Document MM85BEeM2dRqQ59x1VJBGVd7L

PITTSBURGH PLATE GLASS COMPANY CHEMICAL DIVISION LAKE CHARLES, LOUISIANA s HC1 PLANT MANUAL CONFIDENTIAL: Subject to Vrccecz Lv'B Ct-: f 14th Ji-c i;.;.- ! 4hlir!-w itf*. i :----iCi- CoUr January 20, 1966 SL 008948 Manual No. table of contents INTRODUCTION 1 GENERAL DESCRIPTION ............................................................................................................ 2 SAFETY .......................................................................................................................................... 4 Emergency Homs...................................................................................................... Fire Protection................................................................................................... Control Building ....................................................................................... Electrical .............................................................................................................. Relamping ................................................................................................................. Grounding ................................................................................................................. Tools .......................................................................................................................... Procedures ............................................................................................................... Safety Permit ................................................................................ General Fire andExplosion Rules ................................................. General SafetyRules ............................................................................ Special Safety Equipment ............................................................................... 5 6 7 7 8 8 9 10 11 12 14 CHEMICALS IN THE AREA........................................................................................................ 16 DRY HC1 PROCESS ...................................................................................................................... 30 Dry HC1 Process Description....................................................................... 30 1. Vaporized Chlorine System ................................................................... 31 2. H2 System........................................................................................................ 33 3. Shutdown System ................................... 34 4. Burner System............................................................................................... 37 5. Primary Coolers ........................................................................ 40 6. Secondary Coolers ..................................................................................... 41 7. H2SO. Drying System................................................................................. 42 8. HC1 Compressor System............................................................................ 43 9. HC1 Scrubber................................................................................................. 46 Detailed Start-up Procedure ........................................................................ 48 WET HC1 PROCESS ..................................................................................................................... 51 1. Gaseous Chlorine System ........................................................................ 55 2. Hydrogen System............................................................................................ 56 3. Shutdown System............................. 58 4. Burner System............................................................................................... 60 5. Absorber System............................................................................................ 63 a. Absorber Coolers ............................................................................... 63 b. Tails Towers ............................................. 63 c. Seal Pot .................... 63 d. Specific Gravity Indicators ..................................................... 63 e. Tails Tower Jets ............................................................................... 63 f. Start-up Procedure ............................ 67 Subject to Of Hth o> CD CO O O CO 6. Stripper System.......................................................................................... 69 a. Stripper...................... 69 b. Stripper BottomsCoolers ....................................... 69 c. Stripper FeedPump ............................................................................. 69 d. Start-Up ................................................................................................. 71 7. Primary Coolers ......................... 72 8. Secondary Coolers .................................................................................... 73 9. Tertiary Coolers .................................................................................... 74 ABSOBBER-COOLER #2 AND HC1 PRESSURE CONTROL SYSTEM..................................... 75 STORAGE TANKS .................. 77 SCRUBBER SYSTEM...................................................................................................................... 78 CONDENSATE SYSTEM ................................................................................................................. 79 DRYER SYSTEM............................................................................................................................ 80 COMPRESSOR SYSTEM 82 1. HC1 Compressors 1, 2, 3, &4.............................................................. 82 2. HC1 Aftercoolers 1, 2, 3 &4.......................... 82 3. Low Pressure Surge Tank...................................................................... 82 4. High Pressure Surge Tank ..................................................................... 82 5. N2 Compressor and Surge Tank............................................................ 82 6. Surge Drum for #4 Compressor ............................................................ 82 CENTRIFUGAL REFRIGERATION COMPRESSOR AND BRINE SYSTEM .............................. 88 INSTRUMENTATION ...................................................................................................................... 128 ELECTRICAL................................................................................................................................... 133 LABORATORY PROCEDURES ........................................................................................................ 136 1. HC1 Analysis (Orsat) ............................................................................ 136 2. HC1 Analysis (H2 only) ..........................................................................141 3. HC1 Strength................................................................................................. 146 4* HC1 (free chlorine) ................................................................................. 148 OPERATING GRAPHS 1. Absorber Feed as a Function of Rate 2. Stripper Feed as a Function of Rate 3. Excess HC1 SCFH vs. TPD SL 008950 PROCESS FLOWSHEET MECHANICAL FLOWSHEET ELECTRICAL ONE LINE DIAGRAM nA r -V.^,niteDf.tctrcOUrt INTRODUCTION USES AND PURPOSE OF MANUAL This operating manual has been assembled with the following purposes in mind: 1. To aid the operators in becoming familiar with the HC1 plant. 2. To serve as a ready source of reference for the operators throughout their tenure at the HC1 plant. 3. To provide a set of basic procedures so that everyone is working under the same instructions. 4. To serve as a place where data, facts, information, etc. on the unit are centrally located and readily available. Like any new operating manual, it is expected that changes will be warranted in this write-up as operating experience is gained. Please feel free to suggest these changes as it is intended that this manual be kept current and meaningful. It should be remembered that this manual is the property of Pittsburgh Plate Glass, Chemical Division, Lake Charles, and may be recalled at any time. You are personally responsible for the safe keeping of this manual as well as the information therein. This is why the manual is numbered and charged to you. SL 00895 7 C(WP5SSSU order JnatcMiet Court -l- GENERAL DESCRIPTION The HC1 process is broken down into two areas. There is a Dry HG1 plant and a Wet HC1 plant. Both plants nse and Cl2 as feedstock and both plants produce anhydrous HC1 as an end product, but there is a difference in how each plant processes the HC1. Anhydrous (dry) HC1 is produced by burning IL, and in a water- cooled combustion chamber. The reaction is: H2 + Cl2-*- 2 HC1 is fed in a slight excess so that all of the Cl2 is reacted and the product HC1 has 2% to 5% H2 in it. The excess should be large enough so that there is no danger of having any Cl2 in the product stream. The Dry HC1 plant gets its Cl^ from the MC Cl2 vaporizer and its H2 from the H2 compressors in the cell area. The two gases are fed into the bottom of a combustion chamger where they are burned, forming HC1. The HC1 is removed from the top of the combustion chamber and goes through two stages of cooling. The first stage is well water, the second stage is chilled brine. There are two identical sets of burners and coolers. From the coolers the gas goes through an I^SO^ dryer and into the compressor suction. From here the gas is compressed to 50 psig, cooled and sent through 11,000' of 6" schedule 40 pipe to the customer. The Wet HC1 plant gets its Cl2 from the compressors in liquefaction (cell gas) and its frcro the compressors in the cell area. Cell gas Cl2 may be used in the wet process because the inert gas impurities are not carried through the process. H2 and Cl2 are fed to the bottom of a combustion chamber where they are burned forming HC1. The combustion chamber and the feed systems are the same as those in the dry system. The HC1 is fed from the top of the SL 008952 -2- CtJNPlUENTlM*: Meet to Protective Order t Court. 4th Judicial chamber to a cooler absorber, where the gaseous HC1 is absorbed in a weak acid (20%) solution making it strong acid (32%). The inerts are pulled through a tails tower by a steam jet ejector and discharged into the vent scrubber. There are 3 identical sets of burners and absorbers. One dry burner and cooler may be run as a burner absorber system, and there is one absorber that is used for vent streams. The strong acid is sent to storage and from there it is pumped to a stripper. In the stripper, strong acid is fed and gaseous HC1 is cooled in 3 stages, the first stage is cooling tower water and the other two are chilled brine. There are two idential sets of strippers and coolers. After being cooled, the HC1 goes through a H^SO^ dryer, is compressed, cooled and sent to EC. In the near future VC will be tied into the HC1 system. VC will then become the source of HC1 in place of the burners. At this time this manual will be brought up to date. To improve efficiencies in the MC plant, HC1 from the TCE Reactor is fed into the suction of the EC HC1 compressors. To replace this HC1, No. 4 compressor takes its suction gas from the stripper gas, compresses this high purity HC1, cools it and sends it to the MC reactor. SL CONFIDENTIAL: Subject to Protective Of 14th Judicial District C* ,;rt 9) -M tr. "3" SAFETY FOR THE HC1 AREA Due to the nature of the operation and the chemicals involved, the HC1 area is restricted to authorized personnel only. Company vehicles will be permitted to travel on the main approach road through Area "B" and the access road to the control house during normal operations. Special permits will be required to enter any of the operating areas or chained-off areas. Never cross a chain, regardless of whether it is up or down, with a vehicle without a pass. Passes for vehicles will be issued by the operating supervision of the affected area. All passes are immediately revoked if the Area "B" evacuation whistle sounds. If you are operating a vehicle and the emergency horns sound, shut down the vehicle and evacuate the area as quickly as possible on foot. A new pass will be issued to remove the vehicle. "It has been said that all synthetic hydrogen chloride plants blow up sooner or later. This is probably true. Someone will be careless, or some unforeseen event will occur." This is not an idle quotation. We should all remember that the hydrogen-air explosive limits range from 4% to 75% hydrogen by volume and for hydrogen-chlorine the explosive range is 5% to 95% hydrogen or chlorine by volume. As long as the flame in the combustion chamber is maintained, the danger of an explosion is minimized. Causes for flame failure can generally be ascribed to the following conditions: 1. Unequal or insufficient gas pressures into the burner nozzle. Feed gas surges. n Tnfl/'mratfi flow Control SL 008954 4- Subject cf 14th *3 3 Loss of vacuum 4. Condensate build-up. 5. Burner cap and inner pipe failure. 6. Inadequate cooling. Our unit has a "Firetron" fire-eye which will monitor the flame continuously. On flame failure the hydrogen and chlorine valves should close instantaneously preventing any explosive mixture accumulation. This action is completely automatic -- depending only on the proper functioning of this flame failure device. EMERGENCY HORNS The HC1 plant has only one emergency horn, and that horn is the Area "B" evacuation horn. Due to the fact that the HC1 operator and operations are in near proximity and closely associated with the EC-VC operations, it is well that HC1 personnel be familiar with those plant sirens as well as the plant evacuation warbler. For this reason a description of both the horns is included in this manual. There are two distinct emergency horns in the area, the plant or Area "B" evacuation horn and the EC operating area siren. The Area "B" evacuation horn is a continuous warbling sound and may be activated from the EDC or EC-VC control rooms, or the guardhouse. The sounding of this horn will shut down all non-process equipment in area "B" and will cause all non-essential personnel to leave the area. Area "B" in cludes all areas west of Columbia-Southern Road. The Area "B" evacuation horn should be sounded in case of a major break in EC, or if there is some reason to expect a major break, or if there is a possibility that EC vapors coMrtoamrt* SL -5- will escape the operating area. Whenever the evacuation horn is sounded, the guards should be notified of the nature of the emergency if at all possible. If it is desired to evacuate the whole plant, the guards will have to be notified and they will sound the plant evacuation. The guards are the only people able to sound the all-clear. The operating area siren is to evacuate all non-essential personnel from the operating area and to have all arcing devices in the operating area shut down. This siren is controlled by a switch on the panel board or by a switch located near the bottoms Dopp kettle. The area siren should be used in case of a minor spill or a possible spill. It is well to keep in mind the extreme flammability of EC. Should a spill occur, keep it from spreading if at all possible and eliminate all sparking devices in the area. One of the best means to prevent spreading is the use of the fire water system, use it and use it quickly. The arcing devices can be eliminated by sounding the siren or evacuation alarm. Evaluate the situation quickly, and act quickly; it is much better to get someone wet or evacuate them than to have a fire or an explosion. When you are in the operating area and the siren blows or you are in Area "B" and the warbler blows, see to it that all non-essential equipment is shut down (trucks, hysters, welders, etc.) and if you are non-operating personnel get out of the area. All operating personnel should go to their respective control rooms, if possible. FIRE PROTECTION Flammables are present in the HC1 plant in only a few locations. For this reason the fire protection is minimal. All equipment and fixtures are explosion proof, but this is to protect against corrosion. It is possible to have some flammables in the vent as EC from the EC vent stream and from SL 008956 Subject of Mth J the absorbers is being continuously vented. The fire protection in the HC1 plant is provided in two ways, CO and dry chemicals. The C0,, extinguishers 2^ are good for small fires or small electrical fires. The dry chemicals are good for all fires, but leave a harmful residue on electrical equipment. The only CO2 extinguishers will be upstairs in the control room. There are 30# dry chemical units located throughout the unit with at least one ex tinguisher on each level. CONTROL BUILDING The control building is pressurized to prevent accumulation of any vapors inside. Since it is a pressurized building, non-explosion proof electrical equipment canbe used and smoking is permitted inside. The positive pressure is maintained by a fan which draws its intake air across an activated carbon filter. Should a major break occur, the filter would be unable to eliminate all contaminants, therefore the fan should be shut down. To prevent any vapors from entering the building when the fan is off, instrument air bleeds should be opened. (Do not bleed the air system down by taking too much.) To prevent dust from accumulating in the control room, filter bags are in the suction of the air conditioner. For any problems with the air conditioner, notify the supervisor. ELECTRICAL EQUIPMENT The characteristic of HC1 is such that the equipment used in the area is classified as Class I, Group D, but the area is classifed as non-hazardous. The higher classified equipment is used to protect against the corrosive atmosphere present in the plant. The methods and materials of installation are those recommended by Factory Insurance Association. In general, the in stallation is Class I, Group D, Division 2. Motors are TEFC (Totally Enclosed SL 008957 CONFIDENTIAL* Subject to of 14th Coutt Fan Cooled ), lighting is vapor-tight, and all arcing devices are explosion proof with seal-offs. RELAMPING AND RECEPTACLES Vapor-tight fixtures are used in the process area. The relamping procedure will be to first determine the lamps which need changing by turning on all lights. Then, turn off all lights and relamp. To simplify this procedure, circuit breakers for lights in the process area and control laboratory have been grouped in the lighting panels. Globes and guards must be replaced after relamping. GROUNDING Grounds for motors and other electrical devices are contained in the conduit supplying the device and connected to the device frame internally. Motor change-outs should be checked to see that the ground has been replaced. Due to the tendency for hydrocarbons to build up a static electricity charge as a result of movement or agitation, a system of jumpers for pipe flanges has been installed to provide metallic continuity of the piping systems that contain flammable materials. All vessels are grounded at 2 points. The result is a system of lines, tanks, and vessels operating at ground potential. This will not prevent the generation of static charges but should provide adequate leakage to ground to prevent the accumulation of dangerous charges and the re sulting spark. The nearness of the radio transmitting station north of the process area presents a problem in that metal objects will act as receivers of radio frequency energy. It is not practically possible to prevent this effect. It is known that the energy picked up will be amplified if the height of the SL 008958 ampTnorriALi "8" Subject bo Pf of 14th JuNdoic. ia991-1145 object Is a multiple of the transmitter wave length. A particular hazard is created by the use of cranes with long booms. Under certain conditions, depending on boom length and crane location, it is possible to pick up a voltage high enough to bum the person handling a load that is suspended from the crane. This will occur even if the crane is grounded. It is also conceivable that an arc would occur if the crane hooks touch a grounded object. Particular attention should be paid to this problem if the crane height is greater than 90'. It is obviously important that the grounding system be maintained intact. This should be kept in mind when performing maintenance work on any equipment in the EC plant. TOOLS Special spark-proof tools are not required unless there are EC or VC vapors present, or a possibility that EC or VC vapors will become present. Check with operations prior to starting each job to determine the type of tools needed. SL 008959 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 ORGANIC AREA SAFETY PERMIT To be used Co pass restricted equipment into the Organic Area and to be endorsed for the use of such equipment in the _____Ethyl Chloride.________ 'Unit. ipJckYm \Tbttes_____pate: 6 ST }feif/e TruckLocation: .Z3o^ya Equipment: . Please Check 1. Have workmen been provided with proper safety equipment? 2. Are adjacent areas and equipment safe? 3. Has adequate fire protection been provided? Yes No X X X 4. Is presence of operator required? X Remarks Approved ui.ll tiflalc* 2 fvipM toil!Clltec.kid .___ hy* second If a siren or emergency horn sounds, I am to turn off my equipment immediately and evacuate thne area on foot. lartA* ^ESmmpp loyee' s rfS igna ture WELDING OR BURNING PERMIT This permit, when signed, allows welding or burning at: rack bJ*f d awlnet fooler *|3(Location)17j~ It is good for: Date /7 A)At/ CCTime AM To: Date JOoU Time / Special. Comments: SsLn tailll ckggj{ __________ PM Signed: gsuftnw* s-cSfcy (Area Product^m Supervisor) atinneY. T U\ filled tVt 4ov 'tvutl t k , * % ie $i)lecl /Vi.- Soy ol> Jc/i fifcivnin* > eurt t SL 008960 -10- VT1 ''jI\* 'fljf "t I' * * >. f f* COHtflDEHTIAjL* . Subject to Protective Order ", Of 14th Judicial District Court , . 1* 'No.-;,. Sfi-tl,145 /' ! : GENERAL FIRE AND EXPLOSION RULES 1. Personnel entering the organics area will deposit lighters, matches, regular flashlights, etc. at the gate to this area. Safe flashlights have a label showing MSA approved for flammable areas. 2. Anyone entering an operating area should first check with operating personnel. 3. Smoking will be permitted only in the main control building (except the laboratory) where permanent lighters are provided. 4. A vehicle permit signed by an operating supervisor will be required for any vehicle to go into the chained-off roads. Vehicles may drive to the control room to obtain passes, or do business there. 5. An equipment permit signed by the operating supervisor will be required before the following equipment can be carried into the HC1 area: (a) Welding machine . (b) Cutting torches. (c) Electrically-driven drills. (d) Any electrical equipment except explosion-proof flashlights. (e) Gasoline engine driven equipment not previously covered. (f) Lighters, blow-torches or any flame producing equipment. (g) Grinders or chipping equipment. (h) Sandblasting equipment. 6. Only explsion-proof flashlights will be permitted. 7. In case of an emergency warning (siren or plant howler), all vehicles or equipment that are in the area on permits will be shut off immediately, and the occupants will evacuate the area immediately on foot. 8. Do not dump ethyl chloride or other flammables into openings such as sewers or other underground cavities where harmful vapors could be evolved. 9. Do not leave an open sample or container of a flammable material setting around to give off vapors. SL 008961 -li- CONFIDEHTIM#* Subject to Protective Order f 14th Judicial District Court Ho. 91-1145 10 . All steam-out nozzles or hose and purge equipment must be properly grounded to reduce the possibility of an arc from an accumulated static charge. 11. Do not permit air to enter any of the process equipment that contains flammable material. 12. Fire protection equipment is different. Know it well' Report all damges immediately. Do not use the fire hoses for any other purpose. 13. It is intended that all personnel will obtain periodic refresher courses on fire-fighting techniques. GENERAL SAFETY RULES 1. Pumps and Equipment -- any pump or pieces of equipment that are removed from the process stream must be thoroughly cleaned and inspected by a foreman before they are permitted to leave the area for the main shop or other work areas. 2. Regular plant utility hoses are not to be used for solvents because they will become weakened and unsafe to use with pressure. Use the special hose provided. 3. The laboratory hood fans are to operate continuously. Do not attempt to run analyses without the fan being in service, 4. Use Full-Face, Chemox or Scott Air-Pak masks for protection against HC1 vapors, 5. Do not permit chlorine to be heated above 300 F. as it will rapidly corrode most metals at higher temperatures. 6. Clothing that has been wet with HC1 should be removed immediately and the body thoroughly washed with soap and water. SL 008962 -12- CONFIDENTIAL: Subject to Protectiv Order of 14th Judicial District Court No. 91-1145 7. Clearing of Tanks and Process Vessels -- The area supervisor and maintenance supervisor will see that all vessels or tanks are cleaned and checked with an explosion meter before declaring them suitable for maintenance. Clearing Procedure: (a) The tank or vessel will be emptied of its contents and all valves will be closed and tagged. (b) The vapor contents of the tank will be purged with an inert gas. (c) Blinds will be inserted in all connecting lines. (d) Purge the equipment with plenty of air. (e) The equipment will then be checked with an explosion meter before work is begun. When a man is to enter the tank, it will first be checked for sufficient 0^. The apparatus for testing for sufficient oxygen is either a flame or a special metering device. These tests can be run only by a supervisor. (f) Safety belts and safety lines will be required in top exit tanks. 8. If the emergency warning sounds, all personnel not needed for control purposes should walk upwind or crosswind if in fumes to a safe location and remain there until the all-clear sounds. Those personnel required for operation should remain on the job, while taking safety precautions necessary to remain in the area. 9. Tagging -- Same as used throughout the plant. See (Jeneral Section of Production Department Manual. SL 008963 CONFIDENTIAL* et to protective Order Sub] ct .. . t District Court >f 14th Judicial No, 91-U45 SPECIAL SAFETY EQUIPMENT 1. Stretchers (1) (a) Located inside control room 2. Chemox Masks (3) (a) Two in control room (b) One at main gate 3. Full Face Masks (10) (a) Three located in control room (b) One located in day tank area (c) Two in shipping building (d) Two at the main gate (e) Two at the clock area 4. Scott Air-Pak (6) (a) Two in control room (b) One in supervisor's office (c) One in HC1 area (d) One in TE catalyst building (e) One in EC catalyst building 5. Cylinder Type with connecting regulator, hose & mask (1) (a) In EC control room The following is a run-down on the type situations for which each of the masks will be used: (a) Scott Air-Pak - This unit is good for any concentration of gas and can be used for periods up to thirty (30) minutes. The unit can be put on in a few seconds,and because of this its primary use is for major gas breaks requiring quick response to get valves closed or injured men out of con taminated areas. The point to remember with this unit is that it has a life of only 30 minutes and when using it one should not remain in a contamined area for a period of more than ^ 20 minutes. NOTE: THE SCOTT AIR-PAKS IN THE EDC AREA ONLY HAVE A 15-MINUTE LIFE. (b) Chemox - This unit is good for any concentration of gas and xnV> uo O 4J 0 --Q4 > u <2*-h**n. can be used for periods up to one hour. It is a unit which chemically generates breathing oxygen;and because of this, several minutes are required to get this unit operating pro perly. The primary advantage of this unit is its long life. Because of this, the unit should be used in cases where one Z 0) Q I a M tu O. *H u ov SZ o O *H o3 jj o 0 JS V t3o -I M o -14- SL 008964 is required to enter and remain in a contaminated area for more than 45 minutes. (c) Full Face All-Purpose - This unit is good for weak concen trations of gas. One can equip himself with this mask in a few seconds. It should be used only in weakly-contaminated area and for escape purposes. (d) Cylinder Type with Connecting Regulator. Hose and Mask - These units are good in any concentration of gas. They are to be used in the event of gas being pulled into the control room. The important point about using these units is to get the units on before the room becomes excessively contaminated. Since the control rooms are pressurized, contaminating gases can enter only through the intake of the pressurizing unit. When contamination is detected, the pressurizing unit should be shut down and instrument air bleeds behind the panel board and in the laboratory should be opened. SL 008965 COHTIDBHWAt^ coo`t -15 CHEMICALS IN THE AREA In the course of discussion of the HClplant, many abbreviations are used. Since everyone is not necessarily familiar with a majority of the chemicals used in Area "B," a quick review is listed: CaCl2 Calcium Chloride CI2 Chlorine FeCLj Ferric Chloride HC1 gas - Hydrogen Chloride liquid - (mixed with water) - Hydrochloric Acid Muriatic Acid H*9S04, NaOH Sulfuric Acid Caustic, Sodium Hydroxide, Cell Liquor is about 10% NaOH N,, Nitrogen, Inert Oxygen h2 Hydrogen ch4 Methane, Natural Gas C2H4 C2H6 EC EDC Ethylene Ethane Ethyl Chloride Ethylene Dichloride (there are two EDO's, 1,1 & 1,2.) CP CP tp CP MC Per TCE Methyl Chloroform, 1,1,1-Trichloroethane Perchloroethylene, Tetrachloroethylene 1,1,2-Trichloroethane Tri Trichloroethylene VC Vinyl Chloride, Chloroethylene VDC Vinylidene Chloride, 1,1 dichloroethylene There are many more chemicals in the area, and if you need to know the names or abbreviation, see the operating foreman. CONFIDENTIAL! Subject to Protective Order Qi Court. -16- of nth NAME: Caustic Soda (lye) FORMULA: NaOH MOLECULAR WEIGHT: 40.01 BOILING POINT: 2532 F. VAPOR PRESSURE: Normally a solid, but can be mixed with water to form a solution. FREEZING POINT: 604 F. HAZARDOUS PROPERTIES: When mixed with water, caustic soda will react violently, splashing caustic solution on anyone nearby. Caustic soda in the form of solid, flake or liquid attacks any tissue upon contact. The degree of injury depends upon the extent and duration of contact, temperature of the materials and concentration of the materials. TREATMENT: Flush the contacted area immediately with an abundance of water. Remove any clothing or equipment that has been saturated with caustic. After thoroughly flushing the contacted area of the body with water, report to First Aid for further treatment. Eyes should be irrigated at once with plenty of warm water for at least 15 minutes anytime caustic comes in contact with the eye. St 008967 CONFIDENTIAL! Subject to Protective order O 14th Judicial Distript Court 17 No. 9 NAME: Cell Liquor FORMULA: Aqueous solution of NaOH HAZARDOUS PROPERTIES: Cell liquor is an aqueous solution of sodium hydroxide (caustic) and salt and as such should be handled with the caution given any caustic solution. This material has a markedly corrosive action upon all body tissues, and skin contact may result in moderate to severe chemical burns if the exposed surface is not washed im mediately. Eye contact is quite painful and can result in impairment of vision. TREATMENT: Speed in removing cell liquor from contact with the body is important to avoid injury. Removal of all contaminated clothing and thorough washing of the exposed surface is essential. If the eyes are involved, they should be irrigated at once with plenty of warm water for 15 minutes. Call a physician. SL 008968 -18- NAME: Chlorine (CI2) FORMULA: Cl 2 MOLECULAR WEIGHT: 70.91 BOILING POINT: -30 F. VAPOR PRESSURE 75 F.: 92 psig FREEZING POINT: -148 F. LIQUID DENSITY @ 77 F.: 11.6#/gal., 1.391 gm/ml RELATIVE VAPOR DENSITY: 2.45(air= 1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONC: 0.35 to 2 ppm DETECTABLE ODOR CONC: 3.5 ppm HAZARDOUS PROPERTIES: Liquid chlorine is very dangerous to the eyes as is chlorine gas. High concentrations of chlorine gas can cause pneumonitis and edema of the lungs. Lung Irritation is one of the most serious effects of chlorine. TREATMENT: Remove patient from toxic area and loosen all constrictive clothing about the neck. Oxygen should be administered in all cases to prevent cyanosis and relieve the pain of deep respiratory effort. Notify a physician. Chlorine is about 2\ times as heavy as air; therefore, it has a tendency to collect in the low spots or stay near the ground. SL 008969 CONFIDENTIAL* Subject to Protective ord r 1 14th Judicial District Court 19- No. 91-114$ NAME: Ethane FORMULA: C,,H zg MOLECULAR WEIGHT: 30.07 BOILING POINT: -128 F. FREEZING POINT: -277 F. RELATIVE VAPOR DENSITY (air-1.0) 1.04 AUTOIGNITION: 950 F. EXPLOSIVE LIMITS: 3-11% ODOR: Odorless HAZARDOUS PROPERTIES: EThane is a flammable gas. It is the main impurity in the ethylene, and may reach high concentrations in the vent streams. Ethane is a very dangerous explosion hazard upon exposure to heat or flame. It can react vigorously with oxidizing materials. Ethane is moderately toxic, but the slight effects disappear as soon as the patient is removed from the exposure. The main danger with C2H, is asphyxiation. The ethane will displace the oxygen of the air causing the victim to suffocate. TREATMENT: Remove the patient from the contaminated area, perform artificial respiration if breathing has stopped. Report to First Aid. 20- NAME: Ethyl Chloride FORMULA: C^Cl MOLECULAR WEIGHT: 64.52 o BOILING POINT: 54 F. (gas under normal conditions) o VAPOR PRESSURE @75 F.: 1130 mm o FREEZING POINT: -228 F. o LIQUID DENSITY @ 68 F.: 0.893 SL 008971 RELATIVE VAPOR DENSITY (air= 1.0) 2.22 o FLASH POINT: Open Cup -45 F. Closed Cup -58 F AUTOIGNITION: F, EXPLOSIVE LIMITS: 3.6 - 12.0% MAXIMUM ALLOWABLE CONC.: 1000 ppm ODOR: Pungent HAZARDOUS PROPERTIES: The liquid is harmful to the eyes, and if spilled on the skin will cause frostbite. The vapor gives some warning of its presence because it is irritating, but it is possible to tolerate exposure to it until one becomes unconscious. EC is the least toxic of all the chlorinated hydrocarbons. It can cause narcosis, but the effects are usually transient. Continued exposures may cause some kidney deterioration. Inhalation of EC vapor in concentrations of l%(by volume) produces narcotic and anesthetic effects; concen trations of 4% or greater may produce deep or even fatal anesthesia. Although EC is not extremely poisonous, any exposure is very dangerous because of the extreme flammability of the material. When EC is burned, phosgene and HC1 are formed, so never approach burning EC without a gas mask. Any spill of EC will result in an explosive mixture being formed;and because of the high density of the EC gas, the mixture will tend to stay near the ground. It will take very little to explode EC vapors. Static electricity spark, friction spark or an arcing device are all dangerous when EC is spilled. TREATMENT: Remove the injured person from the contaminated area. If breathing has stopped, perform artificial respiration. In any case make sure the person injured is reported to First Aid immediately. If any liquid enters the eye, wash the eye continuously with a large amount of water for at least 15 minutes. If at the end of 15 minutes eye damage is still apparent, continue washing until the doctor arrives or gives new instructions. -21 NAME: Ethylene FORMULA: C H 24 MOLECULAR WEIGHT: 28.05 BOILING POINT: -155 F. FREEZING POINT: -273 F. RELATIVE VAPOR DENSITY: (air 1.0) 0.98 AUTOIGNITION: 1009 F. EXPLOSIVE LIMITS: 3-34% ODOR: Sweet HAZARDOUS PROPERTIES: Ethylene is a flammable gas. It is a very dangerous explosion hazard upon exposure to heat or flame. It can react vigorously with oxidizing materials. Ethylene is moderately toxic, but the slight effects disappear as soon as the patient is removed from the exposure. The main danger with C H is asphyxiation. The ethylene will displace the oxygen of the air,causing the victim to suffocate. (See Methane treatment) TREATMENT:Remove the patient from the area, perform artificial respiration if breathing has stopped. Report to First Aid. SL 008972 `-22-- CONFIDENTIAI** NAME: Freon 11 (trichloromonafluoromethane) FORMULA: CC1.F 3 MOLECULAR WEIGHT: 137.38 o BOILING POINT: 74.7 F. VAPOR PRESSURE @ 75 F.: -14.7 psia LIQUID DENSITY @ 68 F.: 1.5 RELATIVE VAPOR DENSITY: (air = 1.0) 4.8 FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONC.: 1000 ppm in air HAZARDOUS PROPERTIES: Dangerous) When heated to decomposition, it emits highly toxic fumes of phosgene, flourides and chlorides. Never allow any open flames to come in contact with F-ll or any vessels containing it. Never rush into an area where F-ll is burning or might burn without a mask. SL 008973 CONFIDENTIAL? 8ubj*etto Protective order of 14th Judicial District Court No. 91-1145 -23- NAME: Hydrogen FORMULA: H2 MOLECULAR WEIGHT: 2.02 BOILING POINT: -423 F. FREEZING POINT: -434 F. RELATIVE VAPOR DENSITY: (air = 1.0) 0.069 AUTOIGNITION TEMP: 1085 F. EXPLOSIVE LIMITS: 4-747. HAZARDOUS PROPERTIES: Hydrogen is a flammable gas. As may be seen from the explosive range, any concentration is highly dangerous when exposed to heat or flame. Hydrogen gas itself is only slightly toxic, but will displace the 0^ in the air, causing suffocation. Symptoms will be the same as Methane. TREATMENT: Remove the patient from the contaminated area, perform artificial respiration if breathing has stopped. Report to First Aid, SL 008974 -24" NAME: Hydrogen Chloride FORMULA: HC1 MOLECULAR WEIGHT: 36.47 BOILING POINT: -121 F. o VAPOR PRESSURE @75 F.: 36,000 mm FREEZING POINT: -174 F. LIQUID DENSITY: Normally a gas RELATIVE VAPOR DENSITY: 1.26 (air - 1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONC: 10 ppm for 8 hour working day DETECTABLE ODOR CONC: Unknown HAZARDOUS PROPERTIES: Anhydrous hydrogen chloride is a gas which has a corrosive action upon the skin or mucous membranes. In this form, it will cause rapid and severe burns. It is particularly dangerous to the eyes. It is not flammable; however, the gas is highly soluble in water, forming hydrochloric acid, which attacks most metals with the evolution of explosive hydrogen. TREATMENT: Immediate removal from the toxic area and thorough flushing of the patient's body and/or eyes with large quantities of water is of primary importance. Contaminated clothing should be removed from patient while he is being showered with water. It is essential that all affected body surfaces be washed with copious quantities of water for a sufficient time to remove all hydrochloric acid. No attempt should be made to neutralize the acid with alkaline solutions. Medical assistance should be summoned at the earliest possible moment. SL 008Q7C /0 -25- COMF1DEHTI Subject to Protective -Order Of Hth ^Judicial District Court Mo. 91-1145 NAME: Hydrochloric Acid, Muriatic Acid, Wet HCl FORMULA: HCl MOLECULAR WEIGHT: 36.47 BOILING POINT: 166 F. (32% HCl) VAPOR PRESSURE @ 75 F.: 40 mm Hg. FREEZING POINT: 12 F. LIQUID DENSITY @ 68 F.: 1.159 EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONC.: 10 ppm for 8 hr. DETECTABLE ODOR CONC.: 3 ppm HAZARDOUS PROPERTIES: Anhydrous hydrogen chloride is a gas which has a corrosive action upon the skin or mucous membranes. In this form, it will cause rapid and severe burns. It is particularly dangerous to the eyes. It is not flammable; however, the gas is highly soluble in water, forming hydrochloric acid, which attacks most metals with the evolution of explosive hydrogen. TREATMENT: Immediate removal from the toxic area and thorough flushing of the patient's body and/or eyes with large quantities of water is of primary importance. Contaminated clothing should be removed from patient while he is being showered with water. It is essential that all affected body surfaces be washed with copious quantities of water for a sufficient time to remove all hydrochloric acid. No attempt should be made to neutralize the acid with alkaline solutions. Medical assistance should be summoned at the earliest possible moment. SL 008976 -26- NAME: Nitrogen FOIMULA: N2 MOLECULAR WEIGHT: 28.02 PHYSICAL APPEARANCE: Colorless, odorless, inert gas SPECIFIC GRAVITY: 1.0 with relation to air. (Air is 78% N2> HAZARDOUS PROPERTIES: Even though nitrogen is a very safe, inactive gas, it has some inherent dangers since it is used so universally throughout the plant. Its prime use is for padding and sweeping of equipment that has, or has had, flammables in it. The hazard involved is that a vessel may have insufficient oxygen or that nitrogen is used to purge the vessel instead of air, before man-entry. Therefore, in the HC1 plant, every vessel that is entered not only must first be checked for flammability, etc., it must also be checked for sufficient oxygen. Not only that, nitrogen lines, as well as other toxic lines, must be isolated from the vessel before entry and a clean air sweep provided. TREATMENT: Remove person from the oxygen deficient area. Administer artificial respiration if necessary. See Methane for symptoms. SL 008977 -27- CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court No. 91-1145 NAME: Sulfuric Acid FORMULA: H SO 24 MOLECULAR WEIGHT: 98.08 PHYSICAL APPEARANCE: Colorless to cloudy liquid HAZARDOUS PROPERTIES: Highly corrosive to most metals, particularly at concentrations below 75%. This reaction produces H- gas. At concentrations above 75%, H SO, may be handled in steel provided the temperature is never greater than 100 F. Very reactive with water or organic materials with heat being evolved. Contact with the body produces a rapid destruction of the tissue. The acid will continue to destroy the skin until it is washed off. The destruction of the skin will result in a painful and slowhealing burn. PROTECTIVE EQUIMENT: Use rubber gloves and face shields whenever working with H^SO . Use a slicker suit whenever transferring acid, entering then shielded area around the HCl dryer, or where there is any? danger of an acid spill. TREATMENT: Flush the contacted area with an abundance of water. Remove any contaminated clothing or equipment. After thoroughly flushing the affected area, report to First Aid for further treatment. Treat for shock in case of . severe bums. If any of the acid has been swallowed, do not Induce vomiting; if the patient is conscious, wash his mouth with water and feed him as much water as he can drink; get medical help as quickly as possible. Sl 008978 -28- T/Suve oraer NAME: Vinyl Chloride (chloroethylene) FORMULA: C^Cl MOLECULAR WEIGHT: 62.50 BOILING POINT: 8 F. VAPOR PRESSURE (? 75 F. 2700 mm (gas under normal conditions.) FREEZING POINT: -244 F. LIQUID DENSITY <? 68 F.: 0.0908 RELATIVE VAPOR DENSIRY: (air = 1.0) 2.15 FLASH POINT: Open Cut -107F. Closed Cup - 162F. EXPLOSIVE LIMITS: 4-22% MAXIMUM ALLOWABLE CONC.: 500 ppm for 8 hours ODOR: Faintly sweet (smells like phenol when inhibited) HAZARDOUS PROPERTIES: Vinyl chloride is very much like Ethyl Chloride. It is not very poisonous; it is extremely flammable and it has a narcotic effect. Continued exposures may cause some kidney de terioration. Inhalation of vapors greater than 500 ppm may produce a slight narcotic effect. At concentrations of 4% or greater, VC vapors may produce a deep or fatal anesthesia. The main danger with VC is the extreme flammability of the vapors. VC when burning will form phosgene and HC1, so never approach a fire without a gas mask. Any spill of VC will result in an explosive mixture being formed and because of the high density of the VC gas, the mixture will tend to stay near the ground. It will take very little to explode the VC vapors, static electricity spark, friction spark or an arcing device are all dangerous when VC is spilled. TREATMENT: Remove the injured person from the contaminated area; if breathing has stopped, perform artificial respiration. In any case, make sure the person injured is reported to First Aid immediately. If any liquid enters the eye, wash the eye continuously with a large amount of water for at least 15 minutes; then get the person to First Aid. SL 008979 -29- DRY HC1 PROCESS SL 008980 Dry HC1 is produced by the combustion of hydrogen and chlorine in large graphite combustion chambers. H2 and Clare fed to the bottom of the chamber, with the Cl^ flow kept proportional to the H2 flow. The two gases burn in the combustion chamber forming HC1. The HC1 leaves the top of the chamber, flows through a 6" Karbate line, to the Primary Cooler. The gas entering the Primary Cooler generally runs about 400 F., but it is dependent on the rate. The Primary Cooler is cooled by well water and should cool the gases to about 100 F. The cooling water leaves the Primary Cooler and flows uniformly down the outside surface of the combustion chamber. The HC1 gas comes out the bottom of the Primary Cooler into a rubber-lined pipe which carries it to the top of the Secondary Cooler. The Secondary Cooler is cooled o by refrigerated brine at 0 F. The HC1 gas leaves the bottom of the Secondary Cooler at about 40 F., goes through an entrainment separator and into the bottom of a H2S0^ dryer. Sulfuric .acid is pumped from the bottom to the top of the tower where it contacts the HC1 gas by filtering down through a packed section. The HC1 gas leaves the top of the I^SO^ dryer and flows to #5 com pressor. No. 5 compressor compresses the gas from a slight vacuum to about 55 psig. After compression, the gas is cooled by two parallel aftercoolers to o about 100 F. The aftercoolers are cooled with cooling tower water. From the aftercoolers the HC1 is sent through one of two meter runs to the under ground pipeline that goes to the consumer. The pressure on the customer line is controlled by bleeding the excess HC1 through a PCV to #2 Absorber Cooler. Additional HC1 may be added to the system by bleeding HC1 gas from the Wet System (#1, 2, 3 compressor suction line) to the Dry System (suction line to #5 compressor). The dry system consists of 2 burners, 2 primary coolers, 2 secondary coolers and 2 entrainment separators. From the entrainment separators, the HCL from both burners goes through a common system. No. 1 burner is used for -30 producing dry HC1 only, but #2 burner may produce wet or dry HC1, For this reason the Primary Cooler on #2 burner is an Absorber Cooler. The Absorber Cooler may run as either an absorber, or by cutting the weak acid feed off and changing a few valves, the absorber will serve as a primary cooler. All condensate from the dry system is fed through sealpots to the sewer. VAPORIZED CHLORINE SYSTEM A. Equipment 1. Chlorine Vaporizer-62A-70-48 - The chlorine vaporizer is located in Tri-Ethane and is a Type G with a capacity of ll,000#/hr. of chlorine when 5 psig steam is used. 2. Chlorine Surge Drum- 62A-60-419 - The chlorine surge drum is 36" OD x 5'0" tan to tan. The design pressure is 150 psi at 300F. The rupture disc is set to burst at 85 psig and the relief valve is set for 115 psig. B. Operation The chlorine vaporizer is operated by the Tri-Ethane0v 0 operator because it is used to vaporize chlorine for the TCE reactor. Cardinal rules for a vaporizer are: never put steam on a closed-up vaporizer and never make large changes to any controls on or around a vaporizer. The vaporizer floats against the Cl^ supply line and its pressure is controlled by the liquefaction operator. Cl^ is pumped from #7 or #8 Cl^ scale tank with the majority of the C^ being recirculated back to the tank it is being pumped from. By adjusting the valve in the recirculation line, the pressure of the CI2 coming to Per-Tri, EDC, MC and HC1 is set. The liquefaction lead operator is the controller of the valve,and he must be notified any time rates are changed on vaporized Cl . 2 high or low pressure. Failure to do so will result in surging and either The PCV for the vaporized Cl to HC1 is located in the MC plant, north 2 of the vaporizer and east of the MC PCV. The control of this valve comes SL 008981 -31- COHFIDENfJAti Subject to Prbtfcetivl! bfdrft af^uSrSu-icWJ couti from the HC1 board and it should be set at 25 psig. Whenever the block valves around the FCV are open, a close watch on the pressure should be maintained, as any leakage of the valve will cause the CI2 Surge Drum to overpressure and burst the rupture disc. The only way to prevent this is to bleed the leaking CI2 into the burner through the FCV bypass. It is best to remember that most valves in service will leak through. Care should be exercised in shutting down the plant, regardless of whether the shutdown is automatic or manual, to see that the PCV is blocked off immediately. In between the rupture disc and SRV is a bleed. This bleed must be always open; if it is not, it is possible to over pressurize the CI2 Surge Drum. When C^ is leaking out this opening, the rupture disc should be changed. Once per shift this opening should be checked to assure that no corrosion pro ducts are plugging the opening. Burner #2 may be run on gaseous Cl^, but this should never be done when the burner product is going into the dry HC1 system. The impurities in the cell gas would cause the HC1 to be out of spec. The CI2 to each burner is flow controlled by a ratio controller that will keep the CI2 flow proportional to the flow. In case of a system failure, air to the Cl FCV will be cut off and the valve should close. The 2 CI2 flows through a loop just before entering the burner nozzle. The purpose of the loop is to prevent acid from draining from the bottom of the burner back to the FCV. The drain on the burner side of the loop should be checked after a burner shutdown and while the burner is down for acid. SL 008982 -32- H,, SYSTEM A. Equipment 1. Hydrogen Surge Drum - 62A-60-420 - The H Surge Drum is 36" OD by 5'0" tan to tan. The design pressure ofzthe vessel is full vacuum to 75 psi. The rupture disc is set for 75 psig. 2. H2 Cooler - 62A-71-517 - The hydrogen cooler is a 6 5/8" OD ex changer with 26 8' tubes 3/4" OD 16 gauge. The material of construction is steel for everything. B. Operation - The hydrogen line to the HC1 plant is a 4" line that comes from the top of the scrubber in the cell area. The line has several low spots in it that have float traps to remove moisture. These traps should be checked regularly, especially during cold weather. The H2 system has very little extra capacity since the maximum pressure available is about 22 psig. The booster compressor (to other H2 consumers) is set to cut off at about 10 psig. So any failures in the H2 system will result in a rapid pressure loss to 10 psig, then the only consumer will be HC1 so the pressure loss below 10 psig will determine how much to cut back the burner rates. The H2 line runs down the main racks and enters the plant south of the acid storage tanks. The H2 system has a PCV and two meter runs at this point. The PCV should be set to give H2 Pressure to the burners of about 20 psig. This pressure as well as the Cl^ pressure will affect the ratio between the two gases, so care should be taken in changing the pressures on the systems. The larger meter run should be used whenever more than two burners at full rates are operating or the total hydrogen flow is greater than 500 SCFM, From the meter run, the H2 flows through a surge drum and a cooler to the individual burners. The purpose of the cooler is to keep the H2 at a fairly stable temperature for metering at each burner. SL 008983 -33- The hydrogen flow to each burner is controlled by the burner pressure. The burner pressure should be set to keep from -2" to +2" of H^O pressure. The set pressure is maintained by increasing or decreasing the H2 flow. The Hj flow is measured and sent to a ratio controller. The ratio controller keeps the Cl^ flow to the burner in a preset ratio to the H2 flow. The normal ratio is about 1.1 to Cl2, but his will vary according to the pressures and temperatures of the gases. The set ratio is the ratio that gives 3% to 5% excess in the product HC1. Located in each H2 system is a positive shutoff Maxon valve. This valve will shut during any system failure. SHUTDOWN SYSTEM The shutdown system (Dwg. 62A-7703) for the Dry HC1 plant is designed to shut down burner #1 and/or burner #2. When the shutdown system is acti vated, it will close the Maxon valve on the H2 line, close the Cl2 FCV, shut down the compressor, and close the compressor recirculation valve. The Maxon valve is a positive shutoff valve located in the H2 feed system to each burner. It is possible to bypass this valve and it is bypassed during start-up. AT NO OTHER TIME SHOULD THIS VALVE BE BYPASSED. The most dangerous thing to happen around an HC1 plant is to fill the system with H2 and human reflexes are not quick enough to close off a valve that is wide open. The Maxon valve is spring loaded to close and is kept open by an engaging solenoid. The Cl2 FCV is designed to fail closed with a loss of air supply. The shutdown system has a solenoid in the air supply that closes for system failure. Most valves in Cl service gunk up, so in order to assure that no 2 Cl2 is going through the burner, the block valves will have to be closed. SL 008984 -34- CONFIDENTIAL! Subject to Protective Order Of 14th Judicial District -Court No. 91-1145 The compressor recirculation valve will fail closed with loss of air supply. There is a solenoid in the air supply to this valve; and with the loss of both burners, the solenoid will close. Switch 5 will bypass this feature, and it is generally closed. By running with switch 5 closed, loss of both burners will not cause the recirculation valve to close; but should the compressor fail, the solenoid would cause the valve to close. Caution should be used in running with both switch 5 and switch 6 closed as this w ould allow the recirculation valve to stay open with compressor failure and this would result in blowing the customer line pressure back through the dryer, coolers and burners. The compressor will be shut down anytime both burners fail unless switch 7 is closed. Under normal conditions switch 7 will always be closed. The shutdown system is activated by: a flame failure, low burner pressure, high burner pressure, loss of cooling water, or loss of the compressor. A failure of any of the first four items will cause the affected burner to shut down, and failure of the last item will cause both burners to shut down. The shutdown system can be bypassed by timers, and individual parts of it may be bypassed with switches. The reason for the bypass switches and timers is that under different circumstances different items are of importance. The timers are for equipment checking and starting up. Periodically the burner shutdown system should be checked to see what shutdown relays are bypassed and these checked to see if it is necessary for these to be bypassed under the conditions of operation at that time. A flame failure is detected by a "Firetron" photo-conductive cell, which continuously monitors the flame. The fire-eye is located at one of the sight ports on the burner bottom. High and low burner pressure are monitored, recorded and used to control the H2 flow. Cooling water for #1 burner and primary cooler is monitored from the well water going into the SL 008985 -35- CONFIDENTTM.* Subject to protective Order of Hth Judicial bisbr-ict Court cooler. In this line there is a no-flow switch which will close if the flow drops to less than 50 GIM. The cooling water flow is monitored in two spots for #2 burner. Cooling tower water flowing into Cooler Absorber #1 is monitored through a no-flow switch on the inlet as well as is the well water flow to the top of burner #2. Both of these switches must have at least 50 GFM and failure of either one will activate the shutdown system. The compressor shutdown is located in the electrical system to the compressor motor. In case of an emergency shutdown in the HC1 plant, the alarm on the panelboard will indicate the first one to fail. It will be the only one to flash. When the board is acknowledged the others will flash. When it is acknowledged again, all alarms will clear. The sequential alarm system applies to flame, loss of cooling water, high or low burner pressures, or loss of the compressor. The timers that are on each burner system bypass flame failure and high or low burner pressure. These timers may be set for up to 15 minutes and are generally set for 7 minutes. Once they are set they cannot be re set again until time has run out. The system override timer will bypass all safety shutdown relays including compressor failure. The system timer may be set for 60 minutes but is generally set for 25 minutes. Switch 1 when closed will prevent high or low burner pressure from shutting down burner #1. Switch 2 when open is an isolation switch so that #1 burner shutdown system may be worked on and a ground in it will not shut down burner #2. (When switch 2 is open, burner #1 must be shut down.) Switch 3 bypasses high and low pressure shutdown for burner #2, Switch 4 is an isolation switch for burner #2 shutdown system. Switch 5 when closed will allow the HC1 recirculation valve to operate with both burners down. Switch 6 when closed will allow the burners to operate with SL 008986 -36- COHFXDfiNTlM't the compressor down. Care must be used with switch 6, as with it closed the recirculation valve will continue to operate with the compressor down. normally closed. BURNER SYSTEM A. Equipment 1. HC1 Burner - 62A-71-535 & 536 - The HC1 burners (combustion chambers) are 33" chambers. They are constructed of 3" thick graphite rings with each ring 3'3" OD and 5* 8 5/8" high. There are 4 full-sized rings and a top ring that is 3' 8 5/8" high. The rings are stacked on each other and all rest on a 4" thick "Karbate" base. When the sections are cemented together and set on the base, the over-all height is 24' 3 1/8". The sections are cemented together with National Carbon C6 cement and heat cured. The outside of the chambers have a thin washcoat of impervious material to prevent water from being absorbed through the burner walls. The top ring has a 4" thick graphite plate resting on it, and on top of this a water dis tributor. When the distributor is filled with water, the weight of the water, distributor and top will holdthe top on the burner until a pressure of about 20" of K^O is reached. The top has a guide bar so the top resets itself properly whenever it is lifted. The burner has a hole in the bottom plate for the burner nozzle assembly, 2-4" nozzles with quartz sight glasses located near the bottom, and a 3" and a 6" nozzle near the top. The 3" nozzle is for burner pressure and the 6" nozzle is the gas outlet. 2. Burner Nozzle Assembly - The burner nozzle assembly is a National Carbon size 8"Karbate" impervious graphite with silica-coated caps. The diameter of the holes in the caps is to be at least 13/16" and they should be drilled to this diameter if they arrive with smaller holes. The hydrogen feeds in the outermost ring and Cl2 in the center. B. Operation - Chlorine and hydrogen are fed separately through the burner nozzle assembly. The two gases are mixed as they are ejected from the nozzle into the burner. Once a flame is started the two gases will burn when they are mixed. Located on one of the bottom sight glasses is a fire eye. The purpose of the fire-eye is to continuously monitor the flame and anytime the flame disappears the fire eye will activate the shutdown system for that burner. SL 008987 I itb Judicial Ho. --J<t The burner must have some of the heat generated by the reaction dis sipated or the graphite walls will overheat, resulting in oxidation, cracking and leakage. For this reason there is a no-flow switch in the well water line going to each burner. Loss of well water flow will activate the shutdown system for that burner. The no-flow alarm on the well water is alarmed through the no-flow light and alarm on the CTW flow to the absorber. Should the CTW or the well water fail, it should be fairly obvious which one failed. If the switches fail each one may be checked. The well water to each burner is dis tributed at the top of the burner through a water distributor. The water dis tributor causes the water to flow down the sides of the burner in an even manner. Plexiglass is around the burner to prevent the wind from blowing the water layer away and leaving the graphite with no cooling film. Care should be taken in adjusting the well water flow to the burner to see that enough water is used to provide a water layer over the outside of the burner from top to bottom. This will require from 100 GIW to 200GR1, depending on the burner rate. The water is collected at the bottom of the burner in a rubberlined pan and sent to the sewer. The bottom plate has grooves on its bottom to allow some water to flow beneath it. If the grooves are allowed to plug up, the rubber lining will have no protection and will be destroyed. Another problem with the cooling system will be algae. If the burner becomes coated with algae, the cooling water will have little effect. As the algae appears and gets thick enough to retard the heat transfer, it must be removed by (a) heavy chlorination of #8 deep well water, (b) bubbling a few TPD of HC1, in the distribution crown (there is an HC1 ring sparger for this purpose), (c) put Plttabs in the distribution crown, (d) shut burner down and expose it to sunlight, (e) physically scraping the burner. The best method is the HC1 wash when excess HC1 is available. SL 008988 -38- After the H2 and Cl^ burn,the HC1 rises in the burner and leaves at the top through a 6" Karbate line. This line must be water-cooled also and there are spray nozzles to keep It wet. The maximum recommended temperature for "Karbate" is 338 F. This temperature refers to the body temp, not the gas inside the pipe; l.e*, a gas temp of 440 F. and water on the outside of the pipe will give a "Karbate" temperature of about 310 F. The "Karbate" risers have no water on them as it was felt that enough cooling will take place in the vertical run, and the gases will not cause the "Karbate" risers t o overheat. These risers should be checked fairly reguarly, especially at high rates. Near the top of the burner is a pressure transmitter. This pressure is used to control the burner rates. The ideal operating pressure is -2" of H^O, but the burner will operate anywhere in the range of -2" to +2" of 1^0. When the burner pressure falls below the preset rate, the H2 flow will be in creased and since the CI2 flow is kept proportional to the Hg flow, the Gl^ flow is increased. The net result is an increase in HC1 production. High and low pressures may be used to shut down the burner also. The burner nozzle assembly has a hole in the bottom of it. When the burner is operating, this hole should have a plug in it. Whenever the burner is down, this plug should be removed and air allowed to flow through the hole, the burner and the jets for at least 5 minutes. The nozzle assembly also has a U-tube in it. This tube is to drain the condensate formed in the burner to the sewer. There should always be some water in the U-tube to form a seal. Generally some additional water must be added to keep the tube full. Caustion should be used around this condensate as it is 36% muriatic acid. The dry system has two identical burners, numbers 1 and 2. SL 008989 -39- ; to Prot*^tive Grdet of 14th Judicial District Cou Wo. 91*11.4$. PRIMARY COOLERS A, Equipment 1. Primary Cooler #2 (62A-71-537) is a 14" OD shell with 42 "Karbate" tubes 7/8 ID x 12'0" long 2. Primary Cooler #2 (Cooler-absorber #1, 62A-71-818) is a 14" OD shell with 42 "Karbate" tubes 7/8 ID x 16'0" long. At the top of each tube is a graphite weir that is used when the cooler is being used as as absorber. At the bottom of the tubes is a seal pot to separate the HCl gas from the muriatic acid. B. Operation The primary coolers are used as vertical coolers with the cooling water flowing up the shell side and HCl gas flowing down the tube side. There is some difference between #1 and #2 Primary Coolers because #1 is used for cooling HCl, while #2 is used as a cooler or as an absorber. Care must be taken to see that Teflon weirs are never installed in cooler #2 as they will melt when the cooler is being used as a primary cooler. The water system used for cooling is different on each cooler. The water for #1 Primary Cooler is well water and is discharged from the cooler to the top of the burner where it is used to keep the burner walls wetted. The no flow switch is located on the inlet line to the cooler and loss of water will activate the shutdown system. The flow required will be enough water to keep the HCl gas leaving at 100 F. The water flow is generally between 100 Q7H and 200 GPM Enough water should always be used to have enough water to satisfy burner requirements. Water on this exchanger as well as all other "Karbate" exchangers should be throttled on the inlet side. All "Karbate" exchangers have the globe valve located in the inlet side. Cooler-absorber #1 is cooled with cooling tower water. The flow rate required will be about 200 GPM and the HCl gas out will run 110 F. Since loss of cooling would damage the exchanger, the CTW has a no-flow switch in SL 008990 -40- C0HPID8MTIM.1 Subject to Protective Order wth Judicial District Court it. Whenever cooling water is lost, the shutdown system for that burner is activated. The well water going to the burner has its own no-flow switch hit is alarmed and tied into the shutdown system through the CTW no-flow. Moisture that is in the HC1 gas will condense as the gas is cooled. This liquid is collected at the bottom of the cooler and sent to the sewer through a seal pot. Do not attempt to run this condensate to the strong acid storage. The HC1 gas leaves the botton of the Primary Coolers and flows through a rubber-lined pipe to the top of the secondary cooler. When more than one burner isbeing used to provide dry HC1, it is impossible to determine the ex cess H2 by the product stream analyzer. For this reason routine samples must be run on each burner. There is a nozzle in the rubber-lined pipe for this purpose. There are water aspirators located nearby to draw the sample. It is possible to analyze #2 burner through the wet HC1 analyzer. This analyzer is manifolded from the tops of Cooler-Absorbers #1, 3, 4, and 5, but only one can be analyzed at a time. On #1 Cooler-Absorber, there is an air trap on the top tube sheet. This trap is to make sure that cooling water is kept against the tube sheet. Any gases generated or trapped will bleed out through the trap but the water will not. SECONDARY COOLERS A, Equipment 1. The Secondary Coolers (62A-71-540) are a 14" OD shell with 42 "Karbate" finned tubes 7/8" ID x 12*0" long. 2. Mist Eliminator - The mist eliminators are 4" with "Karbate" internals. SL 00899? cohfidbhtam** subject t-o Protect! * 41- B. Operation The secondary coolers are used as vertical coolers with chilled brine flowing up the shell side and HC1 gas flowing down the tube side. Too-rapid cooling of HC1 will cause a fog to form and this results in high moisture HC1. To prvent this from happening, the HG1 gas leaving should never be o cooler than 35 F. Some variation of this temp will result because the gases entering the cooler will be at different temperatures. Whenever high moisture is Indicated by high ^SO^ usage, start raising the exit gas temperature. The exit gas temperature is controlled by throttling the brine into the cooler. From the bottom of the cooler the gases flow through an entrainment separator and into a rubber-lined pipe. From this pipe on,the gases from #1 burner and #2 burner are common and go to the guard dryer. All condensate from the secondary coolers and the entrainment separator is drained to the sewer through a seal pot. --H2_S04. -D--R--Y-I-N--G----S-Y--S-T--E-M- A, Equipment 1. The H2SO4 dryer (62A-73-43)is a 2' 10 5/8" 0D vessle 20' high. The dryer has 6' of 1%" Intalox saddles. The demister section has IV of lV saddles and a 6" Teflon demister. The vessel is protected from pressure by a floating head which is sealed with cell putty. The material of construction is steel. The vessel has one sparger and no distributor. 2. ^SO^ storage is a 3' diameter by 4'0" vessel that will hold 211 gallons with no outage. The vessel is constructed of 36" pipe. 3. H2SO4 Pumps #3 & 4 (62A-55-443 & 443) are Worthington 1% CNG-62 with a 6^" nickel impellers. The wet end of the pumps are constructed of Worthite. The seals used in the pumps are John Crane type 20. The pumps should deliver 25 GFM at 50' head. The motors are 3 HP, 1750 RFM. B. Operation The HC1 flows from the individual entrainment separator into a rubber- lined pipe. The HC1 flows from the rubber-lined pipe into the bottom of the -42- Subject 14th 0 H_^SO^ dryer. The gas then flows up through the packing, through the demister, out the top of the dryer into a steel line that goes to the compressor. The bottom 6* of the dryer is used as an acid reservoir. The acid is pumped from the bottcxn of the dryer, through an acid heater and into the dryer, above the 6' section but below the 1%' section. The bottom of the acid dryer is steam traced and there is a heater on the recirculation line (double-pipe heat exchanger) which has hot water running to it to keep the acid from freezing. o o The acid temperature should be kept between 70 F. and 95 F. Below 70 F. the acid will freeze and above 95 F. the acid is extremely corrosive to steel. The acid is changed whenever its strength gets below 90%. Hot water for the heater is made by bleeding steam into the well water. Adding steam directly to the heat exchanger causes a "hot spot" and therefore rapid deterioration of the steel exchangers. The exchanger is a field - constructed double pipe heat exchanger. HC1 COMPRESSOR SYSTEM A. Equipment 1. HG1 Compressor 62A-56-127 is an Ingersol1-Rand ES-l-HL-2 with a 19" diameter and a 13" stroke. The compressor running at 275 RR1 is to compress 55 TPD of HC1 from 13,7 psia to 64.3 psia. This will require a 150 HP motor. The design pressure of the compressor is 70 psia. The compressor had a capacity of 51 TPD at 275 RIW and the conditions of operation. For this reason the compressor has a new sheave to give an RFM of 291 and this gives a capacity of 55 TPD. 2. HC1 Aftercooler 62A-71-542 & 559 - There are two Brown Fintube size 317-000-420 with 180.9 ft.^ per unit B. Operation The pressure(vacuum) of the compressor suction drum controls the rate at which the HC1 plant operates. The suction pressure is kept constant by re circulating HC1 from the discharge line into the suction line. There is a suction header and a discharge header that were field fabricated from extra strong steel pipe. The headers serve to eliminate vibration irom the compressor SL 008993 -43- CONFIDENTIALi ofProtective Drder Of 14th Judicial District Cour-t No. 9i-ij45 as well as to give sane surge time for control. The discharge pressure of the compressor is controlled by customer demand and by a PCV that sends excess HC1 to the scrubber or to #2 absorber. The compressor discharge temperature should not be allowed to operate continuously above 340 F. The compressor suction header pressure will vary according to the rate desired; i.e., 15" H^O vacuum will give a rate of about 28 TPD while 30" H^O vacuum will give a rate of 54 TPD. The compressor recirculation valve gets its impulse from the suction header and it will bleed enough HC1 back from the compressor discharge to maintain the preset pressure. The suction drum pressure should never be allowed to get over 14.2 psia (10" H^O vacuum) as this will overlad the compressor motor. Conversely, if the compressor is allowed to go on a high vacuum, air can be sucked into the system and it can form explosive mixtures either for us ( in large enough quantities), or for the customer (in his vent from the plant). The compressor discharge is controlled by a PCV in a line that will send the excess HC1 to the scrubber or to #2 absorber. A compressor will discharge to any pressure set until it causes pipe failure, compressor frame failure, motor overload, or a relief valve to go. It is for this reason that the relief valve on the compressor as well as any PCV's in the compressor discharge should be checked. Once every shift the PCV in the compressor dis charge is to be stroked. It is possible when the customer demand is constant to adjust the plant rates so no excess HC1 is produced. This is possible because the customer line is 11,000 ft. long, 6" schedule 40 pipe and this acts as a surge drum. Line pressure should not be allowed to vary too much. When line pressure is varying or the customer intends to change rates, a small amount of HC1 should be allowed to bleed through the PCV to #2 absorber. The PCV is designed so the small valve opens before the large valve opens to give a smooth and CONFlDENtflAt*. SL 008994 Subject to frotectdvfe 0*2^ ^ Of Htft Judicial District fcourt -44- fc0. 91-1145 dependable performance. The meter run for the customer is arranged so that the small orifice may be used when one burner is being used and the large orifice used when two burners are in service. All entrained material in the HC1 to the compressor will be caught in a strainer located in the compressor suction line just above the compressor. When the pressure drop across the strainer becomes too great, it will have to be changed out. The strainer can be bypassed for a short period of time. There is a strainer in the line just before the meter run also. The fintube exchangers are designed to give a gas temperature of 110 F. for the meter run. The two Brown Fintubes are designed to run in parallel aid to run on cooling tower water. When starting up, shutting down, or running the compressor with no HC1 available, the compressor is run on dry air. The air is fed into the com pressor at its suction (below the HC1 block valve) and is allowed to recircu late and discharge to the vent scrubber. Enough air should be used to prevent o the compressor from running a hot discharge (250 F.). The discharge pressure should never be allowed to go below 25 psig as this causes unnecessary wear on the wear shoe. When the compressor is shut down, a small purge of air should be left on the compressor to prevent any moisture from entering. NEVER START A COMPRESSOR WITH A CLOSED DISCHARGE LINE. Open the discharge system through the scrubber, set the pressure at 25 psig, allow recirculation, leave the suction valve closed, open the discharge to suction bypass, put air into the suction line and start the compressor. After the compressor is up to speed, close the discharge to suction bypass slowly. Adjust the air flow to give the proper discharge temperature after the system is lined out. SL 008995 -45- CONFIDENTIAL* Subject to Protective Order of 14th Judicial District Court No. >1-1145 The first distance piece on the compressor is vented to the suction and therefore requires no attention other than to be sure it is open. The second distance piece is to have an air sweep leaving the top and bottom. Enough air should be used to sweep through both valves and have a 3 psig pressure on the chamber. HC1 SCRUBBER A. Equipment 1. Scrubber 62A-60-421 - The HC1 scrubber is a 3' OD by 10' rubberlined vessel. The scrubber has a water distributor and a caustic dis tributor at the top and it is packed with 3' of 1^" Xntalox saddles. 2. Jets - The two steam jets are constructed of Haveg 41 and are size 3 FHA-14 designed to handle 300#;hr. at 26 mm H absolute. B. Operation The vent scrubber is used in start-up and under upset conditions in operations. Under normal circumstances the excess HC1 produced over customer demands will be sent through the customer line PCV to ;-"2 absorber. This extra material may be sent to the scrubber if it is desired. The gaseous feed to the scrubber is fed near the bottom and passes up through the packed section where it contacts water and cell liquor, the inert gases leave the top and are vented above the process platforms. The well water or the cell liquor is fed into the top of the scrubber where it flows through a dis tributor , through the packed section and out the bottom through a seal loop to the sewer. The water flow to the scrubber flows through a rotometer and through a valve network. The valve network was used at one time to open the flow whenever the PCV to the scrubber opened. This is no longer true, and the water should be routed to bypass the solenoid. SL 008996 -46- n# to Protective Ord of 14th Judicial Di.trict Coi No. 91-1145 The cell liquor flow is adjusted by watching the pressure drop in the line when the valve to the scrubber is opened. BEFORE USING ANY CELL LIQUOR THE "TRI-ETHANE^j)PERATOR IS TO BE NOTIFIED. The TE operator will notify the caustic lead operator if more than one pump is required. When the cell liquor line is opened to the scrubber, scxne contact should be maintained with the TE operator, because if HC1 takes too much cell liquor the VDC section will not be able to operate. The cell liquor is needed whenever CI2 is going to the scrubber or when more HC1 is going to the scrubber than the water can handle. During the start-up of any burner, a large amount of water and cell liquor will be required. The two Haveg jets will be operating so the additional load of steam condensation will be added to the scrubber. The two lets will be used to sweep the burners before starting up the burner, to maintain burner pressure when starting up, or to sweep a burner after a shutdown. The jets will handle a load of about 12 TPD and still give burner control. Any wear in the jets will cause a large loss of capacity. START-UP PROCEDURE - Assuming Both Burners Are Down The auxiliary equipment should be running and completely lined out; i.e., refrigeration unit, brine circulation,jets, scrubber with water and cell liquor, vaporizer, and pumps and tower, water on the primary cooler and the burner, and the compressor running on air (unless one burner is in production). Call the cell bridge and notify them you are going to start taking more . Line up the following valves: CI2 - PCV and FCV - closed and blocked SL 008997 H2 - PCV and FCV - closed and blocked (The PCV's are only closed if no other burners are in service) Discharge of the Secondary Cooler - closed Discharge of the Acid Tower to compressor suction - closed (If both burners are down) CONFIDENTIAL: Subject to Protective r<Jer Of 14th Judicial District Court -47- No. 91-U45 Ball-valve to jets open. Check the 11^ FCV with the manual control, be sure it is seated (visual check), block off the impulse to it and open the impulse to the air valve. (This valve will bleed air into the jet suction to give pressure control.) Set the gain on the burner pressure up (.35-----^.5), put it on automatic and set it to control -5" of H^O. HC1 UNIT START-UP PROCEDURES Start up Chlorine Flow First put the CI2 PCV into service by having a man on CI2 FCV bypass bleed excess pressure into burner. With the PCV on manual and closed, open block valves around PCV. If the valve leaks through, adjust pressure to 25 psig with FCV bypass. Adjust to a chlorine flow of 30 on chart with the bypass. Set PCV on Automatic and make sure it is controlling. Check the stack to see if CI2 is being vented. If so, use more cell liquor. Purge the H2 flame arrestor with N2 It should be enough flow to put the burner on a slight pressure when flowin Do this 2 or 3 times for about 15 to 20 seconds each. When CI2 has been purging for 5 minutes, light the lance. Open the appropriate valves only (1 block and the %"). Use only 1^, get small ^ flow, point the lance at shell, throw a match at the end. Adjust flame until a good flame is present. DO NOT POINT on Epoxied base of Burner. With a man at the observation nozzle and water flowing into the U-tube, insert the lance. Be sure that the flame is visible (lance may have to be moved up or down). Allow the burner pressure to settle out. If you can*t see it at all, it is out; get flow off immediately. Wait 5 minutes before trying to start up again. With a man at the observation nozzle, have an operator slowly crack the 1" FCV bypass. The burner will light with a thump and a pressure fluctuation; continue to slowly open the Hj bypass until the H2 flow is 25 on the chart. The only reason to not bring the H2 flow up is malfunctions; i.e., flame failure or some indication on board, flame failure is by observation, not alarm. In the event of anything unusual, get flow off immediately. Have the operator increase the Cl_ bypass flow to 35 tihen to 30, Cl2 to AO, H2, etc. until chlorine flow is 55 or 60 and H2 is 5 less. Adjust at rate slow enough that the burner pressure is controlled. Never allow to be greater than Cl^. SL 008998 -48- CONFIDENTIAL 1 Subject to Protective Ofdet Of 14th Judicial District Court No. 91-1145 Remove lance. Slowly cut back on the H flow to the lance until the flow decreases about 10; then increase H_ through FCV bypass about 10, Continue to do this until the H to tne lance is off. Pull the lance, insert the plug and allow the pressures to line out. Bypass the burner pressure shutdown system (switch 1 or 3). Depress the safety override timer - this activates the CI2 FCV may be operated. solenoid and the Check the Cl FCV out with the operator observing the valve movement. Close the CI2 FCV with manual control. Open upstream and downstream block valves one at a time, watching for leak-through. Put the CI2 flow controller on automatic and adjust the set point to where the valve barely opens. Probably the gain will have to be set to .25 .30. Slowly close FCV bypass. When valve is closed, put controller on cascade with ratio = 1.1 or 1.2. Check to be sure the ratio controller is working and controller is in cascade. Open the block valve downstream of the ^ FCV. Open the impulse to the H2 FCV from the burner pressure. Have the operator toslowly close the block valve in air system. When it is closed, seal off the air controller. Slowly close the 1" H FCV bypass. You probably will have to adjust the gain to approximately .2 to stop surging. Open the Maxon valve. Open the block valve to the Maxon valve; with somebody watching the H flow, slowly close the Maxon valve bypass. 2 Follow A or B A. If the other burner is not in operation, open the valve in the line between the acid tower and the compressor. Have one man cut the air off to the compressor at the same time the valve downstream of secondary cooler is slowly opened. The board will have to be watched for the compressor suction pressure and to make sure the rate increase is not too rapid. Bring the Cl rates to = 120 --^ 140. Slowly close off the ball valve to the jets. Simultaneously increase compressor suction to hold fairly constant rate. SL 008999 CONFIDENTIAL! Subject to Protective Order ufh Judicial District Court Slowly bring the burner to HTM excess. Be sure to do this slowly and never allow system to swing from H2--> Cl^ excess. Put burner pressure shutdown back in service if needed. Line out unit and cut off cell liquor, jets, etc. Hotify HC1 consumers. B. If other burner is in operation: 1* Switch burner pressure control to manual. 2. Slowly change the burner to anH. excess. 3. Sample through the aspirator sec-up and adjust the H2 excess to approximately 3%. 4. Slowly open the valve downstream of the secondary cooler. The ratio controller will have to be adjusted as rates increase. 5. Slowly close ball valve to jet system. 6. Put burner pressure shutdown back in service if needed. SL 009000 -50- CONFIDENTIAL* Subject to Protective Order Of 1-4th Judicial District Court No. 91-1145 WET HG1 PROCESS WET HC1 PROCESS DESCRIPTION The wet HC1 system is a process that will produce the same product as the dry system produces. The end product and the raw material feed are essentially the same for both processes. More dry HC1 capacity was not added because the wet system had many advantages that were desired at the present time. Among these are ease of control, use of cell gas, some surge capacity, and some reclaiming ability. HC1 will form an.azeotrope with water at 20% acid, so the wet system is designed to operate between the azeotrope and concentrated acid (36%). The actual strong acid concentration will be 33% HC1 for economic reasons. HC1 is produced by burning and Cl^ in graphite combustion chambers. The feed system, the control system, and the burners are exactly the same as is used in the dry system with one exception, the chlorine is not vaporized C^. Because inerts will cause no impurity problems in the wet.system, cell gas may be used. Cell gas and are fed into the bottom of the burner, react and the product HC1 is removed at the top through a 6" ''Barbate" line into the absorber-cooler. The gas should enter the top of the absorber-cooler at about 400 F., because the "Barbate" line is water sprayed, and the burner is water-cooled. The gas enters the top of the absorber, flows down the center of the tubes and is absorbed by the weak acid flowing down the tube walls. The heat of solution that is generated is removed by the cooling water flowing through the shell side of the absorber-cooler. The strong acid is removed from the bottom of the absorber-cooler through a seal pot and gravity flows into a strong acid storage tank. The non-condensables, as well as some nonabsorbed HC1, leave the bottom of the absorber and are fed into the bottom SL 009001 -51- of the tails tower. The gas flows up through the 1" pall rings contacting weak acid that is flowing down through the packing. All non-condensables are removed from the top of the tails tower by a steam jet. The steam and the Inerts are fed to the Tails Tower Vent Scrubber, where they are water scrubbed and the inerts vented from a stack above the process platform. The weak acid that is used for absorbing is pumped from the weak acid storage by "Durcon" pumps and fed to the top of the tails towers through TCV's. The temperature used for controlling the weak acid feed is the temperature of the tails tower bottom. This temperature should run between 150 F. and 160 F. From the bottom of the tails tower the weak acid is gravity fed to the top of the absorber-cooler. The weak acid is fed to each tube in the absorbercooler by a weir which causes the acid to spin down the walls of the tube. From the strong acid tank, the muriatic acid is pumped to the top of the stripper through a FCV. The strong acid flows through weirs down the inside walls of the tubes in the stripper. Steam is fed to the shell side of the stripper. When the strong acid is heated, HC1 is liberated and flows back up the middle of the tubes. The weak acid leaves the bottom of the stripper through the bottoms cooler, a level control valve and into the weak acid storage tanks. The HC1 gas leaves the top of the stripper and flows to the top of the primary cooler. The temperature of the gas leaving the top of the stripper controls the stream flow to the stripper and should run about 210 F. at 14.2 psig. The gas flows down the tubes of the primary cooler and is cooled to about 110 F, by cooling tower water flowing up on the shell side. The HC1 gas leaves the bottom of the primary cooler and enters the top of the secondary cooler. The g^s flows down the tube side of the secondary cooler, W TooUc-' >:,uout the bottom, thrbugh the entrainment separator and into the dryer. Brine from the refrigeration unit at 0 F. is fed into the bottom of the shell side of the tertiary cooler, out the top and into the bottom of the shell side of the secondary cooler. From the top of the secondary cooler the brine at 5 F. is fed to the refrigeration machine. All piping for the HC1 gas is Haveg until after the entrainment separator; it then becomes steel. The stripper, primary cooler, secondary cooler, tertiary cooler and entrainment separator are of ,,Karbate" construction on the acid side. The condensate from the cooling system is fed back to the top of the stripper. The condensate is required for good stripper performance. There are two identical stripper systems and the two product streams mix afta: the entrainment separators. From the stripper section, the gas is fed to the bottom of a H^SO^ dryer. The gases flow up the tower contacting HjSO^ acid that is flowing down the packed tower. From the top of the I^SO^ dryer, the gas flows to the compressors. The temperature of the gas entering the tower will be about o0 10 F. and it will warm to about 30 F. The gas is compressed in the compressors from 14.5 psig to 125 psig or from ^ psig to 160 psig. When the compressors are operating at the high pressure, a distance ring will be required on the compressor. This distance ring Is already on the compressors. After compression, the gas is cooled to 110 F. and sent to the EC plant. Some gas is removed from the compressor suction and pumped by #4 compressor to the MC plant. This gas is replaced in the suction line by HC1 from the TCE reactor. The control system around the compressors merits some explanation. Follow this discussion on figure 1, page 54 . In the HC1 plant there is an oversized (60 TH>) absorber-cooler and its tails tower. This absorber is to reclaim all vents from the HC1 plant as well as the EC vent stream. For this reason all FCV's in the HC1 system vent to Absorber-Cooler #2. To keep SL 009003 CONFIDENTIAL* Subject to Protective Order of Hth Judicial District Court No. 91-1X45 the compressor suction pressure constant, there is a PCV that recirculates HC1 from the compressor discharge to the compressor suction. This valve will handle 30 TPD. To prevent the compressor suction pressure from going too high, there is a PCV that will send the excess HC1 to Absorber #2. This valve has a capacity of 60 TPD. There is a rupture disc and a pressure switch that further protects the stripper system from overpressurging. To keep line pressure to the EC plant constant, there is a PCV that will send HC1 to Absorber #2. This PCV actually is 2 valves, one of which is small. The small valve has an orifice in it so that rates may be adjusted upwards before the consumers increase their consumption. The valves are arranged so that the small valve opens first. These two valves have the capacity of 60 TPD, Should something upset the system quick enough, it would be possible to overload AbsoTber-Cooler #2, To prevent this from happening, the absorber has a rupture disc that will burst. All rupture discs vent to the scrubber* All piping in muriatic acid service is "Karbate" or Haveg. All valves in Haveg service are glass-lined with Teflon diaphragms. GASEOUS CHLORINE SYSTEM SL 009005 The gaseous Clj is a 10" line from the chlorine compressors in liquefaction to the organics area. The 10" line goes to the EDC plant where it reduced to a 8" line. The 8" line reduces at the EDC control building to a 6" where there is a valve in the line. The 6" line continues down the eastwest pipe rack. A 4" line takes off the E-W rack and runs to the HCl plant. The CI2 line is insulated and steam traced to the EDC takeoff. From this point on the line is only Insulated. The Cl^ should arrive in the HCl at a pressure of 40 psig. The Cl2 will be pressure reduced to 25 psig. After the PCV, the Clj, flows through a double meter run. When the projected cell gas usage is for 2 burners, use the smaller orifice run. If cell gas is to be used for more than 2 burners. use the large orifice meter. CONFIDENTIAL* Subject to Protective Order 55- of 14fch Judicial District Court No. 91-1145 From the metering station the Cl^ goes to burners .3, 4 and 5. Burner #2 may be fed with cell gas or with vaporized Cl . Never feed cell /L gas to the burner when it is operating in the dry system* In the CI2 feed system to each burner is a FCV. This flow control valve receives its impulse from a ratio controller. The ratio controller will keep the Cl^ flow proportional to the HLj flow. The ratio is set to control 3% to 5% excess in the product gas. The Cl^ FCV is designed to fail closed. Located in the air supply line to each CI2 FCV is a solenoid that will close when the shutdown system is activated. When the solenoid closes the air supply to the FCV the valve will close. Since the valve is in Cl^ service, it is probable the valve will gunk up and stick. After any shutdown, emergency or not, the valve should be blocked off to prevent any leakage. The Cl^ flows through a loop just before entering the burner nozzle. The purpose of the loop is to prevent acid from draining from the bottom of the burner back to the FCV. The drain on the burner side of the loop should be checked after a burner shutdown, and while the burner is down, for acid. h2 srsm (The system for the wet HC1 system is the same as the H system ^2 for the dry HC1 system.) A. Equipment 1. Hydrogen Surge Drum 62A-60-420 - The H Surge Drum is 36" OD x 5*0" tan to tan. The design pressure of the vessel is full vacuum to 75 psi. The rupture disc is set for 75 psig. 2. Ho Cooler 62A-71-517 - The hydrogen cooler is a 6 5/8" OD exchanger with 26 8' tubes 3/4" OD 16 gauge. The material of construction is steel for everything. SL 009006 -56- COHf*t>ENTlAM Subject to Protective, Oraer 14th Judicial District Court .. _ n 1 _ 11 8# Operation The hydr gen line t theHCl plant is a 4" line that comes from the top of the H2 scrubber in the cell area. The line has several low spots in it that have float traps to remove moisture. These traps should be checked regularly, especially during cold weather. The system has very little eactra capacity since the maximum pressure available is about 22 psig. The booster compressor to other consumers is set to cut off at about 10 psig. So any failures in the H2 system will result in a rapid pressure loss to 10 psig, then the only consumer will be HC1. The pressure loss below 10 psig will determine how much to cut beck the burner rates. The H2 line runs down the main rack and enters the plant south of the acid storage tanks. The ^ system has a PCV and two meter runs at this point. The PCV should be set to give pressure to the burners of about 20 psig. This pressure as well as the Cl^ pressure will effect the ratio between the two gases, so care should be taken in changing the pressures on the systems. The larger meter run should be used whenever more than two burners at full rates are operating or the total hydrogen flow is greeter than 500 SCFM, From the meter run the flows through a surge drum and a cooler to the individual burners. The purpose of the cooler is to keep the ft, at a fairly stable temperature for metering at each burner. The hydrogen flow to each burner is controlled by the burner pressure. The burner pressure should be set to keep from -2" to ;+ 2" of pressure. The set pressure is maintained by increasing or decreasing the H flow. The 2 Hj fow is measured and sent to a ratio controller* The ratio controller keeps the CI2 flow to the burner in a preset ratio to the H2 flow. The normal ratio SL 009007 CONMDfcHWt. >obJt to wfSSiSat COTr- ratio is about 1.05 H to Cl,,, but this will vary according to the pressures L ** and temperatures of the gases. The set ratio is the ratio that gives 3Z to 5% excess H2 in the product HC1. Located in each H2 system is a positive shutoff Maxon valve. This valve will shut during any system failure. SHUTDOWN SYSTEM The shutdown system (DWG. 62A-7703) for the wet HC1 system is designed to shut down burners 2, 3, 4 or 5. When the shutdown system is activated, it will shut down the affected burner by closing the Maxon valve on the line, and by closing the solenoid valve in the air supply line to the CI2 FCV. There is some discrepancy in this description concerning #2 burner since it is used in both the wet and dry system. When burner #2 is operating in the wet system, a thorough check of the bypass switches should be made to ascertain that everything is protected and a failure in the dry HC1 will not shut down the wet HC1 or vice versa. The Maxon valve is a positive shutoff valve located in the H2 feed system to each burner. It is possible to bypass this valve and it is bypassed during start-up. AT NO OTHER TIME SHOULD THIS VALVE BE BYPASSED. The most dangerous thing that can happen around aiHCl plant is to fill the system with H2 and human reflexes are not quick enough to close off a valve that is wide open. The Maxon valve is spring loaded to close and is kept open by an engaging solenoid. The Cl2 FCV is designed to fail closed with a loss of air supply. The shutdown system has a solenoid in the air supply that closes for system failure. Most valves in Cl2 service gunk up, so in order to assure that no Cl2 is going through the burner, the block valves will have to be closed. SL 009008 The shutdown system is activated by: a flame failure, low burner pressure, high burner pressure or loss of cooling water. A failure of any of the items will cause the affected burner to shut down. The shutdown systems can be bypassed by timers, and individual parts of it may be by passed with switches. The reason for the bypass switches and timers is that under different circumstances different items are of importance. The timers are for equipment checking and starting up. Periodically the burner shutdown system should be checked to see what shutdown relays are bypassed and these checked to see if it is necessary for these to be bypassed under the conditions of operation at that time. A flame failure is detected by a "Firetron" photo-conductive cell, which continuously monitors the flame. The fire-eye is located at one of the sight ports on each burner bottom. High and low burner pressures are monitored, recorded and used to control the H2 flow. The cooling water flow is monitored in two spots. Cooling tower water flowing into each cooler- absorber is monitored through a no-flow switch on the inlet as is the well C/1 water flow to the top of each burner. Both of these switches must have at least 50 GR1 and failure of either one will activate the shutdown system. In case of an emergency shutdown in the HC1 plant, the alarm on the panelboard will indicate the first one to fail. It will be the only one to flash. When the board is acknowledged, the others will flash; when it is acknowledged again, all alarms will clear. The sequential alarm system applies to flame failure, loss of cooling water, or high or low burner pressure for burners #1, 2, 3, 4, and 5. The timers that are on each burner system bypass flame failure and high or low burner pressure. These timers may be set for up to 15 minutes and are generally set for 7 minutes. Once they are set they cannot be reset again until time has run out. Switch 1 when closed will prevent high or low burner pressure from shutting down the burner. Swtich 2 when open is an COHFlDfcNTlALt 6ubj ct to Protective Order -59- Of 14th Judicial District Ceihrfc No. 91-1145 isolation switch so that the burner shutdown system may be worked on and a ground in it will not shut down other burners. (When switch 2 is open, the burner must be shut down) BURNER SYSTEM A. Equipment 1. HC1 Burner 62A-71-797, 798, and 799- The HC1 burners (combustion chambers) are 33" chambers. They are constructed of 3" thick graphite rings with each ring 3*3" OD and 5* 8-5/8" high. There are 4 full-sized rings and a top ring that is 3* 8-5/8" high. The rings are stacked on each other and all rest on a 4" thick "Karbate" base. When the sections are cemented together and set on the base, the over-all height is 27' 3%". The sections are cemented together with National Carbon C6 cement and heat cured. The outside of the chambers have a think washcoat of impervious material to prevent water from being absorbed through the burner walls. The top ring has a 4" thick graphite plate resting on it, and on top of this a water distributor. When the distributor is filled with water, the weight of the water, distributor and top will hold the top on the burner until a pressure of about 20" of H9O is reached. The top has a guide bar so the top reseats itself properly whenever it is lifted. The burner has a hole in the bottom plate for the burner nozzle assembly, 2 4" nozzles with quartz sight glasses located near the bottom, a 3" and a 6" nozzle near the top. The 3" nozzle is for burner pressure and the 6" nozzle is the gas outlet. 2. Burner nozzle assembly. The burner nozzle assembly is a National Carbon size 8 "Karbate" impervious graphite with silica-coated caps. The diameter of the holes in the caps is to be at least 13/16" and they should be drilled to this diameter if they arrive with smaller holes. The hydrogen feeds in the outermost ring and C^ in the center. B. Operation Chlorine and hydrogen are fed separately through the burner nozzle assembly. The two gases are mixed as they are ejected from the nozzle into the burner. Once a flame is started, the two gases will bum when they are mixed. Located on one of the bottom sight glasses is a fire-eye. The purpose of the fire-eye is to continuously monitor the flame and anytime the flame disappears the fire-eye will activate the shutdown system for that burner. SL 009010 -60- The burner must have some of the heat generated by the reaction dissipated or the graphite walls will overheat resulting in oxidation, cracking and leakage. For this reason there is a no-flow switch in the well water line going to each burner. Loss of well water flow will activate the shutdown system for that burner. The no-flow alarm on the well water is alarmed through the no-flow light and alarm on the CTW flow to each absorber. Should the CTW or the well water fail, it should be fairly obvious which one failed. If the switches fail, each one may be checked. The well water to each burner is distributed at the top of the burner through a water distributor. The water distributor causes the water to flow down the sides of the burner in an even manner. The burner is enclosed in a plexigla$ shield to prevent the wind from blowing the water layer away and leaving the graphite with no cooling film. Care should be taken in adjusting the well water flow to the burner to see to it that enough water is used to provide a water layer over the out side of the burner from top to bottom. This will require from 100 GIM to 200 GPM,depending on the burner rate. The water is collected at the bottom of the burner in a rubber-lined pan and sent to the sewer. The bottom plate has grooves on its bottom to allow some water to flow beneath it. If the grooves are allowed to plug up, the rubber lining will have no protection and will be destroyed. Another problem with the cooling system will be algae. If the burner becomes coated with algae, the cooling water will have little effect. As the algae appears and gets thick enough to retard the heat transfer, it must be removed by (a) heavy chlorination of #8 deep well water, (b) bubbling , a few TPD of HC1 in the distribution crown (there is an HC1 ring sparger for this purpose), (c) put Pittabs in the distribution crown, (d) shut burner down and expose it to sunlight,(e) physically scraping the burner. The best method is the HC1 wash when excess HC1 is available. SL 009011 -61- CONFIDENT***.* Subject to Protective Order of 2.4th Judicial District Court N . 91-H4'5 After the and Cl^ burn, the HC1 rises up the burner and leaves at the top through a 6" Karbate line. This line must be water cooled also and there are spray nozzles to keep it wet. The maximum recommended temperature for "Karbate" is 338 F. Thl$ temperature refers to the body temperature o not the gas inside the pipe; i.e., gas temp of 440 F. and water on the outo side of the pipe will give a "Karbate1' temperature of about 310 F. The "Karbate" risers have no water on them as it was felt that enough cooling will take place in the vevCLcal run and the gases will not cause the "Karbate" risers to overheat. These risers should be checked fairly regularly, especially at high rates. Near the top of the burner is a pressure transmitter. This pressure is used to control the burner rates. The ideal operating pressure is -2" of H20, but the burner will operate anywhere in the range of -2" to +2" of H^O. When the burner pressure falls below the preset rate, the ^ flow will be increased and since the CI2 flow is kept proportional to the flow, the flow is increased. The net result is an increase in HC1 production. High and low pressures may be used to shut down the burner also. The burner nozzle assembly has a hole in the bottom of it. When the burner is operating,this hole should have a plug in it. Whenever the burner is down, this plug should be removed and air allowed to flow through the hole, the burner and the jets for at least 5 minutes. The nozzle assembly also has a U-tube in it. This tube is to drain the condensate formed in the burner to the sewer. There should always be some water in the U-tube to form a seal. Generally, some additional water must be added to keep the tube full. Caution Should be used around this condensate as it is 35% muriactic acid. The wet system has 3 identical burner, numbers 3, 4 and 5. Number 2 burner may be used in either the Vet or the dry system. SL 009012 -62- COHFIOEHT1M.* i ofC*lu4btlhcJtu<dtoicPiarol t Dcitsivtfreic0t Ceoturt 1 , , rf n-U45 ABSORBER SYSTEM A. Equipment 1. Absorber-Cooler 62A-71-800, 801, and 802 - The absorber-coolers are 14" OD steel shelled vertical exchangers. There are 42 7/8" ID tubes constructed of "Karbate" which are 16' long. The shell has 14 segmental baffles. Each tube has a 5-5/16" high Teflon weir at the top. The gas baffle is "Karbate" and the liquid distributor is Teflon. The design pressure of the tube side is 25 psig, of the shell side is 75 psig, both at a temperature of 338 F. The top tube sheet is fixed while the bottom is floating. 2. Tails Towers 62A-67-24,25, and 26 - The tails towers are 12" ID x 10' long Haveg 41 vessels. The tower has 5* of 1" polypropylene Pall Rings on top of 18" of 1%" carbon Raschig Rings. The packing is supported on 12" diameter standard Haveg grid bars. The tower is equipped with a liquid sparger and distributor at the top. Both are constucted of Haveg. 3. Seal Pot - The seal pot is a National Carbon seal pot assembly for series 31A-Absorber. The seal pot is constructed of "Karbate." The top of the liquid leg has a V' Saran pipe plug. The sample cock on the bottom is a CP2356-DA 4. Specific Gravity Indicator - The specific gravity indicator is fabricated by National Carbon to fit on the side of the seal pot. It is equipped with a TI and a 10-25 Baume* hydrometer. 5. Steam Jets - The steam jet ejectors are Schultte and Koerting, 1%" size 8, constructed of Haveg. B. Operation The absorber-cooler is a vertical shell-and-tube exchanger. The gas to be absorbed enters the absorber through an inlet at the upper end of the heat exchanger,flows through a baffle and into the center of the tubes. The HC1 gas flows down the tube and is absorbed by the weak acid flowing down the tube walls. The heat of solution that is generated is removed by 200 GIM of cooling tower water flowing up the shell side of the exchanger. The strong acid is removed from the bottom of the absorber-cooler through a seal pot and flows by gravity into the strong acid storage tank. On the side of the seal kin pot is a specific gravity indicator. The specific gravity is indicated in Baume' f Be = 145 - 145 ^ The sp. gr. of the acid should be around 20 Be, V Sp.Gr.j (The exact sp. gr, will be determined by analysis since the sp. gr. varies with the temp.) The non-condensables, as well as about 30% of the total HC1 fed to the absorber, will leave the bottom of the absorber and are fed into the bottom of the tails towers. The tails towers are packed with 1" polypropylene Pall Rings and 1%T' carbon Raschig Rings. The packing support grids are ex actly 1" apart and the 1" Pall Rings will fall through if they line up right, so a bed of 1%" carbon rings is used toiaolate the Pall Rings from the grid. The Pall Rings cannot be changed for 1%" as the design load for the towers is based on 1" Pall Rings. Weak acid from storage is pumped to the top of the tails tower through a TCV, a sparger and a distributor to the packing, where it contacts the gas. As HC1 is absorbed in the weak acid, the acid will become warmer due to the heat of solution. The temperature of the acid at the bottom of the tower is used to control the TCV that feeds acid to the tower. This temperature should run between 150o F. and 160o F. The exact temperature will o be determined by analysis of the product acid. To make adjustments, a 10 F. temp, change will change the product strength 1%. The temp will cycle about o 10 F. per hour under stable conditions. Under optimum conditions, about 1/3 of the HC1 fed to the absorber will be absorbed in the tails tower. The non-condensables are removed from the top of the tails towers by steam jet ejectors. From the steam jets the inerts plus the steam are fed to the tails tower vent scrubber. The steam jets are sized to pull 131#/hr. at 26 mm H absolute. Since the capacity of the jets is constant, the only way to vary the capacity is to artificially load the system. This is done by bleeding through a PCV into the suction line of the jets. The impulse point for the COHFIOWttM'l 64- Subject to Protective Order t st f 14th Judicial PCV is in the line that comes off the top of the tails tower. The weak acid is gravity fed from the bottom of the tails tower to the top of the absorber-cooler. In the top of the absorber the acid flows through a Teflon distributor (No. 1 absorber-cooler does not have a distributor, and therefore its capacity will be less than the others.) Each tube has a 5-5/16" high weir in the top of it. The weirs are constructed of Teflon in all but #1 Absorber-Cooler which has graphite weirs because of the high temper ature the weirs will reach when the absorber is being used as a cooler. The Teflon weirs may be either white or black, as there is no difference in the properties of the two except the black will machine easier. Each weir has 4 tangential V- notches cut in it so that the acid is "spun" down the tube walls of the absorber. The strong acid is collected in the bottom of the ab sorber, flows through a seal pot, and gravity flows to a strong acid storage tank. The absorber-cooler uses parallel flow of the gas and liquid for two reasons. The first reason is that much higher capacity is realized because higher velocities are possible. The second reason is that the hot gases entering the top of the absorber provide a counter-flow to the cooling water. This allows the strong acid to leave at a cooler temperature. Although the "Karbate" is impervious to most chemicals, it is oxidized by hypochlorus acid. For this reason any free CI2 in the system should be held to an absolute minimum. The top tube sheet must have cooling water held against it to prevent it from over heating. For this reason all air trapped or gases generated on the shell side of the absorber must be removed. Coming out of the top shell flange is a %" line that goes to an air trap. The air trap is a float type trap that will allow gases to pass, but not liquid. As long as this trap is operating, the top tube sheet should not overheat. SL 009015 -65- CORFlDEHTIMi* Subject to Protective Order Of 14th Judicial District Court *Jo. 91-1145 The gas baffle located in the top of the absorber is a "Karbace" plate that serves to distribute the gas over the full diameter of the absorber by means of holes drilled in the plate. The liquid distributor is a Teflon sheet that forms a circle around all the weirs. All liquid, in order to reach the weirs, must flow through holes in the Teflon distributor. In this manner the o acid is fed from 360 . This arrangement of baffles and distribution will allow each tube to handle a maximum of 1 GIM. Attached to the weak acid feed line to each tails tower is a well water line and a rotameter. This line is used to add water to the system. Under normal circumstances the HC1 system will require no water to be added. Should any muriactic acid be sold, leak from the system, or be transferred from the system for any other reason, water will have to be added to make up for it. The wet HC1 plant will use the big jets at the dry HC1 scrubber for starting up. The burner pressure controllers on burners 3, 4, and 5 may be switched so that their impulse is sent to a PCV that will bleed avr into the jet suction. Attached to the gas riser between the absorber and the tails tower is a 3" line that ties into the jets suction. The jets may be used to start up one burner at a time. Both jets will be required as the steam supply has been changed from 125 psig to 75 psig. At the top of the gas riser, between the burner and the absorber, is a piping takeoff for the analyzer. There is one analyzer for burners!^, 3, 4 and 5. A sample line runs from each riser to the analyzer and by correct valving, the gas from a burner may be sent through the analyzer. Only one stream can be sampled at a time and the valve switching should be done at the riser or else the line will fill with condensate. The sample is drawn through the analyzer by a water aspirator. SL 009016 CONFIDENTIAL? -66- Subject to Protective Order of 14tb Judicial District Court No. 91-1145 START-UP PROCEDURE The start-up procedure for the wet HC1 burners is very much similar to the start-up procedure required for the dry burner. The burners will be started up by using the dry HC1 jets. The auxiliary equipment should be running and lined out. They include: dry HC1 jets, scrubber with water and cell liquor, water on the absorbercooler and water on the burner. Before any cell liquor is used, be sure and notify the MC operator. Line up the following (it is assumed that other burners are operating): CI2 PCV - closed and blocked H2 FCV - closed and blocked Weak acid feed to tails tower closed and blocked. Strong acid discharge from the absorber is closed. Valve to jets is open. Call the cell bridge and notify them you are going to start taking more Check the FCV with the manual control, be sure it is seated (visual check), block off the impulse to it and open the impulse to the air valve. (This valve will bleed air into the jet suction to give pressure control.) Set the gain on the burner pressure up (.35--> .5), put it on automatic and set it to control -5" of H^O. Start up Chlorine Flow Adjust a chlorine flow of 30 on chart with the CI2 FCV bypass. Check the stack to see if C^ is being vented. If so, use more cell liquor. Purge the ^ flame arrestor with N It should be enough flow to put the burner on a slight pressure when flowing. Do this 2 or 3 times for about 15 to 20 seconds each. When CI2 has been purging for 5 minutes, light the lance. Open the appropriate valves only (1 block and the %"). Use only H2, get a small H flow, point the lance at the shell, throw a match at the end. Adjust the flame until a good flame is present. Do Not Point on Epoxied base of burner. With a man at the observation nozzle and water flowing into the U-tube, insert the lance. Be sure that the flame is visible (lance may have to be moved up or down). Allow the burner pressure to settle out. If you can*t see it at all it is out; get KL flow off immediately. Wait 5 minutes. With a man at the observation nozzle, have an operator slowly crack the 1" H FCV bypass. Burner will light with a thump and a pressure fluctuation, continue to slowly open the H2 bypass until the H2 flow is 25 on the chart. The only reason to not bring the H- flow up is malfunctions; i.e., flame failure or some indication on board, flame failure is by observation, not alarm. In the event of anything unusual, get H flow off immediately. SL 009017 -67- Have the operator increase the Cl^ bypass flow to 35 then H to 30, Cl to 40, H , etc. until chlorine flow is 55 or 60 and H is less. Adjust a? rate slow enough that the burner pressure ii controlled. Never allow H,, to be greater than Cl^. Remove Lance. Slowly cut back on the H flow to the lance until H flow decreases about 10 then increase through FCV bypass about 10. Continue to do this until the H to the lance is off. Pull the lance, insert the plug and allow the pressures to line out. Close switch 1 on the respective burner. Depress the safety override timer - this activates the CI2 solenoid and the CI2 FCV may be operated. Check the CI2 FCV out with the operator observing the valve movement. Close the CI2 FCV with manual control. Open upstream and downstream block valves one at a time, watching for leak through. Put the CI2 flow controller on automatic and adjust the set point to where the valve barely opens. Probably the gain will have to be set to .25-->.30. Slowly close FCV bypass. When valve is closed, put controller on cascade with ratio = 1.05. Check to be sure the ratio controller is working and controller is in cascade. Open the block valve downstream of the H,, FCV. 2 Open the impulse to the ^ FCV from the burner pressure. Have the operator to slowly close the block valve in air system. When it is closed, seal off the air controller. Slowly close the 1" FCV bypass. You probably will have to adjust the gain to approximately .2 to stop surging. Open the Maxon valve. Open the block valve to the Maxon valve; with somebody watching the H flow, slowly close the Maxon valve bypass. 2 Switch the H^ analyzer to the burner that is being started up. Slowly bring the burner to a H excess. Be sure to do this slowly and never allow the burner to swing from H2 to CI2 excess. When finished, the analyzer should show about 3% H , SL 009018 -68- CQnrioewttW;fve Qrfl t Subject to mb Judicial dip of 1 TO 1 91" 11 court Start up the tails tower. Start up the tails tower iet, line up and put on automatic control and slowly lower to -2" ^0. Open the valve at the bottom of the absorber to the strong acid line. With the weak acid feed valve on manual control and closed, open the block valves around it. Slowly open the weak acid feed valve to the tails towers. Increase the flow very slowly to about 12 GFM. At this point the burner should be operating at about 60% capacity. Slowly close off the line to the jets, never allowing the burner rates to go below 1/3 of capacity. Rates are iicreased by increasing the weak acid flow. Shut down the dry HC1 jets and scrubber. Allow the tails tower to come to operating temperature, put it on automatic control. STRIPPER SYSTEM A. Equipment 1. Strippers 62A-710803 and 804 - The strippers are 38" OD steel shelled vertical exchangers. There are 439 7/8" ID tubes constructed of "Karbate" which are 16' long. Each tube has a 5-5/16" high Teflon weir at the top. The liquid distributor is Teflon. The design pressure of the tube side is 40 psig, of the shell side is 75 psig, both at a temperature of 338 F. The top tube sheet is fixed while the bottom tube sheet is floating. 2. Stripper Bottoms Cooler 62A-71-811 and 812 - The bottoms coolers are 16" OD steel shelled horizontal exchangers. There are 64 7/8" ID tubes constructed of "Karbate" which are 14' long. The tube side is 7 pass, designed for 75 psig at 338 F.The shell side has 18 segmental, top to bottom, baffles and it is designed for 75 psig at 338 F. The tube sheet at the acid inlet is fixed, the other tube sheet is floating. 3. Stripper Feed Pumps 62A-55-862, 863, 864 - The stripper feed and absorber feed pumps are "Durcon" 2 x 2P-10. The pumps are to pump 120 GIM at 118` head. The wet end of the pumps are Durcon which is an epoxy resin; the shafts are Superchlor. The motors are 15 HP, 1800 RFH, The seals are John Crane, type 20. B. Operation The stripper feed pump pulls strong acid from the storage tank and SL 009019 -69- C0Hnoctive order court pumps it through a magnetic flow meter into the top of the stripper. The maximum feed to each stripper is 60 GFM. The strong acid flows through the weirs down the inside walls of the tubes in the stripper. Steam which is on the shell side heats the acid as it falls down the tubes and drives off the HC1. Weak acid (20% HCl) leaves the bottom of the stripper through the bottoms cooler, through a level control valve and to the weak acid storage. The bottoms cooler will require about 300 GFM of cooling tower water to cool the acid to 110 F, Extreme caution must be used to be sure that hot acid never enters the storage tank, as it will cause failure in the glass lining of the tank. HCl gas that leaves the acid as it is heated flows back up the tubes of the stripper and out the top. From the top of the stripper the gas flows through three stages of cooling. The condensate acid from each cooler is collected and sent back to the top of the stripper. The condensate has an effect on the over-all efficiency of the stripper. The stripper rate is controlled by the feed rate of strong acid; this is flow controlled. The steam flow to the strippers is temperature controlled by the temperature of the gas out the top of the stripper. The control temper ature will be determined by the operating pressure and the operating pressure depends on the EC reactor pressure. The stripper system will operate at 14.5 psig to begin with. At this pressure the overhead temperature will be con- oo trolled at 210 F. The bottom temperature of the stripper will be 255 F. The steam used in the strippers is 75 psig, desuperheated steam. Do not, under any circumstances, use steam that has not been desuperheated. The o maximum temperature allowable on the "Karbate" is 338 F. Saturated 75 psig steam temperature is 320 F. SL 009020 10- Subject W Court On the steam to No. 1 stripper is an automatic shutdown control. The shutdown control will stop the steam flowing to No.l stripper. The control is a solenoid in the air supply line to the steam TCV, so when the solenoid closes the air supply to the valve is cutoff and the valve closes. This shutdown system is used to cut rates in the HC1 plant, should a con sumer or a compressor kick off. The PCV's in the HC1 system will handle an emergency shutdown if just one stripper is in service, but if two are in service, then some rupture discs would have to blow, venting HC1 to the scrubbers. The pressure switches are located in the discharge of the entrain ment separators and in the compressor discharge line. The pressure switch in the entrainment separator discharge line is set for 20 psig, while the one in the compressor discharge line is set for 130 psig. It is well to remember that Absorber-Cooler #2 will handle the capacity of one stripper and that all PCV's in the HC1 system feed the excess HC1 to this absorber. The strippers and coolers are protected by a rupture disc in a line going to the dry HC1 scrubber. The rupture discs are located just after the tertiary coolers and are set for 40 psig. There are two strippers, both just alike. START-UP Put cooling water on the primary and the bottoms coolers, put brine on the secondary and the tertiary coolers, put the steam TCV on manual control and closed, put the stripper bottoms LCV on automatic, be sure the lines are open to the dryer, have the dryer in service, and a compressor on. The strippers can be started up with the compressors down by sending HC1 through the suction line PCV to Absorber #2. In any case Absorber-Cooler #2 must be in service prior to starting the strippers up. SL 009021 -71- of After all of the auxiliary equipment is up and lined out, start strong acid feed to the stripper. Be sure the stripper LCV is working, then increase the acid feed to about 20 GR1. Open the steam to the stripper very slowly and continue to increase the steam until the top temperature reaches operating temperature. If the top temperature starts to fall as the steam is increased and the feed has not increased, then cut back on the steam as too much water is going overhead. When operating temperature is reached, check the stripper bottoms strength and adjust the top temperature to get 21% HC1 in the bottom stream. When the stripper is lined out on automatic control, then increase the feed rates to the desired HC1 production. PRIMARY COOLER A. Equipment 1. Primary Coolers 62A-71-805 and 806 are 18" OD steel shelled vertical coolers. There are 85 7/8" ID tubes constructed of "Karbate" which are 16'0" long. The shell has 20 segmental baffles. The top tube sheet is fixed and bottom tube sheet is floating. The design pressure of the shell side is 75 psig and of the tube side is 40 psig, both at 338 F. B. Operation The primary cooler cools the HC1 from the stripper from 210 F. to o 110 F. with cooling tower water. The HC1 enters the top of the tube side and leaves the bottom. The water enters the bottom of the shell side at the rate of 200 GPM and leaves at the top. Some moisture will be. condensed from the HC1. This strong acid leaves the bottom of the cooler and flows back to the stripper. There is a bulls-eye in the condensate line so the amount of condensate may be observed. When the condensate flow is high, it means too much water is coming over with the HC1 (the stripper control temperature is too high) or one of the tubes has developed a leak. The bulls-eye should be checked on every outside round. Each stripper has one primary cooler. CONFIDENTIALt Subject to protective Order SL 009022 72- of 11d4tthh /JJuuddiciciaial District Cou^No. 91-H45 SECONDARY COOLERS A, Equipment 1. The secondary coolers 62A-71-807 and 809 are 18" OD steel shelled vertical coolers. There are 85 7/8" ID tubes constructed of "Karbate" which are 16' long. The shell has 20 segmental baffles. The top tube sheet is fixed and the bottom tube sheet is floating. The design pressure of the shell side is 75 pslg and of the tube side is 40 psig, both at 338 F. B. Operation The secondary cooler cools the HC1 from 110 F. to 40 F. The HC1 leaves the bottom of the primary and is fed into the top of the secondary, where it flows down the tubes and out the bottom. Brine is fed into the bottom and out the top of the shell side. The brine rate will be about 100 GIM. The secondary cooler has a bulls-eye in the condensate line so the condensate rate as well as any tube leakage may be observed. Any high con densate rate should be accompanied by a high feed temperature. The rate of cooling the HC1 gas is extremely important, as a high cooling rate will cause fog to form and consequently high moisture. For this reason the gas from the secondary should never be cooler than 35o F. and should operate around 40o F. The brine system is set up so that the secondary and the tertiary coolers are in series. The brine enters the tertiary, leaves it and enters the secondary before returning to the refrigeration machine. If running the brine in this manner creates an unbalance in the two exchangers (i.e., o in order to hold the 40 F. discharge of the secondary, the final gas must o be 20 F.), then the brine may be valved so that (a) more brine is fed to the tertiary than the secondary, (b) vice versa, and (c) the two exchangers are run in parallel. The brine out of the secondary cooler flows through a pH meter. The pH meter will sound an alarm if the pH should fall indicating a tube failure in the coolers. Should one of the pH meters indicate a low pH, shut down and SL 009023 -73- i Jc^ Protective Order *f 14th Ju^ciai cZt isolate the system immediately, check the brine pH in the laboratory and drain the brine out of the system if the pH is actually low. The high acid in the brine will destroy the refrigeration system. Each pH meter has a recorder but the alarm is common. Only a small amount of the total brine is routed through the meter, so open the lines through the meter and throttle the valve in the main brine line until the brine flowing through the meter is about 3/4 the line capacity as observed through a bulls-eye. Each stripper has one secondary cooler. TERTIARY COOLERS A. Equipment 1. Tertiary Cooles 62A-71-808 and 810 are 18" OD steel shelled vertical coolers. There are 85 7/8" ID finned tubes constructed of "Karbate" which are 16' long. The shell has 20 segmental baffles. The top tube sheet is fixed and the bottom tube sheet is floating. The design pressure of the shell side is 75 psig and of the tube side is 40 psigf both at 338 F. 2. Entrainment Separator - The entrainment separators are National Carbon's size #8. They are constructed of'Karbate" internally. B. Operation o The tertiary coolers cool the HC1 from 40 F. to 10 F. The HC1 leaves the bottom of the secondary and is fed into the top of the tertiary, where it flows down the tubes and out the bottom. From the tertiary the HC1 flows through an entrainment separator, a block valve, and into a steel line where it joins the HC1 from the other stripper system. The tertiary cooler has a bulls-eye in the condensate line, so the condensate rate as well as any tube leakage may be observed. All condensate from the entrainment separator is drained back to the stripper. o Enough brine should be used to get 10 F. HC1. (See brine write-up under the secondary cooler.) SL 009024 -74- CONFIDENTIAL* ffubj ct to Protective Order of l#th Judicial District Court No. 91-1145 SL 009025 ABSORBER-COOLER #2 AND THE HC1 CONTROL SYSTEM A. Equipment: 1. Absorber-Cooler #2 (62A-71-817) is anl8" OD steel shelled vertical exchanger. There are 85 7/8" ID tubes constructed of "Karbate" which are 16' long. This absorber-cooler is exactly like all of the others except larger. 2. Tails Tower #2 (62A-67-23) - This tails tower is 15" ID x 10' long and isexactly like the other tails towers except it is larger. B. Operation This absorber is used to absorb all HC1 that would normally have to be vented. The absorber-cooler has twice the capacity of any of the other absorbers. Weak acid is fed to the top of the tails tower at the rate of 60 GfM and after flowing through the absorber the liquid is sent back to the weak acid storage. If strong enough acid is being made in Absorber-Cooler #2, then the bottom product may be sent to strong acid storage. Under normal circum stances only a small amount of HC1 will be fed to the absorber, but should an emergency occur, up to 60 TPD could be fed. The absorber is protected from over-pressurization by a rupture disc located in the feed line to the absorber. The rupture disc is set for 4 psig and it will vent to the tails tower vent 15 scrubber. Whenever the HC1 stripper^ dry HC1 system, or the EC plant are in operation, Absorber-Cooler #2 should be. The vent HC1 from the EC plant is normally fed to the absorber as is the excess HC1 produced in the dry system. The wet system is designed so a little HC1 is always being vented to the absorber; but should an HC1 consumer shut down or the compressors shut down, up to 60 TPD could be sent to the absorber. The PCV 1 s that feed Absorber-Cooler #2 are: 1. The customer line pressure control valve in the dry plant. Under normal circumstances, this valve will have very little flowing through it. If the customer suddenly shuts down, up to 60 TPD could flow through it. This line can be blocked off and the excess HC1 sent to the scrubber. The upstream pressure on this valve is 45 psig. 2. The vent stream from the EC plant. This stream will generally run CQNFIDERTIMi* -75 Subject to ProtectIvm Order Of 14th Judicial Dist- -* about 7 TPD, The stream will have some EC in it and it may be diverted to a scrubber in the EC plant. The upstream pressure on this valve is 50 psig. Compressor suction line. The compressor suction line pressure is maintained by a recirculation valve that recirculates enough HC1 from the compressor discharge to keep the suction pressure constant. Should the suction line over pressure, then a PCV will open to #2 Absorber-Cooler. This valve will be set for 20 psig at first. If the stripper pressure is raised, then this set point will be raised to 38 psig. This valve will pass up to 60 TPD. If both strippers are operating, No.l stripper will shut down at the same time this valve opens. Compressor discharge line. This PCV is really 2 PCV's, one with a small capacity and an orifice and a flow recorder in it. The small valve will open first and then the large valve will open when the small valve is about 50% open. This PCV system will maintain a constant line pressure to the HC1 consumers. Under normal circum stances, only a small flow will be flowing through this valve. The maximum flow through this system will be 60 TPD, as the second stripper will shut down before the valve is wide open. The upstream pressure on this valve will be 125 psig at first. Vents from the acid storage tanks* Displaced air from the acid tanks is fed into the tails tower #2. High inerts in #2 absorber can be caused by the pressure pad system leaking through this system. -76- CONFIDEjrriALt Subject to Protective Order Of 14 th Judicial District Court No. 91-1145 STORAGE TANKS A, Equipment 1. The Strong and Weak Acid Storage Tanks 62A-60-611, 612, 613 and 614 are 12*diameter by 23'1" long tan to tan. The capacity of the tank is 20,000 gallons with no outage. The inside of the tanks are lined with 7,000 volt "Glasteel." The gaskets used on the tanks are Pfaudler type CRT, which are a type of Teflon envelope. The tanks have tantalum plugs and thermowells, so care should be used in using any other metals around the tanks. The tanks have two "Glasteel" dip tubes (12" long). The tanks are designed for 15 psig and 12" Hg absolute at 300 F. Recommended maximum average temperature is 180 F. Carbon rupture discs are set to relieve at 15 psig, B, Operation These tanks should be treated with kid gloves, no thermal shocks, hot material, pounding on, or dropping on. The top inlets have a short standleg so material falls into the tank and mixes with the material in the tank. This will help prevent damage should hot material inadvertently be dumped in the tank. The dip tubes will also prevent wear of the glass on the sides where it runs down. The dip tubes should be pulled regularly and in spected, Do not allow acid to spill on the outside of the tanks, as the acid eats the steel and liberates which breaks the glass to steel bond, causing failure. The tank failures can be repaired with plugs. SL 009027 -77- COHMOCTTI^ orSer puttie* court of ! 3"ll1n-lU5 MO. SCRUBBER SYSTEM A. Equipment 1. The Tails Tower Vent Scrubber (62A-67-27) is a 20" diameter by lO'O" high Haveg 41 vessel. The vessel has 2 spargers, a packing support tray and 6' of IV Xntalox saddles. The packing support and the packing are constructed of ceramic. The design pressure is 10 psig at 200 F. B. Operation The scrubber is designed to condense all steam from the jets. The scrubbing water will be the cooling tower blowdown. The scrubber will take up to 40 GRi through it. If the cooling tower blowdown is not enough to scrub all steam, then some more water may be added by opening up some well water through the other sparger. Under no conditions allow the water in the scrubber to be warmer than 200 F. Non-condensables are vented from the top of the scrubber through a stack above the platform. It is possible to have flammables in this stack at times. SL 009028 ct 78- #o. A. Equipment CONDENSATE SYSTEM 1. Condensate Collection Tank 62A-60-715 - This is a 5' OD by 10* high steel vessel. The tank will hold 1470 gallons with no outage. The design pressure is 3 ost, external and 12 ce.internal. 2. Desuperheater Feed Pump 62A-55-973 - The desuperheater feed pump is a Moyno 6M4 designed to give 7.5 GIM at 200 psig. The speed decreaser gives an output speed of 420 RPM. The motor is 3 HP, 1800 RIM. 3. Desuperheater - The desuperheater, for all steam fed to the EC and HC1 plants is a Rockwell-Republic SA-30 which will cool 75 psig steam from 550 F. to 315 F. B. Operation The desuperheater cools the 75 psig steam to all areas. The steam must be desuperheated to keep from damaging the "Karbate" in the HC1 strippers. The desuperheater works by cooling the steam with atomized condensate. The condensate is pumped from the condensate storage to the desuperheater where it is atomized with 150 psig steam. The condensate storage tank is equipped with an overflow 9%' above the bottom (1400 gallons). The vapors are vented above the process platform. The overflow goes to the sewer. SL 009029 COHPIOEHTIAI** Subject to protedcistivtreicOtt rdCeor*urt of ,,th -79- DRYER SYSTEM A. Equipment 1. Dryer 62A-73-61 - H SO Dryer #1 is a 36" OD by 16%' tan to tan steel vessel with a^'s" shirt. The dryer is packed with 6' of 1%" Intalox saddles. The saddles are supported on a porcelain gas injection plate. The liquid is distributed with a procelain distributor and all entrained liquid is knocked out with a 6" Teflon demister. The design pressure is 38 psi and full vacuum at 300 F. The relief valve and rupture disc are set for 38 psig. 2. H S04 Pumps #1 and 2, 62A-55-865, 62A-55-866 - The H SO circulation pumps are Goulds type 3196 1 x 2-6 constructed of GA-20. The shaft has a GA-20 sleeve. The seal is a John Crane type 20, The pump is to pump 25 GFM at 25' of head. The motor is 1% HP, 1800 RIM, B. Operation This dryer is surrounded by a shield because it operates under pressure No one is to enter the area without thoroughly checking for leaks, and then he is to walk slowly. If a leak is detected, the area is to be blocked off and full safety equipment put on before entering. The sight glass is tubular and is protected with a shield. Before the S.G. shield is removed, full safety equipment will be put on. The HC1 from the entrainment separators flows through a steel line into the bottom of the dyrer. The gas then flows up through the packing, through the demister, and out the top into a steel line that goes to the com pressor suction. The bottom 4' of the dryer is used as an acid reservoir. The acid is pumped from the bottom of the dryer, through an acid heater and into the dryer below the demister. The bottom of the acid dryer is steam traced and there is a heater on the recirculation line (double pipe heat ex changer) which has hot water running to it to keep the acid from freezing. The acid temperature should be kept between 70 F. and 95F. Below 70 F. the acid will freeze and above 95 F. the acid is extremely corrosive to steel. The acid is changed whenever its strength gets below 90%. SL 009030 -80- Confidential* Subject to Protective Older Of 14th Judicial. District Court No. $1-1145 Hot water for the heater is made by bleeding steam into well water. Adding steam directly to the heat exchanger causes a "hot spot" and therefore rapid deterioration of the steel exchanger. SL 009031 -81- CONFIDENTIAL* Subject to Protective' Order of 14th Judicial District Court Ho. 91-1145 COMPRESSOR SYSTEM A. Equipment 1. HCl Compressors 1, 2, 3 - 62A-56-148, 149, 150. The HC1 compressors are Ingersoll-Rand, 12 x 13 ES-l-NL-2 HCl compressors. The com pressor at 300 RIM will compress 51 TPD HCl from 14 psig to 125 psig. The motor is 150 HP, 900 RIM. The HP required is 127. The SRV's are 1% F2 with an RD under it; both are set for 180 psig. 2. HCl Compressor #4 - 62A-56-176. HCl compressor #4 is a Worthington 8x7 HBB HCl compressor. The compressor at 450 RIM will compress 22 TPD of HCl from 14 psig to 45 psig. The motor required for this is 25 HP, 1800 RIM. The required HP is 22.4. The SRV is a 1% F2set at 90 psig. 3. Aftercoolers - 62A-71-814, 815, 816, 883. Aftercoolers 1, 2 and 3 are Brown Fintube Model 53-l#000420 with 543 ft. . Aftercooler #4 is a Brown Fintube 53-l#000-807.5 containing 98 ft. 4. Low Pressure Surge Tank - 62A-60-616. The Low Pressure Surge Drum is a 24" ID x 24' long steel tank. The design pressure is 150 psig and full vacuum at 300 F. 5. High Pressure Surge Tank - 62A-60-617. The High Pressure Surge Tank is a 24" ID x 24' long steel tank. The design pressure is 300 psig and full vacuum at 400 F. 6. Surge Tank for #4 Compressor - 62A-60-686. The high pressure surge drum for #4 compressor is 42" OD x 5*8" tan to tan. The tank is designed for full vacuum to 100 psi at 250 F. This drum is sized to fit into the discharge pit and give some surge time to #4 com pressor discharge PCV. 7. N2 Compressor - 62A-56-139. The N,, compressor is a Worthington HBB size 3 3/4 x 5, single stage, to compress 20 CFM from 114.7 psia to 239.7 psia. The RIM is 445, and the horsepower required is 11 .3 The compressor is equipped with automatic unloading valves set at 225 psig. 8. n Receiver 62A-60-608 - The N receiver is a 30" ID x 5'0" tan to tan steel tank. The tank is designed for 300 psi at 150 F. The impulse for the unloaders is on the surge drum. The SRV is ID 2 set at 300 psig. Operations The HCl from the dryer flows through a steel line to the low pressure surge tank, which serves as a suction header for compressors 1, 2 and 3. pressure in the suction system is held at 14.5 psig by recirculating gas from the compressor discharge to the suction header. From the suction header the HCl flows to the operating compressors and is discharged at 125 psig SL 009032 -82- CONflTDttJTm* Subject to Protective Order Of 14th Judicial District Court Ho. and 288 F. The gas then flows into the high pressure surge tank. From the H.P. surge tank, the gas is fed to 3 aftercoolers (Nos. 1, 2 and 3) operating in parallel, where the gas is cooled to 110 F. After the aftercoolers, the HC1 is either recirculated back to the suction, or sent to Absorber-Cooler #2 through a PCV that holds the discharge pressure constant, or it is sent to an HC1 consumer. As has been previously explained, it is possible that the HC1 strippers may be run at 25 psig instead of 14.5 psig. To prevent the compressors from overloading, clearance rings will be necessary. These rings have been in stalled on the compressors and will be left on until the capacity is needed. At the higher suction pressure, the frames on the compressors are at the maximum design. The compressor cylinder is designed to go up to 160 psig, and this will be the discharge pressure of the compressors. The maximum working pressure on the distance piece is to be 170 psig. To prevent any overload on the compressors and still allow the compressors to operate,the relief valves are set for 180 psig. Since this is so close to the operating pressure, the relief valves would leak through, so they are isolated with rupture discs. Care should be exercised in starting up the compressors as the relief valve and rupture discs are set for a differential pressure 180-25= 155 PSIG. so it is possible to exceed the rupture point when starting up the compressors. To further complicate the compressor situation, #3 compressor is piped to run in the dry HC1 system as well as in the wet HC1 system. When running in the dry system, the capacity of the compressor is 24.5 TPD without clear ance rings and 20.2 with the rings. To switch from one system to another will require seme valve manipulation. CONFIDENTIAL* 8ubj ct to Protective Order SL -83- f 14th Judicial District Court No. *1-1145 The compressors are designed with two distance pieces to prevent HC1 from getting into the drive end. The first distance piece (one nearest the cylinder) will be pressurized to 10 psi above the discharge pressure with ^ Since the plant pressure is not high enough, a booster compressor 009G3A is used. This compressor will boost the N pressure to 225 psig. The com2 pressor automatically loads and unloads to maintain this pressure. The N 2 compressor discharges the N_ to the N surge tank and from the surge tank -2 the N2 is reduced to 170 psig and fed to each compressor through a roto- CP ' meter. The rotometer will give some idea of the condition of the packing on the shaft. The higher pressure will leak into the cylinder instead of HC1 leaking out. Attached to the first distance piece is a line that goes to Absorber-Cooler #2. An attempt will be made to run the compressors with no on the distance piece and any leakage back through the packing will be sent to the absorber. This system will work until enough leakage causes the distance piece to have a pressure, then the system must be used. The second distance piece has air on it. This air is continuously swept through the piece so any leakage from the first distance piece is purged out. The air should sweep out the top and bottom of the distance piece and enough air added to maintain 3 psig while sweeping out both nozzles. Located in the suction line to each compressor is a strainer. This is a steel sieve that will prevent any large objects from entering the com pressor. When this strainer becomes gunked with corrosion products, the capacity of that compressor is seriously affected. On the discharge of each compressor is a SS expansion joint. This joint should be inspected for cracks periodically. The relief valve relieves from the discharge to the suction so the compressor will overheat if much HC1 leaks through the SRV. The maximum discharge temperature o is 340 F,, so when this temperature is approached, the compressor should be taken out of service. These compressors are equipped with Ni-resist liners, carbon rings, carbon packing and a carbon wear plate. CONFIDENTIAL* Subject to Protective Ordef -84- of l*th Judicial District Court Number 4 compressor is a compressor to pump HC1 to the MC reactor. The HC1 that is removed from the system by this compressor is replaced by HC1 from the TCE reactor. The suction line for #4 compressor is in the line upstream of the low pressure surge tank and the TCE reactor return is into the surge tank. No. 4 compressor is built exactly like the large compressors except it has Teflon packing, and graphite' impregnated Teflon rings and wear plate. The discharge of the compressor goes through a high pressure surge drum, #4 aftercooler, and to the MC reactor. The line pressure is maintained by bleeding the excess HC1 through a PCV back into the suction line to compressors 1, 2 and 3. To maintain a constant pressure on the consumer HC1 line, there is a PCV system which will bleed any excess HC1 back to #2 Absorber-Cooler. In this system there are two valves, one much larger than the other. The small valve will open first. In the line to the small valve is an orifice and this flow is recorded on the control board. The stripper system should always be running at a slightly higher rate than the consumers are taking. The excess HC1 will flow back into the system through this orifice and valve. When all plants are lined out, this flow should be minimal. When consumer rates are going to increase, the stripper system should be increased until the flow through the orifice is greater than the anticipated increase. This system should be lined out before the consumers are allowed to increase rates. When the consumer cuts back on rates, the HC1 operator will know how much to cut the strippers back. The compressor cylinders and heads have cooling water flowing through them. The water is well water and the maximum outlet temperature of this o water is 120 F. The discharge flows into a funnel so a quick check may be made to ascertain that the water is flowing. SL 009035 -85- CO"Fr^iU Order CUCt When shutting down a compressor, block off the suction, open the discharge to suction bypass, close the discharge, and then cut off the power. After the compressor is stopped, open the N2 into the suction line, open the purge line in the discharge line and purge a small stream of through the c ompressor. NEVER START A COMPRESSOR WITH A CLOSED DISCHARGE LINE. To start a compressor,line up the distance piece purges, open the discharge to suction bypass, cut off any N^ and block the purge line, open the discharge and start the compressor. After the compressor is running,throttle back the bypass until the suction pressure is 25 psig (suction header pressure), open the suction line and at the same time close off the bypass. The suction pressure should remain constant. NEVER AT ANY TIME DURING START-PP OR SHUTDOWN OF A COMPRESSOR ALLOW THE DIFFERENTIAL PRESSURE BETWEEN THE SUCTION AND THE DISCHARGE TO EXCEED 150 PSI. SL 009036 -66- Carrier > OPERATING INSTRUCTIONS-- DESIGN DATA Tons Rating Compressor Full Load I-LH.P. 112 Compressor Full Load Spaed (RPM) 8130 Cooler Refrigerant Temp* (F) Refrigerant Condensing Temp,(^FJ -9.h......................... 101 Brine: Brine: Brine: Brine: Brine :Jrine Type Ca Clo Specific Heat (Mixture) Specific Gravity (Mixture) Freezing Point F (Mixture) Flow (GPM) Inlet Temp. (^F) 1 ( 25% bvwt. ) 0.67li 1.25U -20 225 6.ri 3rine Outlet Temp. (F) brine Fouling Factor 0 brine Pressure Drop (Ft.) Refrig. Cond. Water Flow (GPM) 26.2 --j Refrig. Cond. Water Inlet Temp/"('op1) 90 'O oc Kerrig, cond. water Outlet Temp. (F)' Rerrig. cond. water Fouling Factor v- .001 Refrig, Cond. Water Press. Drop (ft.) Turbine Maximum H.P. ' 27.5 - Turbine Full Load Speed - Turbine Ent. Steam Condition (psilg) - Turbine Lvg. steam Condition (in Hg. Vac.) - Turbine Full Load Steam Rate (tf/Kp/Hr) - Steam Cond, Water Flow (GPM) - Steam Cond. Water Inlet Temp. (F) - steam Cond. Water Outlet Temp, (op) - Steam Cond. Water Fouling Faotor - steam cond. water Press, Drop (ft.) - Stoam Cond. Ent. Steam Condition (in rig. Vac.) - Motor - Type Squirrel" cage induction .... Motor - Power Characteristics Motor - Speed (RPM)____________" UdO-5-dO. --------l?7g Sjc>V 1 * 17 P 30 Plr\ oo(ed>:Vi CCoonnccli e'osev- - UtfS1- 6 ;! V . '/7/?-2 \i V SL 009037 87" CONFIDENTIAL: I Subject to Protective Order of 14th Judicial District Court. No. 91-1145 REFRIGERATION UNIT The refrigeration machine is fully described in the Carrier manual. This manual will be located in the foreman's office in the files. It will be under 62A-71-795. The only descriptions left out of the manual concern the modes of control, auxiliary oil pump and the block valve in the economizer line. The compressor suction damper is automatically controlled by the outlet temperature of the brine. The hot gas bypass is manually controlled. The bypass is opened enough to prevent the compressor from hunting. In the line between the economizer and the second stage is a block valve. This valve is to be used whenever the Freon is hot and the compressor is being started up. By closing this valve. Freon from the chiller is prevented from backing through the economizer section and into the turbine. After the compressor is up to speed, and the suction damper partially open, the block valve may be slowly opened. The valve is opened slow enough to prevent over loading the compressor (watch ammeter) or prevent any liquid from entering the turbine. The auxiliary oil pump is to aid in keeping the bearings lubricated during start-ups and shutdowns, to aid in case of an oil pump failure, and to provide a means to remove Freon from the oil when the unit is down. The oil system for the compressor is external. The oil pump discharges out of the compressor through a check valve, a water cooled cooler, through a filter and back into the compressor and the compressor oil system. The auxiliary pump pulls oil from the oil basin in the compressor, through the pump, through a check valve, and into the discharge line of the internal pump. The auxiliary pump, when set on automatic, will come on when the system oil pressure is less than 10 psig, and will kick off when the pressure is 21 psig. The auxiliary SL 009038 CONFIDENTIAL* Subject to Protective Order 88 Of 14th Judicial District Court; No. 91-114* pump should be started before the compressor is started, and stopped after the compressor has stopped turning. If the oil becomes saturated with Freon, put hot water into the oil cooler and circulate oil through it with the o auxiliary pump. The oil should be heated to about 110 F. Hot water is made by injecting steam into the well water before the water enters the cooler. The oil system inside the compressor has a relief valve set at 20 psig. The external oil pump has a relief valve that is set at 20 psig. SL 009039 CONFIDENTIAL* -89 OPERATING INSTRUCTIONS The Carrier Centrifugal Refrigeration Machine is a compact assembly of seven major elements. A list of these elements and their function follows: -7/-7?3 1. COOLER QR EVAPORATOR - which cools the "brine"* passing through the tubes, by the evaporation of the refrigerant in which the tubes are immersed. 2. COMPRESSOR.- whicffirompresses the evaporated refrigerant and discharges it to the condenser. 7/-Vll 3. CONDENSER - which liquefies the refrigerant coming to it from the compressor. 4. ECONOMIZER - which partially cools the condensed refrigerant before passing it on to the evaporator. The cooling of the refrigerant liquid is effected by its partial evaporation. The vapor thus formed is passed to the second stage of the compressor. tA-7/-7?C , Afcfev- IL&S" , 6. PURGE RECOVERY UNIT - which extracts a mixture of air (or other non-condensable gas) and refrigerant from the condenser, condenses and returns recovered refrigerant to the cooler while the air is discharged to the atmosphere. 6. DRIVEsupp^fes the power to drive the compressor. It may be an electric motor driving through speed increasing gears, or a turbine directly connected. 7. CONTROLS - for protection of the various elements of the machine. When specified, additional automatic controls for regulation, are furnished. *N0TE: The term "brine" is used throughout these instructions as applying to the Sub stance cooled, whether it be water, a salt brine, or other fluid. MACHINE DESIGNATION Machine assemblies are designated according to the size of compressor, evaporator, and condenser. For example: 'j 17M43 -7-6 denotes - - - - - 17 - Centrifugal Refrigeration unit M - Two stage (P is 3-stage) 43 - Compressor size 7 - Evaporator size 6 - Condenser size Besides the size designations, each machine is given a serial number which appears on the machine control panel. In referring to machines in correspondence with Carrier Corporation, always give the size, serial number and the name of the owner. REPAIR PARTS In ordering parts or in,correspondence regarding any part of the machine use the designations, figure numbers, etc., assigned in these Instructions - give number and date of page referred to - give serial number of machine, which can be found on name plate on instrument panel. O'i Puwyo - SS-&S7 Oil Coo let' - 626 - 7h 776 0'-/ MoW- 6/m CONFIDENTIAL! Subject to Protective Order Of 14th Judicial District Court No. 91-1145 SECT. JAGE D ATE I7Z-S 4 1-2-46 k~Cio- ISO litho in U.S.A. -90- SUPERSEDES PAGE 4 DATE 12-1-44 SL 009040 Carrier OPERATING INSTRUCTIONS REFRIGERATION CYCLE The Centrifugal Refrigeration System employs the same general type of compression refrigeration cycle used universally. Its unique features are: 1. A Centrifugal Compressor of two or more stages. 2. A low pressure refrigerant, Carrene Ho. s; known otherwise by the trade name. "Freon-11", and the chemical name, trichloromonofluoromethane, Other refrig erants may be used when desirable. 3. An Economizer in the liquid return from Condenser to Evaporator. The use of this pieceeof equipment materially reduces the horsepower required per ton of refrigeration because it increases the efficiency of the refrigeration cycle. It is made possible by the use of a turbo-coinpress or having more than one stage of compression. Condenser M*oe connection DIAGRAMMATIC DRAWING OF CARRIER CENTRIFUGAL REFRIGERATING MACHINE The refrigerunt cycle starting at the evaporator of the machine is as follows: Here the "brine" flowing through the tubes is warmer than the refrigerant in the shell surrounding the tubes. Consequently, heat is transferred from brine to refrig erant. This heat evaporates the refrigerant at a temperature corresponding to the pressure in the evaporator (see pressure-temperature relation chart). The refrigerant evaporated is drawn into the suction of the compressor. The suction gas is partially compressed by the first stage impeller and joins the stream of gas coming from the economizer before entering the second stage impeller. Compression of the mixture of suction and economizer streams is completed by the following stages and the compressed gas is discharged into the condenser. Note that the economizer gas is compressed through only a portion of the total pressure difference between evaporator and condenser. If the economizer were not used, this gas would all be generated in the evaporator and would have to be pumped from the evaporator pressure to the condenser pressure. The pumping of a portion of the flash gas back to the condenser from the intermediate economizer pressure increases the cycle efficiency and saves horsepower * Re/g. U.S. Pat. Off. ____ ____ r * CONFIDENTIAL! Subject to Protect iv OrrTfer SUPERSEDES PAGE 5 DATE 1-2-46 of Hth Judicial District ConiferI.. II7Z-S 91 No. 9X-1H5 PAGE S DATE 3-MS I7M OPERATING INSTRUCTIONS The refrigerant discharged by the compressor condenses on the outside of the condens tubes at a temperature corresponding to the condenser pressure (see pressure-temper ature chart)* This temperature is higher than that of the water in the tubes so the ' >at of condensation is transferred to the condenser water. Th liquefied refrigerant drains from the condenser tubes down through an inside con duit into the condenser float chamber, which is built on the side, at the end of the )oler. The rising refrigerant level in this chamber opens the float valve and allows ie liquid to pass into the economizer chamber, which is built into the end of the cooler* The pressure in the economizer chamber is approximately half way between th ''ondensing and evaporating pressures; consequently, enough of the warm liquid evapor- * tes to cool the remainder to the lower temperature corresponding to the lower pres sure in the economizer chamber. This evaporation takes place by rapid "flashing"into gas as the liquid passes through the float valve and the conduit leading into the econo- Lzer chamber. The evaporated portion passes through eliminators to the compressor, to >ln gas coming from the cooler which has been oompressed by the first stage Impeller. The mixture enters the seoond stage Impeller. The cooled liquid then flows into the economizer float chamber located below the conjnser float chamber. The rising level in the economizer float chamber opens the float valve and allows this liquid to "flash" again into the bottom of the cooler , As the )oler pressure is lower than the economizer pressure, some of the liquid is evaporat d > cool the remainder to the cooler temperature, and this gas passes up through theliquid to the compressor suction. The remaining liquid serves as make-up for the re^^gerant continually being evaporated by the "brine". This completes the cycle. :,:) SECT. PAGE DATE I7Z-5 6 1-2-44 SL 009042 Subject to Protective -Ordei? of 14th Judicial District Court No. 91-1145 92- PRINTED IN U. S. A. SUPERSEDES PAGE & DATE 12-144 Carrier' OPERATING INSTRUCTIONS 1/M REFRIGERANT Hcfrigernnt 11 (Trichloromonoriuoromethnnc, LClqK) is ti colorless liquid nl normal uttnosplif rir pressures mid temperuturcs. It is very volatile and boils at 74.8 I''. It may be handled in open containers with little loss by evaporation. The liquid is about 1.5 times ns heavy as water and weighs about 12-1/2 lb per gal. A mixture of water and liquid refrigerant will separate completely, the water floating above the heavier refrig erant. The liquid will dissolve oils and greases in all proportions. It dries the skin by removing the natural oils. It also dissolves rubber and will, therefore, destroy packing materials containing rubber. The vapor is heavy - about 4.8 times as heavy as air. Being heavy, it will drop to the floor of a room and s' ale in low places. For this reason, openings in the top of chambers containing refrigerant vapor will cause little loss. The odor of the vapor is sweet. Large concentrations in air are not harmful, but will cause dizziness and eventually headache. The vapor will not support combustion and is classed as non-inflammable and non toxic. The refrigerant is shipped in drums of 200 lb net. The quantities for! charging machines depend on the cooler size and may be determined by reference to Part 2 of these instructions. PRESSURE-TEMPERATURE RELATION r o o CD O (*> SUPERSEDES PAGE 7 DATE 3-1-48 -93- No. 91-1145 SECT. 17Z-5 PAGE 7 DATE 6-24-59 17^1 OPERATING INSTRUCTIONS ('Carrier,) SECT. J7Z-5 PAGE 8 DATE 6-24-59 SL 009044 properties of saturated f-h liquid and vapor Tmv, Fvi--w VtteaN *r. Abe. fr./VA* Qftf< /te UomM K,`/Tb. VlHf 11, VIA. i P Pa *1 -20 -18 -16 -14 -12 --10ft -0 -4 -2 0 42 St 6 8 10 12 14 15 18 20 22 24 26 28 90 i2 36 38 40 42 4404 48 50 52 64 56 5ft 60 62 64 66 68 70 72 74 76 78 1.420 1.510 1.805 1.705 1.810 1.920 2.035 2.156 2.283 2.416 2.555 2.700 2.852 2.931 3.0.3 3:179 3.362 3.534 3.724 3.923 4.129 4.342 4.567 4801 6.043 6.294 5.557 5.830 6 115. 6 411 6.718 7.032 7.362 T.702 8.055 8.422 8.804 9 199 9.605 10.02 10.45 10.90 11 37 11.85 12.35 12,87 13.40 13.95 14.51 15.09 15.69 27.03* 0.01002 24.06 26.86* .01004 22.72 26.65* .01005 21.47 26.45* .01007 20.30 26.24* .01008 19.20 26.01* 25.78* 25.63* 25.27* 25.00* 0.01010 .01011 .01013 .01016 .01016 18.17 17.21 16.32 15.47 14.68 24.72* 24.42* 24.11* 23.95* 23.79*23.46' 0.01018 .01019 .01021 .010Z2 .01022 .01024 13.94 13.24 12.68 12.27 11.96 11.38 23.10* 22.73* 22.34* 21.94* 21.52* 0.01026 .01027 .01029 .01031 .01032 10.83 10.31 9.823 9.359 8.925 21.08* 20.62* 20.15* 19.66* 19.14* 0.01034 .01036 .01037 ,01039 .01041 8.619 8.129 7.760 7.414 7.087 18.61* 1B.05* 17.47* 16.87* 16.26* 0.01042 .01044 .01046 .01048 .01049 6-776 6.481 6.200 5.934 5.682 16.61* 14.94* 14.24* 13.52* 12.78* 0.01051 .01053 ,01055 .01056 .01058 6 447 6.220 5.006 4.802 4.607 12.00* 11.20* 10.37* 9.53* 8.66* 0.01060 .01062 .01064 .01066 .01067 4 421 4 245 4.078 3.921 3.770 7.73* 6.78* 5.80* 4.78* 3.72* 0 (11069 .01071 .01073 .01076 .01077 3.626 3.487 3.356 3.229 3.107 2.64* 0.01079 1.53* .01081 0.39* .01083 0.39 .01085 0.99 .01086 2,99ft 2.883 2.779 2.679 2.584 80 16.31 82 16.94 84 17.60 86f 18.28 88 18.97 1.61 0.O1088 2.492 2.24 .01090 2.406 2.90 .01092 2.322 3.5ft .01094 2.242 4.27 .01096 2.165 90 19.69 92 20.43 94 21.19 96 21.97 Oft 22.71 4.99 0.01098 2.091 6.73 .01101 2.020 6.49 .01103 1.952 7.27 ,01105 1.887 8.07 .01107 1.825 100 23.60 102 24.45 104 25.33 106 26.23 106 27.16 8.90 9.75 10.63 11.53 12.45 0.01109 .01111 .01113 .01116 .01117 1.765 1.707 1.662 1.599 1.548 110 28.09 112 29.05 U4 30.04 116 31.07 118 32.11 13.39 14.35 15.34 16.37 17.41 0.01119 .01122 .01124 .01126 .01128 1.499 1.452 1.407 1,363 1.321 WO 33.20 18.50 0.01130 1.281 * tndn* f ew*f MW OTt b>ailiiw* f gundird <M IMWI0W. DtrMltV |JML foMfMInm --40* tnlrnpv from --<0` TfP Liquid lb/ft* l/, Vtpof lb /h" 1/-, Uquld tu /lb lAUnt bill /lb. VApor SlU./lb Uil4 Vtpvr *t /ib *r. tu /tb *r N h hA , *r. 1 99.77 0.04157 99.63 .04401 99.48 .04658 99.33 .04927 99.18 .05209 99.03 0.05503 9R.87 .05810 98.72 .06129 98.57 .00464 98-42 .06613 96.27 98.11 97.96 97.86 97.81 97.65 0.07176 .07554 .07949 .08152 .08361 .08790 97.80 0.09233 97.34 .09697 97.19 .1018 97.03 .1068 96.88 .1120 96.72 0.1174 96.57 .1230 96.41 .1289 96.25 .1349 96.10 .1411 95.94 95.78 95.62 95.46 96.30 0.1476 .1543 .1613 .1685 .1760 95.14 0.1836 94,98 .1916 94.82 .1998 94.66 . .2083 94.60 .2170 94.34 94.18 94.02 93.85 93.69 0.2262 .2356 .2452 .2550 ;265Z 93.53 93.36 93.20 93.04 92.87 0.2758 .286R .2980 ,3097 .3219 92.71 92.54 92.38 92.21 92.04 0.3342 .3469 .3598 .3732 .3870 91-88 0.4012 91.71 ,4157 91.54 .4307 91.38 .4461 91.21 .4610 91.04 90.87 90.70 90.53 90.36 0-4783 .4950 .5122 .5299 .5480 90.18 90.02 89.85 89.68 89.51 0.5666 .5857 .6054 .6256 .6461 89.34 0.6671 89.16 .6885 88.99 .7107 88.82 .7335 88.66 .7670 88.47 0.7808 3.94 85.93 89.87 0.0091 4.33 85.78 90.11 4.73 85.62 90.35 5.12 85.47 90.59 5.62 85.31 90.83 .0100 .0109 .0118 .0127 6.91 6.31 6.70 85.16 85.00 84.85 91.07 91.31 91.55 0.0136 .0145 .0153 7.10 84.69 91.79 7.49 84.54 92.03 .0162 .0171 7,89 8,28 8.68 6.88 84.38 84.23 84.07 84.00 92.27 92.51 92.75 92.88 0.0179 ,Q1BB .0197 .0201 9.08 83.92 93.00 .020 5 9.48 83.76 93.24 .0213 9.88 10.28 10.68 11.07 11.47 83.60 83.45 83.29 83.14 82.98 93.48 93.72 93.97 94.21 94.45 0.0222 .0231 .0239 .0248 .0266 11.87 12.27 12.68 13.08 13.48 82.82 82.66 82.50 82.34 82.18 94,69 94.94 95.18 95.42 95.66 0.0264 .0273 .0281 .0289 .0297 13.88 14.28 14.68 15.08 16.49 82.03 81.87 81.71 81.65 81.38 95.9) 96.15 96 39 96.63 96.87 0.0306 .0314 .0322 .0330 .0338 15.89 16.30 16.70 17,11 17.52 81.22 81.06 80.90 80.73 80.57 97.11 97,36 97.60 97.84 98.08 0.0346 .0354 .0362 .0370 ,0378 17.92 18.33 18.74 19.15 19.66 80.40 80.24 80.07 79.90 79.73 98.32 98 56 98.8) 99.05 99.29 0.0386 .0394 .0402 .0410 .0418 13.96 20.37 20.78 21.19 21.61 79.57 79.40 79.23 79.06 78.8* 99 53 99.77 100.01 100.25 100.49 0.0426 .0434 .0442 .0450 .0457 22.02 22.'43 22.84 23.26 23.68 78.71 100.73 78 54 100.97 78,37 10121 78.19 101.45 78.01 101.69 0.0465 .0473 .0481 .0489 .0496 24,09 24,51 24.93 25.34 26.76 77.84 101-93 77.66 102.17 77.48 102.41 77.31 102.65 77.13 102.89 O.05O4 .0512 .0519 ,0527 .0535 26.18 26.60 27.01 27.43 27.86 76.95 103.12 76.76 103.36 76,58 103.59 76.40 103.83 76.21 104.07 0.0542 .0550 .0557 .0565 ,0572 28.27 28.70 29.12 29.54 29.97 76.03 104.30 75.84 104.54 76.65 104.77 75.46 105.00 76.27 105.24 0.0680 ,0687 .0695 .0602 .0610 30.40 30.82 31.24 31.67 32.10 76.08 105.47 74.89 105.71 74.70 105.9<( 74.50 106.17 74.30 106-40 0.0617 .0625 .0632 .0639 .0647 32.53 74.10 106.63 0.0664 0.2046 .2D43 .2040 .2036 .2033 -20 -18 -16 -14 -12 0.ZO30 2b27 .2024 .2021 .2018 -10 -8 -6 -4 -2 0.2015 .2013 ,2010 .2009 .2008 .2005 0 2 4 5t 6 8 0 2003 .2000 .1995 .1906 .1993 10 12 It 16 18 0.1991 .19B9 .1987 .1985 .1983 20 22 24 26 28 0.1981 .1979 .1977 .1976 .1974 30 32 34 86 38 0.1972 .1970 .1969 .1967 .1966 40 42 44 46 48 0.1964 .1963 .1961 .1960 .1959 60 62 64 56 68 0.1958 .1956 .1955 .1954 .1953 60 62 64 66 68 0.1951 .1950 .1949 .1948 .1947 70 72 74 76 78 0*1047 .1946 .1045 .1944 .1043 80 82 84 86f 88 0.1942 .1941 ,1941 1940 .1939 90 92 94 96 98 0.1938 .1938 .1937 .1937 .1936 0.1936 .1935 .1936 .1934 .1933 0.1933 102 104 106 106 no 112 114 118 118 iso w O so Tw3 O o -u *> * > w Nm E o "ZU T W Ort W) Qw E. A* -rH> S 0. L> a * 00) T-14J -a. 3 CO <W 0 -94- Litho in U.S.A. SUPERSEDES PAGE 8 DATE 1-2-46 (aarner OPERATING INSTRUCTIONS m fri 17P COMPRESSORS 17 17P Is three-stage. T*-y {re designed Tor use with Carrene No. 2 as refrigerant. J 11 11 ` | ` -'1 --*--f----------------- - The 17P at normal speed will produce a corresponding temperature of about 95 F. The speed may be selected greater or less than normal, and at maximum 6peed, ^Nd^MMMMtimmnpaiMMMdwpfvrtmMilMibM^and the 17P type approximately 120 F.f below the condensation temperature. Other refrigerants when desirable, can be used -- these possibly requiring some changes In design from standard. The Compressor Casing and the various stationary passages are of cast iron. The Shaft.is a forging, turned and ground with keyways provided for each impeller. The Impellers are of the built-up type. The hub disc and cover are machined steel forgings. The blading is sheet steel formed to curve backward with respect to the di rection of rotation. The assembly is riveted and lead coated. Each impeller is bal anced after fabrication and the completed rotor is also balanced dynamically. , The Rotor assembly consisting of shaft and impellers runs in two sleeve type bearings. Thermometers are Inserted in the top half of each bearing for indicating their tem perature. Brass Labyrinth packing in the Diaphragms prevents interstage leakage of gas. Similar packing of the shaft at the ends of the casing restricts the flow or gas between the main compressor casing and the Bearing Chambers. In operation the pressure differential across each Impeller produces an axial thrust toward the suction end of the compressor. This thrust is supported by a Kingsbury Thrust' Bearing at the suction end of the shaft. The compressor has a complete lubrication system, including OH Pump, Bearing Oil Rings. Pressure Regulating Yalve, etc. Detailed description of the oil system may*be found under the heading of *Compressor Oil System". COMPRESSOR SHAFT SEAL Description A shaft seal is provided where the shaft extends through the compressor casing. The seal is formed between a ring, called the Rotating Sealing Seat which is vacuum fitted against a shoulder on the shaft -- and the Stationary Sealing Seat attached to the Seal Rousing through a flexible member or Bellows assembly. The faces on these seal seats are carefully formed to make a vacuum-tight joint when in contact on shut down. In order that these faces will s,eal properly when the compressor Is shut down, the Seal Spring between the stationary sealing seat and the Seal Bousing Cover moves the stationary seal seat into contact with the rotating seal seat. Between the hub of the stationary sealing seat and the hub of the rotating sealing seat is locat ed a floating ring. A Seal Oil Reservoir with filter chamber Is attached to the com pressor housing above the seal. The reservoir provides oil to keep the seal faces flooded during shut down periods. An orifice between filter chamber and reservoir re stricts oil flow to the reservoir during starting, if the reservoir has partially drained during shut down. By this means, full oil supply is assured for the seal im mediately on starting. Operation The operation of the seal mechanism is as follows: When the compressor starts up, oil is pumped through external piping and internal passages in the compressor, as out lined in section on "Compressor Oil System", through the filter and to the Interior of the bellow assembly. The oil pressure expands the bellows, moving the stationary sealing seat against the pressure of the spring, back to a stop on the seal housing cover, leaving a space between the faces of this seat and the rotating seal seat on the shaft. The oil in the bellows passes through drilled passages to an oil groove cut eccentrically in the face of the stationary sealing seat. From this groove the oil, filling the space between the seal faces, passes in two directions! a. Across the outer section of the face of the stationary sealing seat and into the space between the shaft and the bellows assembly. Oil flow from this space is prevented by a floating ring called the Inner Floating Ring. b. Across the inner section of the face of the sealing seat and through the clear ance between the rotating sealing seat hub and stationary sealing seat. This flow is restricted by the close clearance.of the floating ring between.these two ...... stnRNTI&t*! SUPERSEDES PAGE 9 DATE 12-1-44 SL 009045 -95- rts as well as by the Outer Floating Ring betwe n s al housing cov r and rotat- RC seal hub. The oil In the space between the shaft and the bellows, as described In paragraph a" above, passes through an opening to the shaft bearing providing a fresh oil sup ply to this bearing. The oil pressure in this space actuates the oil pressure regulatJng valve In the oil pump discharge, acting through a passage In the seal housing and capillary tube connection from this point to the Pressure Regulating Valve- Since pressure Is not developed In this annular space between the bellows and the shaft un til after the seal has opened, the pressure regulating valve remains closed on tarting and the full capacity of the oil pump Is assured for Initial oil supply. Th .ressure in this space also controls the action of the Lou Oil Pressure Cutout. See "Safety Controls". The oil passing between the hubs of the seal seats, as described in paragraph "b" ibove, goes to the Atmospheric Float Chamber- For completion of these circuits "a" and "b" refer to "Compressor Oil System". Dipping operation the oil passing between the seal faces, s-eals the shaft against nward leakage of air. and avoids the necessity of a metal to metal contact of the seal.* 1 2 3 4 5 Item No. 1. Shaft 2. 3. Shaft Labyrinth impeller Lock Nut -eit8hneortioenndend 4. Impeller Lock Nut - discharge end(L.H. T.) 6. Impeller - first stage 6. Impeller - second stage 7. Impeller Spacer 5. Inlet Guide Vane - first stage Item No. 0. inlet Guide Vane - eecond stave In* Intake Wall 11. Discharge Wall 12. Diaphragm - first stage 13. inlet Labyrinth - first stage 14. Inlet Labyrinth - second stave 16. Spacer labyrinth SECT. PAGE date I7Z-S 10 3>i .as -96Litho in U.S.A. SUPERSEDES PAGE t0 DATE 1-2.44 (Carrier) OPERATING INSTRUCTIONS toaewModEND Item No. SEAL END BEARING SEAL 1. Bearing Inspection Cover 2, Bearing inspection Cover Gasket 3. Bearing Liner (Upper and Lower) 4, Lower Shaft Bearing Retainer 6. Upper Shaft Bearing Retainer g. Bearing Cap 7. Oil Kings (2) 8. Thermometer Clamp 8, Thermometer Well ATMOSPHERIC FLOAT VALVE 10. Float Valve Assembly 11. Float Bali 12. Valve Bogy 20< Seal Housing 21. Seal Housing Gasket 22. Bearing Felt Ring 23. Seal Housing Cover 24. Seal Housing Cover Gasket 25. Bellows Assembly 26. Bellows Gaskete(2) 27. Rotating Seal Seat 28. Stationary Seal Seat Assembly 20. Inner Floating Seal Ring 30. Outer Floating Seal Ring 31. Inner Floating Seal Ring Retainer (L.H. T.) 32. outer Floating Seal Ring Retainer 33. shaft End labyrinth 13. Valve Sett 34. Beal Spring 14. Valve Stem 1G. Valve Arm 16. Oil Stop Valve Assembly 17. OH Stop Valve Bellows (Not shown) 18. Oil Stop Valve Seat (Not shown) CONFIDENTIAL* SUPERSEDES PAGE 11 DATE 1-2-44 ^Subject to Protect!v ordqr or 14th Judicial District Court. No. 91-1145 -0 7. ' SECT. PAGE DATE I7Z-5 II 1*1*41 OPERATING INSTRUCTIONS \ --(D PUMP SHAFT ASSEMBLY CONFIDENTIAL! thrust cnb Auction ihc) Item No. OIL PUMP DRIVE 1. Shaft 2. Bracket 3. Worm 4. Worm Gear Wheel 5. Bushing 6. Shaft Lock Nuts(L.H.T.) 7. Worm Gear Lock Nut THRUST END BEARING 10. Bearing Inspection Cover 11. Bearing Inspection Cover Gasket 12. Bearing Liner (Upper and Lor) 13. Lower Shaft Bearing Retainer 14. Upper Shaft Bearing Retainer 15. Bearing Cap 16. oil Hinge (2) 17. Thermometer Well 18. Thermometer Clamp SECT. PAGE DATE I7Z-5 12 3-1-48 Item No. OIL PUMP CHAMBER 20. Chamber Cover 21. Chamber Cover Gasket 22. oil Cooler Assembly 23. Oil Pump Assembly 24. Oil Belief Valve 2&. Oil Discharge Pipe 26. Oil Heater THRUST BEARING 30* Thrust End Cover 31. Thrust Disc 32. Kingsbury Thrust Bearing. 33. Thrust Bearing Housing 34. Oil Strainer Assembly 36. OH Strainer Cap 36. Pump Drive Oil Nozzle 37. Worm Look Nut 38. Worm Spacer 30. Thrust Bearing Shoes(2) 40> Thrust Bearing Housing Floating Ring "98- Lithe In U.1.A SUPERSEDES PAGE 12 DATE I- 2-46 OPERATING INSTRUCTIONS l/ftfl i In general, this system consists of an Oil Pump of the gear type, driven from the main compressor shaft, and supplying oil through various connections and passages for the Thrust Bearing, the two Shaft Bearings, the oil pump Worm Gear Drive and for the Shaft Seal; -- with the necessary gauges and control valves to permit the system to operate automatically. The oil pressure or feed circuits are as follows: When the compressor starts, the pump 1 starts to circulate oil -- which is applied first entirely to the thrust bearing 3. From the thrust, the oil divides into two circuits -- A. Through Strainer 29 and the proper orifices to the pump drive gear 2, and the rear shaft bearing 4. B. Through Check Valve 5 and Filter 7 to the shaft seal and front shaft bearing 9. In reference to circuit A, since the thrust, rear Journal bearing and worm drive are all located above the Oil Pump Chamber> th return flow of oil from these parts simply drops back t SUPERSEDES PAGE 13 DATE 6-2-47 ,j wnr i uhNTlnL! rTtitbject to Protective Orde of 14th Judicial District Co ? _-9o9o_- **<> 91-1145 SECT. PAGE DATE I7Z-5 13 3-1-46 17 M / OPERATING INSTRUCTIONS In reference to circuit B supplying oil to the front bearing and for the operation 3f the shaft seal, since part of the oil passes to the atmosphere, various valves are required in the supply as well as in the return to the pump chamber. In this circuit when pump pressure, on starting, has reached approximately 8 pounds, the /alve No. 5 -- which is set to open at this pressure on its inlet -- allows oil to pass from manifold 18 through filter 7 and to seal 8. (If the seal oil reservoir 6 is not full, a small part of the oil passes through orifice 28 to fill the reser voir) , The oil pressure then passes through the seal bellows, expands the bellows, moving the stationary seal back against its stop and allowing the oil to pass through the seal in two directions - (l) Inside the compressor and (II) to the atmosphere, as explained in detail under the paragraph on "Shaft Seal". The oil passing to the vacuum side of the seal (refer to I above) flows to the front bearing 9, through an opening in the inner floating seal ring 12 which is located in the seal housing, to prevent unnecessary flow of oil from the vacuum side of seal. The searing overflow drops to the bottom of the Bearing Chamber 10 draining back to the. Oil PumP Chamber through the proper passage in manifold 18, In reference to II above, the oil passing to atmosphere is restricted by floating rings between stationary seal and rotating seal hubsand between housing cover and ro tating seal hub. Most of it passes directly to the Atmospheric Float Chamber 13. Th rater Jacketed seal housing cover 11, cools this oil and minimizes the refrigerant Loss from it. A small amount passes these rings and is returned to the atmosphere float chamber 13 through connection 30. Prom the float chamber the oil goes through the Automatic Oil Stop Valve 16, up to bearing chamber 10, - where It returns through e Manifold, to the oil pump chamber, with the oil overflow from the front bearing. t1 returns from the atmospheric float chamber since the pressure in the bearing cham ber is always below atmospheric, -- this pressure being equalized with the compressor iuction through the rear Shaft Labyrinth, -and therefore always is a vaccuum during operation. rrom the Bearing Chamber, the oil flows by gravity through the manifold 18, to the oil pump chamber. Automatic stop valve 16 is provided to prevent flow of refrigerant vapor from the machine in case the pressure inside the machine during shutdown, rises above itmospheric. The valve is set to open at approximately eight pounds, and is actuated Dy an oil pressure line taken from the oil pump discharge and, therefore, opens Im mediately after the compressor Is started. Valve 16 also prevents outside air from entering into the machine when the machine pressure Is below atmospheric. This valve is necessary because the atmospheric float valve 14 is designed for level control only, and is not a stop valve. Valv 17 is the Oil Pressure Regulator. It is actuated by pressure "back of seal" through line 15 and con trols oil pressure by returning excess oil back to the oil pump chamber. 0506 Oil Pressure Gauges 22 and 23 on control panel, Indicate the seal reservoir pressui and the pressure "back of seal", respectively. When the reservoir is full, 22 Indi cates the pressure on the seal bellows. Gauge 23 indicates the pressure in the space Detween the seal and inner floating ring, or "back of seal" pressure, which controls valve 17. Air Vent and Vacuum Breaker 27 admits atmospheric pressure during shut down, to th seal oil reservoir to maintain a head of Perft^e8 as a gravity liECT. PAGE SATE I7Z-5 14 1-2-46 Subject to Protective Order of I4th Judicial District Court N . 91-1145 -100- PRINTED IN U. S. A, SUPERSEDES PAGE 14 DATE 12-1-44 ) OPERATING INSTRUCTIONS 5 ii The Oil Healer 31 fecats the oil during shut-down to prevent excessive absorption of refrigerant by the oil. A flow switch (not by Carrier) may be located in the water supply to the oil cooler manifold. This auto matically turns on the heater when the water supply is shut off by hand, and cuts the heater off when the water is turned on. The Oil CoolerW$ cools the oil as it is returned to the pump chamber during operation. Bearing Thermometers 24 and 25 indicate the temperature of the shaft bearings. Oil Rings 20 and 21 bring additional oil from the bearing wells to the shaft. Relief Valve 26 in the oil pump discharge line, relieves any unusually high pressure that may occur accidentally, and thus protects the system against any damage. SL 00905J SUPERSEDES PAGE IS DATE 1-3-46 -101- SECT. 17Z-3 PAGE IS DATE 6-24-59 1721/3 OPERATING INSTRUCTIONS (Carrier) Item No. 1. Water Box with Nozzles'" 2. Water Box Cover - nozzle end 3. Water Box - plain end 4. Casket (Water Box to Tube Sheet) .5. Gasket (Water Box to Cover) - nozzle end 6 Gasket (Water Box to Tube Sheet ) - plain end 7. Inspection Cover - either end 8. Gasket - Inspection Cover 9. Condenser and Economizer Liquor Float Valve Assemblies 10. Ruptww Vrivc f-( "NOTE: For three-pass construction, there is a water box with nozzle on each end. SECT. 172-5 PAGE 16 DATE 6-24-59 litho in U.S.A. -102- SUPERSEDES PAGE 16 DATE 1-2-46 Carrier OPERATING INSTRUCTIONS 17Q COOLER The 17Q Coolers are shell and tube flooded type. See cuts showing construction de tails. The standard construction includes Lo-Fin copper Tubes rolled into cupro-nickel Tube Sheets. Other metals are furnished if required by particular"brine"conditions. The tubes are provided with belled ends so that the advantage of a removable tube is obtained. They are rolled into the tube sheets and expanded into two internal Support Sheets . The normal refrigerant charge covers only about 50% of the tube bundle. During op eration, however, the ebullition or violent boiling of the refrigerant completely covers the bundle. Above the tube bundle are Eliminators to prevent the carry-over of liquid refriger ant particles into the compressor suction. Inspection Covers are provided in the ends of the cooler to permit access to the eliminators. Set' cxTt* }5p-i - lbA v*9trPve wl eh 15 i" wars ting '-daum is also provided on cooler. The cooler Hater Boxes are designed for a maximum working pressure of 200 lb. Sq. In, and are tested in excess of this pressure. They are provided with the neces sary Division Plates to give the required flow. The Hater Box Covers may be removed without disturbing any refrigerant joint since the tube sheets are welded into the cooler end flanges. Vent and Drain openings are provided in the water circdit. A Refrigerant Thermometer is provided to indicate the temperature within the cooler riurine operation, A Refrigerant Sight Glass is provided for observing the charging and operating re frigerant level. A Charging Valve with connection will be found on the side of the cooler for the addition and removal of refrigerant. The connection is carried to the bottom of the cooler so that complete drainage or refrigeration is possible. A Refrigerant Drain to atmosphere is also provided near the charging connection. EXPANSION THERMOMETER CHAMBER A small chamber is welded to the cooler shell, at a point opposite the economizer and above the tube bundle. An opening in the shell permits free passage from the cham ber to the cooler. A continuous supply of liquid from the condenser float chamber is brought to the expansion chamber while the machine Is running. This expands in the chamber which is at cooler pressure and, therefore, maintains a small body of liquid and gas passing to the cooler through the above mentioned opening. The bulb of the refrigerant thermometer and the refrigerant safety thermostat bulb are Inserted in this expansion chamber. SL 009053 CONFIDE***^ Subject of 14th Order ct courts SUPERSEDES PAGE 17 DATE 12-1-44 -103- SECT. PAGE DATE I7Z-S 17 1-2-46 OPERATING INSTRUCTIONS artier ECONOMIZER A complete description of the function of the economizer is given under the heading of "Refrigerant Cycle". It is located in the cooler shell at the end opposite the compressor suction connection. It is above the tube bundle and entirely separate from the cooler gas space. The economizer is a chamber with the necessary passages and float valves, connected by an internal conduit passing longitudinally through the cooler gas space to the compressor second stage inlet. This connection maintains a pressure in the chamber intermediate between the cooler and condenser pressures and carries away the vapor generated in the chamber. Before entering the conduit, the economizer vapor passes through an eliminator which extracts any free liquid and drains it back into the chamber. On the front of the economizer Will be found a chamber for two float valves. In the top is the Condenser Float Valve which keeps the condenser drained of refrigerant and admits the refrigerant from the condenser into the economizer chamber , In the bottom is the Economizer Float Valve which returns the refrigerant to the cooler. FROM CONDENSER \ secl page DATE 17Z-S ig 1-2-46 ECONOMIZER -104 PRINTED IN U.S. A. Bub!?* lk JattC. of DUtrict SUPERSEDES PAGE 18 DATE 12-1-44 (Carrier) OPERATING INSTRUCTIONS 17M 17R CONDENSER The 17R Condensers are shell and tube type using the same tubing as the 17Q Coolers, The standard tube bundle employs copper tubes rolled into steel Tube Sheets. Other metals arc furnished if required to meet water conditions. The ends of the tubes are belled where they are rolled into the sheets and the advantage of a removable tube is thus obtained. The tubes are supported by two intermediate support sheets. An important function of the condenser is to collect and concentrate non-condensable gases so that they may be removed by the purge recovery system. The top portion of the condenser is baffled for this reason. This Baffle encloses a portion of the first water pass. The non-condensables rise to this location because of their lower density and because it is the coolest portion of the condenser. A perforated baffle is installed along the tube bundle to prevent direct impact of the compressor discharge on the tubes - and to distribute the gas longitudinally through the condenser. The condensed refrigerant leaves the condenser through a bottom connection at one end and flows into the condenser float chamber in the cooler shell below. The Water Boxes of most condensers are designed for a maximum working pressure of 200 lb. per sq iD and are hydrostatically tested in excess of this pressure. They are provided with the necessary Division Plates to give the required flow. Water Box Covers may be removed without disturbing any refrigerant joint since the tube sheets are welded into the condenser end flanges. Vent and Drain openings are provided in the water circuit. The condenser is connected to the compressor and the cooler shell with expansion joints to allow for differences in expansion between them. SL 009055 Item No. 1. Water 2. Water 3. Water Dox with Nozzles* Box Cover - nozzle end Box - plain end Item No. 4. Gasket (Water Box to TubeSheet) 5. Gasket (Water Box to Cover) - nozzle end 6. Gasket (Water Box to TubeSheet) *plain end *NOTE: For three pass construction, there is a water box with nozzle on eachend. SUPERSEDES PAGE 19 DATE 1-2-46 -105- SEC1. 17Z-5 PAGE 19 DATE 6-24-59 <a % L,V0 i'' AO&' Carrier) OPERATING INSTRUCTIONS VIM TYPE "L" PURGE RECOVERY SYSTEM The presence of even a small amount of water in a refrigeration system is to be avoided at all times; otherwise excessive corrosion of various parts of the system may occur. Any appreciable amount of water is due to a leak in one of the water circuits. The pressure within a portion of the centrifugal refrigeration system is less than atmospheric; therefore the possibility exists that air may enter the system. Since air contains water vapor, a small amount of (O water will enter whenever air enters. The function of the purge system is to indicate air and water leaks into the refrigeration system, and to recover refrigerant which is mixed with these gases. The air is automatically purged to the atmosphere, the refrigerant automatically returned to the cooler as a liquid, and the water, if present, trapped in a compartment from which it can be drained manually. Thus the purge and recovery system maintains the highest possible refrigerating efficiency. Information regarding the Purge Recovery System is given below, with respect to the diagram and the items as numbered thereon: 9. Sight Glass for the oil level in the compressor and auxiliary oil reservoir, located in the front of the casing. 1. Stop Valve on main condenser. Open except during repairs. 10. Oil Separator removes oil from the compressor discharge gas. 2. Pressure Reducing Valve in suction line to regulate the compressor suction pressure. See page 37 for explanation of duty and suggested setting point. 11. Condenser cooled by air from a fan on tne compressor motor. It liquifies most of the re frigerant and water vapor contained in the mixture delivered by the compressor. 3. Stop Valve in suction line, located in end of the casing and marked "From Condenser." This valve is to be open when the purge unit is in operation, and closed at all other times. 4. Suction Pressure Gauge on front of casing. * ft -O* JCe*S o*4 -U O >w , < ' < H (It * a -3 * +> 4 M 0 ** -4 #fhi Chm ign & U 8**? S'* .A "*> 3 -H W Compressor to be operated continuously when the centrifugal compressor is operating, and before starting the machine, as required by the presence of air. Discharge Pressure Gauge on front of casing. High Pressure Cut-out Switch connected to compressor discharge. Adjusted to stop the compressor if the condenser pressure increases to about 110 lb because of some abnormal con dition. The switch closes again automatically on reduction of pressure to about 75 lb. Auxiliary Oil Reservoir This reservoir serves as a chamber to relieve the refrigerant from the compressor crankcase to the suction line with out loss of oil, and to contain extra oil for the compressor. SUPERSEDES PAGE 21 DATE 7-15-54 -107- 12. Evacuator Chamber for separation of air, re frigerant and water. Flanged compartments provide ready access for inspection or repairs. 13. Inlet Opening from purge condenser. 14. Trap - Refrigerant, being heavier than water, falls to the bottom of the trap and forms a seal. As more liquid enters, the level is built up, causing water to flow over the Water Weir (15) and refrigerant to flow over the Refrigermt Weir (16). 17. Settling Compartment A quiet area where the water and refrigerant separate. 18. Float Valve designed to open when the liquid level rises, allowing the gas pressure to force the liquid refrigerant into the economizer. 19. Loop Seal prevents liquid refrigerant from collecting in the water compartment. 20. Sight Glass on lower liquid compartment, visi ble at the end of the casing, shows refrigerant level in the separator. SECT. 17Z-S PAGE 21 DATE t-15-59 ft i OPERATING INSTRUCTIONS arner 21. Sight Glass on upper compartment indicates the presence of water. 22. Stop Valve at end of casing permits water to be drained from the upper compartment. The valve is marked "Water Drain" and is closed except when draining water. 23. Automatic Relief Valve to purge air to the atmosphere. See page 37 for suggested setting. 24. Stop Valve marked "Refrigerant Return", in the return liquid refrigerant line, located at the end of the casing. Open only when purge is operating. 25. Stop Valve on economizer in the return refrig erant connection. Open at all times except when machine is shut down for a long period, or is being tested. 26. Plug in oil filling connection of reservoir. Pressure in the system must be balanced with the atmospheric pressure to add oil through this fitting. 220V -5-#0-- 27. Cap for draining oil from the compressor crank case and oil reservoir. Oil may also be added through this connection if (a) a packless re frigerant valve is installed in place of cap at this connection, and (b) the purge compressor is operated on a vacuum. 28. Connections between auxiliary reservoir and compressor crankcase. 29. Motor and Belt not shown. 30. Wiring Diagram inside the casing. 31. Casing completely encloses the purge recovery unit and is removable to provide access to the equipment. See Sect. 17Z-5, pages 40 - 41, "Leak Testing" for the use of the following parts: 32. Plugged Tee 33. Capped Tee 34. Temporary Connector Pipe IIOV-ir-0 Mr 9 6 u PURGE RECOVERY UNIT NOTES: 1. Starter wiring diagrams shown are suggestions only. Check starter manufacturer's wiring diagrams for details. .2 220 volts is the maximum voltage recommended In the purge unit control circuit. If a higher voltage motor is used, a transformer reducing from the line voltage to 110 volts for the control circuit is rec ommended. to ** > tM U -*t AU E 4ut -m*4 +' to a at t 3. 220 volt, 3 phase motcrs are the standard for the purge compressor. 4. 110 and 220 volts, single phase; 208, 220, 440 and 550 volt, 3 phase motcrs are available for, the purge units. Specify voltcxje and current characteristics in purchase order to factory. W IC S* -4 o o **r 0 +>0 * 9 at n $ JC is 9 10 c TYPE "L" PURGE UNIT WIRING DIAGRAM sect. 17Z-5 PAGE 22 DATE 1-15*59 Litiis in U.S.A. -108- SUPERSEDES PAGE 22 DATE 7-15-54 (Carrier) OPERATING INSTRUCTIONS .|/iwl 009059 SUPERSEDES PAGE 23 DATE 7-15-54 PURGE SEPARATION CHAMBER -109- SECT. 17Z-5 PAGE 23 DATE 1-15*59 Brine Storage Tank - 62A-60-618- The brine storage tank is a 5' OD tank by 6*0*' high. The total capacity of the tank is 880 gallons. The tank is designed for atmospheric storage. The tank is designed to hold the contents of the brine system, so the tank should be nearly empty the majority of the time. The tank cannot float against the line as it will overflow. The brine strength should be maintained to give a freezing point of around -40 F. The caustic strength should be from 0.2 to 0.3 and chromate strength 0.4 to 0.5 as Na C^O . Brine Circulation Pumps - 62A-55-867 and 868 - The brine circulation pumps are Gould's 3196 size 2 x 3-6. The pump end is ductile iron. The impeller is 5 5/16" which will pump 225 G1M at 100' head. The shaft has a S3 sleeve. The motor is 15 HP, 3500 RW. The seals are John Crane, type 9, internally mounted. -110- OPERATING INSTRUCTIONS arner OPERATING CONTROL -- MANUAL There are listed below three methods for controlling the capacity output of a machln . 2, Throttling the suction of the compressor. 3. Increasing the discharge pressure of the compressor. The three methods above are given In order of their efficiency. At partial loads the power requirements will be least if the compressor speed is reduced - not quite as low if the suction is throttled - and highest if the condenser water is thfottled. to increase the discharge pressure. SpeedJ^K%rol 1) mayie^ffecte^l^itjvariojp^tfays dypengJWTg Ai thfi^ntf^y of driv^'on iAch>rfes fr lvejjrxliy tum>lpwS, speedjrfy be adjustpd'oy meanSof theVmai'rtfal spWed control in t^^Mlrbine governor system. furnished alteTM Separdu specific type used. nous e of a operating Suction Damper Control (No. 2) is obtained by means of a throttling damper built Into the cooler suction flange. By throttling the compressor suction, the pressure differential through which the compressor must handle the refrigerant vapor, is in creased. The centrifugal compressor has a very flat characteristic, l.e., the pres sure differential against which it will deliver, is definitely limited by the speed at which it is running. Consequently, increasing the differential will result in a de crease in the amount of refrigerant pumped. Therefore, throttling of the suction of 4J the compressor is a very effective method o.f capacity control. Suction damper control requires somewhat more power at partial loads. This is som times over-balanced by its effectiveness in maintaining stable (non-surging) opera tion to lower loads than the variable speed control. For this reason, some machines are equipped with dampers even though the main control has variable speed. 3 $o "C u O 44 Q,,> *o4 *2 ->< 4*J4 irt < Wf^ O *W --y Condenser Vater Control (No. 3) is very seldom used. When machines are arranged to z Q *j* use city water or other costly water for condensing purposes, it has advantages. a 7! ^ Again the flat compressor characteristic explained under Suction Damper Control ha above, makes the condenser water throttling control possible. By throttling the con- 2 o* o denser water, the condenser pressure is increased. This increases the pressure differential on the compressor and reduces the capacity. Occasionally the lowest speed available by means of the variable speed control *urnished, may be insufficiently low to meet the operating conditions. In such a ase the condens r water may be throttled and the c mpressor speed requirement' rj-013 * 4J <-3 O 0) JB -r*> X) W to brought up into the range of the speed control. SECT. PAGE DATE I7Z-5 26 1-2-46 SL 009061 -lii- NTED IN U. S, A. SUPERSEDES PAGE 26 DATE 12.1-44 OPERATING INSTRUCTIONS Automatic Suction Damper Control - Synchronous or Squirrel Cage Motor DIRECT ACTING TEMPERATURE CONTROLLER o___X DAMPER MOTOR WITH POSITIVE POSITIONER. DEVICE SUCTION DAMPER IN COOLER SUCTION FLANGE NORMALLY CLOSEO WITH AIR OFF THERMAL BULB IN BRINE LEAVING COOLER For automatic damper control, a temperature controller regulates the degree of damper throttling hy supplying to or bleeding air from a pneumatic damper motor. Automatic Cond< tor Drive SL 009062 For automatic Conden laphragm valve In the con denser watSr dlsohar^T Is automatically positioned In resporita to changes of the deliv ered brine temperatfOre. This Is done by means of a Reverse Acting temperature con troller which supplies air to or bleeds alf from the valve dlapn^gm. A similar con trol may also when water Is scaroe or expensive er for conservation tC0NF*DENTIAL: SUPERSEDES PAGE 29 DATE I2.M4 1l4th4Jut^hcxl>arlotDecistitvricOt rCdeorurt -1X2- NO` 91-n<* SECT. PAGE DATE 177-5 29 1-2-46 /'Tv ,`20'. OPERATING INSTRUCTIONS BY-PASS - HOT GAS TYPE One of the characteristics of a centrifugal compress * is the * fact that the compressor will "surge" if the suction volume is reduced helow a certain limit. Surging* will occur when the evaporator does not carry a large enough load to evaporate a sufficient amount of refrigerant. Surging of a centrifugal compressor is perfectly natural. Occasional surging will .not damage a centrifugal compressor, however, continued surging will heat up the compressor and may ultimately cause high hearing temperatures. The operating efficiency of the compressor during periods of surge is extremely low and the effective temperature lift that can he achieved is reduced. 7or this reason a hot gas hy-pass when desirable is installed between the condenser and the evaporator to keep the compressor out of the surge region. See note at end of this section. The hy-pass should only he operated when necessary, that is,' when the compressor would otherwise begin to surge* As soon as the load has Increased beyond the surge point, the hy-pass should he closed. W r o O t> O 0 GO Since the gas leaving the condenser is hot, continual by-passing of this gas /tight cause the compressor to overheat. 7or this reason, an automatic liquid injection device is connected to the hy-pass and th temperature of the gas is reduced by flashing liquid refrigerant into the gas stream. Each auto*.j.qula injection system com^'lses a pair of flanges (one of which Is special) in the hot gas Hr. a liquid line gm . from the condenser to the special flange, and a liqu line strainer with two shut-off valves. A) 0 ; Go o As the hy-pass valve is opened, a pressure drop will exist O t) -*GO* <: * 5 G across the orifice which is a function of the rate of gab flow through **# 4J the orifice. In other words, the higher the flow of hot1 gas throu^i the H< O Gm HY hy-pass and orifice, the lower the pressure helow the orifice will be come in relation to condenser pressure, and the greater will he the avail able pressure drop to force desuperheating liquid through the 1-quld line. -0) a * K *0* -4 *H Hfl fmt H "e ' Thus, as the amount of hot by-pass gas is increased or decreased with A2, O -hU DI* . operation requirements, by opening or dosing valve, the amount of de superheating liquid forced through the liquid line Is correspondingly VP * r3> X:: I and automatically increased or decreased. The two shut-off valves (G) in the liquid line (E) are normally to he left wide open and will he closed only to service or clean the dirt 1.-i J45J I ! JO w* : 3*11 strainer (K). It should he noted that *;ie special flange (D), through which the liquid enters the hot gas stream. Just helow the orifice (Plate 7), is Installed at a slightly higher level than the surface of the liquid lying in the bottom of the condenser. Thus, when no hot gas Is flowing through the hy-pass, there will he no liquid flow. The special flange 1b used merely to provide a means of distribut ing the liquid into the hot gas stream, below the orifice, as evenly and as finely as possible. The flange is made with a groove in one face, for the circumferential distribution of liquid. The liquid then enters the gas stream through a 1/8" wide slot, formed between the undercut inner face of the flange and the orifice plate, ( NOTE:. In some cases it is possible for greater efficiency to use a;partial# hy-pass. the condenser gas going to a compressor stage other: than the suction, by means of the connection from an econ miser, r 5-15-53 -113- HP-lJf purchased REGULATOR, BACK PRCSSlRE, REVERSE ACT I KG POSIT IO.VCk * CIIANDC.0 PCX o*i s/as/iii ADDED jiUPEhDEQE!,; no. SEE NOTE 2 A*D I or 1 TO date KfG'D BY: MFR'S TYPE: BLACK, SIVALLS A BRYSON INC. 70-11-2-R STYLE: TYPE: NORMAL OPEN AIR PRESSURE: MAX. STATIC PRESS. ON BODY: MAX. INLET PRESS.: SERVICE: MATERIAL: DOUBLE .PORTED NORMALLY CLOSED DIAPHRAGM SPRING LOADED CONTROL VALVE VALVE TO CLOSE ON AIR FAILURE. TOP i COTTOM GUIDED THROTTLE PLUG. VALVE TO CLOSE AT 9t, FULLY OPEN AT 3# ON D,. ` -AGM a. 175 PSI AT IOO*F. '' 125 PS 1 AT MAX. TEMP, Of 360*P. X. REFRIGERANT It, 12, 1)3 80DY -- 125 PSI FLANGED CAST IRON, STAINLESS STEEL TRIM STEM - STAINLESS STEEL PACKING - TEFLON DIAPHRAGM - BUNA "N" WITH NYLON FABRIC INSERT X.X 'V 'V NOTES: I. VENOOR TO ATTACH OPERATING INSTRUCTIONS ON EACH UNIT. 2. SUPERSEDES EF67MP48) TO EF67MP791 DATED 3/24/61 ISSUEO FOR PURCHASING ONLY. 3. . FLANGES TO BE IN ACCORDANCE WITH ASA B16.I. PART NO. SIZE EF67MP40I 2 EF67MP60I EF67MP7I \ 4 EF67MP79I 6 n N-S. IONS A _L__ C_1___D_ r .G 4,a* 2.1 4 to 20f 4 Hr4 2`? 'Gj n'l *4; 6 4 i6j 21!' isl 9 9 44 *4 *4 "f HI II 4 6 7? i. ..I 5 6 3 4 15 1 \> 0o s4 2*23 MRCftINCftY 1)1(0 fQ9 IMUfc* VA4.VS CARRIER CO*r, MUST Ot NOT/PfCO BCfORC ANY CHANCE 19 MADC PROM THC CONSTRUCTION OCflKCO BY APPROVCO SAMPLt* OR OVOS* usco on: 17 SERIES -f-jr 1*^ aYiftV^blcC^ all U*C AND PUBLICATION RIOHTB tRCSCRVACO - PROPERTY Of CARR ICR CORPORATION,'CYRACUBt, N.V* . *' . . ' ' -114- ' CMQINCCRIKD STaKOARDS \ k '-VA.LV:" Hoy <=,*: rr-lirQuio*:::^ SL 009065 oooooooooooooooooooo th:s is the personal property or carrier corporation ALUUSE IS rCt.CISOEK EXCEPT ON ITS WRITTEN CONSENT , oo et l4t m**;*.. if* C-OnWD^otVe-O^AcT CW**! VlHi, CH'3_ A?'D_ _Jl_cc;-i.' RATE?i'r-OV'IJi7' SCALE RZV'D TITLE _ . -.- Au-yoMAfiC'.. ... Wot a.s . JESSf/p./ .. ... . (Cr>.?Fler) no. : *115- OPERATING INSTRUCTIONS earner GENERAL INSTRUCTIONS PART rt - OPERATION STARTING 1. Check oil levels, etc. for compressor, motor, gear, turbine, couplings, etc. 2. Start condenser water through condenser, being careful to avoid water hammer. 3. Start "brine" circulation through cooler, being careful to avoid water hammer. 4. Be sure air pressure is available for any air operated controls. 5. If a great deal of air is in the machine, run purge unit to remove it. This will practically never be necessary unless a vacuum of more than 10 Inches has been broken by admitting air. In any case, start the purge recovery unit before starting the machine. To start purge recovery unit, open valves 3 and 21 (see description of purge recovery unit and also diagram) and turn start ing switch on front of casing, to "On" position. The unit should be operated continuously while the main machine is running. 6, On synchronous motor driven machines, close suction damper only as far as. necessary to start and then onen damper as soon as compressor reaches full speed. C o u rt Ho-. >1-1145 14th J u d ic ia l R* t ONjtet tor F r *eS cttivr iec Ot rder COHflDEHTIM** .z 3tV*v/TT au*rfr*vvi oi _. . puw\va 8 On rmaottooir driven mad* ines, close holding circuit for safety controls by hold- lng button on motor panei"* standi 9. Bring machine up to speed, observing seal oil gauges to make sure oil pres sure is developed. If oil pressure does not develop within 10 seconds, stop machine and re-start. 10. On automatically controlled machines, opening of the air supply to the control ler causes the machine to come under the supervision of the automatic control. See Part 1, under the heading of "Operating Controls" and "Safety Controls". 11. Open cooling water valve supplying compressor oil cooler, gear or turbine oil cooler and seal Jacket. The water to compressor oil cooler should be kept low until t^e highest bearing temperature reaches 130. Then adjust to give 140 to 180 bearing temperature. Keep under observation, the temperatures of ell bearings on compressor, gear, motor or turbine until they have level ed off at a satisfactory point. Immediately after starting, there may be a period of surging until evacuation of air from the condenser has been completed. During this period, the ma chine should be run at high speed. The high speed will produce a high con denser pressure and accelerate the process of purging. However, the con denser pressure should not exceed 15 lb./sq. in. gauge during this period and the input current on the motor driven machines should not be run over 100$ of the full load motor rating (see motor name plate). Do not overcool evaporator or non-freeze control will stop the machine. As soon as the ma chine has steadied and all air has been purged, the speed or damper may be adjusted to give the desired "brine" temperature. If surging persists after all air has been purged and speed has been adjusted to give the desired brine temperature, it is an indication of a light load. Surging operation is perfectly normal for centrifigal compressors and is no cause for alarm. At very low loads, (10$ to 20$ or full load) surging will cause the compressor to overheat and bearing temperatures will go above normal. Continuous operation under such conditions is Inadvisable. If con tinuous operation is desired under these extremely light load conditions a by-pass may be necessary. SECT. PAGE DATE I/ Z-5 32 3-1-48 SL 009066 Litho in U.S.A. -116- SUPERSEDES PAGE 32 DATE 1-2-46 earner OPERATING INbIKUUIUNb ti# IVI ROUTINE OPERATION To Increase oil pressure, loosen the locknut on the regulator and turn the adjusting screw clockwise (tighten it). To reduce oil pressure, loosen locknut and turn screw counter-clockwise. Maximum pressure (at high speed) 25 lb. - minimum (at low speed) 8 lb. approx. Adjustment of the amount of cooling water through the uump chamber coil, controls oil temperature. Bearing temperatures as shown on the bearing thermometers, ordin arily should be from 140 to 170, but under some operating conditions may go beyond this range. Oil temperature should not be too low, to prevent excessive absorption, of refrigerant in the oil. The oil filter should be replaced periodically depending on the service, but at least yearly as its main purpose is to protect the seal. The thrust housing strainer should be cleaned yearly. Record the addition and removal of oil on the operating log so that the reasons for any excessive amounts can be investigated. Change oil yearly. All oil valves are set and locked during factory tests on the compressor. Adjustment by the operator of any valves other than the pressure regulator should be made only after proper diagnosis. See that oil is at proper levels in all parts of the oiling system as explained In the various Instructions. At W(y\ih *uW utoitw doum. Do not permit cooling- water to flow through the oil cooler or seal housing cover on shut down. This minimizes refrigerant absorption on the oil. During shut-down, the oil will absorb refrigerant. The colder the oil the greater the absorption. The higher pressure during shut-down the greater the absorption. On start up, the pressure reduction may cause the refrigerant to boil out of the oil with re sultant foaming. Excessive foaming Is a possible cause of oil being carried Into the refrigerant spaces. The electric heater minimizes these conditions. CHECK ALL SAFETY CONThOLS PERIODICALLY, BUT BE CAREFUL NOT TO OVERCOOL THE BMNF CAUSING DAMAGE TO THE TUBES. The three primary duties of the average operator are: 1. To adjust the refrigeration output to the requirements of the load with th use of thfe least power. 2. 'Maintain complete and clear records of the operating conditions Including all tem peratures, pressures, speeds, and control positions - also refrigerant and oil levels and amount of each when charged or withdrawn. 3. Inspect and maintain the equipment and furnish the necessary servicing such as lubrication, painting and simple adjustments. In carrying out No. 1, the operator should know approximately at all times the amount of load being carried by the machine and should through experience have a general idea of the frequency, magnitude and time of load changes which normally occur. In this way he is prepared for many of the load changes and may achieve real economies by ither cooling down slightly before an Increase in load so that the machine does not have to be pushed or by unloading and saving power before the load goes off. To increase the output or reduce the temperature of brine being delivered by variable speed machines, it is only nec ssary to Increase speed. To reduce output or raise tem perature , reduce speed SUPERSEDES PAGE 33 DATE .24A SL 009067 CONFIDENTIAL *0. S/ m OPERATING INbiKUUIUNb Xs&mttr If circumstances arise (low load and cold condenser water) where the control cannot urther reduce speed but still less load or higher brine temperature is required, throttle the condenser water. This will raise the condensing temperature and require higher speed bringing the required speed within the range of the control. The output and delivered brine temperature of constant speed machines with suction damper control is regulated as follows: Open the damper to increase load or lower brine temperature. Close damper to reduce load or raise brine temperature. The damper should always be closed on starting. On machines equipped with variable speed drive and suction damper control, it is often possible, at the expense of a slight Increased power requirement, to stabilize the compressor at low load by partially dosing the damper. At the same time the speed will have to be increased to counteract the pressure drop across the damper and still maintain the same brine conditions and load. je problems of operation naturally Increase when the refrigeration installatlqj consists of more than one unit. To achieve the greatest economy, the output ol^riultiple units\perating together on the same load must be balanced. To obtain a balance with multiple units, It Is first necessary to balarffce the brine and condenser water rates so that the flow through each unit is proportional to Its full load rcNlng. For example, suppose the plant consists of two uprfs; the smaller unit rated at\fiO tons and the larger one at 5oo tons. Suppose tpf total brine flow is 1600 gpm and th^^otal condenser water flow is 2000 gpm. The t^al plant capacity Is 800 tons. DivldlnXthe total brine and water quantities by w obtain: ,,\ 1600 Bri^e rate ~ '~qq" -- 2 Opm per total plant capacity, _ 2000 _ Condenser water rater --8570^07 ~ 2-^/2 Opm per ton ' "N The flows of brine and conde ;er water should^then be: Brine Flows Small Machine gpm= 300 x 2 -- >600 Large Machine gpm= 500 x 2 -- 1 pm Total Condenser Flows Small Machine gpm = 300 x l/2 -- 750 G? Large Machine gpm -- 500 Xj l-\/2 -- 1250 Opm> Tol 2000 Gpm CONFIDENTIAL* Subject to Protective Orde* of 14th Judicial District Cbufct No. 91*1145 If flow meters are ofTt available for making theseVlow adjustments, they may be made by observing the pij^Ssure drops across the coolers anc^sondensers. The gauges used for indicating these pressure drops should be located so theV read only the drop across the cooler or condenser and do not Include any additional piping, valves, or fittings. For pressure d^jps not exceeding 15 lb, per Sq. In., one 36"^Wrcury "0" tube may be connected across the coolers and condensers of one maehlne afteVyanother and the pres sure drops^ecorded. Due uf the complexity of the calculations to obtain the relation be^teen these pres sure drops on multiple machine Installations, It will be necessary for yl>u to obtain thls^pecificdlly for your installation. It is advisable to perform this balancing imtmyft&tely after Installation while the Carrier operator Is available. He wlliNassist su in th proper procedure. SECT. PAGE DATE I7Z-5 34 1-2-46 $L 009068 -118" PRINTED IN U.S. A. SUPERSEDES PAGE 34 DATE 12-1-44 Varner) OPERATING INSTRUCTIONS U iwi When proper balance of flows has been made, the valve positions should be'noted and whenevfct more than one machine is used the water and brine valve positions of the uplts operatingSfeould be so adjusted. The flow through other units should be shut With the brS*e and condenser water flows of multiple machines adjusted i^^fhis manner, it is only neces%*jy to adjust the individual machine speeds or damperjwtJsltions so that the temperature diffce.j^ence (between entering and leaving brine) on y? coolers in opera tion is alike. The temperature differences on condensers may ala^lje used as a guide. The plant is then operatirt^most efficiently since each mach*re is carrying its propor tionate share of the load. Increases in load should be taKbesby adjusting eoc/t^ffiachine to a higher output and reductions in load by adjusting eocAmachine to^^f^lower output. Always attempt to keep temperature differences alike. When load r'afctCes the temperature differences across the coolers and condensers will become les&^tfxpeY^nce will indicate when machines may be shut down and the load transferred^brf^the remalnihgsunits, by increasing the output of each. Automatically contraW#idL machines will, of course, perform^K^the manner outlined above provided eacjK'Sontroller is set for the same brine temperattte<^and the brine and condenser flow^^rfre properly balanced. WultipJ.tf'Tnachine installations of identical units, having identical ratlngs^jeed no balaitfrffig of water and brine flows. All valves of any unit may be opened wide as^nng as it 4s operating. The load should, of course, be divided equally between the units iJ Operation as explained above. SL 09069 SUPERSEDES PAGE 35 DATE 12-1-44 Sub-feet C^NPrlDENTlAL .* f 14tl* J"0icialO^r"r7c^- *o. 91-a 4 5 ivt -119- SECT. PAGE DATE I7Z-5 35 1-2-46 um OPERATING INSTRUCTIONS <L,<trrwr PURGE RECOVERY UNIT AND REFRIGERANT LOSSES The operation of the purge recovery system is automatic, once it is placed in operation by turning switch on side to "ON" position and by opening valves 1, 3, 21 and 22. An increase in head pressure in the condenser, which pressure occurs either suddenly or gradually during operation (all other conditions of load, speed, temperature, etc., remaining uniform), indicates the presence of air. Observation of the difference between outgoing condenser water temperature and the temperature shown on the condenser gauge may also be useful in determining the presence of air, since an increase in this difference under the same circumstances as outlined above may be caused by air. Similarly, an increase in the cooler pressure (or decrease in the vacuum) over the pressure corresponding to the cooler temperature, during operation, may be caused by air. The air should be removed by operation of the purge unit until normal pressures are re-established and the cause of any air ieak found and corrected. The purge must be operated continuously when the main machine is operating. Since some refrigerant leaves the purge recovery relief valve with the air purged, excessive air leakage into the machine will cause excessive refrigerant loss. The normal refrigerant loss for these machines depends on operating conditions. The type of operation, however, is something over which Carrier has no control. Therefore Carrier rannot assume responsibility for refrigerant losses. Keep careful logs of refrigerant charged and the shutdown level in the evaporator. Excessive refrigerant loss ould be noted and the cause corrected. If a machine operating with a pressure (not vacuum) in the condenser is perfectly tight or leaks only slightly during operation, but shows a large gain in air when shut down under vacuum for a few hours, a serious leak exists on the high pressure side of the system. Such a leak will leak outward during operation and will result in a refrigerant loss. It should, of course, be found and corrected. The removal of moisture from the machine is even more important than the removal of air. This is also accomplished by the purge recovery unit. The source of moisture in a machine may be either humidity from the air leaking in or a small water or brine leak in cooler or condenser. If any amount of water is removed by the purge, a leak is indicated. Air leakage, as indicated by high dis charge pressure on the purge or discharging of air through the purge relief valve, can account for small amounts of water, since the air entering the machine will contain some moisture. If no air leakage is indicated, water in .he purge is an indication of a direct water leak. All leaks must be repaired immediately, or serious damage to .he tubes and other internal machine parts will result. The purpose of the purge is to indicate leaks, not to pump air and water through the machine. A continuous water leak is dcngeious, even though the water is continuously removed. Corrosive products entering with the water cannot be evaporated and removed. SL 009070 CONFIDENTIAL? Subject to Protective 0TM* ofJ 1m4-thh JJuuddiicciiaall District Court HO. 91-U45 SECT. 17Z-5 PAGE 36 )ATE 1-15-59 -120PRINTED IN U. S. A. SUPERSEDES PAGE 36 DATE 1*2-46 Carrier OPERATING INSTRUCTIONS 1/ m Pressure reducing valve 2 (See Purge Diagram) must be adjusted to produce a suction pres sure on the purge recovery unit, which will not allow condensation In the suction line be tween valve 2 and the purge recovery unit. If condensation occurs, the condensate will run Into the crankcase of the purge recovery compressor, causing foaming and excessive oil loss. The table below Is a guide for adjusting valve 2. When this valve is wide open, there exists a pressure drop of a few pounds across the valve. Consequently, the suction pressure cannot be adjusted higher than a few pounds below the machine condensing pressure. The adjustment of relief valve 20 In the purge recovery unit must also be related to the room temperature for best refrigerant recovery. Adjustment may be made with a screw driver by removing the top of the purge recovery unit casing. For recommended pressures providing condenser pressure permits, see table below. If large quantities of air, without refrigerant, are. being removed from the machine (such as, after repairs, before recharging), the rate of removal may be increased by discharging the air from the water removal valve 19, Room Air Temperature 65 75 85 95 105 115 Suction Pressure (Maxi mum allowable) By Ad justment of Valve 2 5" Vac. 0-lb. gauge 3.5 lb. gauge 7-Lb. gauge Wide Open Wide Open Relief Pressure - By Adjustment of Valve 20 76-80 75-80 95-100 95-100 105-110 105-110 -- -- - - --- If liquid rises to the upper glass, normal delivery of refrigerant has ceased because valve 21 is closed or because the float valve is not opening. If liquid Is not visible In the lower glass, the float valve is falling to close properly. If any water collects, It will be seen on top of the liquid refrigerant, through this glass and It should be drained. The amount of water entering with air, is small. Ac cordingly, If an appreciable amount collects regularly, a leak In cooler or condenser hr? probably occurred which must be located and corrected. Use the same oil In the purge compressor as is used in the main compressor. To add oil shut down the compressor, close valves 3 and 21, remove plug 24 In top of oil sight glass and add oil. Oil can be drained through plug 25. Check oil level dally. Oil level showing at any point in the glass with compressor running or shut down is satisfactory. Oil level is subject to considerable variation. Check belt tension periodically to prevent slipping. Check relief valve dally for tightness when closed to prevent loss of refrigerant. Keep condenser clear of dust by brushing monthly. High pressure cut-out shuts unit down if condenser pressure reaches 110 lb. for any reason. CAUTION: It automatically remakes contact to start unit on 76 lb. Single phase motors have "ln-built" thermal overload stopping motor on overload. CAUTION: This automatically re-sets Itself to start motor after a few minutes. SL 009071 SUPERSEDES PAGE 37 DATE 12-1-44 -121 COHMDEHTlALl Subject to Protective fljfder Of 14th Judicial District Court Mo. 91-H45 SECT. PAGE DATE I7Z-5 37 1-2-46 Instructions for adjustment Is printed on, or inside, each cut-out device on the pane1. The usual settings, which are subject to considerable variation are as follows: Low oil pressure A cuts out at 6 lb. and in at 12 lb. High condenser pressure B cuts out at 15 lb. and in at 8 lb. Refrigerant temperature cut-out C is set by the erecting engineer after operation according to each Job to cut out slightly below the minimum design temperature with proper regard to freezing point of the "brine" used. It cuts in on a rise of several degrees. The chilled water or "brine" temperature cut-out D is set after operation to cut out slightly below minimum leaving chilled water temperature. It cuts in on a rise of several degrees. The performance of these controls should be observed during oper ation and should be tested at least yearly to insure correct functioning. 0parat I on The only difference in motor and turbine panel functioning is due to the different methods that must be used in shutting down a motor and a turbine. In the case of the motor, it is simply necessary to shut off the power by electrically de-energizing the low voltage release. In the case of the turbine, it is necessary to shut off the steam by mechanically tripping the overspeed mechanism. In each case, low compressor oil pressure, high condenser pressure, low refrigerant temperature and low leaving chilled water or "brine" temperature will shut down the machine. Low oil pressure may damage bearings and seal -- high condenser pressure may cause overloading of compres sor, gear or motor and may result in damage to condenser. Low refrigerant or "brine" temperature may cause bursting of tubes due to .freezing. Therefore, it is necessary to limit operating pressures and temperatures. With the motor driven machine, as far as the safety controls are concerned, on starting the only operation is to hold momentary contact button P, which shorts out the low pressure cut-out since, until the compressor is running, no oil pressure ex ists and contacts A are open. With thr fsrHin il HTT'IT Tim i li I nn dun tn **'" ii" 1 IJ"p "" y,J---- --- ' 1 f"11""1 ' r n tm IjiI.i'Ii mi ai 11---- TM-- n1-..' ' if Tp~mttnn io an ....................... . tv iiinr-iTWiw.1 II r .tbn nn mi UAHs--W-u on huh . SECT. PAGE DATE I7Z.5 38 1.2-46 SL 009072 M | ..mi As, T**| mil njiull ftublect to Protective Order of 14th Judicial District Court Ho. 91-1145 -122- 4TED IN U. 5. A. SUPERSEDES PAGE 38 DATE 12-1-44 Carrier) OPERATING INSTRUCTIONS jr the start button has been push d and the relay assumes the position desc^ above, thm^operator manually sets the turbine overspeed trip mechanism. There Js no mechanical cbqnectlon between the overspeed trip mechanism and the solenoid>^Tunger which operates It* After the trip mechanism has been set by hand the operator is free to manipulate his steam valves, casing drains and any other equlpment^riecessary. When the turbine hAs been satisfactorily warmed up and drained of conden^Tte, the operator may bring the turbine compressor unit up to operating speeds, asydutllned in the standard operating instructions. As soon as compressor oil pressure has developed a circuit Is completed through w^e oil pressurestat into coll Me. 1 through contacts A and B of the mechanically latchelL relay. When this coll lsyenergized, the m chanlc- ally latched relay shifts posltloiNto that shown In Sketch 2. This breaks the oil pressure by-pass and cuts the oil prbesurestat into the^ontrol circuit. The solenoid Is held In the up position by the circuit going througn contacts G and H through the stop button and Into the solenoid coll and then backAo the line. The pilot goes out and the contacts are made-which sets up th^connexions ready for the operation of coil 2 when the start button Is pushed. If any one of the safety devices opens, the'VBlenold plunger is released and the tur bine speed trip Is given a sharp mechanical JftoW which releases the valve and. If it is present opens the vacuum breaker. If the clears itself immediately, the con trol circuit assumes a safe position an^n;he solenoid plunger is re-energized. Howev r, the overspeed trip mechanism must be asset manually^efore further operation is pos sible*. If the pilot light L remains on^ 18 an indication lat the compressor oil pressure has not reached a satisfactory^Operating point. If the start button is pished during the operation of th^^init with all of the safety devices in a safe position^ all that will happen is that the^elay will shift to th starting position and imedlately snap back to the run position. There is sufficient ovr 7lap in the contacl^E* F> G end H so that this should causeV^o difficulty or inter ruption of service. The unit may be^topped during a normal shutdown by just pushing ftme Stop button which momentarily breaks the solenoid circuit causing the plunger to r^ll. Or, the steam throttl^valve may be closed manually or the overspeed trip mechanism released manually. Xegardless of the method used, as soon as the compressor has reached a low enough sjfted so that it is not maintaining satisfactory oil pressure, the safety con trol circuit will function in its normal manner and release the solenoid plunder. This meanXthat the turbine overspeed trip mechanism must be reset at every start-upVof the equipment. SL 009073 SUPERSEDES PAGE 39 DATE 12-1-44 COHFlDENTIAt.. "123 1I SECT, PAGE DATE I7Z-5 39 1-2-46 OPERATING INSTRUCTIONS REFRIGERANT In ordering refrigerant, be sure to specify Carrene No. 2. Other refrigerants are used in different types of Carrier machines. CHARGING REFRIGERANT CAUTION: At temperatures above 74F, the drum will be under pressure. Therefore to prevent loss of refrigerant or personal injury, never open drums to atmosphere when above this temperature. While it is possible, when the refrigerant In the drums is below 60 F., to charge from an open drum without loss, it is recommended that a leakage-tight connection be made from the drum to the charging valve on the side of the cooler. To assist in this procedure, a special type of plug is furnished in the side of each drum. This is a 2" plug in which is inserted a smaller 3/4" plug. Inside the drum, covering his 3/4" opening is a friction cap similar to a bottle cap. This cap prevents leakage nto or out of the drum when the 3/4" plug is unscrewed and removed. TO CHARGE THE MACHINE WITH REFRIGERANT AFTER INSTALLATION, proceed as follows: The machine will be under a high vacuum as required for the test and dehydration. 1. Make up a 3/4" nipple into a standard globe valve and Close the valve. 2. Remove the 3/4" plug described above. 3. Sere- the valve with nipple into the opening, turning it in far enough to push off the Inside cap. Open the valve slightly for indication that the cap is off. 4. Elevate the drum in a horizontal position by means of a chain hoist or proper sup port, near the cooler charging valve and high enough to allow the refrigerant to flow, as a liquid, by gravity from the drum into the cooler charging valve. 6. Rotate the drum so that the valve is at the bottom. 6. Connect the two valves with a piece of copper tubing and the necessary fittings, making all Joints tight. 7. Open both valves and allow the refrigerant to be drawn in by the vacuum of the machine. 8. When drum is empty, as determined by shaking it slightly, close valve on cooler and disconnect the drum. Remove the drum valve for use with the next drum. TO ADD REFRIGERANT to a machine to bring the refrigerant level up to standard, pro ceed as above, or simply allow the refrigerant to be drawn in as a gas from the drum resting on the floor. The refrigerant can be added while the machine is in operation or Idle. See section on Cooler for proper refrigerant levels to be maintained. It is a good plan to keep on hand enough empty drums to hold the entire charge of re frigerant in the event it is desired at any time to remove the refrigerant for repairs or for storage during seasonal shut-downs. REMOVING REFRIGERANT OR TESTING FOR LEAKS To remove refrigerant from the cooler, the following procedure is recommended. Inject air into the machine until a pressure of 0 lb. gauge exists, using the purge recovery system as outlined below. Connect tubing to the charging connection and allow the re frigerant to blow out into drum. In removing refrigerant, less loss will occur if the refrigerant is cold. Always 1 ave space in the drum for expansion to prevent excessive pressure when the drum warms up. SECT. PAGE DATE 17Z*5 40 1-2-46 SL 009074 -124- PRINTED IN U.S. A. SUPERSEDES PAGE 40 PATE 12-1-44 rt rder Cou tO c tiv e s tri No. 91-1145 c i te D o l C O N F ID E N T IA L * Pr c ia i to ud ct J S u b je 14th f o / *r 1 _ --__ . . v OPEKAIINti IN5> I KUU IIUNO i # ivi The purge recovery system can be used to develop an air pressure in the centrifugul machine for the purpose of removing refrigerant or for testing for leaks. See diagram of unit. For this purpose, plugged tees 32 and 33 have been provided together with a separate connector pipe 34. To build up a pressure in the machine with both the centrifugal machine and the purge recovery unit shut down, proceed as follows: Open valve 22 to drain any water that may be in evacuator chamber, and to relieve the pressure in it. Leave valve open. Close valves 3 and 24. Remove plug from 33 admitting air to the centrifugal machine and breaking vacuum. Connect pipe 34 to 33 and to the water drain connection at bottom of cabinet, as shown by dotted line in diagram. Remove plug from 32. Close switch, placing purge recovery unit in operation. Continue operation until required pressure is reached (usually 5 lb. and not more than 8 lb.). If air pressure is developed in the system for the purpose of testing for leaks while the system is charged with refrigerant, the air should always be evacuated through the purge recovery system to conserve refriger ant, as follows: Stop purge recovery unit. Close valves 25 and 22. Remove pipe 34 and replace plugs in 32 and 33Open valves 3, 24 and 25. Start recovery unit and evacuate air. SL 009075 SUPERSEDES PAfC 41 DATE 1-2-44 ; ,. -125- ot so '1' co' SECT. 172-5 PAGE 41 DATE 6-24-59 OPERATING INSTRUCTIONS I/M 9 J .0 6 0 0 COOLER AH0 CONDENSER The only operating duties pertaining to the brine cooler and condenser are: 1. Maintaining the proper refrigerant level In the cooler. 2. Maintaining the tubes of both cooler and condenser In an efficient condition. The correct refrigerant charging level as indicated by the cross wire on the sight glass must be observed when the machine is shut down. The Initial shut down level should not be lower than 1/2" below the cross wire. Size Cooler Charge in Lb. Maximum Distance below Cross Wire for Minimum Level . In. 3 700 4 700 5 800 6 1100 7 1200 8 1800 9 2000 10 2800 11 3800 12 6200 15/16 1-1/8 1-1/8 1-1/8 1-1/4 1-3/8 1-1/2 1-1/2 1-1/2 1-1/2 After the machine has been in operation for an indefinitely long time, the shut down liquid level will reach the values given In the above table, due to loss of refriger- ant. When this condition has occurred, additional refrigerant should be charged into the system to bring the refrigerant shut-down level up to, but not higher than the cross wire. Coolers should not be overcharged unless specific Instructions are received from Carrier Corporation, A method of determining whether the tube bundle of either cooler or condenser is op erating efficiently or not is to observe the relation between the change in temperature of the condenser water or brine passing through the tube bundle and the temperature difference between the leaving water or brine and the refrigerant temperature. In most cases, the brine and condenser water rates (Gpm) are held constant. Under such condi tions the temperature change of brine or condenser water is a direct Indication of the load. The greater the load, the greater will become the temperature difference between the leaving water or condenser cooler "brine" and the refrigerant. The values of these temperature differences at full load should be noted when the machine is first operated, and a comparison made from time to time thereafter. As coolers or condensers become dirty or scaled on the water or brine side, the tempera ture differences between leaving water or brine will increase. An increase of more than 2 or 3 (at full load) indicates that cleaning of tubes should be undertaken. In taking readings of the temperature difference between leaving condenser water and condensing temperature (read from condenser pressure gauge) always be sure no air is present in the condenser. The presence of air will greatly reduce the condenser effi ciency. The purge unit should be in continuous operation for a day before readings are taken. CARE OF TUBES IN COOLER AND CONDENSER Careful, regular attention to the condition of the tubes particularly in the condens er, is absolutely necessary not only for good performance, but to secure best possible life. Neglect, particularly during the first season of operation after installation, SUPERSEDES PAGE 43 DATE 12.1.44 172-5 43 1-2-46 earner) OPERATING INSTRUCTIONS SHUT-DOWN PERIODS There are two types of shut-down periods: 1. The stand-by shut-down during which the machine must be available for instant use. 2. The extended shut-down during which the machine is definitely out of service. STAND-BY SHUT-DOWN. During this type of shut-down: 1. The purge recovery compressor should be operated as necessary to keep the pressure In the machine slightly below atmospheric. 2. Care should be taken to keep the machine free of leaks. 3. If building up of machine pressureN is due to a warm machine room rather than the leakage of air Into the machine, a small quantity of water below 70 circulated through the cooler or condenser either intermittently or continuously will hold the machine pressure below atmospheric, or sufficient cooling effect can be ob tained from periodic operation of the purge recovery unit to accomplish the same result. 4. Unless other reasons prohibit (electric service demand charge or lack of steam), the machine should be operated a few minutes only, once a week to circulate the oil and reduce the refrigerant temperature. CAUTION: In following this instruction be sure the refrigerant temperature in the cooler is not lowered below the freezing point of the water or brine in the tubes. 5. Maintain oil level In seal reservoir and in suction damper stuffing box. 6. Maintain machine room above freezing temperature. EXTENDED SHUT-DOWN. If It is known that the system is free of leaks and the purge r covery unit satisfactorily holds down the machine pressure, It is sufficient to follow the instructions for stand-by shut-down. There are, however, additional precautions that should be taken when the machine Is shut down for long periods: 1. If freezing temperatures are likely at the machine location, drain all wat r from compressor, gear and turbine oil coolers. Also, drain water from the condenser, cooler, seal Jacket, steam condenser, pumps, piping, etc. 2. Under certain conditions during long shut-down, it is possible that the oil may become excessively diluted by refrigerant. A certain amount of dilution always oc curs but the oil level in the pump chamber should not be allowed to rise Into the rear bearing chamber. If this occurs, remove the entire charge of oil from the machine and tag motor switch or turbine accordingly. 3. in restarting after long shut-down periods, follow the Instructions under the auction on lubrication. SL 009077 SUPERSEDES PAGE 47 DATE 12.1-44 -i , Af?Z r:ocective Order Of 14th Judicial District Court 51-1145 -127* SECT, PAGE DAT? I7Z-5 47 J -2-46 INSTRUMENTATION GENERAL One of the major requirements in a plant like the HC1 Plant is smooth, uninterrupted control of the plant streams in order to obtain specification grade product. A distillation column cannot be operated with varying flows. Columns can take hours to level out after an upset, and rapid changes in operating conditions can cause such upsets with re sulting poor quality product. To obtain the desired type of control, the HC1 Plant has been equipped with automatic instruments wherever practical. A thorough job of instrumentation has been done on this plant, but certain points must be understood to get full and efficient use of the instruments. The instruments are the operator's tools, and how he uses them determines how efficiently the plant will operate and how good will be the quality of the product produced. All Important control points in the HC1 Plant are transmitted to the operating room where they are continuously recorded or Indicated. The first indication of trouble within the plant will generally be from these instruments. These should be continuously checked for indications of abnormalities. Most of the records and/or indicators will be read and logged on the data sheets. The instruments serve as your safety guard. All points in the plant which can cause serious trouble or operating difficulties have been equipped with alarm devices to give warning when abnormalities occur. If an alarm sounds for any reason, it should be checked immediately. Do not ignore the warning system. It is there for your protection as well as for protection of the equipment. SL 009078 -128- to Prtective Order Or 14tn Judicial District Court No. 91-1145 ALARM SYSTEM When an abnormality occurs, it will be alarmed by a horn blowing and by a flashing light on the panel board. Under normal operation, the warning lights will show green as long as a piece of equipment is in operation. If a high flow, high pressure, high level, etc., occurs, the horn will blow and the warning light will flash red. If a low flow, low pressure, or low level occurs, the horn will blow and the warning light will flash amber. Pumps are also connected to wanting lights. As long as a pump is in operation, the light on the panel board will show green. If for any reason a pump is shut down or stops, the light will flash red. In almost all motors in the area, the alarm horn will blow in addition to the flashing light. The motors that are not connected to the horn are on intermittent service and not continuously operating units. The horn will continue to blow and the light flash until an acknowledgement is made. This is done by pressing the acknowledgement button located at the bottom center of the panel board. When this button is pressed, the horn will stop and the light will stop flashing. But, until the trouble is corrected, the light will show either red or amber depending upon the nature of the trouble. When the correction is made it will change back to green. CHECKING ALARMS A failure in the alarm system could result in serious trouble. For this reason, the alarm system should be checked periodically to be sure it is functioning properly. To check it, pull out on the acknowledgement button and turn it to the high alarm. Check all warning lights to see if they show red. If they do not, there is either a burned-out bulb or a defect in the circuit - either of which should be corrected immediately. SL 009079 -129- Repeat this procedure for both the normal and low alarm position. Make this check at least once per shift. Safe operation depends upon this system's functioning properly. RECORDER-CONTROLLER OPERATION The recorder-controller instruments are Taylor Transcope Recording Receivers and are provided with manual and automatic operation. Under normal conditions, these will be operated on automatic control, but during start-up or shutdown, or possibly in the case of trouble, the manual control can be used. When on manual control, the process valve can be operated from the panel board by regulating the output pressure to the control valve with the set point adjusting knob on the lower right hand comer of the instrument facing. The automatic valves go from full open to full close (or vice versa in the case of an air pressure closing valve) at an output air pressure variation of 15 to 3 psig. This pressure is indicated on the scale at the top of the controller (on the instrument facing at the panel board). The approximate opening of the valve is indicated by this scale, i.e. 9 psig output is half open, 6 psig and 12 psig are 1/4 and 3/4 open or vice versa depending on valve action. The output pressure will remain at the value set by the set point adjusting knob while the instrument is on manual control, and the valve opening will not vary. When the instrument is on automatic control, the set point is adjusted to the desired control point by the set point adjusting knob. The instrument will then attempt to regulate the process to this control point by opening or closing the automatic valve. At proper control, the set point and the indicator pen will remain opposite each other. The opening or the closing of the automatic valve to maintain this condition will be shown by the variation in output air pressure. COHFIDBOTIAL: **?. <* nf.ic?1ou SL 009080 -130- The recorder-controllers can be readily switched from manual to automatic, or from automatic to manual control, but care must be exercised when doing this. If the indicated control point and the instrument set point do not correspond when the switch is made, a snap action of the automatic valve will occur. This will serve to upset the system as well as being hard on the instruments. The following procedures should be followed when making the transfer to avoid "bumping" the system during the change-over. Manual to Automatic 1. Set the transfer lever at the "Seal" position. This isolates the control valve from the controller air circuits and seals the pressure that is on the control valve at that time. 2. Adjust the set point adjusting knob until the set pointer indicates the same output pressure as the output gauge. 3. Set the transfer lever to the "Automatic" position. The process is now on automatic control. Automatic to Manual 1. Note the output pressure and then set the transfer lever at the "Seal" position. 2. Adjust the set pointer with the set point adjusting knob until it corresponds to the same pressure as noted in step one. 3. Set the transfer lever to the manual position. The process is now on manual control. SET POINT CHANGES The number one rule for operation of this type of plant is smooth steady control. The purpose of automatic instruments is to provide this control and they should be handled with this in mind. The instrument set point can be set at the desired control point, and the instrument will regulate the control valve until this point corresponds to what is actually occuring in the process. By raising or lowering the set point, the control point is changed accordingly. It must SL 009081 -131- CONFIDENTIAL* Subject to Protectiv Order of I4tb Judicial District Cou be remembered though, that when a set point change is made, the instrument will attempt to correct for this change immediately. If a large change is made, this could result in complete opening or closing of the automatic valve which could be severe enough to upset the system. Use small stepwise adjustments and give the system time to "catch-up" before making the next step. This will result in a smooth change and little cycling of the process. SL 009082 COHn^cti've <*** -132- ot .y** ELECTRICAL SYSTEM The electrical ties in the EC plant are fairly straight forward. Dwgs. 62A-7100 shows the ties and typical circuitry necessary for each motor. The only thing unique about the EC electrical system is the fact that the 13.8 KV source may come from either EDC or Per-Tri. Because of this many different arrangements may be used in feeding the organics area, see Dwg. 20A-901-1. Normally the power for EC-HCl-VC will come from Per-Tri through breaker 0-408 and disconnect 0-503. The Per-Tri power comes from Powerhouse Bus #1. Air Circuit Breaker 0-309 in the EDC switch room will normally be closed with disconnect 0-502 open, the cable is hot but protected. Never keep the cable hot by opening 0-309 and closing 0-502, as any fault in the cable will cause the EC-HCl-VC plants to come down by opening 0-408. Until the H-138 feeder cable from the powerhouse to EDC is increased in size it will carry only EDC, Per-Tri, EC-HC1 but not VC. Before any tie that would connect EC-HCl-VC, when VC is operating, to the EDC cable the area super vision will have to determine the relative loads of the plants. In case of an emergency, leave the units down until the proper decision can be made by the area foreman. Emergency ties may be made by the shift engineers until the VC plant if running. Anytime a tie is made, even though it is an emergency, be sure and take your time and do all things in proper sequence. Any omissions from safe practices are forbidden. When the EC-HC1 bus loses power, the shift engineer should proceed immediately to the EC-HC1 switchroom and take a quick look at the 13.8 system, odor and a visual check of the general area will suffice. If SL 009083 133- COMF1DENTIAL* ozone damage is present then finish shutting the plants down. If the trouble appears to be elsewhere: 1. Call Powerhouse Switchboard Operator (417), tell him you are switching load from PH Bus #1 to PH Bus #4. 2. Open disconnect 0-503 (feed from Per-Tri). 3. Close disconnect 0-502 (feed from EDO). If power is back on the bus and stays on, then start back up the motors. If Power is not back, then nothing can be done. Per-Tri cannot be tied to the EDC bus without considerable delay as disconnect 0-404 is inter locked with the powerhouse OCB, i.e., the 0CB in the powerhouse will have to be opened and the key removed and used to open disconnect 0-404. The same thing is true with the EDC disconnect 0-301. Normal switching of the power source for EC-HC1-VC will be done by maintenance with the co-operation of operations. Although operations will never make this switch, it is well that they know how and serve as a double check. The procedure is as follows: 1. Close 0-309 (in EDC) momentarily (be sure 0-502 is open), if it doesn't drop out, the cable from EDC to EC has no fault. Be sure 0-309 is open before proceeding. 2. Close 0-502 (in EC). 3. Call Powerhouse Switchboard Operator (417). Notify him that load is going to be switched from PH Bus #1 to PH Bus #4. The operator is to check and see that the synchronous tie breakers are closed. Then the powerhouse operator is to equalize the voltages on the two buses. The voltage meters that must be equal are the ones on the EDC and the EC buses in the respective switchgear rooms. 4. After voltages are equal, close 0-309 (in EDC). 5. Open 0-408 (in Per-Tri). 6. Open disconnect 0-503 in EC. There are many other combinations of operating and switching that may be done. Each procedure is similar to the one given above. It is best SL 009084 134 ve Ordo' to remember that all of this switching is done with 13,8 KV present and therefore any ties made into a faulted bus will cause some damage. Anytime a tie is made into a bus that might have a fault the consequences of the arcing damage must be weighed against the dangers of the plant having only emergency power. SL 009085 135ir>. LABORATORY PROCEDURES HG1 ANALYSIS (ORSAT) 1. Test: Total Impurities in HC1 Product. 2. Apparatus: a. 500 ml. sample bottle connected to 1000 ml. levelling bottle. b. Fisher orsat. 3. Reagents: a. Dilute aklaline arsenite. b. Diphenyl carbazone - "chloride indicator". c. 0.3419 N Hg(N0sj) 2, d. Fhenolphthalein Indicator. e. 2.5 N H2SO4. , Qxsorbent - 02 determination. 4. Sampling and Procedure: a. Procedure for obtaining sample. 1. Fill both tubes of sample bottle completely with alkaline arsenite. 2. Purge sample line approximately 2-4 minutes. 3. Connect sample line to tubing that runs to the bottom of sample bottle. 4. Allow gas to bubble slowly into bottle, until at least 150 mis. of residual have been caught. (Mark on sample bottle.) 5. Allow sample to reach room temperature before analyzing. b, Orsat procedure. 1. Charge slow combustion pipette with 90 mis. of air. 2. Connect sample bottle to orsat and raise levelling bottle above sample bottle. 3. Lower levelling bulb on orsat and open stopcock of measuring burette first, then open stopcock on sample bottle. Then, by pinching the tube on the levelling bulb, transfer approxi mately 20 mis. of residuals to orsat and record as Reading "A". Discard through manifold. This will remove air from manifold system. 4. Then transfer exactly 100 mis. of residuals to measuring burette and record as Reading "B". Transfer the 100 mis. to the oxsorbent pipette for storage. 5. Measure remaining residuals and record as Reading "C". Discard through manifold. Close off stopcock above slow manifold and the manifold from the atmosphere. This step is important, in order to prevent contaminating sample with air. Readings A + B + C ** Total Mis. Residuals ("D"). SL 009086 -136- 6. Return gas from oxsorbent pipette to measuring burette 2-3 times or until consecutive readings are obtain d. Record as Reading "E", Reading "B" - Reading "E" - Mis. O2. 7. Turn on filament in slow combustion pipette. 8. Return all gas to oxsorbent pipette except 10 mis., which will be burned for H2 determination. 9. After getting exactly 10 mis.> pinch off tubing on levelling bulb and open stopcock slowly to slow combustion pipette and then the measuring burette. Very slowly allow gas to pass over hot filament until the 10 mis, have been introduced. Then, slowly run gas back and forth across filament 2-3 times. Turn off filament and allow gas and filament to cool before returning gas to measuring burette. Return and record as Reading "F". 100 - Reading "F" x 2/3 x Reading "E" - "G" (mis. H2). Reading "E" - "G" - Mis. N2. IMPORTANT: If Reading "F" should exceed 15 mis., orsat should be checked for leaks and combustion step repeated. c. Titration of HC1. 1. Drain alkaline arsenite from 500 ml. sample bottle to 1000 ml. levelling bottle. Wash sample bottle with distilled H2O and drain into levelling bottle. 2. Pinch off tubing at exit of levelling bottle; dilute with distilled H2O to the 1000 ml. mark. Stopper and shake. 3. Pipette 100 mis, of this dilution into a 250 ml. beaker. Add approximately 50 cc's of distilled water and 5-10 drops phenolphthaleln indicator. 4. Titrate to clear end point with 2.5 N H2SO4. 5. Add 5-10 drops diphenyl carbazone bromphenol blue indicator and titrate to canary yellow end point with 2.5 N H2SO4, 6. Titrate to wine colored end point with 0.3419 Hg(N03)2. 7. Mis. 0.3419 Hg(N03)2 x 83.140 = Mis. HC1 at 25C for 100 ml. sample. 5. Calculations: Per 100 mis. of 700 1000 dilution Density HCl vapor at 25C * 0.001501 g/cc "From Handbook of Physics" Titer x 0.3419 x 0.0365 x 700 = T x 83.140 = Mis. HCl at 25C ("H") 0.001501 x 100 x 700 1000 A + B + C = D (Total mis. of residuals) B 100 ml. aliquot E * Reading after 02 absorbed F = Reading after burning H2 G = Mis. H2 in 100 ml. aliquot H = Mis. HCl B - E = Mis, 02 in 100 ml, aliquot 100 - Reading F x 2/3 x Reading E = G Mis, H2 itulOO ml. aliquot IQ ; ` SL 009087 *137- , CONFIDENTIAL* Subject ?to,Protectt^reott <jcf .1n4tthh Judicial Dis** l 1 -11 4^ ,, - '.; ' "i j Reading E - G * Mis. N2 in 100 ml. aliquot llZZuitZiv lu.2UnLT^f<mnd ba,:k t0 total vo1TM' Total mis. Residuals (D) = 0/5 M la Aliquot (100 mis.) (B) Mis. 02, H2 and N2 found x D/B Total Mis, of Conation,- Y inn Total Mis. of Sample (D + H) " % Constituent SL 009088 CO*e orfl t Subject to je^act Court o l*th *138** u: . ?, , r-: . < t, , DATA SHEET 100 ml. sample. *Mls. Hg(N03)2 x 83.140 = Mis. HC1 CH) x 100 = D+H A+B+C =D Total Mis. Residuals D+H Total Mis. Sample ** Aliquot: 100 Mis. % HC1 Use 10 mis. of aliquot for H2 determination and 90 mis. of air. B - E = Mis. 02 x D/B * Mis. On x 100 = % 02 D+H 100 - Reading F x 2/3 x Reading E = Mis. H9 (G) x D/B = Mis. H-, x 100 = % Ho 10 D + H Reading E - G Mis. N2 x D/B = Mis. N? x 100 * % No ***100.00% * This factor is good only when 700 mis. alkaline arsenite were used initially, diluted to 1000 mis. and 100 mis. of this dilution used to determine HC1. ** To correct mis. of 02, H2 and N2 found back to total volume of residuals caught, multiply mis. of each found by D/B. *** If total is more or less than 100.00%, add or subtract difference from % HC1. SL 009089 SL 009090 Volume of HC1 at 25C Ml3. 0.3419 Hg(KCH)9 For 100 ml. sample - T x 83.140 = Mis. HC1 at 25C Mis. Titer 0 1 2 3 4 5 6 7 8 9 10 0.0 0.0 83.140 166.280 249.420 332.560 415.700 498.840 581.980 665.120 748.260 831.400 0.1 8.314 91.454 174.594 257.734 340.874 424.014 507.154 590.294 673.434 756.574 839.714 0.2 16.628 99.768 182.908 266.048 349.188 432.328 515.468 598.608 681.748 764.888 848.028 0.3 0.4 24.942 108.082 191.222 274.362 357.502 440.642 523.782 606.922 690.062 773.202 856.342 33.256 116.396 199.536 282.676 365.816 448.956 532.096 615.236 698.376 781.516 . 864.656 0.5 41.570 124.710 207.850 290.990 374.130 457.270 540.410 623.550 706.690 789.830 872.970 For !50 ml. sample - T x 116.289 = Mis>. HC1 Mis. Titer 0.0 0 0.0 1 166.289 22 332.578 3 498.867 4 665.156 5 831.445 6 997.734 7 1164.023 8 1330.312 9 1496.601 10 1662.890 0.1 16.629 182.919 349.209 515.499 681.789 848.079 1014.369 1180.659 1346.949 1513.239 1679.529 0.2 33.258 199.548 365.838 532.128 698.418 864.708 1030.998 1197.288 1363.578 1529.868 1696.158 0.3 49.887 216.177 382.467 548.757 715.047 881.337 1047.627 1213.917 1380.207 1546.497 1712.787 0.4 66.516 232.806 399.906 565.386 731.676 897.966 1064.256 1230.546 1396.836 1563.126 1729.416 0.5 83.145 249.435 415.725 582.015 748.305 914.595 1080.885 1247.750 1413.465 1579.755 1746.045 0.6 49.884 133.024 216.164 299.304 382.444 465.584 548.724 631.864 715.004 798.144 881.284 0.6 99.773 266.064 432.354 598.644 764.934 931.224 1097.514 1263.804 1430.094 1596.384 1762.674 0.7 58.198 141.338 224.478 307.618 390.758 473.898 557.038 640.178 723.318 806.458 889.598 0.7 116.402 282.693 448.983 615.273 781.563 947.853 1114.143 1280.433 1446.723 1613.013 1779.303 0.8 66.512 149.652 232.792 315.932 399.072 482.212 565.352 648.492 731.632 814.772 897.912 0.8 133.031 299.322 465.612 631.902 798.192 964.482 1130.772 1297.062 2463.352 1629.642 1795.932 0.9 74.826 157.966 241.106 324.246 407.386 490.526 573.666 656.806 739.946 823.086 906.226 0.9 149.660 315.951 482.241 648.531 814.821 981.111 1147.401 1313.691 1479.981 1646.271 1812.561 COWPlOBMTIALt t liSC? i? froteetlv. Order t IIth Judicial metrict Court Oe U-H45 HC1 ANALYSIS (H? ONLY) 1. Test: Percentages of HC1 and H2 in HC1 Product. 2. Apparatus: a, 500 ml. gas burette with leveling bottle. b. Fisher Orsat (with slow combustion unit). 3. Reagents: Confining solution. 4. Sampling & Procedure: a. Sampling 1. Place approximately 700 ml. of confining solution in the leveling bottle. Change confining solution once per week (Tuevday)* 2. Fill connecting tube by running small amount of confining solu tion into burette. 3. Connect water bubbler tube and sample line to burette. Purge for about 5 minutes. 4. Close stopcocks and sample valve so as to leave a slight pressure in burette. 5. Vent burette to atmospheric pressure by rotating stopcock on small end until no "HCl fog" comes from burette. 6. Allow confining solution to enter burette and absorb the HCl. Do not shake. Rock burette several times to bubble residual gas in confining solution. b. Orsat Procedure 1. Transfer exactly 70,0 ml. of air into the slow combustion unit 2. Fill rubber connecting tube on burette and orsat sample tube with confining solution. 3. Transfer all of residual gas to the measuring burette by bringing confining solution from 500 ml. gas burette into the orsat sample tube. 4. Measure volume of residual gas and record as Volume A - (Va). 5. Turn on slow combustion unit filament and SIX)WLY transfer residual gas into slow combustion unit. Make three more passes to and from combustion unit. Do not allow confining solution to come in contact with hot part of filament support column. 6. Turn off filament and allow to cool to room temperature. KEEP CONFINING SOLUTION BELOW HOT PART OF FILAMENT COLUMN. 7. Transfer entire volume of gas to the measuring burette. Allow liquid to drain from burette walls (about 30 seconds). Read and record as Volume B (Vfe). 5. Calculations: Basis: 500 ml. sample size vctTo **?$*>* SL 009091 H41* S* o* a. Percentage of HCl % HCl = 100 - <va x 2) 10 or read from Table I b. Percentage of H2 (Uncorrected for CO) 1. Contraction Volume = Vc Vc = )Va + 70.0 ml.) - Vb 2. % H2 = (Vc x 2/3) x 2/10 or read from Table II t f SL 009092 -142- TABLE X Percentage of H& Basis i $00 al. ftanpleBlse . -iit; ^ Volune A (ml.) (Residual Oas) 0.0 0.1 0.2 JL 0.4 0.5 ' : 0.6 0.7 0.8 0.9 10 *98.00 97.98 97.96 97.94 97.92 97.90 97i88 97.86 97.84 97*82 11 97.8 . 97.78 \t'yn97.76 12 97.60 97.58 97.56 13 97.40 97.38 97.36 14 ,* 97.20 97.18 97.16 97.74 97.72 97.54 97.52 97.34 ! 97.32 97.14 97.12 97.70 97.68' 97.56; 97.48 97.30 97.28 97.10- 97.08 97.66 97.64 97.46. 97.44 97.26 97.24 97.06 97.04 97.62 97.42 97.22 97.02 15 97.00 96.98 496.96 96.94 96.92 96.90 96.88 96.86 96.84 96.82 16 96.80 96.78 96.76 96.74 96.72 96.70 96.68 96.66 96.64 96.62 17 96.60 96.58 96.56 96.54 96.52 96.50 96.48 96,46 96.44 96.42 18 96.40 96*38 96.36 96.34 96.32 96.30 96.28 96.26 96.24 96.22 19 96.20 96.18 96.16 96.14 96.12 96.10 96.08 96.06 96.04" 96.02 20 96.00 95.98 95.96 95.94 95.92 95.90 95.88 95.86 95.84 95.82 21 95.60 95.78 95.76 95.74 95*72 95.70 99.68 95.66 95.64 95.66 22 95.60 95.58 ,95.56- 95.54 95.52 95.50 95.48 95.46 95.44 95.42 23 95*40 95.38 95.36 95.34 95.32 95.30 95.28 95.26 95.24 95^22 f 24 95.20 95.18 95.16 95.14- 95.12 95.10 95.08 95.06 95.04 95.02 25 95.00 94.98 94.96 94.94 94.92 94.90 94.88 94.86 94.84 94,82 26 94.80 94.78 94.76 94.74. -94.72 .94.70* 94.68 94.66 94.64 94.62 27 94.60 94.58 94.56 94.54 94.52 94.5? 94.48 94.46 94.44 ' 94.42 28 94.40 94.38 94.36 94.34 94.32 94.30 94.28. 94.26 94.24 94.22 29 94.20 94.18 94.16 94.14 94.12 94.10 94.08 ' 94.06 94.04 94.02 30 94.00 93.98 93.96 93*94 93*92 93.90 9V.88 93*86 93.84 93.82 . ci 009093 * $ HC1 100 * Va X 2 , IT ' CONFIDENTIAL* 0 Subject to Protective Order -143* " Of 14th judicial District Court 3 Ho. 91-1145 :. TABLE IX Percentage of Ha (Uncorrected for CO) B&slei $00 ml* Semple 81m Volume C (Contraction) '1 . * t'- 1 0*0 10 .1.53 0*1 1.35 0.2 1.35 11 ' 1.47 1.48 1.49 12 1.50 i.a 1.53 13 1.73 l4 . 1.67 1.75 1.88 1.75 1.89 15 2.00 2.01 2.03 15. 2.13 2.15 2.15 17 2.27 2*28 2.29 1 2,4o 2.41 .2.43 19 2*53 2.55 2.55 20 2.57 2.58 2.69 21 2*80 2.81 2.83 22 2.93 2.95 2.95 23 3.07 3.08 3.09 3.20 3*21 . 3.23 25 3.34 3.35 3.36 25 3.47 3.48 3.50 27 3.50 3*62 3.63 28 3.74 3.75 3.76 29 3.67 3*66 3.90 0.3 * 1.37 1.39 1.51 - 1.52 1.54 1*65 1.77 1.91 2.04 1.79 1.92 2.05 2.17 2.19 2.31 2.32 2.44 2.45 2.57 2,71 2.84 2.59 2.72 2.85 2.97 2.99 3.H 3.24 3.12 3.25 3.36 3.39 3.51 3.64 3.52 3.66 3.76 3.91 3.79 3.92 0.5 . 0.6 , *- 1.40 1.4l 0.7 1.43 1.53 1.67 1.60 1.55 1.58. 1.81 1.56 1.69 1.83 1.93; : 1.95 1.95 2.07 2.08 2.09 . 2.20 2.21 2.23 2.33 2.35 2*36 2.47 2.48 2.49 2.50 2.6l 2.63 2.73; 2.75 Zi&7 2.88 3.00 3*01 2.76 2.89 3.03 3.13 3.27 3.4o 3.15 . 3*16 3.28 3.29 3*42 3.43 3.54 3.67 3.55 3.58 3.56 3.70 3.60 ; 3.82 3.94 3.95 3.83 3.95 0.8 1.44 1.57 1.71 1.84 1.97 2.11 2.24 2.37 2.51'* 2.64 2,77 2.91 3.04 3.17 3.31 3*44 3.58 3.71 3*84 3.98 2sS1.45 1.59, 1.72 1.85 1.99 2.12. 2.25 2.39 2.52 2.65 2.79 2.92 3.05 3-19 3.32 3.46 3.59 3.72 3.86 3.99 SL 009094 Subjectc.otonfPidreontetciatliv*e order Of lth Judicial District Court. #ip* 91-1145 TABLE II (Continued) Percentage of H2 (Uncorrected for CO) Basle: 500 ml* Semple Size volume C (Contraction) o.d 0.1 0.2 :2JL 0.4 30 4.00 4.02 M3 4.04 4.06 31 4*14 4.15 4.16 4.17 4.19 3a 4.27 4.28 . 4*30 4.31 4.32 J33 4*40 4.42 4.^3 4.44 4.46 34 4.54 ' 4.55 4.56 `4.58 4.59 35 4.67 4.68 4.70 4.71 4.72 .36 4.80 4.82: 4.83, *' 4.84 4.86 37 4.93 38' 5.07 4.95 5.08 4.96 5*10 4.98 , 4.99 5.11 5.12 39 5.20 5.22 5*23 5-24, 5.26 & 1 "w 0ii- 0.6 4.07 *4.08 - 4.10 4.20 4.22 4.23 4.34 4.35 4.36 4.47 . " t4.48.,.,* .4.50 4.60 4.62 ` ` 4.63 4.74 4.87 4.75 4.76 4.88 . 4.90 5.00 * 5.02 5.03 5.14 5.15 5*16 5.27 5.28 5.3 0.8 4.11 4;24 4.38 4.51 4.64 4.78 4.91 . 5.04 5.18 5.31 0.9 4.12: 4.26 : 4*39 4.52 4.66, 4.79 , 4.92 5.06 5.19 5*32 SL 009095 * Ha (VC X 2/3) X 2 ----------- 335----------- COKFIDEIfTIM.* fSu1b4tjehcJt utodicPiarol teDci titvreicOtrdCeorurt of Ho. 51-1145 VC - (Va + 70.0) - Vb Volume A * Va . Residual Gas Volume Volume B Vb Volume after Combusti n Volume C * Vc Contraction Volume * 28c -145- HC1 STRENGTH 1. Test: Acidity as HC1 Grams/Liter - Effluent 2. Apparatus: a. 250 ml, beaker, b. 50 ml. graduated cylinder. c. 50 ml. burette. d. Stirring rod. 3. Reagents: a. 1.0 N NaOH. b. Fhenolphthalein indicator. 4. Procedure: a. Measure 50 mis, of effluent water into 250 ml. beaker and add approximately 100 mis. distilled water. b. Add 5-10 drops phenolphthalein indicator and titrate to finest permanent pink color with 1.0 N NaOH. 5. Calculations: Mis. NaOH x 1.0 x 0.0365 x 1000 = g/1 HC1 T x 0.73 = b/1 HC1 Sample Size SL 009096 -146 HC1 STRENGTH Tentative HC1 Analytical Control Test 50 mis. Sample 1.0 N NaOH T x 0.73 - g/1 HC1 Mis: 1.0 N NaOH Mis. Titer 0.0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 0 0.0 0.07 0.15 0.22 0.29 0.37 0.44 0.51 0.58 0.66 1 0.73 0.80 0.88 0.95 1.02 1.10 1.17 1.24 1.31 1.39 2 1.46 1.53 1.61 1.68 1.75 1.83 1.90 1.97 2.04 2.12 3 2.19 2.26 2.34 2.41 2.48 2.56 2.63 2.70 2.77 2.85 4 2.92 2.99 3.07 3.14 3.21 3.29 3.36 3.43 3.50 3.58 5 3.65 3.72 3.80 3.87 3.94 4.02 4.09 4.16 4.23 4.31 6 4.38 4.45 4.53 4.60 .4.67 4.75 4.82 4.89 4.96 5.04 7 5.11 5.18 5.26 5.33 5.40 5.48 5.55 5.62 5.69 5.77 8 5.84 5.91 5.99 6.06 6.13 6.21 6.28 6.35 6.42 6.50 9 6.57 6.64 6.72 6.79 6.86 6.94 7.01 7.08 7.15 7.23 10 7.30 7.37 7.45 7.52 7.59 7.67 7.74 7.81 7.88 7.96 SL 009097 -147- c* HC1 (FREE CHLORINE1) l. Test: Free Chlorine in HC1 2. Apparatus: a, 1-32 oz. clear sample bottle (wide mouth), b, 1 - 2-hole No, 9 rubber stopper fitted with polyethylene tubing, 3. Reagents: a. Ortho-Tolidine. b. Carbon Tetrachloride.* 4. Procedure: V a. Fill 32 oz. bottle approximately half full with distilled water. b. Add 1-2 cc's Ortho-Tolidine and shake. c. Add carbon tetrachloride until a 1/4 to 1/2 inch layer is present on bottom of bottle. d. Insert polyethylene tubing from sample point into carbon tetra- chlorine layer. e. Regulate flow to approximately 1-2 bubbles a second. f. The presence of a yellow color indicates the presence of free chlorine. g. If free chlorine is present, notify supervisor. * Carbon tetrachloride liquid and vapor are hazardous. Avoid Prolonged contact with either. Use only with adequate ventilation. SL 009098  I- TTTTh :. '' ft t :.? - i --"Hf" *y /eeJ as a ji^ihfibvi b Rate. f V, i ,, detiij-tji- ; i .et%y./r. \ "c t- f +1" -i-.i u- j ) ! I i ff f- f | * -149- t ' .If, D W G .20A -934 fnn-iH.w _C-WSOtPLjO| WELL. WUU l^-l66Q-)l-PUO& li* STEfcH r- IGSTj-X- PL IQ) 4l ft a* -BMO-frPL IOT. CELL LIQUOR. or- ri^x-pnot plp kk 4*- lie-3-W_loi C.T. WASTER. SUPPLY tf-^io-PLicn c.T.wwea returm T-ftlBft'ttPLIO't. feglKifc SUPPLY y-yUit)tPLm fettme gcniaia COMT. OH C GwOA- LOt*> ^-0.101-Pi tec* COA/77 OA/OUti &2.A-/OS2- REVISIONS tO'**XA6B-K- RLE S'-^iba-x-Pli B fVsgy- *-x=x- &*m) V-vni-Pwioe* i*io<l.-PLiei SB t*vife4 aw 1 F*tvr | COMT. OV1 QWGi j C*"VA- ISA MOKE U V*. Css) Z~A37T-X-/>/&/ Zr/07&'X'fiU0t 3 frVEMT ftURUta* H-X-tOI CX3M CPOROIMLE. R atcoMQkav cooler e-iot. o- MIST 1 ftLlMIMAXOR. mj a XI 'f U* -t>---- tX)--1 y>ax.ao-x-PL voa -oo- HVDftO&lM wrtafr l1 -CXI------ '4V(/1-*MC4 A aewfctt . . __ 4A*-i-LVtoa-X'PtI04 J'-WI-X- PLlOA A*n.c*t>'i.-PL>oa WY0aot>fcH ------------ CoOI>nrln^etcitvive0 or ^= ub^cet to r,f0oiL,ttrrilccttC^rti w JU5o! n-n ' * -'LTl<*-PLl0 , ?? 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AMPS tM7SAAUPT/M6 f/OO A SAAME AAS T7P TSS -22S AMP SAAME AAS T7PS T*T). yssr/c AL see new os /to re* cos/tmol c s/s tea. 7-MA/M MOA/ZOMTAL BUS TO BE MATED 600 AMAS 0 YEMT/CAL 6 C/S TOSS *A76 306 AM AS. All 005 WOAA TO OS SUYEA ALATSO 4 SCf/TABLY AAACSO TO W/TASTAMP A MAX//4UM OS SO,006 AMS AMASASS SMOAT CtACtMT CUAAEMT. 9- /MCOM/M6 IfS/S CAOLC9 0//LL OS TOP SED W/TWO SOO MCSi CABLES ASA PHASE. f- OUT 66/M6 CABLES SAOM SrAATSAS. ETC.W/LL LSAVE TME C0A/7A0L CEMTEAS SAOM rste ros. ssf mm St- SMYS/CAL AMAAMDSMEATS OS STAATEAS A/SO OAEAAEAS AAS 70 ME AS SMOW/t 0/t T/fESSDMW//Y65, STAATEAS SMALL OS OS TWO C/MCU/T BASAAEP como/mat/om type. *-OE*L0AD 3/AETALL/C PSlA VS (EXTEAHAL HA MO ASSET TYSE A/tO/SS/V COMPEWSATSp) AAS 70 OS PAOVfOEO /ASALL TOASS A/tASSS. MEATEA ELEMENTS AAS TO OS Pi/ACMASS'D 4 J/YSTALLED BY OWMSA AT LATSA OATS. a- OWE EXTRA MOAMALLY OPE0 AUX/LIAAY CCMTACT /S TO OS PPOV/OED WfeACJt MOTOA STAATSA COMTACTOA. L3*LAMACO/D MAMEPL AYES'. LETTS* HE/60 T 67 C/ACUtT MUMSA TO OE-jf" LETTSA ME/6AT OS C/ACU/7 DESCM/PTtOM TO OS-jf* LET7EA ME/6MT OS BUS MUHBEM TO OS *. LETTSAS TO OS WM/TE OMOLAC0 BACA6*60AD. M-VEM06PS MAASPLATS TO OS LOCATED 76* AMO CSM7EA OS ZfOrOA COMTAOL CSMTSAS W/A LAMACO/O //A/tSALATE SMOW/M6 TMS BUS MUMOSA D/AECTLf BELOW. MLmms octa/lld /n/orhat/on ZVL? tp*r 9960332 LAC4HSB. AAV llw VSt oaas A/A A/o. rm* wmsL CDH5Q iO*C> c Trot / cm. ai2 C*L>* SO A /s /3 c 7702 / CM. Its2 C,IS ' SOA /s 0 etes/aasorroA^ SUMP ML P /O/ MO TOA MO. M/D/ PUMP MO. P/62 AOT0A MO. M/62 1 zauauirr / ** our AiMT AXATT **A3GUV*A& 1 /4'C., | 4*3 4 3*/2 K-,4*S/3*/3 CAT *776/ STA/PSS* SEED PUMP MO./ CAT * 7702 STAtPPSA SEED PUMP MO-2 c 7703 / c 7104 / c 7 70S / c 7704 / ca 2 tut > SOA /s A9 / c nsC S. O 1 A . /SA /. CM itS- / C T.OI A /SA /* O CM iSS- s / crjCs \ 20* M-S PUMP MOT0A PUMP MOTOA SUMP MOTOA SUMP MOTOA MO. P/03 MO. M/C3 MO. P/04 M6. A t64 i fi'C.j fc,*'3 I THAU, /'C~, ft. *J3 MO. P/OS MO M/OS i T/fAf, /-c.j }C */2 MO. PX /O* | T/TA Y, fC.j & */Z MO. MX/09 CAT *7703 AOSOAOSA SEED SUMS CAT *7104 A* 54 C/AC UL A T/OM PUMP MO / CAT mTTOS M SA C/ACUL A T/OM PUMP MO-2 CAT 7106 ALSO* C/ACULAT/OM PUMP MO- J c 7701 / o 7709 / c. 7709 / c 77/0 t r 77// / c 77/2 / a 77/3 / 77/4 a 77/S n CM tlS/ C ^ 5% 2 20A aS 50A AS 2 ,cMn.s- i. 1 CZIB% > So* AS .cm as- ( 2 tc nit \ SoA AS cm. as- . / CL MAM N ISA A rts- \ .^1 2, lCS ' ISA 1 CM Its- \ t lev SAM /SA / ^^ \L JOOA O 0 /3 /2 /2 - . O PUMP MO. PX/09 MOTOA MO. MX *09 | taay, re., *L *rz CMT +776T MtSCU C/ACULAT/OM PUMP *0-4 COMPASSSOA A/OtfHtA MOTOA MO. A f/4 77TAY, Ne'e.,It .4*3 4J*<* SU/iP MOTOA MO. S/ZO MO. MX//S i t-aay, Ne'e.,X.,4*3 43*iz PUMP MOTO* MO. */// MO- MY//L i T/tAY, Yi'e,3t,4'3 43-/2 CMT 7109 MCL COMPASSSOA ML PAD CMT *7700 BA/ME SUMP MO. / CAT 77/0 BA/ME SUMP MO. 2 SUSP MO. 6/06 i T/tAt, re., & */t MOTOA MO. A//* CMT *77// MSS C/M/7 Pi/AOE ASCOTEAY PUMP MO. P//2 MOTOA MO. M//4 POMP AO S//3 MOTOA MO A/EO PUTUEM SPACE ONL Y i /c.. ,Jt,*/2 i T/TAY, /C.,%.,*/2 CAT *77/2 DESUPEAMSArSA PEED PUMP CMT *77/3 MCL AES COMP &L SUMS CAT *77/4 SVTt/EB /OO AMP s*. /OO AMP TAtP TYPE T/iSP CAT *T7/S 3SAAE AC 3 7T/L A O O SCf TOAS SPACE OMLY CAT mTT/C SUTUAE A 77/7 4 ns a /oo V PO/iP MO- P-/7 MOTOA MO. M-/7 TAAf.S'e.Th.-S'r. * / ** flwr.-ve.. * CAT * 77/1 COOL /MG TOWS* SUMP S3 DM? tosr VS0KCO P4SMYX& o*v. PLM M 4SIAM M/O. OkWM A/e. raw* mgas COMSU iCtd/7 asocat^TYcrr I c/yjsxrr 4 trot a/xr E 77/8 / /SOA so 30 OPtXATXS COHTIt/OUStY T/tAY, 2`e., t* fi 77/7 / t 46A 6 C mo t 2 CM its C B 70 A zs A O SPAAS X1 coMPftrssc* He- tin Moron. Ho.M*at < TKAY, C., Tk, **U3*tZ 2-jS dCTim 00-40mug 4cv arjtwrr ns. K/T/i 4*i.ANT AT /SOYf m/Dl/C r/C/Y) TWWL eOAA/SWO AM* RfMt OTW AMMTAUV ^Munr /^MAMM/SLorm PAISA. Aml PE<p 2(0.20 2S/.7S 240.2*- 2/.* 4*NfF>S * 273 353 f jf 27 NJ4AAC /QLoror pjaaosfPUG C/AT -- TT/3 0*t 4 r/./YT C/&TT//YG T3AMJT. A CMT *7 7/7 SPAMS S/ZE / CKT 17*0 MCL COMtMfWon HO 4 WObtect to Protective Order t > Judicial Diatxict Court 1------------- m. n-im----------------- ton wet. PLANT OftAWiNfi NO*A plot plan sec 0ft*A-7ooe CO co 4ta&tftOS&^Nfe PITTSBURGH PLATE CLASS COMPANY ommical emnoN LAKE CHARLES. LOUISIANA MCL PLAMT /ELBG770/&42. 9moouGlt AHor>aa aavmoiG C*VP ow OMffzN'd /5A/r EMMDur *-* ttoa________________________________________ r OS TEALAMD 6/24/4* - .... MOASE P.SY4 U.O.UTOW. DWG. NC >.62A-7IQq SC PH H ^ D S IOK C L pounds p e r hour- R'odacf P/eaJ Q P h -Q7- .1 - J**; r*