Document OJRzdp9zMkpjz0o3DgBLY7vw1

I >artment: CMP a Title: R-1300 CONTROLLED SHUTDOWN FOR MAINTENANCE Scope: TO PROVIDE THE NECESSARY INFORMATION NEEDED T6 ASSIST THE OPERATOR KITH THE SAFE AND PROPER METHOD TO PREPARE R-1300 FOR MAINTAINCE Major Hazard(s): METHYL CHLORIDE, METHYLENE CHLORIDE, CHLORINE,.^T;::, CHLORINATED ORGANICS Safety Equipment Required: BLOCK MINIMUM REQUIREMENTS *7 : .. NOTE: ALL ITEMS ASSOCIATED WITH THE QUENCH SYSTEM WILL'"HAVEcTO BE MANUALLY MANIPULATED ON THE MOD.>:v down; R1300/AGive` them. anlestimat:edy:imev?iimL'^we5?wiii^Ibel'down..';;;tU; B* Check the/.amount. o* ui 11 be able.to;handle! reduce R-250 rates C. If we are.running reflux drum' level'and the M1/M2 flow tdJthe^reactbV.^'Let ' it stabilize ' before moving 1-.- D. Move R-1300 to st*ep 109 Jto 'be'g*in,r' edJuci'ng; ^R-1300 to minimum feed rates . -( SESEE ( R-1300 SHUTDOWN %PRO )X*l V- 2. Ensure that the following automatically takes place when R-1300 is moved to step 109.(SEE R-1300 SHUTDOWN PRO) A. The Ml valve AO(112) begin ramping down to bring rates to a mininum load. B. M1/M2 recycle control valve will begin ramping down until shut. MONITOR D-1511 LEVEL TO ENSURE M1/M2 IS NOT RAMPING DOWN FASTER THAN D-1511 CAN HANDLE IT. C. The feed control valve to C-1500 should begin cutting C-1500 controlling D-1450 level. The controller will stop at a minimum flow setpoint. If the level in D-1450 is dropping faster than C-1500 feed controller is reducing its rates, you can place C-1500 feed control valve on flow control by giving AK(825) a value. 3. Monitor the incoming HCL flow A. Reduce R-250 rates to maintain the incoming HCL flow at the rates it was running prior to shutting down. f B. Monitor HCL purification recycle. The rates might not have to be reduced as much if we are recycleing alot. 3. , ."i ;V 00 01P868 O0NFIDFNTTAI 4.Shut down R-1300 I A. Ensure that D-1450, T-1500 & D-1525 levels are approx. 25-35% B. Once R-1300 has reached its minimum rates shut R-1300 down by placing it in step 110. - " C. Monitor the Ml header pressure, chlorine header pressure. D. Ensure that the C12 AOV,'s close and the N2 AOV opensi&.Also ensure that the N2' AOV closes after approx 1 min. X 5. Ensure that the following autbmatically takes place in the distillation system when R-1300 is shutdown, (master distillation sequence) A. C-1500 overheads back*.to D-1450. B. C-1510 overheads,is;going to T-1500 C. C-1520 btms is reroutedito.T-1500 DK(121) "FALSE" DK( 61) - "FALSE"i> Isolate R-1300 'foriinairitenance W'-'V-vv, ' - . ,, .i ;: - ' ' . ' ' , - ' - ' ' ', .y- -v/''- u* -. A. Place the ; quench i.system in step 204 from step 206 ;, ' .; - : B. Isolate all feed streams: v*.. C. Block in 'the-'AIRito ; the following AOV's J: a - Vapor organics from S-1300 AOV at R-1300 b - Chlorine to R-1300 AOV'S c - N2 AOV'S D. Manually block in the steam to RE-1 reboilers (tarpot) and let the tarpot system just circulate. * ENSURE THAT WE ARE NOT SENDING C1510/1520 REBOILERS TO THE TARPOT. E. Manually block in D-1320 to D-l at the manual block valve upstream of the distillation tiepoints and also to T-1500. F. Manually block in E-1320 outlet 20" butterfly valve. G. Manually block in make-up feeds to D-1320: a. D-1330 DRAIN b. P-1555 A/B (T-1555 A/B) c. P-1520 A/B (C-1520) DO 012B69 CONFTDFIMTTAL, '. Drain D-1320 A. Place D-1320 .pump (P-1320) and D-1320 level control valve AO(213) in manual and pump the contents of D-1320 to E-1450. shut down the pumps. B. Hook up tubing from. the-;low point on D-1320 back to E-1450 and pressure any"residuhl liquid to E-1450 by placing the N2 AOV (DO-103) in manual and open it up (or by using a N2 hose). C. Manually block D-1320 to E-1450. 8. Depressure and clearing the system. A. Shutdown all fans (EC-1320 *s). DK(61) through dk{66) B. Hook up 3/4"tubing-frpm E-1320 fans banks to a throx drop and depressure theljsystem.^A^ ' fv C. After the system^isVdepressured,-pressure the system back up with nitrogen^ to .;70, psig^jusihg.*DO( 303/313) and again depressure to ; vent. recoveryrl'Z. D. Continue to" pad "and!depad uhtil^the , system is clear E!. Once clear .of organics,:;put a N2 purge to atmosphere.????????? F ' Tag-the^systemrput|nsineeded ^-:^^^;f;'^r-'.v. . -: . JHE/GR 5/92 , ' j , /.,V* *-v* ; - R1300CSD.PRO i:' DO 012870 00NFTDFNTTAI. li_Jpar'ttment: CMP Job Title: MOD V FANS (prepare for maintenance) Scope: To properly take down and get ready any of the MOD V operated fans For Maintenance. Major Hazard(s): Heat, electrical, column pressure. Safety Equipment Required: Minimum block standards. Fuses have to be pulled if the-fan motor is to be worked on, or if V . IV'- entering the fan shroud/housing area. is to be taken out of service. -.V t'j V>*; . ' ' tags are necessary' to v; yy. sable the f S. THIER DK .i,i;:>^t VALUES IS AT THE END OF/THIS PROCEDURE OR' YOU CAN CHECK THE : v " DOVTRAN CODE BY CALLING VUP, THE .(DO) ITSELF). / ** w ' ' . , `1 j S, 7i ly \v** T '.w*-*'.' i 'S' A '* . .` , * '' 7" ' ' V *\ m ' . " ` ' ' * /- ` " . 4 ';^3.' :The board operator shouldvthen.-operate the v . on the front of the mod-can and tag. * * ................. . disconnect * _ V ** switch"' 1 ' '4.' Once' the fanJ has ' been"rdisabled-bythe board operator, the outside operator can place the field switch in the "OFF" position. 5. Rack out the " VARIABLE SPEED DRIVE " in the motor control center first. Then rack out the " MAIN SWITCH GEAR 6. Pull the fuses, if we have to work on the motor or enter the fan shroud/housing area. 7. The field switch should always be checked by two (2) different people to make sure the fan won't run. One of these people must be the person performing job or there foreman and the other must be the operator who is issuing the permit. The operator will have to check the field switch by placing it in the " HAND" position. S. If everything checks out O.K.. the maintenance personnel can begin working on the fan. 9. Once finished, the outside operator should rack in the " MAIN ( SWITCH GEAR " first and then the '' VARIABLE SPEED DRI\E GEAR". 10. Place the field switch in the " AUTO " position. 4 i, r- w f. , , v; 00 012871 \ CONFIDENTIAL ihe board operator can then place the disconnect switch to its proper run condition and if he wants the fan to run he can iniate a (DK) function. The following is a list of each system which has variable speed drive fans or MOD V operated fans. 7 E-1320 SYSTEM ME-1320 A DO(202) DK{61) ME-1320 B DO(212) DK(62) - ,v ME-1320 C -. . ` D0(222) DK(63) ME-1320 D 7, Y DO(232) DK( 64 ) > ME-1320 EV-Hs-j-X -,D0( 203 ) :- 7-7 ' DK(65) 7 77 y j? _ *,,'V. ' 1 - ... ME-1320 F do(213) F DK( 66 ) - --T ^- .7'..' )* .. v, .e > ' ." , 'Vv-r'i- ' ,' V T ,E-1420 SYSTEM . . ME-1420' ; DO(201 );Y: 77 DK(54) . y u V;/vv-. '' ME-1420 B DO (211 )7;; . . . DK( 55 ) i / * "TJ`'VT'`v"''. . r'- ME-1420 ; DO(221 hfe . DK(5 6) : ;L V r ME-1.420>d;^RV^4)O( 231 >Y'iDK( 57 :E-1510 SYSTEM +' -AYr''-.*' ; v't EC-1510 A Ar-Yi 'DO(106) Y dk( 6) r - ; y. EC-1510 B ~ DO( 116). DK( 16 ) 'V;/ , ' EC-1510 C 7 DO(12 6 ): ' DK( 26 ) ^ ;- C' J 'r T: EC-1510 D EC-1510 E DO( 136 )DO (107) 7 DK( 36 ) ` DK( 7 ) ' .. y_.'- , Vm: ' *7. EC-1510 F ^ Y DO(.l 17) : ' i 7 . DK( 17) -- . *,, -**r ?* ,. & j * .* . m f` rm-. '= : i - E-1520 SYSTEM EC-1520 A EC-1520 B EC-1520 C EC-1520 D DO(201 ) DO(211) DO(221) DO(231) DK(53) DK(59) DK(60) DK( 66 ) E-1525 SYSTEM EC-1525 A EC-1525 B DO(230) DO(240} DK(731 DK(75 ) C-1540 SYSTEM EC-1540 EC-1540 EC-1540 EC-1540 A B C D DO(301 ) DO(311) DO(321) DO(331) DK(103 ) DK(109 ) DK(llO) DK(116 ) BOTTOMS FANS < E-l530/40/50 ) DO(3 2 8 ) DO(3 3 8 ) DK(123) DK(125) COOLING TOWER FA-1020 A FA-1020 B DO(501 ) DO(511 ) DK(200) . DK(202) GR/FC/CD/91 MODVFAN- PRO 6-, j:.. 'DO 012872 - CONFIDENTIAL / * : - .- :': v:iigffSBSS4w^ .:.... ' 'v- R - CHLORINATED METHANES ' r" : "'"v - -. SAFE JOB PROCEDURE ipartment: CMP Job Title: EMERGENCY PROCEDURE IN THE EVENT OF A MOTHER BOARD FAILURE Scope: General information on possible ways to determine which mother board has failed and corrective measures ' ' 'r"im WAYS TO DETERMINE WHICH MOTHER BOARD FAILED 1- DS LIGHT s7 indicates which computer is driving the graphics . .' display and alarm scan. This DS light is lit all the time when N-; the left computer is driving the. graphic.^display and when the-g:.- /;.; light is off the right computer^i s'driving the' graphic d i splay^'3^'K-N; They will automatically swap this;, job backwards and. forwards a time basis. ' * '.-V- N-:' T - ^ ' ; ?V- Another check that can.be done...is'-;open' the door bn the MODV can .and on the inside, you will see!,rows of; DO CARDS with lights.on; i. -P- ! them". In each row of cards therMeft^ rowTis Tor the left compute : > and the right row is for the' right computer.r All the' lights"should'^' be on (may be dimly lit)if any.-of N the slights are'off or blinking..-N -V then that computer is probably having, problems. .. ';^ By knowing the above informationif,the system is acting up : when the DS #7 light is on then it is likely the left computer' (mother board) is the problem or if. thej,system has problems with.., DS ?7 light off it is likely the" right doraputer is the problem. '"* ' 2. If you can the determine which computer is giving problems then that computer can be haulted by using the switch below the computer and the other computer will contiue to run the process. In the event the wrong computer was haulted just turn the switch back on and hault the other one. NOTE: If system is acting strange, the system can be shutdown and problems with the computer can be repaired and system restarted. NOTE: If you haulted a computer always contact the area engineer as soon as possible so he/she can notified the proper people to have it reparied or contact the MOD 5 hardware group directly, the mod hardware group is on call on a 24 hour basis. NOTE : MOD 5 hardware group piicne -6248 after hours 2S5-6770 '7/18/91 MODMOTHER.PRO v r V-2 "y, -' ' - > ' 'V. do 01P873 CONFTDFNTTAI i /artment: CMP ( /b Title: Quench Start Up. Procedure Scope: To Provide The Operator Kith The Necessary Information Needed To Assist The Operator With The Safe And Proper Method To Start-up The D-1320 System Major Hazard(s): Chemical Exposure, . Hot Piping, Inert Atmosphere. Safety Equipment Required: Minimum Block Standards. *********************************************** a********************************* * NOTE: REMEMBER THAT BOTH THE QUENCH SYSTEM AND R-1300 ARE TIED * * TOGETHER DUE TO THE FACT THAT THERE ARE NO BLOCK VALVES TO * ****************IS*O**L*A*T*E**O*N*E**F*R*O*M**T*H*E**O*T*H*E*R*. *************************************** 1. Ensure that the following transmitters are , line up * AI(223) pressure trans on D-1320. * AI(201/211) D-1320 level * AI(222) Quench recycle * AI(233) P-1320 discharge press * AI(207) D-1320 blowdown to E-l 2. Line up the following control valves, fans and P--1320 s. Also place P-1320A/B in automatic. * AO(203) Recirculation control valve * AO(213) D-1320 to D-1450 blowdown control valve * A0(223) M3/M4 from T-1555 or C1520 btms * Ensure that the fans and variable drive on fans are racked in and ready for use. 3. Start up at least THREE fans on E-1320 using DK<61) through DK<66). NOTE: Be sure at least 2 fans running on E-1420 to terminate to step 205. 4. Place the quench system in step 20b. 5. Add about 45% level to D-1320 from either C-1520 bottoms or from T-1555 (must manually line up in the field). Open AO(223) by making DK(71) "TRUE". * P-1320 A/B will energize and recirculate back to D-1320 when the level gets to within 10% of the level setpoint AK(20ii 6. Line up D-1320 manual block valve and control valve to.D-1 and start up the D1 system, (see D1 start up procedure). E 2/92 QUENCHSU.PRO 00 012874 C0NF T DFNT T At.