Document QgkYn9OR4dGYNX26wDJx5KNQ7

INCINERATOR EXHAUST MONITOR CLASS "A" DESIGN ABERDEEN CHEMICAL PLANT WORK BY: tinny Sharf Co-Op Process Engineer REVIEWED BY: Veldon E. Messick Senior Process Engineer APPROVED BY Richard A. Frohreich Chief Process Engineer DTH 000105928 INCINERATOR EXHAUST MONITOR ABERDEEN CHEMICAL PLANT TABLE OF CONTENTS I.PURPOSE OF DESIGN II. PROCESS DESCRIPTION III. EQUIPMENT AND INSTRUMENT SPECIFICATIONS IV. DRAWINGS DTH 000105929 INCINERATOR EXHAUST MONITOR ABERDEEN CHEMICAL PLANT PURPOSE OF DESIGN The purpose of this design is to provide a VCM detection system specifically for the exhaust of either of the inert vent incinerators. This system will monitor the exhaust stack of the "on stream" incinerator for the presence of VCM. Presently, the incinerator exhaust is monitored for VCM by the fixed point monitoring system. This stream is analyzed once every ten minutes by the monitoring system which is set at a span of 0-10 ppm VCM. The vinyl chloride standard states that any emissions from the incinerator "which averaged over any hour period (commencing on the hour) are in excess of the emission limits" (10 ppm) must be reported to the EPA. Use of the existing continuous monitoring system with a span of 0-10 ppm VCM presents a problem each time the incinerator exhaust exceeds 10 ppm or registers full scale. The exact concentration of VCM cannot be obtained and it is not positively known whether the vinyl chloride standard is exceeded. Also, with the present system, the possibility of cross contamination between sampling points exists. To correct these problems, this design proposes to install a gas chromatograph specifically for the inert vent incinerator exhaust. The proposed system will have a span of 0-60 ppm VCM and will analyze the exhaust every ten minutes. With this system, if the incinerator exhaust exceeds the maximum span of 60 ppm VCM, the average will be over 10 ppm VCM and the emission will need to be reported. If the exhaust exceeds 10 ppm but is less than 60 ppm, an hourly average can then be calculated for the emission. This system will also eliminate cross contamination problems. DTH 000105930 INCINERATOR EXHAUST MONITOR ABERDEEN CHEMICAL PLANT II. PROCESS DESCRIPTION A slip stream is taken from an incinerator exhaust stack and is filtered, dried, and pulled to the sample conditioning system. The sample conditioning system filters the sample again and sends it to the analyzer section. (The conditioning system also provides a means of calibrating the gas chromatograph with a gas standard for span and separation.) In the analyzer section sample separation is accomplished with a stripper configuration for the columns. The first column "strips" the "heavies" from the "lights" and the second column separates VCM from the "lights". A Flame Ionization Detector (FID) analyzes the VCM concentration and sends the raw signal to the Control Section. The Control Section sends a processed signal to the bargraph recorder and the Fixed Point Monitor Data Computer, both located in the Vinyl Control Room. As an option, the Control Section may send the processed signal to a second bargraph recorder located in the Old Large Reactor Control Room for the purpose of checking span adjustment and separation. The fixed point monitor data computer will receive the signal from the gas chromatograph and be reprogrammed to perform the following: 1) If the VCM concentration exceeds 10.0 ppm, the existing incinerator alarm will be activated. The concentration, time, and location will be immediately printed on the printer associated with the data computer located in the control room. These readings above 10.0 ppm will also be printed out with the shift summary. (See attached shift report format) 2) Hourly concentration averages (commencing on the hour) will be calculated. These hourly averages will be printed at the end of each 12 hour shift. (7 AM and 7PM). (See attached shift report format). 3) If any hourly average exceeds 10.0 ppm, the concentration, time (at the beginning of the hour), and location are to be printed immediately along with the message "INCINERATOR EXHAUST HAS EXCEEDED ALLOWABLE LIMITS. CONTACT OPERATIONS SUPERINTENDENT AND CHIEF PROCESS ENGINEER IMMEDIATELY". A) A monthly summary will consist of the actual number of data points grouped into the following ranges: a) 0.0 - 0.5 PPM b) 0.5 - 1.0 PPM c) 1.0 - 5.0 PPM d) Over 5.0 PPM DTH 000105931 The percentages of the data points in each of these ranges will also be calculated. (See attached monthly report format). INCINERATOR EXHAUST MONITOR ABERDEEN CHEMICAL PLANT PROCESS DESCRIPTION (Continued) 5) The data computer will be connected to the incinerator selector switch. This switch will indicate which incinerator is being used. The data computer will print which incinerator is being used on the shift summaries. Also, when the incinerators are switched, the data computer will print immediately the date, time, and indicate which incinerator is now in service. A record of the switches will be printed out on the monthly summary. 6) Shift reports will be stored so that any shift can be printed out on demand anytime during the following two weeks. DTH 000105932 INCINERATOR EXHAUST MONITOR DTH 000105933 (OA 3 i wzM HPn CzMJ H EEi CO H oz CpOy Es OBi pOci MZ CHO sa Bi OH 3 zo wz M 5: H CzJ O O W <O5 W s M o % 3 H ~u n0>o) ooZo no ps4 a o o W CM CO ABERDEEN CHEMICAL PLANT DTH 000105934 M CD 0> T3 a) S joj H 43 44 CM 2a 9*S O o 43 a4-1 o 2 0CO0 c rl M T3 (U Cd ,> 0) w s* u zs 2 M 2 Pu Pc t m o o o in o ui <U i 1 1 00 M 3 cd pi o o m o o i-H CU > 6 -<aHu 43 4-1 4-1 W (3 2a ^cd 43 43 4-1 44 CoM cO 2 to >% M cd H Q (0 13 43 O 44 IQ) /*--.s a 4U4 Xcu) 0Cd) CO 4a3 M C 44 <4 O -H CO 44 CO 13 3 O Cu CO co co cd cd &s u o cMd Mcd (U cu ee uC oC cu H -rl 43 44 *J <U CO CO g <U <U -H 33 4 M M 43 `O cd 44 44 a) CO CO cd Cd 44 W W Cd V-/ 1--^ cu ft cu <u cu 43 43 pi HH DeretJ ENGINEERING CENTER PONCA CITY. OKLAHOMA SPECIFICATION SHEET ULAl. project - ItiC.it&zAr'ciz. afe no -------------- DATE L'lS'ul W. O. NO -- MADE 8YjTL_ INO NO. APP'D BY \J&n\ REO. NO. B. M NO P O. NO. MbM/TcZ. ITEM NO. 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C,Azz\t.B 0a& Drveb ~To Bcmovg mAcer Moicrurzo T J A NO OoM TAMM A NTS Uttihk -Trie OApriEB <pAt AtEemB U5P Ah ID AIoumtoto On AnAlvzcB , P/n ^u(p\ziz-ooi. Ly.lt HDCV- IToARP Hr*r. MAiNTTJANCjT CoN\)E-N(LKKLO p/a/ So 'T^Z "03-00 1. SJdtep >____________________________________________________________________________________________________________________________ /, QjDNTR.nl. SeQjTmN Dp <OiA& ChRoMAToGlzAPP To C&NtAiM The- Followim^, aUaduus.- (0 AIdmi-tcp/zJ ^uemcee..- (nfs) Ampuf/pk- ') i>uAe ' VAlvc A feO fuAl 7-------------------*----- ------------------------------------------------------ C/dmpoaI lmt to/a* e:/a dpV. DTH 000105936 | SHEET__2-------- OF ^ REV. >_. F-270-9A Analyzer Section 5Jt } The Analyzer Section of the Model 1000 Chromatograph is designed to perform the high-speed analyses re quired by the technological advances of recent years. Although the need ex isted for near-continuous analyses of process streams, suitable gas chro matograph equipment was not availa ble prior to the introduction of the Model 1000. The heart of this high-speed analytical system is the Micro Packed Column, used exclusively in the Model 1000. With efficiencies as high as 115 plates per inch, the length of columns re quired for most analyses ranges from 2 inches to 24 inches. The resolution of the Micro Packed Column is complemented by the HighSpeed Micro Detectors; both Thermal Conductivity and Flame Ionization types have been designed and are manufactured by Honeywell. The Honeywell chromatographic valve makes it possible to utilize the com plete potential of the high-speed micro gas chromatograph. This diaphragm valve produces sample sizes and pro files demanded by micro gas chroma tography techniques. It contains very few moving parts and due to the ex tremely short movement of the pistons the valve is capable of operating, con servatively, for several million cycles. These components, the Micro-Packed Column, Micro Detectors and sample and column-switching valves have been packaged in an analyzer de signed to provide the ultimate in ther mal stability and accessibility. Analyz er oven temperature is controlled by an all solid-state proportional tempera ture controller. Several modifications to the widely used heated air type of temperature control system have re sulted in an analyzer design that per mits the full sensitivity of the Micro Detector to be utilized. The Model 1000 analyzer section is designed for use with modern comput er-chromatograph data collection or control systems. Since the Micro De tector bridge assembly and preamplifi er are in this section, a computer can be used for the timing, automatic range attenuation, and baseline cor rection without the need for special in terface modules. For further informa tion on Computer Controlled Chromat ograph Systems please refer to Hon eywell's brochure, GC-16 Computer Chromatograph System. To simplify maintenance and trouble shooting, the temperature controller, preamplifier and solenoid-switching cards are plug-in type assemblies. Manual valve control switches are lo cated at the analyzer to further facili tate maintenance. Dual-Pac and MultiAnalyzer Chromatography Systems The Dual-Pac Analyzer design houses two separate analysis applications in a single, standard-size oven. The Multi-Analyzer design uses one Control Section for multiple analyzer sections with separate programming controls for each analysis. Honeywell H-1000 Dual-Pac and MultiAnalyzer Systems can be custom as sembled to meet the requirements of your specific multi-analysis applica tion; from a single control section and a single Dual-Pac Analyzer Section, to a single control section and multiple analyzer sections. For any configura tion, the H-1000 Dual-Pac and MultiAnalyzer Systems represent the opti mum equipment utilization for reduced system costs and minimum mounting and installation space requirement. Chromatographic Valve DTH 000105937 4 Flame Ionization Detector Analyzer Section DTH 000105938 Control Section The Control Section of the Model 1000 consists of a series of plug-in assem blies, or modules, permitting each chromatograph to be "custom de signed" for the intended process ap plication by the selection and installa tion of appropriate modules. Modules are easily replaced from the front of the Control Section simplifying troubleshooting or maintenance. All electrical contacts are gold-plated over nickel providing long-term reliabil ity even when the equipment is oper ated in areas where corrosive atmo spheres prevail. Control Section modules include: The MONITOR Module which is essentially a "power control" and maintenance module containing a meter and selector switch for monitoring various parameters of the chromatograph. 2 The SEQUENCER Module is the functional center of the Model 1000 Process Gas Chromato graph. The module contains the precision crystal-controlled digital clock on which all system timing is based and the mode selection switch that determines the analy sis mode (Auto, Gate, Spectrum, Manual) of the equipment. It also contains the programming switches and control circuitry for selection of sample valve duration and analysis cycle time. 3 The AMPLIFIER Module provides final amplification for the pream plifier output from the detector bridge in the Analyzer oven. It al so contains the Auto Zero circuit ry and an internal calibration cir cuit. Two types are available for use with the Thermal Conductivity detector, the Flame Ionization de tector or the Flame Photometric detector. 4 The DUAL VALVE Module con tains programming switches and control circuitry for two separate column-switching valves. Toggle switches on the front of the panel permit automatic or manual actu ation of either valve. 5 The DUAL COMPONENT Module contains programming switches and control circuitry for two sepa rate component gates. Separate front of panel controls for each gate permit operator selection of gate start time and duration, and precise adjustment of amplifier gain during the respective gates. Two types of Dual Component modules are available: Without memory circuits, if bargraph readout is desired, or With two independent mem ory circuits, each having ap propriate Zero and Span ad justments to provide outputs suitable for a trend recorder or a computer. Either type of module includes a dedicated Auto Zero function which automatically occurs at the gate opening, unless inhibited by a jumper. 6 The RATIO Module produces an analog output proportional to the ratio of two selected process components. This module oper ates in conjunction with, and re ceives gating information from, a Dual Component Module. TEST MOD II is a maintenance module which can be installed in any available component/valve module position in the Control Section without affecting normal system operation. The unit con tains indicators and controls that are used to quickly determine the operational status of various sys tem functions that are performed during an analysis. 8 The STREAM SELECTOR Module contains programming switches and control circuitry for automatic or manual selection of any one of up to ten sample streams for anal ysis. In automatic mode, streams to be analyzed are selected by front-panel switches and each stream, in sequence, is automat ically analyzed. In the manual mode, each successive stream is selected by depressing a STEP pushbutton. In either mode, se lected streams can be bypassed by positioning on/off switches to the off position. 9 The INTEGRATOR Module pro duces an analog output propor tional to the area of the compo nent peaks detected during a se lected portion of an analysis. On completion of the integrator gate, a value proportional to the total area of the peaks detected during the integrator gate, is stored in an output memory circuit. In Auto operating mode, the stored value is updated during each succes sive analysis. DTH 000105939 I 10 The COMPUTER INTERFACE Module consists of a short-term memory circuit for storage of component peak values and switch closures for computer readout of each successively stored peak. Zero and Span ad justments are provided on the front of the panel. The BTU COMPUTER Module produces an analog output di rectly proportional to the BTU content of up to eight stream components in a monitored sample. The unit includes six short-term peak memory cir cuits, input circuits for two ad ditional peak values from exter nal memories, a summing am plifier and a long-term output memory circuit. DTH 000105940 7 Display and Readout Industry-proved through years of ser vice in rugged process environments, the ElectroniK 111 Strip Chart Potenti ometer is now available with a servo system customized especially to han dle the high-speed analysis of the Model 1000 Process Gas Chromatograph. In addition, the recorder incorporates a unique electric writing system in place of the conventional ink and cap illary arrangement. In this system a heated stylus is used which, when heated by the current from a power supply, makes a permanent blue re cord comparable to a conventional ink record on the heat-sensitive strip chart supplied. For information concerning additional types of data display and data reduc tion systems, contact the Honeywell office nearest you. 1 KNOCKOUTMCMSIOf PON I KNOCKOUTS TOPS BOTTOM POK 1/4 INCH COMMIT ElectroniK 111 Recorder VutroniK Trend Recorder