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Operating Procedures Unit PVC Reactors Page { III. OPERATING PROCEDURES (CONTINUED) V. Incinerator General Information The incinerators remove VCM from the recovered monomer (RVCM) receivers inert vent stream via combustion with air. The vinyl chloride emission standard limits the maximum concentration of vinyl chloride in atmospheric vents to 10 ppm. To reduce the VCM level in the RVCM receiver inert vent stream, the inerts stream is first cooled to 40F by the chillers on top of the receivers to condense the majority of the contained VCM. Inerts (and VCM) are 'iurh in a high efficiency burner at an operating temperature of 2-r460-F. ______ ____ Hydrogen chloride is a^byproduct)of combustion. 224-6 The liquid seal flame arrestor prevents burning VCM or natural gas from flashing back through the inert vent line to the VCM re ceivers. The flame arrestor is a small vessel filled 1/3 to 1/2 full with an ethylene glycol solution. The inert vent line from the recovered VCM receivers enters the flame arrestor just above the liquid level. Internal baffles direct the flow of gases down- / n- /. ward, into the liquid. The inerts and VCM vapors pass <mder neath.) the baffle and exi^t out the top of the flame arrestor. A separate line runs to each incinerator from the flame arrestor. DTH 000112137 Operating Procedures tJevJj&te unit PVC Reactors Page 2- III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) General Information (Continued) The combustion gases from the incinerator are scrubbed with water in the quench tank and the packed scrubber. The incinerator's effluent gases are cooled and the hydrogen chloride is absorbed in the water, forming hydrochloric acid. & BothAthe incinerators are not to be operated at the same time. Each incinerator has a double block and bleed valve assembly in the inerts feed line. These block valves will be closed whenever the incinerator is not in "high fire". This prevents flashback from one incinerator to the other. A manual block valve at the flame arrestor should be closed for the incinerator that is being used as the spare. The major operating parameters of incinerator operations are as follows: 1. Both incinerators will operate continuously, either in the "high-fire"^ or "low-fire" position orA"pilot-on" position, a. The "high-fire", or vent position is used when venting the inerts stream to the incinerator. This position provides maxijimu^ombustion air flow to the incinerator's combustion chamber to insure that sufficient air is available for com bustion. DTH 000112138 Operating Procedures ^J*u/s& Unit PVC Reactors Page 3 III. OPERATING PROCEDURES V. Incinerator (Continued) General Information (Continued) b. The "low-fire" position is used when venting is not re quired. This reduces combustion air flow to the inciner ator so that natural gas flow can be minimized. This posi tion keeps the flame stable and keeps the incinerator in a "ready" state. c. The "pilot-on" position may be used on the spare incinera tor to conserve energy but to have the incinerator operat-T ing. Only the pilot tight will be lit and will be fed a natural gas stream. The incinerator will have to be warmed up before use, which will take about 12 hours. 2. An increase in pressure on the old unit RVCM receivers indi cates the need to vent inerts from the receivers. The panel operator will vent the inerts if the pressure is above the max imum pressure given on the receiver pressure indicator, or according to the Shift Supervisor's instructions. 3. The incinerator s combustion chamber will operate at approxi7VCO o mately 2-y40G F at all times and will be controlled by the dual^c'/t^?'^ 'i\sc<L When insufficient VCM is present to sustain the combustion chamber temperature, supplemental natural gas will be added. DTH 000112139 Operating Procedures iiwfliS Unit PVC Reactors Page Lf III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) General Information (Continued) When excess VCM is present and the combustion chamber tempera- ....dh-k ) /J ture is brgk, steam will be added to decrease the temperature. Sudden changes in temperature can damage the combustion chamber firebrick and refractory. 4. The hot combustion gases flow from the combustion chamber through a Hastelloy tube into the quench chamber. Water is sprayed on the outside of the Hastelloy tube, cooling both the tube and the combustion gases. This cooling is required to prevent "melting" of the quench chamber liner. 5. Hydrogen chloride is removed from the combustion gases by the quench chamber and scrubber water spray. This produces a hy drochloric acid solution which overflows from the quench tank into the sewer. Hydrochloric acid can cause seve^ burns. In case of contact, wash the exposed area thoroughly with water and contact the Shift Supervisor immediately. DTH 000112140 Operating Procedures Unit PVC Reactors Page 5 III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) General Information (Continued) 6. Special operating procedures must be followed during initial start-up of the incinerator to dry and cure the firebrick. The same procedure should be followed if the incinerator has been shutdown for an extended period of time and the combustion chamber temperature dropped to less than 1,000F. Modified procedures can be used for short shutdowns. 7. The chief operator will check the incinerator at least twice per shift. Attention will be given to flow, pressure, and temperature indicators that are provided at the incinerator site. 8. A constant amount of quench/scrubber water is supplied to the quench tank and the scrubber from the cooling water blowdown. g. City water will be used as the emergency source for the quench water in the event of a power outage or of low water flow. DTH 000112141 Operating Procedures A&O -Q4-Unit PVC Reactors Page III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Safety Procedures Items which are of particular concern for working safely around the incineration system are as follows: 1. Hydrochloric Acid - One of the byproducts from the combustion of vinyl chloride is hydrogen chloride. The hydrogen chloride is absorbed in water forming hydrochloric acid. Hydrochloric acid and hydrogen chloride are poisonous and very corrosive. Contact with either one causes burns and ulceration of the skin. A safety shower and eyewash basin are provided at the incinerator site. The eyes or skin should be flushed immedi ately with water for five minutes or more following contact with hydrochloric acid. Any water in the incinerator area may contain hydrochloric acid. When working around the quench chamber or scrubber where there is any possibility of coming in contact with the process streams, full face mask, protective rubber gloves (not cloth or leather) and clothing are required to avoid skin contact. The quench chamber and scrubber water should be drained to the sewer and then flushed with city water before opening -the unit0 for maintenance or inspection. DTH 000112142 Operating Procedures faduASbd Unit PVC Reactors Page III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Safety Procedures (Continued) 2. Hot Metal Temperature - The shell of the combustion chamber is not insulated. If it were insulated, high temperatures would be generated at the carbon steel surface which would affect the integrity of the metal. When the incinerator is operating, the outside surface temperature of the combustion chamber will ex ceed 300F. Contact with the combustion chamber must be avoided unless protective clothing is worn. 3. Explosive Mixtures - When the fuel gas and combustion air con trol valves are adjusted for proper firing rates, an oxygen is analyzer should be used to determine the quantity of oxygen in the stack gases. Excess oxygen should \alwasy> be present in the (Pi\d do p r<? 5 stack gases to avoid forming explosive gas mixtures/ itui amount of oxygen in the stack gases should range from three to , j n`j / seven percent on a dry gas basis under all firing conditions. The unit should never be run during oxygen deficient conditions (that is, when no oxygen is detected in the stack gases). If this whlii lo happen3, the incinerator must be shutdown and placed in the purge cycle to remove the flammable gases. 000112143 dth puJ Operating Procedures Unit PVC Reactors Page $ III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Local PapfjL Switches The chief operator must be familiar with all of the switches at each incinerator local panel. Care must be taken to assure that all switches are in their proper positions for safe incinerator operation. The following switches or pushbuttons are located on the local panel at each incinerator. Each local panel operates only the equipment associated with the specific incinerator that the panel is nearest. Figure 10 in the Appendix shows the local panel layout. 1. Air Blower Start Button - Starts the incinerator air blower. 2. Air Blower Stop Button - Stops the incinerator air blower. 3. Purge Start Pushbutton - Starts the unit purge cycle. (in 4. On-Off Switch - Can be used as^emergency shutdown switch. f / // --, Must be on for the incinerator to light, vt/ 0{4 5. Warm Up/Rrm Mode Switch - WARM-UP only allows the pilot flame to light. This will allow the temperature to run about 500-600F. In the RUN position, the main flame can be lighted. When the main flame lights, the pilot kicks off after 10 seconds. 6. Burner Selector Switch (Low-Fire, High-Fire, Remote) - ^Remote* allows control room operation of the burner . The incinerator can be placed in low-fire or high-fire from the local panel using the switch, U !> I u/i (/ `iiC( n' L: (W A<7/^'7 M [fiani-uJt^ -j re . t (r <> /uc<'f' *^ U ^< Cl DTH 000112144 Operating Procedures /V&4 .old Unit PVC Reactors Page Cj III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Local Panel Switches (Continued) 7. Burner Start Pushbutton - Ignites the flame for the pilot and/ , (juJ, SfVik- or main burner by opening the fuel gas valves r-depending-on the WARM-UP/RUN mode switch position^'V-Vm/Ao s uJ-lic k ih {'it* 8. Horn Silence Button - Silences the alarm horn at the local panel. 9. Annunciator Lamp Test Button - Can be used to test the local alarm panel to make sure all lights are operational. The following indicating lights are on the local panel: 1. Blower On - Indicates that the motor is running on the air blower. 2. Purging - Indicates that air is purging the combustion chamber. The purge time is set up on a timer that is adjustable by in strument maintenance personnel. 3. Purge Complete - Must come on before the pilot or main flame can lighty, Xt indicates that the purging timer has completed its cycle. 4. Pilot On - Indicates that the fuel gas valves to the pilot light are open. * 5. Flame On - Indicates whether or not the pilot or main flame js lit as seen by the flame scanner. DTH 000112145 Operating Procedures fJevO-QHr Unit PVC Reactors Page (o III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Start-Up Procedures 1. Set all circuits and safety limits for normal conditions as follows: a. Set the total water flow (flow indicating switch downstream of the strainers) at (80% on the/scalejf^/ r. b. The "City Water" alarm on the local panel should be off. See Troubleshooting procedures for clearing the alarm. c. Set the scrubber water flow (flow indicating switch down- ___ . -fli-li-'Wl*!. \ stream of the glo/e valve) at on theAscalef(i y/'Mj d. The fuel gas pressure (pressure gauge downstream of the pressure regulator) at the incinerator should be 3 psig. e. The steam pressure (pressure gauge upstream of the steam control valve) at the incinerator should be greater than 100 ^isp. f. The liquid seal flame arrestor must he 1/3 to 1/2 full with f. ^ liquidow/ bbtk i/al'^ c<^C/ 2. Place the operation mode switch in the WARM-UP position. cti 3. Place the on-off switch in the "x&f" position and the burner selector switch on *low-fire at the local panel. The auto matic block valves in the fuel gas line must be closed^ 'iiszjL DTH 000112146 Operating Procedures Unit PVC Reactors Page |t III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Start-Up Procedure (Continued) 4. Start the air blower by pressing the blower start pushbutton. ;l The blower-on indicating light should come on. 5. Turn the local burner selector switch to high-fire. 6. Tell the lead operator to switch the fuel gas temperature con troller to manual and make sure the fuel control valve is wide open so that fuel gas flow to the main burner will not be re stricted. Check the combustion air pressure (^Jand purge air flow to the pyrometers. The combustion air pressure should be about 1.5 psig and a flow rate of 7.0 CFM is required to each pyro meter. 8. To start the purge -swifceh Lu fclie^ON 0 pu sipress the purge start pushbutton. The "purging" light should come on. This light will remain on until the purge cycle is comlete and the Spurge-complete*light comes on.9 9. The pilot is ready to be ignited. Turn the burner selector switch to low-fire. DTH 000112147 Operating Procedures /'Jguo (fH4 Unit PVC Reactors Page /2-- III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Start-Up Procedure (Continued) 10. Depress and hold the burner start pushbutton. The solenoid valves in the pilot line should open and the ^pilot-on^light will come on indicating the flow of fuel gas to the pilot. If the pilot is ignited and the flame is proven within ten seconds, the`ilame-on^light will come on. The burner push button can then be released. 11. If the pilot flame has not been established within ten seconds after depressing the burner start button, the solenoid valves will close and the/pilot-on'and ^urge complete11 lights will go off. Turn the burner selector back to high-fire. The unit must be repurged starting from step 8. 12. After the pilot flame has been proven, the pilot will remain on until the operation mode switch is turned to the RUN posi tion. In the RUN position, the solenoid valves in the main fuel gas line will open, igniting the main flame and after ten seconds the pilot solenoid valves will close. As long as the main burner flame is proven, the flame-on light will re main on. The incinerator is ready to proceed through a proper heat-up schedule (step 16). DTH 000112148 Operating Procedures {le^J Unit PVC Reactors Page III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Start-Up Procedure (Continued) 13. If the main burner does not ignite and the pilot flame is out, the main fuel gas solenoid valve will close. Turn the burner selector switch back to high-fire. The incinerator has to be restarted from step 8. 14. If the refractory does not require curing and the incinerator has not cooled to below 1000F, the unit can be brought on line without proceeding through the heating schedule outlined below (step 16). Turn the burner selector switch to the remote position at the local panel. In the control room, the board operator controls the temperature rise by manually regulating the fuel gas control valve. The temperature should be raised approximately 125F per hour. This can be observed by checking the refractory temperature indicators on the local panel at the incinerator. When the firebox temperatue is lScoQ above'2688 F, the low temperature light on the control panel will go off and the light will come on. 15. When the ready light comes on, the lead operator will put the temperature controller for the fuel gas in automatic. The in cinerator is now ready for inert venting. 000112149 DTH Operating Procedures Miuj ftjfrft Unit PVC Reactors Page \Lf III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Start-Up Procedure (Continued) 16. If the refractory must be cured, the combustion air and fuel gas valve will have to be unlinked temporarily. The air valve will be throttled as a means of temperature regulation during the first phase of the cure. a. Raise the temperature to 250F during a three-hour period. Hold the temperature at this level for a minimum of six teen hours. The continuous pilot will be used for this phase. The operation mode switch should be on WARM-^UP. b. Raise the temperature to 1100F over a seventeen-hour period, at a rate of approximately 50F per hour. This will require turning the operation mode switch to the RUN ~^v positionm^ikfe change over from pilot to low-fire main flame,,rauot occur during thio time. The pilot will only heat the incinerator to about 500-600F. c. Increase the temperature at a rate of 100F per hour to 1500F over a four-hour period. d. Raise the temperature from 1500F to 2400F over a fivehour period, at a rate of approximately 175F per hour. Relink the combustion air and fuel gas control and place the fuel gas controller on automatic. ,. , i?1* ,, . sL&vXH &X --QrfrltfF' , (. . (wets 5Luti' Am fog. iA-nipif UidJ ItUvtJilCoffry I'tCk) A<^a 4v ^Oi)CF. DTH 000112150 Operating Procedures d Unit PVC Reactors Page (5 III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Relighting Procedure The following procedure will be used to relight either incinerator if it is shutdown during operation. The condition that caused the shutdown should first be corrected per the Troubleshooting proce dures in this section. This procedure should not be used if the temperature has cooled below 1000F. If the temperature is below 1000F, refer to the Start-Up Procedures. The relighting proce dure is posted on the local panel at each incinerator. The incin erator must be re-lit from the local panel. 1. The incinerator blower must be on. 2. The incinerator should be "ON" and in the RUN mode. 3. Put the burner selector switch in high-fire. The fuel gas con trol valve should be showing wide open on the control room in dicator. 4. Press the purge start pushbutton. The"purging1*light should come on. 5. When the'^purge complete!' light comes on (within three minutes), put the burner in low fire. The*'purging'* light should go off when the'purge complete11 light comes on. C^> c%frt te*vC, j C: L(Jz 'His pc^ r/uh' no jut 6. Press and hold the burner start pushbutton. Tne"pilot on^light should come on and the^flame on1light should come on within ten seconds. -3 DTH ooqh215^ Operating Procedures 0d Unit PVC Reactors Page \y III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Relighting Procedure (Continued) =9 7. When the'lflame or!1 light comes on, release the burner start button. The^pilot on'and 'purge complete4*light should go off when the Aflame on*light comes on. 7" 8. Put the burner in remote to allow operation from the control room. 9. If the procedure is followed and the incinerator will not re light, instrument maintenance may be required. Notify the Shift Supervisor and follow his instructions. Inerts Venting Procedure Inerts are vented out of the old unit receivers to the on-line in cinerator as needed. The inerts collect in the receivers and will cause the pressure to rise on the tanks. The new unit lead opera tor will monitor the receiver pressures and vent inerts to the in cinerator if the pressure is above the maximum allowable pressure which is shown on the receiver pressure indicator, or upon the Shift Supervisor's instructions. The maximum allowable pressure is changed at the discretion of the Operations Supervisor. ft NOTE: The receiver^ should not be vented .of the pressure is below the 'jllrminble pressure. This will cause efficiency losses due to burning excessive VCM out of the receivers. DTH 000112152 Operating Procedures A/ov-Oid Unit PVC Reactors Page / 7 III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Relighting Procedure (Continued) 1. Check the indicator light on the incinerator to be vented to and make sure it is READY. If the READY light is not on, the hi ht LOW TEMPERATURE/should be on, indicating that the incinerator temperature is less than 3000F and cannot be vented to. Ifro 2. When the READY light is on, press the high fire switch on the incinerator that is to be vented to. This opens the double block valves going to the incinerator. The HIGH--FIRE light will come on in the control room after a few seconds. --^ 3. Set the inert flow controller setpoint at 3 roots of flow (300 SCFH) . ~....... ----- ------------ ------- - NOTE; Flows above 300 SCFH will cause channeling in the re ceiver chillers and will cause too much VCM to be burned and the inerts will not leave the receivers as fast. Flows below 300 SCFH will allow very slow venting of the inerts. / i f ' takes- several' minutes..(5-7 minuter)--fur--the rampvalve to r open- arnl- f or -tl^e--fdrew--to--show-on - the - f low indicator. j The lead j ' operator will monitor the flow until it reaches the setpoint and lines out. DTH 000112153 Operating Procedures A/<2u/94d Unit PVC Reactors Page [g III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Relighting Procedure (Continued) Record on the incinerator checklist the time that venting begins. When the receiver pressure falls to below the vent pressure, the lead operator will pi^t the incinerator back in low'fire. The control* valves^will close and the incinerator {^<7!. flow should drop to zero. is The lead operator will record) the time that the vent was shut .A off on the incinerator checklist. Glycol Supply Drum Fill Procedure The glycol supply drum holds ethylene glycol for filling the incin erator liquid seal flame arrestor as needed. Pressure is main tained at 10 psig on the supply drum using nitrogen. When the supply drum level gets below 1/4 full, glycol must be made up into the drum using the following procedure: 1. Move a 55-gallon drum of ethylene glycol to the supply drum area. 2. Install a drum pump in the drum of ethylene glycol. 3. Attached a hose from the discharge of the drum pump to the hose connection on the supply drum. 4. Check the valves in the outlet of the supply drum and make sure they are closed. DTH 000112154 Operating Procedures New Unit PVC Reactors Page III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Glycol Supply Drum Fill Procedure (Continued) 5. Close the valve in the nitrogen supply line, l, V-'v . IT pd'h USMf TiJ 6. Slowly open the valve in tlie ethylene glycol inlet line to the supply drum. 7. Fill the supply drum about 2/3 full. 8. Close the valve in the glycol inlet line. 9. Disconnect the pump from the supply drum. 10. Re-open the valve in the nitrogen supply line and make sure the pressure holds at 10 psig. The flame arrestor can now be filled as needed from the supply drum. / Make sure the pressure on the glycol supply drum is higher than the pressure on the flame arrestor before filling the flame arrestor. Control Room Panel Alarms The following are control room panel alarms for the incinerator. Steps that must be taken to correct the problem are given for each item. Each incinerator can be normally shut down by pti'nJc switch in the con- trol room or by the en--eff switch at the local panel. DTH 000112155 d'ro'p "fU b fa* o>U<H Ux ^ ^-y\Cjill4^-l. fd(froCj^\ 01 ( (( ci^o^Mx^c` &jjj<^yt ^ CQM^-- t xy 7''" t?v / ^ ' >/ ^ s^>/-^ ff ft /_r 6^ Y ^ "U'-'d-' s4 -(<-'2^ 5 i^CiJ VpLdlfiJ ^ ft r<^' \J')\1^^ Uf 'ftn kcUof* t&d sf/ .3 4t^L wIm drorti - DTH 000112156 Operating Procedures New Unit PVC Reactors Page (,) III. OPERATING PROCEDURE (CONTINUED) V. Incinerator (Continued) Control Room Panel Alarms (Continued) The double block and bleed arrangement for the fuel gas and inert vent line will close automatically during all emergency shutdown conditions. When the incinerator is in a shutdown mode, the unit will be purged with air from the air blower. The air blower will continue to run unless the shutdown was caused by air blower failure. Steam will be used to purge th^unit if the air blower fails. Steam flow should last two minutes. If the problem which created the shutdown cannot be solved in a short period of tiem, the blower should be shut off to avoid excessively cooling the re fractory (to less than 1,000F); however, do not shut the blower off until the steam line is blocked in. The steam purge comes on automatically anytime the air blower motor stops. The steam line should be blocked in to avoid cooling the refractory unnecessarily. 1. Incinerator Shutdown Alarm (or Shutdown Summary Alarm^ - This can be caused by any of the following emergency conditions which automatically shut down the incinerator: a. High fuel gas pressure*5 C' pinf b. Low fuel gas pressure/ ( C. -7 >(-')# c. Flame failure," d. High firebox temperature^ i'71 CO ' t e. Low water flow (3<? <? ;v.i n>t DTH 000112157 Operating Procedures New Unit PVC Reactors Page *;. ( III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) --Con-t-rol -P---a--n-;-e--l---R--oom:---A--l-a--r--m---s-- --(-C--o---n--t-i-n--u--e---d-)--' (, _J. ,t ( i A?flh (i'tf-A j\ K Low"combust Ion aiF^ressuri^J/~"7;7^,n- ) g. High quench effluent temperature^ ( iyOcF h. Air blower failure^ . je/pcvit \ i. Waste gas (inerts) high pressure^ 5$ fb>9^i<,<r-f't t#tkfr-m*)#*) < The lead operator will notify the chief operator i*f^necegsarys that C,the incinerator has shutdown. The chief operator will proceed to i/the local panel to identify the problem per the local panel alarms and to correct the problem and restart the incinerator as soon as possible. Each potential problem will be discussed below. 2. High Firebox Temperature Shutdown or Refractory High Tempera ture (Setpoint 2800F) - This alarm and shutdown should normally follow a high firebox temperature alarm and condition (see below for corrective measures). If the alarm sounds, check the temperature indicator for the firebox temperature as measured by the pyrometers. If normal conditions exist, the alarm indicates a burned out thermocouple. A maintenance work (uiii -ri'^rtw c.<up order should be processed as soon as possible/since the unit f'fpa.i will shutdown if the spare thermocouple burns out. DTH 000112158 Operating Procedures New Unit PVC Reactors Page III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Control Room Panel Alarms (Continued) 3. High Firebox Temperature (Setpoint 2600F)_)^ a. Check the pyrometer signals for error. Switch to the other pyrometer if this is the source of the problem. b. Check the temperature controller to make sure the fuel gas valve is closed. The setpoint for the fuel gas temperature control valve should always be less than the setpoint for the steam temperature control valve. If the fuel gas valve is closed, the steam valve should be open. c. Switch to low-fire if venting. In the low-fire mode have an outside operator check steam flow and pressure. If the temperature continues to rise, the unit will automatically shut down. d. Check the combustion air pressure/and line for sufficient air supply to the burner. I.9C0 o ( 4. Low Firebox Temperature (Setpoint F))^ a. Check the temperature indicators to see if the controlling pyrometer signal is in error. If it appears to be drift ing, switch to the other, pyrometer for control. y b. Cheeky steam temperature control valve for steam addition. The steam valve should be closed. The setpoint for the fuel gas temperature control valve should always be greater than the setpoint for the steam temperature control valve. DTH 000112159 Operating Procedures New Unit PVC Reactors Page o III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Control Room Panel Alarms (Continued) t Check the fuel gas temperature controller to make sure the fuel gas valve is fully open. If the temperature continues to drop while venting, switch to low-fire. d. If the temperature is decreasing in the low-fire mode, ( i:'^ have aaoutside operator check the fuel gas flow and burner pressure. If the burner pressure is not normal, the burner may be plugged or the gas regulator may be malfunctioning. Shut the unit down^W'' (tHWcf e. Check the combustion air pressure and- line for sufficient air supply to the burner. u> -<tc~ (J MX tiiji-l' Gfib t'&Hj hnlcKi^ -/p n*t* SfP). 'rf // /'/ /j {&&& 5. Steam Valve Open - This alarm comes on when the steam valve 7 '56^* L ' kywV' p.tc that is used for cooling comes on. Upon acknowledging the j 'fpJ'rJ2fain I Hfvuhlai^ iT alarm, the lead operator should check the fuel gas valve toj \JSuJ(s-Xt make sure it is closed. If it is not closed, either the fuel gas temperature control valve setpoint is set incorrectly or there is a malfunction in the instruments, requiring a main tenance work order. The setpoint for the fuel gas temperature control valve should always be set below the steam temperature control valve setpoint. The lead operator will also check the flow of inerts to the incinerator and may need to reduce the flow if it is too high. The flow should normally be set at 3 roots of flow/ .3'-''0 itF'ft) < DTH 000112160 Operating Procedures New Unit PVC Reactors Page ij. III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Control Room Panel Alarms (Continued) 6. Malfunction Alarm (or Malfunction Summary Alarm) - This alarm i i\'d\^ '~W\cct o ft) It t M //is on at the local incinerator panel. The lead operator will notify the chief operator who will check the local panel and correct the alarm condition as soon as possible. 7. Total Water Low Flow (Setpoint 30 gpm) - A water flow less than 30 gpm through the total water flow meter will shutdown either incinerator if it is in the RUN mode. a. Check the water pressure before and after the strainer. If the pressure drop is excessive (more than 20 psig), switch to the spare strainer and clean the dirty strainer Cl '.Cl as soon as possible, / it i/\& tetri htto $<' C G-C 5 fa uTtej < G .. J, b. Check the water valves to make sure they are open from the cooling water blowdown line to the total water flow meter. c. Check the total water flow globe valve and open it as needed to get the flow back to the required 46 gpm.8 8. Exhaust Stack Low 0^, Concentration (Setpoint % Oxygen) - This alarm comes on if the oxygen in the exhaust stack gases ,galls below 2 percent. DTH 000112161 Operating Procedures New Unit PVC Reactors Page 05 III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Control Room Panel Alarms (Continued) If this alarm comes on, the incinerator must be shutdown and placed in the purge cycle to remove the flammable gases. The Car' fuel gas and combustion control valves linkages should also be checked to make sure they are tight and that proper amounts of air are being fed to the burner. 9. Incinerator Feed, High VCM Concentration (Setpoint % VCM) This alarm comes on in high fire if the VCM concentration in the inert gas stream rises to % VCM according to the inlet gas analyzer. The following should be checked: a. Check the receiver pressure. If it is below the set venting pressure, put the incinerator in low-fire to stop the flow of VCM to the incinerator. b. Have the chief operator check the operation of the Frick refrigeration unit. The chief operator should make sure that the switch is on to the receivers that are in service and that the suction ( 35 psig) and discharge pressures (125-150 psig) are normal. jyjH 000112162 Operating Procedures New Unit PVC Reactors Page III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Control Room Panel Alarms (Continued) 10. Incinerator Feed High (^Concentration (Setpoint % Oxygen) This alarm indicates that the oxygen concentration in the in ert gas feed stream is too high, as measured by the inlet gas analyzer. This could cause a potentially explosive condition. All sources of getting air into the recovery system should be checked and any valves open to the atmosphere must be closed. Notify the Shift Supervisor for instructions. The two following alarms are control room panel alarms for the west incinerator that are not included on the east incinerator control room panel: 11. High Quench Effluent Temperature (Setpoint 160F) - a. Check the temperature controller to make sure the incin erator operating conditions are normal and that steam is properly cooling the combustion chamber as needed. b. If the incinerator water flow is below 46 gpm, adjust it as needed to reach the desired flow. Switch water strainers, if needed. c. If the temperature does not drop, put the incinerator in low-fire to lower the temperature. Temperatures above 180F can damage the water scrubber and will shutdown the incinerator. DTH 000112163 Operating Procedures New Unit PVC Reactors Page 27 III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Control Room Panel Alarms (Continued) 12. City Water On (Setpoint 35 gpm) - Cooling water flow switches automatically to city water if the total water, flow drops to -fcr /j, below 35 gpm. A manual switch/north of the D-500/600/700 >/ cooling tower/tis used to/\ switch Jatek to^tower watery. LtT-j l t a. Check to make sure the cooling water blowdown line is not blocked in or plugged. b. If the switch was caused by a power outage, do not reset the valve until the power has been restored completely. C, Slcm'/c /I -/c (jl* %hllh. 'Wji -f /i - rs'iuUi iLr The following alarms for the liquid level in the liquid seal flame arrestor are also located in the control room;: near--the--pushbuttons 13. High Liquid Level, Flame Arrestor - Have the chief operator check the flame arrestor .and the glycol supply drum to make -f/vr l/alm ts-iS.1 sure they are/closed. 14. Low Liquid Level, Flame Arrestor - Have the chief operator check the flame arrestor for leakage, especially the sample valve and bleed valve on the level gauge. 000U2164 Operating Procedures New Unit PVC Reactors Page III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Local Panel Alarms n The following alarms are shown on the anm^ciator panel at the local control panel for each incinerator. The chief operator must take the necessary steps to correct each condition and clear the alarm as soon as possible when one of these alarms go off. Each alarm either causes a malfunction or shutdown alarm on the control room panel and the lead operator will notify the chief operator when either of the alarms go off. Items 1-7 are malfunction alarms and items 8-16 are shutdown alarms. 1. Low Scrubber Water Flow (Setpoint 3.5 gpm) a. Immediately check the water pressure at the gauges near )J the total flow indicating shutdown switch. Ifymore than a 10 psig differential pressure, switch to the spare strainer. b. If the water flow hasfl-^ increased after switching strainers, open the globe valve for the scrubber water further. 2. High Quench Effluent Temperature or High Scrubber Temperature (Setpoint 160F) - See item 11 under Control Room Panel Alarms. DTH 000112165 Operating Procedures New Unit PVC Reactors Page ^cj III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Local Panel Alarms (Continued) 3. High Quench Tank Level (Setpoint 10" Water Column) a. Check the water flow at the total water flow indicator. If the flow is above 50 gpm (100% on the scale), close the globe valve at the quench tank until flow is about 46 gpm (90% on the scale). b. Open the drain valve on the quench drain seal leg. Close the valve after the level drops below the high level setpoint. c. If the incinerator is in the high-fire mode of operation, put it in the low-fire mode. If the level does not de crease immediately, close the glove valve for the quench tank feed. Do not decrease the flow below the setpoint for the low total water flow (60% on the scale). d. If a high level continues and burner operation becomes erratic (increased gas and air pressure at the burner, poor temperature control, etc.), shut the unit down before the water level reaches the firebox. After the unit is shutdown, block in water flow to the unit and drain the level until it reaches^normal operating conditions. DTH 000112166 Operating Procedures New Unit PVC Reactors Page III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Local Panel Alarms (Continued) 4. High Fuel Gas Pressure (Setpoint 3 psig) ^ a. Check the fuel gas pressure regulator. It may be stuck partially open. b. Decrease the setpoint for the fuel gas temperature control valve. Observe the burner pressure at the pressure gauge located downstream of the fuel gas control valve. If pressure does not decrease, the burner may be plugged. Shutdown of the unit may be required to unplug the line. 5. Steam Low Pressure (Setpoint 60 psig) - Sufficient steam pres sure is needed for cooling the incinerator in high-fire. The chief operator will instruct the lead operator to put the in cinerator in low-fire until steam pressure is regained. f6. City Water On (Setpoint 35 gpm) - Sejt Control Panel Alarm Number 12^t 7. Refractory Thermocouple Failure - Indicates a malfunction in one of the thermocouples. Use the spare thermocouple and have the broken one repaired as soon as possible. DTH 000112167 Operating Procedures New Unit PVC Reactors Page 3 j III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Local Panel Alarms (Continued) 8. Waste Gas (Inerts High Pressure (Setpoint 5 psig) - The incin erator being vented to will shut down if the inerts pressure at the incinerator exceeds 5 psig. Check the pressure control, (j'f- '//*? r^ci't'toi'Uj (U^d '-Ml. -f{cltd lrt-'ltL "h valve setpoint^and reduce prior to re-starting the incin- erator. Monitor the pressure following startup. Watch for ex cessive cycling or the pressure switch may be defective. Write instrument maintenance work orders for repairing these as soon as possible. 9. Low Fuel Gas Pressure (Setpoint 0.3 psig) - The incinerator flame may not be able to be sustained if the fuel gas pressure falls below 0.3 psig. Check the fuel gas regulator and pres sure switch and make sure the valves are fully open. 10. Fuel Gas High Pressure (Setpoint 5 psig) - Follow the same steps given for the malfunction alarm, number 4 (above). DTH 000112168 Operating Procedures New Unit PVC Reactors Page ^ 2,, III. OPERATING PROCEDURES (CONTINUED) V. Incinertor (Continued) Local Panel Alarms (Continued) 11. Combustion Air Low Pressure (Setpoint 1 psig) - Proper oxygen levels are necessary for safe incineration of the inerts. If the air blower pressure falls below 1 psig going into the burner, the unit will shut down. Check the air blower suction f'ittfft for pluggage and make sure the blower is running. Then check the pressures using correct gauges and check the pres sure switch. 12. Air Blower Failure - Failure of the air blower motor will^ shut down the incinerator. Check the blower motor and/or have the shutdown switch checked. The air blower must be running or the unit will not startup. 13. Refractory High Temperature (Setpoint 2800F) - Same as number 2 under Control Panel Alarms. 14. Flame Failure - Indicates that the flame scanner cannot see a flame. Maintenance may need to pull and clean the face of the scanner. TV ^ riaw-b un7 / n* s/i(-klu' b C-L, cjo?d, /'U.U. xu rfro, / n 'jfu i/tth* ch(iu,!tf lrsCie. iOiU LC<A 15. Low Total Water Flow (Setpoint 30.43) - Same as number 7 under ? w ^ $('!>' 4;//ft iPol < Control Panel Alarms/above). V. DTH 000112169 Operating Procedures New Unit PVC Reactors Page 33 III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Local Panel Alarms (Continued) 16. Scrubber High Temperature Shutdown (180E) - Take the steps given in number 11 under Control Panel Alarms (above). DTH 000112170 (fperating Manual ld Unit PVC Reactors rag^ | IIP. OPERATING PROCEDURES (CONTINUED) J. Methocel Makeup General Information The methocel solution used in the plant is a 1.5% solution of Methocel in water. The methocel must be mixed with water, heated and agitated for a specified length of time, then cooled to make a good quality colloid solution. The "A" operator must makeup methocel as soon as possible after the methocel makeup tank is emptied to prevent reactor charging downtime. The methocel makeup procedures must be followed very carefully by the "A" operator. Methocel makeup has a big effect on the particle size of the resin produced. Carelessness in making up methocel can cause several reactor coarse batches resulting in p large product lossftj.Every "A" operator must be careful to makeup methocel exactly by the also ; procedures^ everytime. Care should 409P be exerqped when working in the methocel tank area. Methocel is very slick and spills will present a dangerous slipping hazard. Procedure 1. When the methocel makeup tank comes empty, the "A" operator will notify the lead operator that he is going to makeup methocel. 2. If necessary, the "A" operator will rinse the colloid makeup tank with water to the sewer until it is clean. This will require opening two valves to the sewer drain. The methocel DTH 000112171 Operating Manual Old Unit PVC Reactors Page 7" III. OPERATING PROCEDURES (CONTINUED) J. Methocel Makeup Procedure transfer pump discharge valve into the methocel charge tank must be closed when rinsing out the makeup tank to prevent getting water accidently into the charge tank. This valve is at the top of the charge tank. Buildup of undissolved methocel in the tank must be cleaned out of the tank for methocel makeup to be consistent. Close the valves to the sewer after rinsing the tank and re-open the valve to the charge tank. 3. The "A" operator will close the valve at the bottom of the -h methocel makeup tank^that transfer cannot ^ake place during makeup. 4. The "A" operator will take 3 bags of Dow F-50 Methocel powder (50 pounds per bag) to the top of the colloid makeup tank. The lead operator will check to see if the charge water pumps are available for making up methocel when notified by the "A" operator. As soon as the pumps are available he will notify the "A" operator that he is ready to put hot water into the methocel makeup tank. The charge water pumps should not be used for any other operation while charging hot water into the methocel makeup tank. I)TH 000112172 Operating Manual Old Unit PVC Reactors Page ^ III. OPERATING PROCEDURES (CONTINUED) J. Methocel Makeup Procedure 5. The "A" operator will proceed to the top of the methocel makeup tank and tell the lead operator to start the charge water pump. 6. The lead operator will: a. Put the charge water temperature controller in manual and close the valverp >This prevents cooling off the water charged into the methocel makeup tank which will lengthen the solution heat-up time. b. Turn on one charge pump. c. Open the pump discharge valve. d. Monitor the hot water charge counter on the panel and reset it to zero when it stops counting. e. Tell the "A" operator to open the hot water valve going into the makeup tank. 7. The "A" operator will open the valve and monitor the water flow into the tank when the lead operator notified him to open the valve. .8 The "A" operator will let the water flow into the makeup tank until it touches the top agitator blade. This will be a little more than half full and the water counter will show about 72 counts. He will then shut the hot water valve at the tank, and tell the lead operator to cut off the charge pump. DTH 000112173 Operating Manual Old Unit PVC Reactors Page III. OPERATING PROCEDURES (CONTINUED) J. Methocel Makeup (Continued) Procedure ^ 9. The lead opertor will then close the hot water charge pump, discharge valve, shut off the pump, and put the hot water charge temperature controller back in automatic. 10 The "A" operator will use the following steps to finish the methocel solution makeup: a. Start the makeup tank agitator. dr b. Open the steam valve to the jacket and the jacket ohain valve to the sewer. c. Allow the water to heat to 180F. d. Shut the steam valve to the jacket and the jacket drain valve to the sewer. ,/ a e. Carefully cut the bagsyjopen with a safety knife. Add the Methocel powder very slowly with the agitator on. Each bag should take about one minute to add. If the powder is added too quickly, it will form lumps and not dissolve properly. Be careful not to drop the bag into the tank. Carry the empty bags to a trash container. NOTE: A dust mask must be worn while adding the methocel __ powder to the hot water. JLXS f. Allow thirty minutes to let the agitator thoroughly mix the powder into the hot water. Visually check the mixture for lumps and continue to mix if lumps are present after thirty minutes. DTH 000112174 Operating Manual Old Unit PVC Reactors Page III. OPERATING PROCEDURES (CONTINUED) J. Methocel Makeup (Ced) Procedure g. When the mixture contains no lumps, open the cold water valve to the tank and fill the tank until the outage is 3 inches from the top of the tank. NOTE: If there is a lot of foam on top of the solution, fill the tank until the foam gets to the top of the tank. Return to the tank in about 30 minutes and most of the foam should have dissipated and the tank can be filled up to a 3 inch outage. h. Start the methocel makeup tank cooler as soon as cold water is added to the tank. This will require opening the cooling wal^: inlet and outlet valves. i. Monitor the temperature of the tank while it is cooling. When the temperature is 85F, close the cooling jacket valves and turn off the agitator. It is very important to cool the colloid solution completely each time to produce a good quality colloid solution j. A sample of the solution can be taken when it reaches 95F. Make sure the tank temperature is 95F or below before sampling. Use the following sample procedure: DTH 000112175 Operating Manual Old Unit PVC Reactors Page ^ III. OPERATING PROCEDURES (CONTINUED) J. Methocel Makeup, Procedure Q*J) (1) Obtain a^2 oz. glass jar for sampling. (2) Go to the top of the makeup tank and fill the jar with methocel solution. (3) Pour the bottle contents back into the tank to flush out the bottle. (4) Refill the bottle and put a clean cap on it. (5) Rinse off your hands and the bottle. (6) Take the sample to the lab and log it in on the methocel log for analysis. Be sure to notify lab personnel that you brought the sample so they can check it as soon as possible. 11. The lab will analyze the sample by both the scope test and oven test. If the scope test is good and methocel is needed for charging, enough methocel can be pumped over to complete the charge upon the Shift Supervisor's instructions. The oven test takes about two hours to complete. If it should come up bad, there will still be time to add methocel to the reactor that was charged per the scope test result. Both tests have to have a result of 1.40% solids to 1.60% solids for the batch to be acceptable. If either result is not within specification, resamples must be taken and the Shift ern6^~ Supervisor's instructions followed as to whether^a new batch must be madeup. DTH 000112176 Operating Manual Old Unit PVC Reactors Page ~j III. OPERATING PROCEDURES (CONTINUED) J. Methocel Makeup ) Troubleshooting 1. The Tank Will Not Heat Up - Check the cooling water valve for leakage. It may be leaking by and cooling off the tank. 2. The Tank Will Not Cool Down - Cooling in the old unit is very slow, sometimes taking four or five hours. If the tank is cooling off at a slower rate than normal, check the jacket valve and make sure it is not leaking through. 3. Agitator Will Not Run - This requires an emergency maintenance work order. Methocel cannot be madeup unless properly agitated. 0001121T7 dth