamber (Pair) Plenum Damper Position Switch ZSH-3808 ZSL-3817 #1 Furnace Center Chamber (Pair) Plenum Damper Position Switch ZSH-3817 ZSL-3818 #1 Furnace Center Chamber (North) Plenum Damper Position Switch ZSH-3818 ZSL-3819 #1 Furnace North Chamber Plenum Damper Position Switch ZSH-3819 ZSL-3832 #1 Furnace Natural Gas to Pilots Block Valve Position Switch ZSL-3834 #1 Furnace Natural Gas Manual Vent Valve ZSL-A051 to #1 Furnace #1 to #28 Burner Supervisory Valve Position Switch ZSL-A078 PCI-3621 #1 Furnace Center Chamber Bridgewall Temperature High Switch PLC-3809 #1 Furnace Trip Switch from Control Room PSH-3423 #1 Furnace Natural Gas Pressure High Switch PSL-3423 #1 Furnace Natural Gas Pressure Low Switch BSL-A001 to #1 Furnace #1 to #28 Burner Flame Out Switch BSL-A028 PSL-18 #1 Furnace Operators Panel Low Pressure Switch PSL-19 #1 Furnace Fireye Amplifier Cabinet Low Pressure Switch PSL-20 #1 Furnace Controller Cabinet #1 Low Pressure Switch SL 012097 CONFIDENTIAL: Subject to Protective i dt-h Judicial District 4 PSL-21 #1 Furnace Controller Cabinet #2 Low Pressure Switch HS-A101 to #1 Furnace.Burner #1 to #28 Ignition Switch HS-A128 HS-A506 #1 Furnace Trip Switch Field HS-A001 #1 Furnace Alarm Reset Switch HS-A500 #1 Furnace Start Switch #2 Furnace Flame Management System (FMS) (KTI Package) ZSL-3853 #2 Furnace Natural Gas Double Block & Bleed Position Switch ZSL-3855 #2 Furnace Stack Damper Position Switch ZSH-3855 ZSL-3856 #2 Furnace South Chamber Plenum Damper Position Switch ZSH-3856 ZSL-3857 #2 Furnace Center Chamber (South) Plenum Damper Position Switch ZSH-3857 ZSL-3858 #2 Furnace Center Chamber (Pair) Plenum Damper Position Switch ZSH-3858 ZSL-3867 #2 Furnace Center Chamber (Pair) Plenum Damper Position Switch ZSH-3867 N ZSL-3868 #2 Furnace North Chamber (North) Plenum Damper Position Switch ZSH-3868 ZSL-3869 #2 Furnace North Chamber Plenum Damper Position Switch ZSH-3869 ZSL-3887 #2 Furnace Natural Gas to Pilots Block Valve Position Switch ZSl-3889 #2 Furnace Natural Gas Manual Vent Valve Position Switch ZSL-B051 to #2 Furnace.#1 to #28 Burner Supervisory Valve Position Switch ZSL-B078 PLC-3671 #2 Furnace Center Chamber Bridgewall Temperature High Switch PLC-3859 #2 Furnace Trip Switch from Control Room PSH-3473 #2 Furnace Natural Gas Pressure High Switch PSL-3473 #2 Furnace Natural Gas Pressure Low Switch BSL-B001 to#2 Furnac'' BSL-B020 Rm-ner Flame Out Switch SL 012098 PSL- #2 Furnace CONFIDENTIAL; to Protective Order 5 PSL- #2 Furnace PSL- #2 Furnace PSL- #2 Furnace HS-B101 to #2 Furnace Burner #1 to #28 Ignition Switch HS-B128 HS-B506 #2 Furnace Trip Switch (Field) HS-B001 #2 Furnace Alarm Reset Switch HS-B500 #2 Furnace Start Switch IV. . FT-3011, FT-3016 measure #1 Furnace #1 pass feed flow. If FT-3011 drops below 15 gpm then a vote is cast after 30 seconds to trip the #1 furnace due to loss of feed. FT-3016 functions in the same man ner. An alarm is generated at 25 gpm on droppinq flow. TE-3616 measures #1 Furnace #1 pass outlet TMT. If this temperature rises above 1550F then a vote is cast to trip the furnace due to loss of feed. An alarm is generated at 1500F on rising temperature. If any two votes are cast by FT-3011, FT-3016 or TE-3616, then the #1 Furnace is shutdown. FT-3012, FT-3017 measure #1 Furnace #2 pass feed flow. TE-3618 measures #1 Furnace #2 pass outlet TMT. These each cast one vote to shutdown the furnace at the same values as given above for FT-3011, FT-3016 and TE-3616 respectively. If any two votes are cast by FT-3012, FT-3017 or TE-3618, then the #1 Furnace is shutdown. Si. 012099 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 6 TE-3621-B measures the #1 Furnace center chamber bridgewall tempera ture. This is used to switch on a signal to the #1 Furnace Flame Management System at 1400F. This signal is used to bypass purging on furnace start-up sequence if the temperature is above 1400F. HS-3809 is a board mounted trip switch that can cause the shutdown of #1 Furnace. All of the above mentioned shutdowns are the stopping of furnace firing only. FT-3061, FT-3066 measure the #2 Furnace #1 pass feed flow. TE-3666 measures the #2 Furnace #1 pass outlet TMT. These function in the same manner as FT-3011, FT-3016 and TE-3616 described above except they function to shutdown #2 Furnace. FT-3062, FT-3067 measure the #2 Furnace #2 pass feed flow. TE-3668 measures the #2 Furnace #2 pass outlet TMT. These function the same as FT-3012, FT-3017 and TE-3618 described above except they function to shutdown #2 Furnace. TE-3671-B measures the #2 Furnace center chamber bridgewall tempera ture. This is used the same as 'TE-3621-B except on the #2 Furnace Flame Management System. HS-3859 is a board mounted trip switch that can cause the shutdown of #2 Furnace. All of the above mentioned shutdowns are the stopping of furnace firing only. SL 012100 CONFIDENTIAL! Subject to Protective Order of 14th Judicial District Court No. 91-1145 7 Vapor detectors 6A-1, 6A-2, 6A-3, 6A-4, 6A-5, 6A-6, 6A-7, 6A-8, 6A-9, 6A-10, 6A-11 and 6A-12 are used to detect the presence of flammable vapors in the furnace area and the adjacent south end of the process area. These detectors are also used as inputs to the deluge system. Refer to the deluge system write-up for information concerning opera tion of that system. Should anyone of these detectors sense a 20% LFL of flammable vapors then a vapor detector alarm will sound. At 40% LFL,anyone of these detectors will cause the deluge valves in the furnace area and south end of the pro cess area to be turned on. (Including the hydroshield.) At 40% LFL(each of these detectors cast one vote to shutdown both of the furnaces. If any two of these detectors cast a vote then both furnaces are shutdown. In addition to stopping firng of the furnaces, snuffing steam is automatically started to both furnaces and deluge valve #1 (water spray below furnaces) is started. Each detector may cast only one vote per occurance. Pressing the reset button on the particular alarming detec tor or causing that detector to alarm twice while the system is "Armed" will not result in a shutdown. It requires that another detector reach 40% LFL for a shutdown to be initiated. The occurance is "over" at the point when the reset switch, HS-3801 is pressed. HS-3800 is a board mounted trip initiated switch that manually activates the shutdown of both furnaces in exactly the same manner as the vapor detector shutdown. It stops firing of both furnaces, turns on snuffing steam to both furnaces and turns on deluge valve #1. In addition^it also starts deluge valves #2 and #3 since these would also be operating in the event of an automatic vapor detector initiated shutdown of the furnaces. SL 012101 Subject bo oistn 8 of: i144tthh JudlCl NO. ,_U45 HS-3905 is a field mounted trip initiated switch that functions in exactly the same manner as HS-3800. HS-3801 field mounted reset switch is used in the event that one of the vapor detectors cast a vote to shutdown the furnaces. If the area is determined to be safe and the reset button on the alarming detector is pressed, then the field mounted reset switch, HS-3801, is pressed and the vote cast by the detector is cancelled. This switch is located on the furnace oxygen analyzer house. If the detector is determined to be faulty then it should not be reset. This will leave it in the alarm state. The reset in the field, HS-3801, may then be pressed and the vote cast by the detector will be cancelled. This bypasses that detector as far as the furnace shutdown system and deluge valves #2 and #3 are concerned. If at anytime the detector is determined to be 0K;it may be unbypassed by pressing the reset on the front of the detector. f This switch is also used after a shutdown has occured, to reset the system. All of the above described inputs are to PLC III. All of the functions and logic are provided by PLC III. The following inputs are related to the Flame Management System (FMS) for #1 Furnace. The following is a description of how these inputs function in that system. In all cases the shutdown that results from the FMS is to stop gas firing of the furnace. SL 012102 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 9 ZSL-3803, #1 Furnace Natural gas double block & bleed switch is used by the FMS to identify when the main gas supply to #1 Furnace is off. This valve must be closed prior to purging the furnace for start-up. ZSH-3805, #1 Furnace Stack damper wide open position switch is used by the FMS to identify if the stack damper is wide open. ZSH-3806, 3807, 3808, 3817, 3818 and 3819 - #1 Furnace plenum dampers wide open position switches are used by the FMS to identify if the plen|m dampers are wide open. All of the dampers, both in the stack and in the plenum must be wide open prior to purging the furnace for start-up. ZSL-3805, #1 Furnace Stack damper closed position switch is used by the FMS to identify if the stack damper goes closed. ZSL-3806, 3807, 3808, 3817, 3818 and 3819 - #1 Furnace plenum dampers closed position, switches are used by the FMS to identify if any plenum dampers go closed. If any dampers go closed, then the FMS sounds an audible alarm in the field. After 10 seconds the FMS will shutdown the #1 Furnace. If the damper is reopened within 10 seconds the shutdown is reset. Damper switches 3808 and 3817 must both go closed, since both of these dampers supply air to the center chamber, center row of burners. The air supply is not shut-off until both dampers are closed. ZSL-3832, #1 Furnace Natural gas to Pilots Block valve position switch is used by the FMS to identify if the pilot valve is closed. This valve must be closed in order to purge the furnace for start-up. If SL 012103 ive Order trict Court No. 91-1145 \q this valve is closed during operation of the furnace^it will cause the furnace to trip. Upon opening this valve after the purge is completed, (1) power is supplied to the pilot gas header vent valve causing it to close after a 5 second delay (to allow air to purge from the line), (2) the light labeled "OK to Light" on the operators panel comes on, (3) power is turned on to all of the fireye amplifiers, (4) a permissive circuit is supplied to light pilots and continue with the furnace start-up. ZSL-3834, #1 Furnace Natural Gas Manual vent valve position switch is used by the FMS to identify the position of the manual vent valve. This switch operates a light on the operators panel for the FMS (in the field). This light serves as a reminder that this valve must be cleared prior to putting natural gas to the furnace. ZSL-A051 to ZSL-A078, #1 Furnace, #1 to #28 Burner, supervisory valve position switches are used by the FMS to identify the position of the supervisory valves. These valves must all be closed prior to purging #1 furnace for start-up. After purging, none of these valves can be opened until its corresponding pilot is on. If any valve is open before the main fuel gas block valve is opened, it will result in the furnace having to be purged again. After this valve is opened, if any supervisory valve is opened before its corresponding pilot is hit, the local audible alarm for #1 Furnace will sound. It can only be silenced by closing the supervisory valve. The supervisory valve must be closed before a permissive circuit can be obtained for lighting a pilot. If at anytime after a main burner is lit, it goes out, then the supervisory valve must be closed before the local audible alarm will silence. To SL 012104 CONFIDENT'^ oraer -Subhjeiecctt. to P ro] tetnctstric- court ,f uth 9i-u 11 allow for malfunctioning position switches, the audible will silence 10 minutes after the reset is pressed even if the valve is left open. PLC-3621, #1 Furnace, Center Chamber Bridewall Temperature High Switch, is used by the FMS to determine if the furnace firebox temperature is above 1400F. If the temperature is above 1400F after a shutdown, then the purge cycle may be skipped. This signal is provided to the FMS by PLC III. (See TE-3621-B above.) PLC-3809, #1 Furnace, Trip Switch is used by the FMS to determine if a furnace shutdown is called for by PLC III. This shutdown can be the result of any of the functions or inputs to PLC III described above. PSH-3423, #1 Furnace, Natural Gas Pressure High Switch, is used by the FMS to determine gas pressure in the main fuel gas header downstream of the fuel gas flow control valve. If at anytime after the first ,, main burner is lit, the gas pressure goes above 15 PSIG, a furnace shutdown will occur. The FMS also uses this signal to send and input to the control room alarm system via UJR-3424. PSL-3423, #1 Furnace, Natural Gas Pressure Low Switch, is used by the FMS to determine gas pressure in the main gas header downstream of the fuel gas flow control valve. If at anytime after the first main burner is lit, the gas pressure goes below 0.5 PSIG, a furnace shutdown will occur. The FMS also uses this signal to send an input to the control room alarm system via UJR-3423. BSL-A001 to BSL-A028, #1 Furnace,#1 to #28 burner on switches are used by the FMS to identify which pilots and/or burners are lit. If at any time during furnace operation all fires are detected to be out, then a SL 012105 CONFXDEHTIM,: Subject to Protective Order of 14th Judicial District Couc No. 91-1145 ^ furnace shutdown will occur. At anytime if one or more fires (pilot or burner) go out due to failure then the FMS sends an alarm to the control room via PIC-3812. This alarm identifies to the operator to go to the FMS operators panel to see what fires have gone out and take appropriate action. The signal to the control room can be reset at this point even if the fires are not relighted. In the event that all fires are detected to be out and the main gas valve is indicated to be closed (ZSL-3803) and the pilot gas supply valve is indicated to be closed (ZSL-3823), the FMS will send a signal to the control room, via PLC-3813, indicating all fires out. This indicator lamp on 01 P-4 should come on after any* trip is initiated, to confirm that the shutdown has occured properly. PSL-18 #1 Furnace, Operators Panel, Low Pressure Switch is used by the FMS to determine if the cabinet purge pressure drops below 0.1 PSI6. In the event that it does, the FMS will sound the audible alarm. The alarm can be silenced by pressing the reset. The FMS also turns on a low purge pressure alarm light on the operators panel, that will stay on as long as the low pressure is experienced. PSL-19 #1 Furnace, Fireye Amplifier Cabinet, Low Pressure Switch is used by the FMS in exactly the same manner as PSL-18. In addition to a light on the operators panel, a light is also turned on on the Fireye Cabinet. PSL-20 #1 Furnace, Controller Cabinet #1, Low Pressure Switch functions exactly the same as PSL-19. PSL-21 #1 Furnace, Controller Cabinet #2, Low Pressure Switch functions exactly the same as PSL-19. SL 012106 CONFPIDroEtNeTcItKiv^e Qy der 13 HS-101 to HS-128, #1 Furnace, Burner #1 to #28, Ignitor Switch is used by the FMS to initiate a pilot ignition sequence. After the OK to Light indicator is on, pressing any ignitor switch initiates a 15 second attempt to light the associated pilot. (The pilot gas sole noid is turned on during the attempt.) If the pilot is ignited during the period, as indicated by the associated Fireye switch, BSL-A001 to BSL-A028, then the pilot will remain on. If at the end of the sequence the flame is not on, the pilot gas and ignitor are turned off and a 50 second waiting period is imposed. If during the 15 second trial the pilot fire comes, on, the ignitor is stopped. If the fire goes out during the 15 second period, the ignitor will automatically come back on for the remainder of the 15 seconds. If the pilot is lighted and later goes off due to failure, no 50 second waiting period is imposed. HS-506, #1 Furnace, Trip Switch is mounted on the FMS operators panel and is used by the FMS to initiate a trip of #1 Furnace. HS-001, #1 Furnace, Alarm Reset switch is mounted on the FMS operators panel. It is used to silence the audible alarm for #1 Furnace and to reset the flame failure alarm, PLC-3812, that is sent to the control room. HS-500, #1 Furnace, Start Switch is mounted on the FMS operators panel. It is used to initiate the purge cycle on furnace start-up. The inputs for the #2 Furnace Flame Management System are listed on page 4 and 5. The function of these inputs are exactly the same as that des cribed for the corresponding inputs to the #1 Furnace Flame Management System. SL 012107 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 14 There are two levels of shutdown associated with the furnace shutdown system. The first level;is a shutdown of the fuel gas firing of either furnace. In this case shutdown means that: (1) All of the maxon valves on each of the 28 burners are closed. This is done by turning off the 120 volt AC power supplied to each by the FMS, (2) All of the pilot sole noid valves on each of the 28 burners are closed. This is done by turning off the 120 volt AC power supplied to each by the FMS, (3) Turning off all power to each of the 28 Fireye amplifier circuits supplied to them by the FMS, (4) Closing the pilot gas supply valve and opening the pilot gas bleed valve. This is done by turning off the 120 volt power supplied by the FMS to both of these valVes. This double blocks and bleeds the pilot gas supply, (5) Closing the main fuel gas by turning off the 120 volt power, supplied by the FMS, to the main gas double block and bleed. This causes the two block valves in the main fuel gas to close and the bleed valve to open. It also closes the gas flow control valve by de-energizing a solenoid valve in the air supply to the diaphram; and (6) the FMS is put into a logic state that requires that it be taken through a start-up sequence in order to re start the furnace. The first level of shutdown is managed, as described above, by the Flame Management System. This level of shutdown is caused when any of the input items, which are connected to the Flame Management System, indicate that a shutdown is necessary. In addition, this level of shutdown may be in- volked from the control room by PLC III. This is accomplished by PLC III sending a signal to the Flame Management System indicating for it to cause a furnace shutdown. This can result from any of the input items to PLC III, related to the loss of feed flow, indicating that a shutdown is necessary. These are described above in Part IV. SL 012108 CONFIDENT!*^ oraer subject J[|fStrict Court of l<th JU^o! 91-H 15 The second level of shutdown is an extension of the first level. It is involked by PLC III as a result of vapor detector inputs indicating that a shutdown is required. In this case, both furnaces are shutdown, exactly the same as described above, by a signal being sent from PLC III to the Flame Management System for each furnace, #1 and #2. In addition to this, several other things are done which are managed directly by PLC III. These are: (1) Snuffing steam is started to both furnaces. This is done, by PLC III turning off 120 volt power to solenoids HY-3810 and HY-3811 (#1 Furnace) and HY-3860 and HY-3861 (#2 Furnace) which are in the air and nitrogen supply to the diaphrams of HV-3810, HV-3811, HV-3860 and HV-3861 respectively. (2) Deluge valve #1 is started. This is done by turning off 120 volt power to DV-1 which starts water flow by bleecfing air pressure off of the deluge valve activation circuit. (3) Note that deluge valves #2 and #3 will already be on as a result of the first detec tor reading the 40% LFL. Refer to the deluge system write-up for details on the operation or activation of deluge valves or the system in general. The second level of shutdown may also be activated as described above in Part IV by a board mounted hand switch, HS-3800, or a field mounted hand switch, HS-3905. The vapor detector initiated shutdown of both furnaces requires that two detectors reach a 40% LFL. When the first detector reaches the 40% LFL, the shutdown system is termed to be in an "Armed" state. Deluge valves #2 and #3 will be activated by the detector, when it reaches 40% LFL. If the problem causing the detector to alarm can be corrected before a second alarm reaches 40% LFL, then the SL 012109 SL 012110 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 16 shutdown system may be disarmed. This is done by pressing a reset switch, HS-3801, located in the furnace area. The "Armed" light will be extinguished when HS-3801 is pressed. The deluge valves will con tinue until the water flow is manually stopped and the deluge valves reset in the field. In order to correct the problem causing the detec tor to alarm, the following considerations apply: (1) If a small leak is the cause of the alarm, and it is safe to approach the leak and termi nate it, this should be done. Then the detector may be reset, on the detector front panel and then the field reset, HS-3801, may be pressed to disarm the system. (2) If the alarm appears to be the result of a faulty detector, the' detector should not reset. The furnace area should be carefully inspected to be sure there are no small leaks. This is referably done with a portable gas detector. If the area is safe, then the field reset, HS-3801, may be pressed and the system will be disarmed. The faulty detector should be left unreset. This will bypass the faulty detector, as described above, until it can be repaired. (3) If there is any doubt as to whether the area is safe to enter, then the system should be left armed. If a second detector reaches 40% LFL, then the system has performed as intended. If a shutdown is caused by a second detector, then the system responds, as described above for a level two shutdown. After the problems that caused the shutdown, such as a vapor cloud, have been corrected the shutdown should be reset. This is done using HS-3801. When this button is pressed it will (1) cause snuffing steam to stop immediately, (2) extinguish the trip initiated light, (3) cease calling for the deluge valves DV-1, 2 and 3 to be on, and (4) cease calling for each furnace's Flame Management System to shutdown that furnace. This enables the operator to stop the deluge water by resetting the deluge valves in the field; and, enables start-up CON FT Subject tc P rctective Order of X4th Judici al District Court No. 93-1145 17 of the furnaces by putting each through a proper flame management sys tem start-up sequence. (Note: The Loss of flow shutdown also must be bypassed for start-up.) If a vapor detector is determined to be faulty during a shutdown, it may be bypassed in the same manner as described above. It should be left in the alarm state and not reset. When system reset,HS-3801Jin the field is pressed, it will bypass that detector,thus not allowing it to vote on any subsequent occurances as long as the detector is not reset. If at anytime later, it is decided that the detector is OK, it can be reset and it will be unbypassed. Anytime one of the detectors on the furnace shutdown system is bypassed in the manner described above, then PLC III should sound the alarm bell and print a message every 4 hours to serve as a reminder to correct the situa tion. The bell can be silenced using the ACK button on 0IP-6A. Each detector has a trouble circuit and a trouble alarm. Anytime the detector goes into the trouble mode, then the alarms are no longer functional and cannot cause the shutdown system to be armed or tripped by that detector. Whenever a detector goes into this mode, it will sound the alarm bell and print a message. The bell and message should be repeated every 8 hours as long as the trouble mode is active. The bell can be silenced by pressing the ACK button on 0IP-6A. The logic for the Furnace Shutdown System is provided by several devices. First, the Flame Management System logic, for each furnace, is provided by two programmable logic controllers located in cabinets in the field. Each cabinet contains one Modi con 484 PLC and a number of relays associated with the system. There is also one cabinet for each system that houses SL 012111 Qpvnv-t nP.MTlhh i Subject to Pt* of 14th Judicia 18 all of the Fireye amplifiers for that furnace. The functional indicator lights and switches for each system are provided on a field mounted opera tors panel. Power is supplied to the FMS for each furnace by the Uninterruptable Power Supply (UPS). (#1 Furnace - UPS Circuit #CIP-6) (#2 Furnace UPS Circuit #CIP-5). If this power is lost or turned off it will result in a furnace shutdown. If the cabinet doors on any of the field mounted cabinets are opened during furnace operation it will turn off power to that cabinet which will result in a shutdown of the associated furnace. There are also power switches on the outside of the FMS operators panel. Turning these off cuts power to the panel and will result in a furnace shutdown. Second, the remainder of the shutdown system logic is provided by PIC III. The functional indicator lights and switches are provided, in the control room, on OIP-4 and 0IP-6A. The power to these is supplied by the UPS (UPS Circuit # CIP-15). If the power is turned off, it will result in a shut down of both furnaces. There is a message typewriter associated with PLC III. It provides prealarm and shutdown messages. r THE LIGHTS AND SWITCHES LOCATED ON 0IP-6A, IN THE CONTROL ROOM, ARE RELATED TO THE OPERATION OF THE VAPOR DETECTOR INITIATED SHUTDOWN OF BOTH FURNACES. THESE ARE:. Vapor Detector Shutdown of Both Furnaces Bypassed - (HI-6AL4). This red indicating lamp on aluminum mounting, will come on flashing anytime the bypass of the vapor detector inputs to the furnace shutdown system occurs. This occurs whenever the keyed bypass of DV-2 (Detectors 6A-1 through 6A-8) or DV-3 (Detectors 6A-9 through 6A-12) is manually initiated. The operation of either of these bypass switches will also cause the system bypass light to come on flashing. This light SL 0121U Subje of 14tn CUNi?XDI:.bTlf'^; ^ to Protective O rder judicial Diciric^ Court No - o 1 19 will come on and blink at noticeable rate until such time as the bypass is removed. The light is provided to clearly indicate to the operators that the vapor detector initiated shutdown of the furnaces is bypassed and to serve as a reminder not to leave it this way. This bypass in no way affects the low flow shutdown of either furnace or a trip ol either furnace by its respective flame management system. This bypass does not affect HS-3800 or HS-3905 operation. These will still cause a shutdown of both furnaces if either is pressed. Vapor Detector Shutdown of Both Furnaces Armed - (Hi-3801). This amber light in an aluminum mounting is used to indicate that the "first vote" by a vapor detector for furnace shutdown, has occured. It will come on flashing when the first vote occurs. The audible alarm (bell) will occur as a result of the corresponding vapor detector reaching tne 40% LFL. Pressing the acknowledge pushbutton on 0IP-6A will silence the bell and cause the armed light to go constant on. This is a signal to the operator that a shutdown of the furnaces due to a possible vapor cloud is eminent. A message is printed that the system is armed. Vapor Detector Shutdown of Both Furnaces Trip Initiated - (HI/HS-3800). This red indicator light with an integral pushbutton on a red aluminum mounting is used to indicate that a trip has been initiated by (1) the vapor detectors, (2) the pressing of the integral pushbutton, or (3) pressing the field mounted pushbutton. The pressing of this button causes the same things to occur as the auto system. These are: (1) Trip the natural gas to both furnaces, (2) Trip the snuffing steam of both furnaces and (3) Trip the deluge valve DV-1, DV-2, DV-3. Pressing this button will cause a messaae to occur. If the trip is manually SL 012113 cofibsW;! initiated the light will come on with no alarm but a message will be printed. If the trip is automatically initiated, the light will come on flashing, the bell will sound and a message be printed. The bell can be silenced by pressing the ACK button on 0IP-6A. This button is still functional even if one or both of the related keyed bypasses are in the bypass position. The reset of this system can be done only from the field using the reset button HS-3801. When the reset is pressed, the trip initi ated light will go out. When the trip initiated light goes on, the armed light will go off. Vapor Detector Shutdown of Both Furnaces All Flames Out - (HI-3802). This red indicator light on an aluminum mount ing is used to feedback from the field to the operator that the trip of both furnaces has been accomplished. This light is activated by a signal from the FMS that identifies when all flame scanners in both furnaces see no fires and^both the pilot and main gas valves are closed on each. This light will come on flashing and cause an audible alarm. The audible may be silenced and the light go constant on^when the ACK button is pressed. This alarm also serves to identify whenever the FMS causes a shutdown to occur. In this case the shutdown is initiated in the field, so the trip initiated light will not be on. No. 1 EDC Furnace Snuffing Steam Run/Trip - (HS-3810). This switch is used to manually trip the snuffing steam valves to #1 EDC cracking furnace. Anytime a trip is manually initi ated it will cause the associated light to come on constant and a message to be printed. The light will stay constant on until the switch is moved to the run position. This switch is a red knob on an aluminum mounting. r SL 012114 CONFIDENTIAL 0rder ciiVv-iect. + n protect.iv No. 1 EDC Furnace Snuffing Steam Trip Initiated - (HI-3810). This red light on an aluminum mounting will operate as described above. In addition it will come on anytime a snuffing steam trip is initiated by a vapor detector initiated shutdown of the fur naces. In this case it will come on constant and stay on as long as the shutdown system calls for it. The snuffing steam may be stopped by manually closing block valves at the control stations. In order to get the shutdown system to stop calling for it, the reset button located on the analyzer shelter in the furnace area must be pressed. No, 2 EDC Furnace Snuffing Steam Run/Trip - (HS-3860). This switch is used to manually trip the snuffing steam valves to #2 EDC cracking furnace. Anytime a trip is manually initiated it will cause the associated light to come on constant and a message to be printed. The light will stay constant on until the switch is moved to the run position. This switch is a red knob on an aluminum mounting. No, 2 EDC Furnace Snuffing Steam Trip Initiated - (HI-3860). This red light on an aluminum mounting will operate as described above. In addition it will come on anytime a snuffing steam trip is initiated by a vapor detector initiated shutdown of the fur naces. In this case it will come on constant and stay on as long as the shutdown system calls for it. The snuffing steam may be stopped by manually closing block valves at the control stations. In order to get the shutdown system to stop calling for it, the reset button located on the analyzer shelter in the furnace area must be pressed. Vapor Detector Bypass and Deluge Trips SL 012115 Furnace Floor DV-1 Trip - (HS-6AD1). This black pushbutton on an aluminum CONFIDENTIAL; Subject, tc Pro^9'_:tivd Order 22 of 14th Ond e i a ] Di 1 ri ct Ccur t No. 7 A- 11 4 5 mounting is used to trip the deluge underneath the furnace floor area, this system is also activated by heat activated devices or the Furnace Shutdown System on vapor detector initiation. It is not tripped by vapor detectors alone. There is no visual or audible alarm associated with this pushbutton. The alarm is accomplished as described in item 2 of 0IP-6A write-up. A message does print out whenever the button is pressed. Vapor Detector Bypass and Deluge Trip Switch Furnace Area DV-2/SD Run/Bypass - (HS-6AB2). This two position key switch mounted on an aluminum mounting is used to bypass the input of vapor detectors 6A-l'through 6A-8. This is a key switch since it also results in the Furnace Vapor Detector Shutdown System being partially bypassed. It causes indicator lights to be activated as described in in items 4 and 8 of 0IP-6A write-up. The key can only be withdrawn when the switch is in the run position. Whenever the key is in the bypass position it prevents the vapor detector from auto trip of DV-2 or "voting" in the Furnace Shutdown System. A message will be printed anytime this switch is put to bypass. Vapor Detector Bypass and Deluge Trip Switch Furnace Area DV-2 Trip - (HS-6AD2). This black pushbutton on an aluminum mounting is used to manually trip DV-2, the furnace area deluge. This is the only function it serves. It is still functional even if the keyed bypass described in the Furnace Area DV-2/SD Run/Bypass above, is in the bypass state. The alarming of this function is handled as described in item 2 of 0IP-6A write-up. A message will be printed whenever the button is pressed. SL 012116 CONFIDENTIAL: Subject to Protective Order 23 of 14th Judicial District Court No. 91-1145 Vapor Detector Bypass and Deluge Trip Switch H^O Shield/Refrig. DV-3/SD Run/Bypass - (HS-6AB3). This key switch functions the same as described in Furnace Area DV-2/SD Run/Bypass above, except that it applies to DV-3 and vapor detectors 6A-9 through 6A-12. The mounting is aluminum. Vapor Detector Bypass and Deluge Trip Switch HpO Shield/Refrig. DV-3 Trip - (HS-6AD3). This black pushbutton on an aluminum mounting functions the same as described in Furnace Area DV-2 Trip above, except that it acts on DV-3, THE LIGHTS AND SWITCHES LOCATED ON 01 P-4 IN THE CONTROL ROOM, ARE RELATED TO THE OPERATION OF THE LOW FURNACE FEED FLOW SHUTDOWN OF EACH FURNACETHESE ARE: No. 1 EDC Furnace Low Flow Run/Bypass - (HS-3816). This key switch on an aluminum mounting is used to bypass the low flow shutdown of #1 Furnace. When this switch is placed in the bypass position, it prevents an automatic shutdown of #1 Furnace due to the low flow voting system. The switch does not prevent a manual trip using HS-3809 trip initiated switch, a vapor detector initi ated trip, a trip initiated by HS-3800 or HS-3905 or a trip by the flame management system for #1 Furnace. When the switch is placed in the bypass position its companion light, HI-3816, will come on and blink at a notice able rate. A message is printed on PLC III typewriter. No. 1 EDC Furnace Low Flow Bypass - (HI-3816). This red indicator light on an aluminum mounting functions in association with the keyed bypass switch HS-3816, as described above. SL 012117 No. 1 EDC Furnace *SSS;Cil.'Vi-iect order 24 Start-up Bypass - (HI/HS-3814). This red indicator light with an integral pushbutton in an aluminum mounting is used to initiate a start-up bypass and so indicate. When the button is pressed a start-up bypass will begin. The red indicator light will come on constant and the PLC III message type writer will print a message. When start-up bypass is initiated it prevents the two flow transmitter signals for each pass on #1 Furnace from causing a shutdown. The TMT is not affected by start-up bypass and if either should go into a high alarm state during start-up, it will cast its vote and arm the shutdown system. The two flows on each pass will remain bypassed for 1 hour. By the end of the hour, both flows on each pass must be established, If any one is not, then when the bypass time expires, it will cast its vote. If two, on the same pass, are not establihsed, then the furnace will shut down when the time expires. During the start-up bypass period, as the flows come up and go above the shutdown value, they will be automatically unbypasscd by the shutdown system, after they have been above the trip value, continu ously, for 1 minute. The start-up bypass can only be used if the furnace is in a shutdown con dition. Pressing during normal operation will have no effect. If the button is pressed during the start-up period a message will be printed indicating the time remaining and any signals that are not above the trip point. When the keyed bypass switch (HS-3816) is in the "Bypass" position pressing the start-up bypass will result in a message print of any para meters that are in the trip condition. Whenever a low flow shutdown has occured the shutdown will seal itself and remain on until the start-up bypass is pressed. This will clear the shutdown signal from PLC III going to the Flame Management System. SL 012118 Subject of l4th 25 The start-up bypass does not prevent the manual trip HS-3809, a vapor detector trip, a trip initiated by HS-3800 or HS-3905 or a trip by the Flame Management System for #1 Furnace. No. 1 EDC Furnace Flame Out All/One - (HI-3813/HI-3812). This two part red/amber indicating lamp in an aluminum mounting gives the status of the burners on #1 Furnace. The ALL portion of the light is red. It is turned on by a signal from the FMS, PLC-3813. This is done by PLC III monitoring a set of contacts in the FMS for #1 Furnace. When the contacts are open, the PLC III will indicate that all the fires are out. The FMS will open these contacts if (1) no fireye sees a flame, (2) the main fuel gas valve is closed and (3) the pilot gas valve is closed. This signal is a feedback from the field to the opera tor that a shutdown has occured. When the all fires out light is turned on it will come on flashing and cause an audible and a message to be printed. When the ACK on #4 MOD III console is pressed, the audible is silenced and the light will go constant on. It will stay this way as long as the con tacts PLC-3813 are open. The ONE portion of the light is amber. It is turned on by a signal from the FMS, PLC-3812. This is done by monitoring a set of contacts in the FMS for #1 Furnace. When the contacts are open, the PLC III will indicate that one (or more) fires are out. The FMS will open these contacts if any one or more fireyes indicate that fires have gone out. When the One Flame Out Light is turned on it will come on flashing and cause an audible and a message to be printed. When the ACK on #4 MOD III console is pressed, the audible is silenced and the light will go constant on. The contact (PLC-3812) in the FMS may be closed, to clear the alarm light (HI-3812), SL 012119 Subject C c-- 1-- 4V* ;1 ,-: d 1 ; Co'Ti-'t even if the burner or burners are not relit. This can be done by pressing the reset on the FMS operators panel in the field. No. 1 EDC Furnace Low Flow Armed - (HI-3804). This amber lamp in an aluminum mounting is used to indicate when one of the trip initiators (FT-3011, FT-3016, FT-3012, FT-3017, TE-3816, TE-3618) has cast a vote to shutdown. This light will come on flashing, cause an audible alarm and print a message. The audible may be silenced and the light go constant on by pressing the ACK on #4 MOD III console. The only way to disarm the system and cancel the vote, is to return the signal, that cast the vote to a normal state. At that point the light will go out. This light comes on immediately in the event that a flow has cast the vote, even though there is a 30 second delay on the trip action from these. The message prints immediately also. Even if both flow meters on a pass go low,and cast votes at the same time, the armed light and the messages print immediately. This is necessary so that the operator will have a chance to take corrective action. Then,30 seconds later, if no corrections are made, the trip will occur. No. 1 EDC Furnace Trip Initiated - (HS/HI-3809). This red indicator lamp with an integral pushbutton on a red aluminum mounting is used to indicate the status of the low Flow initiated shutdown of #1 Furnace. The integral pushbutton is used to manually initiate a shutdown of #1 Furnace. The light will be on anytime the system is calling for a trip of the #1 Furnace. The system will automatically call for a shutdown when one of the initiators cast a second vote^after a 30 second delay if the initiator was a flow). When this occurs the lamp will come on flashing, the audible alarm SL 012120 CONI' Protective Orde, Subject to ial District Court Qf 14th Judic No. 91-1145 27 will sound and a message will be printed. The audible is silenced by pressing the ACK on H MOD III console. The system will call for a shutdown when the integral pushbutton is pressed, when this occurs, the lamp will come on constant and a message will be printed. The pushbutton is always functional even if the start-up bypass (HS-3816) or the keyed bypass (HS-3814) are in the bypass state. The indicator lamp HI-3809 also acts as a status indicator for the Low Flow initiated system. Whenever the system is calling for a shutdown, even when in the start-up bypass or keyed bypass mode, the lamp will be on. It will automatically go off whenever the shutdown has cleared. The initiators that are causing the shutdown to be initiated can be identified by pressing the start-up bypass switch, HS-3816, when in either of the by pass modes just described. Whenever the trip initiated light comes on, the armed light should go off. THE LIGHTS AND SWITCHES FOR THE LOW FLOW INITIATED SHUTDOWN OF #2 FURNACE ARE ALSO LOCATED ON OIP-4. THE FUNCTION OF THESE IS EXACTLY THE SAME AS THAT DESCRIBED FOR THE CORRESPONDING LIGHTS AND SWITCHES ON #1 FURNACE. THESE LIGHTS AND SWITCHES ARE: No. 2 EDC Furnace Low Flow Run Bypass (HS-3866) No. 2 EDC Furnace Low Flow Bypass (HS-3866) No. 2 EDC Furnace Start-up Bypass (HI/HS-3864) No. 2 EDC Furnace Flame Out ALL/ONE (HI-3863/HI-3862) No. 2 EDC Furnace Low Flow Armed (HI-3854) No. 2 EDC Furnace Trip Initiated (HS/HI-3859) SL 01212J CONFIDENTIAL: Subject to Protective ,_ court 28 THE LIGHTS AND SWITCHES LOCATED IN THE FIELD ON THE FLAME MANAGEMENT SYSTEM OPERATORS PANEL ARE RELATED TO ITS OPERATION. THESE ARE DESCRIBED AS FOLLOWS: #1 Furnace FMS: Furnace Start HS-5QQ is used to initiate purge time on start-up of furnace. Other items that must be permissive are all dampers fully open, all supervisory valves closed, main gas double block & bleed closed and pilot gas supply valve closed. Pilot gas valve open. - L-572 - light is on when the pilot gas valve is open. All gas off - L-505 - light is on when all supervisory valves are closed and the main fuel gas double block & bleed is closed and the pilot gas valve is closed. Furnace off light - L-506 - light is one when the main gas double block & bleed is closed and when the pilot gas is closed and no flame detector sees any fire, pilot or main burner. All dampers fully open - L-509 - light is on when the stack dampers and all 6 plenum dampers are fully open. Damper closed - L-510 - light comes on anytime a damper, stack or plenum goes fully closed. After a 10 second delay this will result in a furnace shutdown. The light comes on immediately upon damper closing. Purge on - L-501 - light comes on when the start button is pressed (other conditins permissive) and goes out at the end of the purge time. SL 012122 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Cour No. 91-1145 2g Purge QK/Hot Furnace - L-504 - light comes on at the end of the purge time. The furnace start button must be pressed to get this light on. It will come on immediately if the furnace is hot. If the furnace is not hot, it will come on at the end of the 5 minute purge time. OK to Light - L-502 - light comes on after the main pilot block valve is manually armed (provided it has a permissive circuit to arm). This light will stay on as long as the main pilot valve is open. The light will go out on a shutdown at which point the main pilot valve also closes. Vent Valve Closed - L-508 - light is one when the vent valve is closed. This light serves as* a reminder that the manual vent valve must be closed prior to start-up. #1 to #28 Burner On - BL-A001 to BL-A028 - lights. These lights come on whenever the associated fireye sees a flame (pilot or main burner). Fuel gas on - L-507 - light comes on when the main gas valve, XV-3803, is opened. Trip Switch, HS-506, is mounted on the FMS operators panel and is used by the FMS to initiate a trip of #1 Furnace. Burner #1 to #28 Ignitor Switch, HS-A101 to HS-A128, is used by the FMS to initiate a pilot ignition seguence. Alarm Reset Switch, HS-001, is mounted on the FMS operators panel. It is used to silence the audible alarm for #1 Furance and to reset the flame failure alarm PLC-3812 that is sent to the control room. * SL 012123 bUO ]GC of ,, -11h . J VS 0 r d e r r: r rr)H -r h 30 Operator Panel, Low Purge Pressure - L-18 - indicator lamp for the opera tors panel. It comes on and stays on whenever PSL-18 indicates a low pressure. Fireye Amplifier Cabinet Low Purge Pressure indicator lamp - L-19A is mounted on the operators panel. L-19B is mounted on the amplifier cabinet. These come on and stay on whenever PSL-19 indicates a low pressure. Controller Cabinet #1 Low Purge Pressure indicator lamp - L-20A - is mounted on the operator panel.. L-20B is mounted on the Controller Cabinet #1. These come on and stay on whenever PSL-20 indicates a low pressure. Controller Cabinet #2 Low Purge Pressure indicator lamp - L-21A - is mounted on the operator panel - L-20B - is mounted on the Controller Cabinet #2. These come on and stay on whenever PSL-21 indicates a low pressure. #1 to #28 Supervisory Valve Open - ZL-A051 to ZL-A078 - indicator lamp. These lights come on whenever the associated supervisory valves are in the open position. THE #2 FURNACE FMS LIGHTS AND SWITCHES FUNCTION IN EXACTLY THE SAME MANNER AS THOSE DESCRIBED ABOVE FOR #1 FURNACE. VII. Start-up In order to start-up one or both furnaces after a shutdown. It is necessary to carry the furnace through the purge and light sequence that is controlled by the Flame Management System (FMS). It is first necessary that any shut down request from PLC III in the control room be cleared. This is done by resetting any alarming vapor detectors (unless they are determined to be faulty) and pressing the reset pushbutton, HS-3801, in the field. The SL 012124 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court31 No. 91-1145 start-up bypass switch (HS-3814) on OIP-4 should be pressed. This should only be done at a point where it will be less than 1 hour before EDC feed flow is to be started to the respective furnace. The master byoass of low flow (HS-3816 or HS-3866) or vapor detector shutdown (HS-6AB2 & HS-6AB3i should only be used for maintenance purposes. Prior to pressing the start-up bypass on OIP-4 the furnace should be put into a status that will allow the purge to be started immediately after the start-up bypass is initiated. For #1 Furnace this is done by: (1) Opening all dampers on the furnace to the wide open position. This will be confirmed by the "All Dampers Open" light, L-509, on the FMS operators panel in the field, (2) Closing all FM block valves on the gas lines to each burner. This is confirmed by the "All Gas Off" light, L-505, on the FMS operators panel. It is also necessary that the main fuel gas block, XV-3832, be closed to get L-505 to come on. If it does not light, then the supervisory valve open lights, ZL-051 to Zl-078, should be checked to see which is open (be sure all bulbs are good). If no valve is open then the position switch, ZSL-3803 and ZSL-3832, should be checked. Lights L-572 and L-507 should be off. If one is not, then this is preventing start. (3) Fuel gas should be available up to the inlet side of the main gas double block & bleed (PCV-3425 should be in operation and pro perly adjusted). (4) the furnace feed pumps should be on and the flow control valves adjusted to supply the desired start-up flowrate. The flow will be returning to the Heavies still reflux tank via the start-up line rather than going through the furnace. The FF economizer should not have any product still bottoms flow. (5) The flame detector sensor at each burner should be checked and the lenses cleaned. The ignitors for each burner should be cleaned and dried. (6) The fuel gas flow controller SL 012125 CONFIDENTIAL: Subject to Protective Order 32 of 14th Judicial District Court No- 91-1145 in the control room should be adjusted so that it is calling for zero fuel gas flow. (7) The fuel gas adjustment valves to each chamber of the furnace should be open. (8) The bypass around the fuel gas control valve, FV-3025, should be sealed closed. After the above conditions are satisfied and the start-up bypass on 01 P-4 is initiated there is one hour to ignite the burners and get fur nace fuel flow established. The first step is to press the start button, HS-500, on the FMS operators panel. Purge On light, L-501, should come on. The purge should run for 5 minutes. If the furnace is not (above 1400F) then the Purge OK/ Hot Furnace light, L-504, should come on and the purge step is bypassed. If not, it will come on at the end of the purge time. The furnace fire box should now be checked at several points, with an explosion meter to ensure that it is free of flammable vapors. The pilot gas supply valve may now be opened. This will supply gas up to each pilot solenoid valve. The "Pilot Gas On" light, L-572, should come on at this point. The pilot gas bleed valve, XV-3833, will close 5 seconds after the pilot gas valve is opened. The ignition sequence for the pilot should now be started. This is done by pressing the ignition pushbutton, HS-A101 to HS-A128. The pilots will attempt to light for 15 seconds. Any that fail will be locked out for 50 seconds. If all fail, the pilot gas supply will trip, and the purge sequence will have to be redone in order to open it. Preferably all pilots should be lit before any main burners. After the pilots are lit the main fuel gas supply valve, XV-3803, may be opened. This will be indicated by L-507, Fuel Gas On light. The bleed valve will have closed after the first pilot was indicated to be on. SL 012126 rt *f/5 AT* CO T,wv*-ectivi In order to light main burners, the board mounted fuel gas controller should be asking for the valve to be closed. This will cause the signal selector in the field to select the signal from the field mounted fuel gas pressure controller. The pressure controller, PIC-3476, should be set for a low pressure so that the burners will fire at a low rate. Once the pilot for a given burner is on, then the maxon valve for that main burner may be opend. After the maxon is opened the main burner may.be lit by slowly opening the supervisory valve. The main flame should come on. When the supervisory valve is opened, it starts a timer that causes the pilot to go off in 10 seconds. The main flame must be established by this time and the fireye detecting it in order to keep the burner on. If it is not, then the maxon will close. The pilot is turned off at the end of the 10 second trial period. As each subsequent burner is lit, the pressure controller should maintain the fuel gas flow, by pressure control, such that the main flames are at a steady, low firing rate. After all burners are lit, the control of FV-3025 may be taken using the board mounted controller. The firing may be brought up by simply opening FIC-3025. This should cause the signal selector to choose FIC-3025 when its signal becomes greater than the PIC3426. EDC feed flow should be started to the furnace before the firing rate is increased. Feed flow is started by opening the downstream block valve of the control station, thus allowing the feed to start into the furnace and closing the valve in the start-up line. The low flow shutdown should clear at this point. If it does, the trip initiated light on OIP-4 should go out. This serves as a shutdown system status indicator. Pressing it after the SL 012127 r CONFTnFKTlp,`L * Subject to P of 14th Judici No. start-up bypass is in effect will result in a message print of any para meter that has not cleared its trip valve and may still result in a shut down. The Product still bottoms flow should be put through the FF econo mizer. Fuel gas flow to the furnace should be increased to bring up the crossover temperature to vaporization. EDC feed flow and fuel gas flow should be brought up together to the desired flowrate and eventually to the desired conversion. Heat-up should be restricted to a rate of 90F/ hour for the flue gas temperature if the refactory has cooled during the outage or 50F/hour for the process outlet temperature. Decoking Start-up When the furnaces are to be decoked, there will not be any feed flows. For this reason the Low flow shutdown feature will have to be bypassed using the keyed bypass switch. During this operation overheating of the tubes due to loss of flow can still occur. If a loss of flow does occur, it will be necessary for the operator to manually trip the furnace. There are sufficient flow and temperature alarms in the control room for the operator to do this. The Flame Management and vapor detector shutdown features will still be active. The start-up sequence is the same as described above with the exception that no EDC furnace feed flow is established. In its place, decoking steam flow is started instead. VIII. The PLC III will generate a number of alarm messages to warn of parameters moving toward shutdown conditions and to record the Status of the system. These are: FT-3011 #1 Furnace #1 Pass Feed Flow Low @ 25 gpm FT-3011 #1 Furnace #1 Pass Feed Flow Low Trip @ 15 gpm FT-3016 #1 Furnace #1 Pass Feed Flow Low @ 25 gpm SL 012128 r 35 FT-3016 #1 Furnace #1 Pass Feed Flow Low Trip 0 15 gpm FT-3012 #1 Furnace #2 Pass Feed Flow Low 0 25 9 pm FT-3012 #1 Furnace #2 Pass Feed Flow Low Trip 0 15 gpm FT-3017 #1 Furnace n Pass Feed Flow Low @ 25 gpm FT-3017 #1 Furnace #2 Pass Feed Flow Low Trip 0 15 gpm FT-3061 n Furnace #1 Pass Feed Flow Low @ 25 gpm FT-3061 #2 Furnace #1 Pass Feed Flow Low Trip 0 15 gpm FT-3066 #2 Furnace #1 Pass Feed Flow Low 0 25 gpm FT-3066 #2 Furnace #1 Pass Feed Flow Low Trip 0 15 gpm FT-3062 #2 Furnace #2 Pass Feed Flow Low 0 25 gpm FT-3062 #2 Furnace #2 Pass Feed Flow Low Trip 0 15 gpm FT-306 7 #2 Furnace #2 Pass Feed Flow Low 0 25 gpm FT-3067 #2 Furnace #2 Feed Flow Low Trip 0 15 gpm , Vj AtAA * o .Vv va vV /CfAr C<) /'<tvo</V<o AA > `y ) Oy v') * <*40^^Av* A 0 HS-3809 #1 Furnace Manual Trip Initiated HS-3859 #2 Furnace Manula Trip Initiated #1 Furnace Low Flow Shutdown Armed #2 Furnace Low Flow Shutdown Armed TE-3616 #1 Furnace #1 Pass Radiant TMT 0 Floor High 1500F TE-3616 #1 Furnace #1 Pass Radiant TMT 0 Floor High Trip 1550F TE-3618 #1 Furnace n Pass Radiant TMT 0 Floor High 1500F TE-3618 #1 Furnace n Pass Radiant TMT 0 Floor High Trip 1550F TE-3666 n Furnace #1 Pass Radiant TMT 0 Floor High 1500F TE-3666 #2 Furnace #1 Pass Radiant TMT 0 Floor High Trip 1550F TE-3667 #2 Furnace #2 Pass Radiant TMT @ Floor High 1500F TE-3667 #2 Furnace #2 Pass Radiant TMT 0 Floor High Trip 1550F SL 012129 36 #1 Furnace Low Flow Shutdown Trip Initiated #2 Furnace Low Flow Shutdown Trip Initiated #1 Furnace Low Flow Shutdown Trip Bypassed #2 Furnace Low Flow Shutdown Trip Bypassed PLC-3813 #1 Furnace All Fires Out PLC-3863 #1 Furnace All Fires Out cCfo 3*V #1 Furnace Start-up Bypass Started #2 Furnace Start-up Bypass Started #1 Furnace Start-up Bypass Time Remaining min. Parameters in Trip #1 Pass _____ #2 Pass _____ #2 Furnace Start-up Bypass Time REmaining min. Parameters in Trip #1 Pass _____ #2 Pass #1 Furnace Burner Failures PLC-3812 #2 Furnace Burner Failures PLC-3862 6A-1 Vapor Detector 40% LFL High 6A-2 Vapor Detector 40% LFL High 6A-3 Vapor Detector 40% LFL High 6A-4 Vapor Detector 40% LFL High 6A-5 Vapor Detector 40% LFL High 6A-6 Vapor Detector 40% LFL High 6A-7 Vapor Detector 40% LFL High 6A-8 Vapor Detector 40% LFL High 6A-9 Vapor Detector 40% LFL High 6A-10 Vapor Detector 40% LFL High SL 012130 37 6A-11 Vapor Detector 40% LFl High 6A-12 Vapor Detector 40% LFL High Note: The vapor detector high alarms are redundant with the deluge system alarms. These alarmsare listed here for reference only. need only be generated by one system. #1 and #2 Furnace Vapor Detector Shutdown Armed #1 and #2 Furnace Vapor Detector Shutdown Initiated HS-3800/HS-3905 #1 and #2 Furnace Shutdown Manually Initiated #1 and #2 Furnace Vapor Detector Shutdown Disarmed Vapor Detector ____ Not Reset (Repeat every 4 hours) Vapor Detector in trouble mode (Repeat every 8 hours) Vapor Detectors 6A-1 to 8 Bypassed to Furnace Shutdown System #^ S' Vapor Detectors 6A-9 to 12 Bypassed to Furnace Shutdown System #1 Furnace Snuffing Steam Manually Initiated #2 Furnace Snuffing Steam Manually Initiated In addition to the PLC III generated alarms there are a number of back-up or redundant alarms generated by the Computer/MOD III system. There are also a number of alarms and indications developed by the Computer/MOD III that do not have trip associated with them but are none-the-less very necessary for the safe operation of the furnaces. These are: MOD III FT-3011 #1 Furnace #1 Pass Feed Flow Deviation + 2% FT-3011 #1 Furnace #1 Pass Feed Flow Output Low = 5% FT-3012 #1 Furnace #2 Pass Feed Flow Deviation + 2% FT-3012 #1 Furnace #2 Pass Feed Flow Output Low = 5% SL 012131 38 FT-3061 #2 Furnace #1 Pass Feed Flow Deviation + 2% FT-3061 #2 Furnace #1 Pass Feed Flow Output Low = 5% FT-3062 #2 Furnace #2 Pass Feed Flow Deviation + 2% FT-3062 #2 Furnace #2 Pass Feed Flow Output Low = 5% FT-3025 #1 FurnaceNatural Gas Flow Deviation + 2% FT-3025 #1 FurnaceNatural Gas Flow Output High -98% FT-3075 #2 FurnaceNatural Gas Flow Deviation + 2% FT-3075 #2 FurnaceNatural Gas Flow Output High -98% Computer Alarms FT-3016 #1 Furnace #1 Pass Feed Flow Low @ 10 gpm FT-3017 #1 Furnace #2 Pass Feed Flow Low @ 10 gpm FT-3066 #2 Furnace #1 Pass Feed Flow Low @ 10 gpm FT-3066 #2 Furnace #2 Pass Feed Flow Low 0 10 gpm 6QA) roA?r Ao s' *& j3<v7 2 S' O '*y t; 3 O ,0 ''Y* S' PT-3411 #1 Furnace #1 Pass Inlet Pressure High 280 PSIG . PT-3412 #1 Furnace #2 Pass Inlet Pressure High 280 PSIG PT-3461 #2 Furnace #1 Pass Inlet Pressure High 280 PSIG PT-3462 #2 Furnace #2 Pass Inlet Pressure High 280 PSIG PT-3436 #1 Furnace #1 Pass Outlet Pressure High 150 PSIG PT-3436 #1 Furnace #1 Pass Outlet Pressure Low 100 PSIG PT-3437 #1 Furnace #2 Pass Outlet Pressure High 150 PSIG PT-3437 #1 Furnace #2 Pass Outlet Pressure Low 100 PSIG PT-3486 #2 Furnace n Pass Outlet Pressure High 150 PSIG PT-3486 #2 Furnace #1 Pass Outlet Pressure Low 100 PSIG PT-3487 #2 Furnace #2 Pass Outlet Pressure High 150 PSIG PT-3487 #2 Furnace #2 Pass Outlet Pressure Low 100 PSIG SL 012132 39 PT-3420 #1 Furnace Draft Pressure High 0.0" H0 PSL-3423 #1 Furnace Natural Gas Pressure Low - 0.5 PSIG PSH-3424 #1 Furnace Natural Gas Pressure High - 15 PSIG o* O1 PT-3470 #2 Furnace Draft Pressure High 0.0" H^O PSL-3472 #2 Furnace Natural Gas Pressure Low - 0.5 PSIG PSH-3474 #2 Furnace Natural Gas Pressure High - 15 PSIG TE-3611 #1 Furnace Stack Temperature High 450F TE-3661 #2 Furnace Stack Temperature High 450F ^v % /> 0 V,0u,0,'*> 0)x>; SX, x sV TE-3620 #1 Furnace South Chamber Bridgewall"Temperature High 1600F o TE-3621A #1 Furnace Center Chamber Bridgewall Temperature High 1600 F TE-3622 #1 Furnace North Chamber Bridgewall Temperature High 1600F TE-3670 #2 Furnace South Chamber Bridgewall Temperature High 1600F o TE-3671A #2 Furnace Center Chamber Bridgewall Temperature High 1600 F TE-3672 #2 Furnace North Chamber Bridgewall Temperature High 1600F * TE-3628 #1 Furnace #1 Pass Radiant Section TMT High 1500F TE-3632 #1 Furnace #2 Pass Radiant Section TMT High 1500F TE-3678 #2 Furnace #1 Pass Radiant Section TMT High 1500F TE-3680 #2 Furnace #2 Pass Radiant Section TMT High 1500F TE-3636 #1 Furnace #1 Pass Outlet Temperature High 1000F TE-3637 #1 Furnace #2 Pass Outlet Temperature High 1000F TE-3686 #2 Furnace #1 Pass Outlet Temperature High 1000F TE-3687 #2 Furnace #2 Pass Outlet Temperature High 1000F Computer Alarms when in Decoking Mode FT-3021 #1 Furnace #1 Pass Decoking Steam Flow Low 3000 #/hr SL 012133 40 FT-3021 #1 Furnace n Pass Decoking Steam Flow High 13,500 #/hr FT-3022 #1 Furnace #2 Pass Decoking Steam Flow Low 3,000 #/hr FT-3022 #1 Furnace #2 Pass Decoking Steam Flow High 13,500 #/hr FT-3071 #2 Furnace #1 Pass Decoking Steam Flow Low 3,000 #/hr FT-3071 #2 Furnace #1 Pass Decoking Steam Flow High 13,500 #/hr FT-3072 #2 Furnace #2 Pass Decoking Steam Flow Low 3,000 #/hr FT-3072 #2 Furnace #2 Pass Decoking Steam Flow High 13,500 #/hr u i^ Q)! o3 ^o 4J g-% % * 0 w^ t <U Q ^ S 7 g*S 0 0 FT-3030 #1 Furnace #1 Pass Decoking Air Flow Low 3,000 #/hr FT-3030 #1 Furnace #1 Pass Decoking Air Flow High 5,500 #/hr FT-3031 #1 Furnace #2 Pass Decoking Air Flow Low 3,000 #/hr U O^ JrP<-D,-*ju3^ 0 ^ <* O FT-3031 #1 Furnace #2 Pass Decoking Air Flow High 5,500 #/hr FT-3080 #2 Furnace #1 Pass Docoking Air Flow Low 3,000 #/hr FT-3080 #2 Furnace n Pass Decoking Air Flow High 5,500 #/hr FT-3081 #2 Furnace #2 Pass Decoking Air Flow Low 3,000 #/hr FT-3081 #2 Furnace #2 Pass Docoking Air Flow High 5,500 #/hr f TE-3612 #1 Furnace #1 Pass Convection Section TMT High 750F TE-3614 #1 Furnace #2 Pass Convection Section TMT High 750F TE-3662 #2 Furnace #1 Pass Convection Section TMT High 750F TE-3664 #2 Furnace #2 Pass Convection Section TMT High 750F IX. The basis for several Furnace SDS valves follows: TE-3621B/TE-3671B - Purge bypass temperature of 1400F was chosen based on reference to this value in the literature. The criteria should be that the temperature be above the auto ignition temperature of CH^ (or #2 Fuel oil if it is used). SL 012134 41 FT-3011, 3016, 3012, 3017, 3061, 3066, 3062 and 3067 - Low flow trip of 15 gpm was chosen by the flowmeter range. The desired case is loss of flow, but a value must be picked at which the flowmeter is likely to give a reasonably good approximate value for flowrate. The orifice meter is only accurate down to 25 gpm at best, so at 15 gpm it is possible that the flow might actually be + by a fair amount. The situation to be avoided is for the flow to get to essentially zero, in reality, and for the meter valve not to cause a trip. This should not be possible if 15 gpm is used for the meter value. The 30 second delay time on this is used to allow the operator to correct for small upsets and control loop problems. The 30 setonds comes from experience. It has proven not to have allowed much overheating, while at the same time it has been suffi cient to correct problems. It is true that the furnace can be overheated and damaged even with feed flow above 25 gpm. This overheating can happen anytime there is an imbalance-in feed and firing. The Loss of flow system is intended to cover the worst case of complete loss of feed. TE-3616, 3618, 3666, 3668 - Radiant section TMT trip val es are based on providing a suitable margin above normal operation temperature for the alarm and trip, so long as the temperature and pressure under a worst case will not result in a tube rupture. The end of run^TMT can be as high as 1440F so the alarm and trip are above this. The tube can safely operate up into the 1800F range for short periods. Values of 1500F alarm and 1550F trip for these temperature are felt to meet these criteria. The time delay of 10 seconds on the damper closed trip of the furnaces is to allow that the dampers be normally adjusted as a part of routine operation. SL 0)2)35 conp^rmtials Subject to Pi' f 14th JuMdoic- ia91-1145 42 PSL/PSH-3423 & 3473 - The valves of 0.5 PSIG low and 15 PSIG were selected to be outside the normal design operating range. X. The following documents serve as references: 1. Loop alarm sheets for all loop numbers given above. 2. Loop sheets for all loop numbers given above. 3. PLC I/O Schedule Drawing No. 4. PLC III Ladder Listing Program Printout. 5. Flame Management System Controller #1 Ladder Listing Program Printout. 6. Flame Management System Controller #2 Ladder Listing Program Printout. 7. KTI Logic Diagram 8. KTI Elementary Diagram XI. Troubleshooting There is very little that can be done by an operator or instrument mechanic on the Furnace Shutdown System. This results from the fact that essentially all of the logic is handled by programmable logic controllers (PLC's). The operator should first attempt to identify the problem. If the pro blem is a result of a faulty input signal, then an instrument man can correct it. If the problem appears to be the result of a logic failure then a computer technician is required to correct it. f The most likely input signal failures are: Faulty position switch failures. These are all on the FM system and most are indicated by a lamp so that identification of the problem should be easy. Flame detector failure. If a flame fails to light it is probably the Fireye detector. This usually can be corrected by cleaning the lense. It may also be caused by a faulty ignitor. SL 012136 _,. confidential: Subject to Protective Order of 14th Judicial District Com No. 91-1145 43 Low purge pressure. This is indicated by a local alarm and alarm light. The operator should first determine if the purge source has been lost. If it has not, then it could be a faulty pressure switch. These cannot be worked on while the furnace is in operation. Faulty transmitter input to the Loss of Flow system. This can be easily identified by the operator since there are dual flow meters and the flow meters also go th the computer. The temperature trip also has other back-ups. If the faulty signal results in a system armed light the sys tem should not be bypassed to prevent trip. The instrument should be repaired ASAP. Only while the mechanic is working on the faulty instru ment should the keyed bypass be used. Faulty Vapor detector signals. These can be identified by use of a port able vapor detector. If the detector is faulty, it should be left in the alarm state and an instrument mechanic should repair it ASAP. r Ur""rt SL 012137 CAUSES OF SIGNAL LOSS IN CATALYTIC TYPE COMBUSTIBLE GAS SENSORS Interfering or contamination gases or substances which may adversely affect proper operation of the instrument are as follows: A. Materials that may dog the pores of the flame arrestor thereby reducing the gas diffusion rate into the sensor are: 1) Dirt and Oil a. A dust cover should be installed to protect the flame arrestor whenever these conditions exit. b. The dust cover can be cleaned as part of routine maintenance. Clean in an organic solvent using an ultrasonic bath. 2) Corrosion Products. a. This occurs when CI2 (chlorine) or HC1 are present. A dust cover provides some protection. b. Replace the dust cover as part of routine maintenance. 3) Flame arrestor clogged during painting and house cleaning. a. The sensor should be covered by a plastic bag. Remove the bag as soon as possible. Make this a check point in your maintenance procedures. 4) Polymer formation in the flame arrestor. a. This sometimes occurs where monomer vapors such as 1,3 butadiene, styrene, isoprene, etc., are present. B. Substances that cover or tie up the active sites on the catalytic surface of the sensor's active element. Tins occurs in the presence of volatile metal organics, gases, or vapors of hydrides, and volatile compounds containing phosphorous, boron, silicon, etc. EXAMPLES: lead tetraethyl phosphine diborane silane trimethyl chiorsilane hydrogen fluoride boron trifluoride phosphate esters silicone oils and greases RTV silicone sealants SL 012138 The catalytic metals are removed from the sensor's active elements. 1) Some substances react with the catalytic metal forming a volatile compound. This erodes the metal from the surface and, given sufficient exposure to these types of material, all or most of the metal catalyst can be removed from the surface of the sensor's active element. 2) Halogens and halogen containing compounds are materials of this nature. EXAMPLE: Chlorine Bromine Iodine Hydrogen chloride, bromide or iodide Organic halides Trichloroethylene dichlorobenzene vinyl chloride freons Halon 1301 (Bromotrifiuromethane) 3) A brief exposure to one of these materials may increase the sensitivity of the sensor. This is usually a temporary effect as a result of etching the catalytic surface. This is sometirties used as a means to activate a sensor that has a degraded signal. THIS IS A PRACTICE THA TIS UNRELIABLE AND MA Y GIVE A FALSE SENSE OFSECURITY. Extended exposure to high concentrations of combustible gases and air. 1) Extended exposure of a detector element to certain concentrations of combus tible gases and/or air can introduce stress to the element that may seriously affect its performance, and therefore re-calibration should be carried out or the sensor replaced, or both, after an alarm due to an indication of a high concentra tion. The degree of damage to a sensor is a combination of the type of contaminant, its concentration in the ambient atmosphere and the length of time the sensor is exposed. 1) The loss of sensitivity is generally discovered when the sensor is calibrated. When this occurs, first ascertain whether the calibration has been correctly carried out, the calibration system is functioning properly, and the correct gas mixture is being used. 2) The calibration schedule should reflect the probable exposure of the sensor to known conditions that affect the quality of sensor signal. 3) When it is known that the sensor has been exposed to high concentrations of a poison, extended exposure to high concentrations of combustible gas/air mix tures. or other unusual conditions, it should be recalibrated at that time and a few days later to look for a significant shift in its sensitivity. CONFIDENTIAL? ive Order No. 9I-H45trict Court 012142 CO 1 i; lu 9 '2 :i i 21 222 2 * + / .j j , uo 7V\i j; > i 10 A* J 172 11 M a Hi! >n mini: i\i:, 1 [ :sn \ 3 2) 36 32 36 33 33 30 12 1 2 l / I;- l\j 14 13 19 119'" i i ?" 1 19 1 19 "Ton' jon V2 vs ,r2 K2 (12 U\) 22 1 * ! - * } l"J />LS 23 29 10 11 1 ' Lt 111 1 J2 V9 - nr 247 CP 2 :>1 13 1 'ft 2 \ -a. 7 | 230 1 12 93 30c'p 1 iU 1 20 20 20 20 CONFIDENTIAL: jj.Su^jiect to Protective Order <Df 14th du&xcxal District Court ife: ^-ii4S appendix IV St '*'44 8.0 SL 012145 [ ]FETROCOnjMCJ EMGinEERS5 desighers P. O. Box 3971 Beaumont, Texaa 77704 713--84S-2417 PP6- 4/>Pe 14.Client ,,________________ _____ ______________________________________ - \Z/mzP - PZjf}e/<L/Ty sr&c^ ___ Ref. Date 777-. /Page _______ Of / Job No. /or /z//o /?/!. JCblleP .. v- - IP Px , TetMexY P/w#*** M* ExAoSl V 1/M/7TS : CL , l-ldL.AtJD dPj SL 012146 Subject to Protective Order of 14th Judicial District Court No. ^l-j.14 5 | PETROCon,inc.| EHGinEERS 5 DE5IGMER5 P. 0. Box 3971 Beaumont. Tex** 77704 713-842-2417 cam -Aaxs csmxles, <lA, RefDofe Job No. /oAjy&o Subject &0EATa/z Aor,*** - Sv*,~**a'r Checked By r/^xy ffk&uj/?e:<d -1. A <7-/0*/ -- Of/ ^JA/lfTiE z. ^ n/ A4 jaj jtS 3. ^ 7^T/V ssf/A/VTEZ 4, " /="Z? T~ Memr*jcr\ stamp* eb o.e 0,2 ar <s>. / / &,oz <2. c. c/r CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 SL 012147 1 PETROCon,inc.| EnQinEER5 5 DESIGNERS P. 0. Box 3971 -" Subject ^ of 14t Beaumont, Texas 77704 ivc Oier -: '-'nU^ 713/842-2417 May IS, 1980 PPG Industries, Inc. P. 0. Box 1000 Lake Charles, LA 70601 Attention: Walter Oglesby Process Engineer VCM II - RELIABILITY STUDY LEVEL III PETR0C0N JOB NO. P79.57 SUBJECT: GAS CHROMATOGRAPHIC ANALYSIS BACK-UP OXYGEN ANALYSIS Gentlemen: Attached is the ternary diagram explosive range for an OHC Reactor Vent System operating at maximum pressure (near 65 psia). As seen on Page ID there is a large safe operating range, however, the increased ethylene costs warrant not operating with C2H4/HCL ratios much greater than design (0.483 Lb. C2H4/Lb. HCL). We recommend to alarm a feed condition of C2H4/HCL ratio of greater than 0.66. As s^en on Page IF the economic and safe operating range is limited to a smaller area. In addition to this feed ratio alarm we recommend using the process gas chromatograph and it's output to alarm various ratios in the unit system. If a oxygen/HCL ratio of 0.0549 was alarmed this would represent a line shown on Page 1G. This would be a diversified backup to the oxygen analyzers. Alarm valves of C2H4/HCL ratios of greater than 0.483 and less than 0.67 in the vent system would limit the ecomomic and safe operating range of the vent system to the shaded area shown on Page 1G. If you think these suggestions warrant further consideration, please forward same to Byron. I will be happy to discuss this at your convenience. Sincerely yours, PETROCON/ INC. f PAK/dsh Enclosures P. A. Kelley Project Engineer SL 012148 if;'. PETROConjnc a EnGIPIEERS S DE5IGMER5 P O. Bo* 397; Beaumont, Te*ai 77704 a- //*%? Z*?. s/,z/0g J=b l/CMTF- J?&u/)/3/u7-Y srisoY, ITT Ui, 4#/^ -/?V , ^7-/4? /sMrJX>U//J 713--332-4504 Pag ,-lAatJk. Job No m r7 pp Peu-eY ,, 774:4 t-EEo Data _______ 0 PQ5/G*J P&vT ^ 3 s&c. PohjT O /ostc. S^UTDouJaJ q Zjl/1 AdSP/ATE- SO, Recycle Data a Pew T (g) ST) MATEO PoiuT CY Pkvi6U% E*Gj3S/CaJ ____ EXPLORE. SHADED APEA PEPKBSEUTS OPSPZfl TJA/6 RAN&E. WHE&iE XF FSED LeDAJDxT/ONE EX/ST /=JZ MDHS. THAA/ 3 SYOA/DS, A TYPE \HP\TTEtJ ALA iZM RhSULTS. aJo sPutdoia/a/ is /fljmat^d/J SL 012149 CONFIDEHTIMj: Subject to protective Or&ef District Court of 14th judicial MO , ql .11/ % PETROCOnjnC EnGinEERS 5 DE5IGrtER5 P. 0. Box 3971 Beaumont, Texas 777Q4 713--332-4504 Page Job No of ..J'L SHADED AKZA RPSNrS 0?aAT/tS$ WtiafcE TF COa/DjTjDAJS F.'A/ST TA/3TANT Z/4UTDGWN IS /NlTJATBD, AhJ- . SL 012151 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Ceuet No. 91-1145 SHAPED AREA REPRasenrs SAFE sPEFATJa/A Raa/ae Ad\never apt ail spaded area js Ah edohdsshd dReRAtj^je FAa/As* St 012,52 COKfXDENTI^t r^STriet ^ ig im nci ii in t> .Qciit i l l Pog* l.PETROConjnc EnG!nEER55DE5lGMER5 mnJob No* a .= --..... P. O 3ox 397! \ Beoufinonf, Texas 77704 EAkE -Aw/Ce AM . / .C1#ot f ffjfs a^ ^/7/vC> /Tftf >--' RReef.f. ! ---------- .... 3. I/CaJIT- /3so/)s/irrr sn/0Y.iM> ~n~r ,,7 I 3--332 4504 Dot# U/Ba p/jKs.UY ______A/CD -/?v , RAr/O MmFS^^ e. 2 of3 Oxroew A^aly^^ff hCl /~~EEO DaTA ^ P5/G*J 3 S&c. PonuT q /ostc. $^utooujaj q ztfME0/Ar& SO. Rkcrtiz DatA q 0BS/4* few T~ (gj 5T)F4/fTEQ PonJ T Pktvtoot xj%j?$/6*/ ____ &KPUO%rie. SPADEOPPeA SHdWAJ /S OXYSEti lEXELS \ 3E tvjBea/ 4 AMD 7 X. 3on ^ M r/2 a r/soMs 3b rIMFEM TEED k TWO Xflti&ti ARE ALAZmeD. CmoeNTiZAT/OfilS ASDUE 7% IMITATE SHUTDOWN lMMkDjAmLY.AfJfpBcti^ Order' 1 59?^SL?tKrlot Court Sb: i=U SL 012153 =r .k |PETROCOn,iriC I - a .....a Clnt EnGinEER5s desighers P 0 Bo* 3971 Beaumont, Texas 77704 /-A R#f __ Dots 713-332-4504 ifof 3. Pog Job No,msi- i' i/O/UT- ^ao^s/<urr 5r^fY, La^iHT. Ry IMMu11 * $ebrt ^^ , y&r/Q Arfw/smtjmu/v rch,,M By (rinM ~ i.j SL 012154 mum l i t ii t-i u ih ot df'ETROCOninC t EnGinEERS 5 DESIGNERS P O Jo< 3Q7 > Beaumont. Teai 77704 7!3--232 4504 Poo*_Zy of Job No. 7M1 Page 4^ Of --- PETROCOmnC.i lr __ EnGinEERS s designers P O. 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