Document M989z6XGw0OK9Dza0QRJ3jpz
VCM TANK FARM COMPRESSOR UPGRADE
OPERATING PROCEDURES
September 8,1992
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VCM TANK FARM COMPRESSOR UPGRADE OPERATING PROCEDURE September 8, 1992
TABLE OF CONTENTS
I. PROJECT BACKGROUND............................................................................2
II. PROCESS DESCRIPTION..........................................................................4
III. NORMAL OPERATIONS..............................................................................7
IV. NON-ROUTINE CONDITIONS................................................................9
V. SAFETY AND ENVIRONMENTAL .....................................................13
VI.
DCS TIE - IN LIST...........................................................................14
VII. DCS INTERLOCKS...................................................................................15
VIII. DCS GRAPHIC...........................................................................................17
IX.
PIPING AND INSTRUMENTSDIAGRAM...........................................18
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VAB.0001107940
VCM TANK FARM COMPRESSOR UPGRADE OPERATING PROCEDURE September 8, 1992
I. Project Background
On several occasions the railcar unloading system has shut down. There has been a catastrophic failure of the compressors causing damage to the compressor housing and internals. Most failures also have caused some emission of VCM. These failures are caused by liquid entering the compressor chamber or the compressors running outside their design conditions.
This project installed instrumentation for safer operation of the Corken compressors in the VCM tank farm. The instrumentation installed will shut down the railcar unloading system before it can reach its designed operational limits.
The tank farm instrumentation includes the following:
1. INDIVIDUAL COMPRESSOR SHUT DOWN
A. Low oil pressure switch on each compressor crank case.
B. Low pressure switch on each compressor inlet.
C. High temperature switch on each compressor discharge line.
D. High liquid level switch on each compressor knock-out pot suction line.
E. High compressor head temperature.
2. ALL COMPRESSORS SHUT DOWN
A. High pressure switch on any compressor discharge line.
B. High high level switch on VCM storage sphere knock-out pot.
C. Interlocks with existing instrumentation: 1. Liquid VCM unloading valve (00H102) closed. 2. VCM Vapor unloading valve (00H103)
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VAB.0001107941
VCM TANK FARM COMPRESSOR UPGRADE OPERATING PROCEDURE September 8, 1992
I. Project Background (continued)
3. Sphere deluge system (00H105) on. 4. Railcar deluge system (00H001) on. 5. Railcar unloading isolation valve,
(00X120) closed. 6. Bullet deluge (00H002) on.
D. High pressure in emission recovery system K.O. pot.
Each of the above switches provides an input to the DCS. The DCS is responsible for providing output for enabling the motor run circuit for the compressors. Ladder logic is used to implement the interlocking for compressor shutdowns.
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VAB.0001107942
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VCM TANK FARM COMPRESSOR UPGRADE OPERATING PROCEDURE September 8, 1992
II. Process Description
High temperature switches, 00TSH214-254, located on the discharge line of the compressors are DCS inputs (see attached P&I D). The DCS will shut down the individual compressor it is serving at 230 degrees F.
High temperature switches, 00TSH210-250, connected to the compressor heads are tied into the DCS. The DCS will shut down the individual compressor at 340 degrees F.
Low pressure switches, 00PSL210-250, located on each compressor crank case is tied into the DCS. The DCS will shut down the individual compressor when the oil pressure drops to 12 psig. A 10 second delay is included with each switch to allow for start-up.
Low pressure switches, 00PSL212-252, connected to the inlet of the compressors are tied into the DCS. The DCS will shut down the individual compressors at 8 psig.
High level switches, 00LSH213-253, are located on the suction of each compressor knock-out pot. These switches are tied onto the DCS. The DCS will shut down the individual compressor when a high level of liquid VCM is detected.
High pressure switches, 00PSH211-251, are connected to the discharge line of each compressor. These switches are DCS inputs. All compressors will be shut down if any discharge lines reach 150 psig. The flex hoses are the weak link in the unloading system. All compressors will be shut down before the flex hoses reach a hazardous pressure (625 psi is the flex hose MAWP).
The high pressure switch, 00PSH012, on the emissions recovery system (ERS) knock-out pot, is tied into the DCS. The DCS will shut down all compressors when the ERS pressure reaches 75 psig.
The high-high level switch, 00LSHH011, is located on the sphere knock-out pot. This switch is tied into the DCS. All compressors will be shut down if high liquid VCM level is detected. This will keep the
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VAB.0001107943
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VCM TANK FARM COMPRESSOR UPGRADE OPERATING PROCEDURE September 8, 1992
II. Process Description (Continued)
sphere knock-out pot from overflowing into the compressor inlet.
All switches in the VCM tank farm compressor area are tied into the DCS. This system consists of 37 discrete inputs and 5 discrete outputs (see DCS tie-in list). A VCM unloading graphic is located on the dryer operator terminal. The switches generate alarms on the DCS when engaged. These alarms are included in the ladder logic for energising the compressors. This provides compressor shut downs when alarm conditions occur (see DCS interlocks list).
Interlocks with other equipment also shut down the compressors in the following instances:
1. Either the liquid VCM unloading valve (00H102) or the VCM vapor supply valve is closed (O0H103).
2. The sphere deluge system is activated (00H105).
3. The railcar deluge system is activated (00H001)
4. Bullet deluge system is activated (00H002).
5. Railcar unloading isolation valve is activated (00X120).
The vinyl lead operator will use two-way radios to communicate with the yard operator. The vinyl lead operator must enable the compressors from the tank farm graphic to allow them to be started. Although the compressors are energized from the DCS, the yard operator is required to start the compressors from a local hand switch. The compressors9 hand switches are located at each compressor.
A drain line runs from the vapor header of the sphere to the ERS. This line is used to drain any liquid out of the vapor line before the compressors are started. A check valve is installed in this line.
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VAB.0001107944
VCM TANK FARM COMPRESSOR upgrade OPERATING PROCEDURE 8. 1992
II. Process Description (Continued) All lines down stream of the drain line including the compressor knock-out pots and compressor inlets, are heat traced and insulated to keep VCM from condensing during winter conditions.
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VAB.0001107945
VCM TANK FARM COMPRESSOR UPGRADE OPERATING PROCEDURE September 8, 1992
III. Normal Operation
The VCM Tank Farm Compressor Upgrade project installed equipment for constant monitoring of the VCM compressors by the DCS. When design conditions are met, the DCS will energize the compressors to a field hand switch. The operator will visually check the system before the unloading process is started. The compressors must be started by the yard operator.
The following steps will be taken during unloading startup:
1. Hook up railcars.
2. Check the valves that are between the railroad tracks going to each unloading station which is to be used for unloading railcars. All the valves must be open.
3. Go to the compressor shed and put on the breathing air mask and hook up to breathing air system.
Open the main liquid valve on the west side of the compressor shed on the sphere liquid line. This valve normally stays open.
5. Visually inspect each liquid unloading line. The valves on this line must be open to allow liquid flow.
6 Open the main vapor valve on the sphere vapor line. This valve normally stays open.
7 Position the 4-way valve to allow vapor flow to the suction of the compressors.
***8
Before starting any compressor open the valve on
the line fro the sphere vapor header to the
Emissions Rec<
(ERS)
remove any
liquid VCM in the vapor lines, Also open header
to compressor suction line and K.O. pot close
these valves after liquid removal this should
take approximately l minute.
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VAB.0001107946
VCM TANK FARM COMPRESSOR UPGRADE OPERATING PROCEDURE September 8, 1992
III. Normal Operation (Continued)
9. Open the inlet and outlet valves on the sphere knock-out pot. These valves normally stay open.
10. Inspect the vapor lines through the shed to insure all of the appropriate valves are open.
11. Check liquid VCM level in the sphere knock-out pot. If high level exists manually pump out some of the liquid from the knock-out pot. If you cannot see through the sight glass, turn the pump to the manual position and then turn it to the auto position. The pump will run in the auto position if there is a high level in the K.O.
pot.
Check valves on should be
knock-out pots These during normal operation.
13. Start compressors by putting the Hand-Off-Auto switch in auto and depressing the start button.
14. If compressors do not start, follow the outline in section IV for non-routine conditions.
15. Monitor compressor discharge pressure.
16. Monitor flow indicators. Green indicates flow.
17. Log in railcar numbers.
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VAB.0001107947
VCM TANK FARM COMPRESSOR UPGRADE OPERATING PROCEDURE September 8, 1992
IV. Non-Routine Conditions
Any conditions which result in the compressors shutting down or not starting is a non--routine condition. The DCS is set up to shut down the compressors or keep them from starting under the following condition:
1. High Compressor Discharge Temperature.
2. High Compressor Head Temperature.
3. Low Compressor Oil Pressure.
4. Low Compressor Inlet Pressure.
5. High Liquid Level in the compressor knock-out pots.
6. High Compressor Discharge pressure.
7. High-High Liquid Level in the sphere knock-out pot.
8. High Pressure in the ERS pot.
9. The Liquid VCM Unloading and the Vapor VCM Supply Valves are closed.
10. The Sphere, Railcar, or Bullet Deluge systems are activated.
11. The Railcar Unloading Isolation Valve is closed.
Each of these conditions will cause an alarm in the vinyl control room at the dryer operator's console (see VCM tank farm graphic). Should an alarm occur, the dryer lead operator will immediately contact the yard operator, using the two-way radio, to inform him of the alarm that occurred.
The yard operator should contact the dryer panel operator if a compressor will not start when the hand switch is switched on. The dryer operator can now help in trouble-shooting these type of problems.
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VAB.0001107948
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VCM TANK FARM COMPRESSOR UPGRADE OPERATING PROCEDURE September 8, 1992
IV. Non-Routine Conditions (Continued)
Action should be taken on each alarm as indicated below:
1. High Discharge Temperature - Individual compressor shut down.
Should high discharge temperature occur, check the compressor discharge line for closed or partially closed valves. Open any valves that may be closed. Try again to start up the compressor.
If no valves are closed, isolate the compressor and allow to cool. After the compressor has cooled, determine the cause of the high temperature before restarting.
2. High Head Temperature - Individual compressor shut down.
In the event of a high head temperature shut down, isolate the compressor and allow to cool. After cooled determine the cause of the high head temperature before restarting the compressor.
3. Low Oil Pressure - Individual compressor shut down.
Have the oil level checked by maintenance and also check for leaks.
4. Low Inlet Pressure - Individual compressor shut down.
L
This is an indication that there is liquid in the compressor knock-out pot. Open the valve on the bottom of the compressor knock-out pot that goes to the ERS. After pot has drained, close this valve.
Should more than one compressor have liquid in the knock-out pot the drain line on the sphere vapor line should be opened to allow liquid to be removed from this line. The sphere knock-out pot should also be drained using the procedure
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VAB.0001107949
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VCM TANK FARM COMPRESSOR UPGRADE OPERATING PROCEDURE September 8, 1992
IV. Non-Routine conditions (Continued)
outlined in 7. below (High-High Liquid Level in the sphere knock-out pot).
5. High Liquid Level in the compressor knock-out pot - Individual compressor shut down.
Follow the same procedure outlined in 4. above (Low Inlet Pressure).
6. High Outlet Pressure - All compressors shut down.
This indicates that one of the valves going from the compressors to the railcars is probably closed or partially closed. Inspect the lines from the compressor for any closed valves.
7. High-High Liquid Level in the sphere knock-out pot - All compressors shut down.
To manually drain the sphere knock-out pot, place the VCM recycle pump switch in the "HAND" position. This switch is located on a panel on the south side of the knock-out pot. The recycle pump will pump the contents of the pot to the sphere. When the level in the pot has dropped below the low level switch, place the pump switch back in the "AUTO" position.
8. High Pressure in the ERS knock-out pot - All compressors shut down.
A high ERS pressure shutdown indicates that the emissions recovery system is backed up or not functioning properly. The yard operator should inform the vinyl supervisor of the situation. VCM unloading must be halted until the ERS problems are corrected.
9. Either the liquid VCM unloading or the VCM vapor supply valves are closed - All compressors shut down.
The yard operator will determine the reason the valve is closed. Open the valve if no reason for its closure is determined, and re-start the
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VAB.0001107950
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VCM TANK FARM COMPRESSOR UPGRADE OPERATING PROCEDURE September 8, 1992
IV. Non-Routine Conditions (Continued) compressors.
10. Sphere, Railcar, or Bullet Deluge systems are activated - All compressors shut down. The yard operator will determine the reason the deluge system is activated. Compressors should not be re-started until the deluge is shut off.
11. The Railcar Unloading Isolation Valve is closed All compressors shut down. The yard operator will determine the reason the railcar unloading isolation valve is closed. If no reason for its closure is determined, open the valve and re-start the compressors.
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VAB.0001107951
J
*K FARM COMPRESSOR UPGRADE OPERATING PROCEDURE
September 8, 1992 SAFETY AND ENVIRONMENTAL This project provides a safer operation of the compressors during railcar unloading procedures. The ultimate result of this project is a reduced chance for VCM emissions. This project provides an added security to plant workers, the community, and the environment.
VAB.0001107952
*
It
DCS TAG
00LA213 00LA223 00LA233 00LA243 00LA253 00LA011 00TA210 00TA220 O0TA230 00TA240
00TA2S0 00TA214 00TA224 00TA234 00TA244 OOTA254 00PA212 00PA222
00PA232 00PA242 00PA252 00PA210 00PA220 00PA230 00PA240 00PA250 00PA211 00PA221 00PA231 00PA241 00PA251 00PA012 00HM210 00HM220 OOHM230 00HM240 |00HM250
DCS TIE - IN LIST
INPUT
COMPONENT P&l D NUMBER
00LSH213
00LSH223 00LSH233 00L8H243 00LSH253 00LSHH011 00TSH210 00TSH220
0OTSH230 1 00TSH240
00TSH250
OOTSH214
00TSH224
00TSH234 1 00TSH244 1 00TSH254
00PSL212 | OOPSL222 00PSL232
00PSL242 00PSL252
00PSL210 00PSL220 00PSL230
00PSL24Q 00PSL250
00PSH211
mm........................................................
IIMW
00PSH221
00PSH231 00PSH241
00PSH251 OOPSHOI2 00HMR210 00HMR220 00HMR230 00HMR240 00HMR250
LSH-101 LSH-102
LSH-103 LSH-104 LSH-105 LSHH-101 TSH-106 TSH-107 TSH-108 TSH-109 TSH-110
TSH-101 TSH-102 TSH-103 TSH-104 TSH-105 PSL-106 PSL-107 | PSL-108
PSL-109 PSL-110 PSLPSL-102 PSL-103 PSL-104 PSL-105 PSH-101 PSH-102 PSH-103 PSH-104 PSH-105 PSH-106 CP-101 CP-102 CP-103 | CP-104 |CP-105
1 1 |
| |
00HM210 00HM220 00HM230 00HM240 00HM250
/f
A
OUTPUT
CP-101 CP-102 CP-103 CP-104 CP-105
VAB.0001107953
DCS INTERLOCKS LIST
ALL COMPRESSOR SHUT DOWN INTERLOCK
DCS TAG IDISCRIPTION
00PA211 HIGH DISCHARGE PRESSURE ON CP-101 00PA221 HIGH DISCHARGE PRESSURE ON CP-102 00PA231 ! HIGH DISCHARGE PRESSURE ON CP-103 00PA241 HIGH DISCHARGE PRESSURE ON CP-104 00PA251 HIGH DISCHARGE PRESSURE ON CP-105 00LA011 HIGH LEVEL IN THE VCM SPHERE KNOCK-OUT POT OOPA012 HIGH PRESSURE IN THE ERS KNOCK-OUT POT 00HA105 ' SPHERE DELUGE SYSTEM ACTIVATED 00HA001 RAILCAR DELUGE SYSTEM ACTIVATED 00HA002 BULLET DELUGE SYSTEM ACTIVATED OOXV120 RAILCAR ISOLATION VALVE 00HV102 VCM UQUID UNLOADING VALVE lOOHVI 03 JVCM VAPOR SUPPLY VALVE
COMPONENT IPgJ D NUMBE
00PSH211 00PSH221 00PSH231 1 00PSH241 00PSH2S1 OOLSHHO11 OOPSHO12
P8H-101 PSH-102 PSH-103 PSH-104 PSH-105 ! LSHH-101 PSH-106 i
n
CP-101 SHUT DOWN INTERLOCK
DCS TAG IDESCRIPTION
COMPONENT!P3J D NU
00LA213 ICOMPRESSOR KNOCK-OUT POT HIGH UQUID LEVEL
218 L8H
00PA212 COMPRESSOR ICO. POT LOW DISCHARGE PRESSURE ![0OP8U12
00TA210 HIGH COMPRESSOR HEAD TEMPERATURE
| 00TSH210
psl-ios TSH-106
00TA214 HIGH COMPRESSOR DISCHARGE TEMPERATURE
00TSH214 T8H-101
00PA210 LOW COMPRESSOR OIL PRESSURE
OOPSL210 PSL-101
ALL COm MPRESSOR SHUT DOWN ACTIVATED WHEN ALL ALARMS ARE OFF. THE VINYL LEAD OPERATOR MUST ENABLE THE
COMPRESSOR FROM THE TANK FARM GRAPHIC BEFORE THE DCS WILL ENERGIZE
00HM210 . A YARD OPERATOR WILL BE REQUIRED TO START CP-101 THROUGH A LOCAL HAND SWITCH.
CP-102 SHUT DOWN INTERLOCK
DCS TAG I DESCRIPTION
COMPONENT IP&J D NUMBE
00LA223 COMPRESSOR KNOCK-OUT POT HIGH LIQUID LEVEL I00LSH223
00PA222 COMPRESSOR K.O. POT LOW DISCHARGE PRESSURE 00PSL222
00TA220 HIGH COMPRESSOR HEAD TEMPERATURE
00TSH220
00TA224 HIGH COMPRESSOR DISCHARGE TEMPERATURE 00PA220 IlOW COMPRESSOR OIL PRESSURE
00TSH224 00PSL220
ALL COMPRESSOR SHUT DOWN ACTIVATED
-1(g PSL-107
TSH-102 PSL-102
ALARMS ARE OFF, THE VINYL LEAD
. ...________
COMPRESSOR FROM THE TANK FARM GRAPHIC BEFORE THE DCS WILL ENERGIZE 00HM220 . A YARD OPERATOR WILL BE REQUIRED TO START CP-102 THROUGH A LOCAL HAND SWITCH.
DCS INTERLOCKS LIST
(Continued...)
CP-103 SHUT DOWN INTERLOCK
DCS TAG DESCRIPTION
COMPONENT P&l D NUMBE
00LA233 COMPRESSOR KNOCK-OUT POT HIGH UQUID LEVEL 00PA232 COMPRESSOR K.O. POT LOW DISCHARGE PRESSURE 00TA230 HIGH COMPRESSOR HEAD TEMPERATURE 00TA234 HIGH COMPRESSOR DISCHARGE TEMPERATURE 00PA230 LOW COMPRESSOR OIL PRESSURE ALL COMPRESSOR SHUT DOWN ACTIVATED
00LSH233 00PSL232 00TSH230 00TSH234 00PSL230
LSH-103 PSL-108 TSH-108 TSH-103 PSL-103
WHEN ALL ALARMS ARE OFF, THE VINYL LEAD OPERATOR MUST ENABLE THE COMPRESSOR FROM THE TANK FARM GRAPHIC BEFORE THE DCS WILL ENERGIZE 00HM230 . A YARD OPERATOR WILL BE REQUIRED TO START CP-103 THROUGH A LOCAL HAND SWITCH.________________________________________________ ________
A
CP-104 SHUT DOWN INTERLOCK
DCS TAG DESCRIPTION
COMPONENT
00LA243 COMPRESSOR KNOCK-OUT POT HIGH LIQUID LEVEL j00LSH243
00PA242 COMPRESSOR K.O. POT LOW DISCHARGE PRESSURE I00PSL242
00TA240 HIGH COMPRESSOR HEAD TEMPERATURE
(00TSH240
00TA244 HIGH COMPRESSOR DISCHARGE TEMPERATURE
I00TSH244
00PA240 LOW COMPRESSOR OIL PRESSURE
|00PSL240
ALL COMPRESSOR SHUT DOWN ACTIVATED
|LSH-104 |PSL-108
ITSH-109 IT8H-104 |PSL-104
WHEN ALL ALARMS ARE OFF, THE VINYL LEAD OPERATOR MUST ENABLE THE COMPRESSOR FROM THE TANK FARM GRAPHIC BEFORE THE DCS WILL ENERGIZE
00HM240 . A YARD OPERATOR WILL BE REQUIRED TO START CP-104 THROUGH A LOCAL HAND SWITCH.
CP-105 SHUT DOWN INTERLOCK
DCS TAG DESCRIPTION
COMPONENT P&l D NUMBER
00LA253 COMPRESSOR KNOCK-OUT POT HIGH LIQUID LEVEL
00PA252 COMPRESSOR K.O. POT LOW DISCHARGE
OOTA250
COMPRESSOR HEAD TEMPERATURE
U0IAZ04
COMPRESSOR DISCHARGE TEMPERATURE
00PA250
COMPRESSOR
ALL COMPRESSOR SHUT DOWN ACTIVATED
IOOLSH253 00PSL252 00TSH250 00TSH254 00PSL250
LSH-105 PSL-110 TSH-110 TSH-105 PSL-105
WHEN ALL ALARMS ARE OFF, THE VINYL LEAD OPERATOR MUST ENABLE THE COMPRESSOR FROM THE TANK FARM GRAPHIC BEFORE THE DCS WILL ENERGIZE 00HM250 . A YARD OPERATOR WILL BE REQUIRED TO START CP-105 THROUGH A LOCAL HAND SWITCH.
VAB.0001107955
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