Document RjXgepydwXa4BQYYmprno2D98

fRoLKr H<-= C//S-TS -v < Qr7^ i v * v 3e>## jJ'&Sx^-l -pp^ - Iac?1 <C*j^<l<^t PPG INDUSTRIES, INC LAKE CHARLES COMPLEX "A" DOCK EDC LOADING OPERATIONS MANUAL With Marine Vapor Recovery June 1993 LAKE CHARLES QUALITY POLICY We the employees of the Lake Charles P'ant are dedicated to meeting the requirements of oor customers 10C-/c o* the time We will do our jobs in a way that contributes to the success of our customers, the success 0< our company and at the same time, pro motes the weu-bemg of *he members " ? r =ma Oha-'es "ear- SL 085471 SL 085472 PPG INDUSTRIES, INC. LAKE CHARLES COMPLEX "A" DOCK EDC LOADING OPERATIONS MANUAL With Marine Vapor Recovery June 1993 LAKE CHARLES QUALITY POLICY Ws. the employees of the Lake Charles Plant, are dedicated to meeting the requirements of our customers 100% of the time. We will do our jobs In a way that contributes to the success of our customers, the success of our company and, at the same time, pro motes the well-being of the members of our Lake Charles team, SL 085473 SL 085474 table of contents SL 085475 TABLE OF CONTENTS Page CFR 154.840 CROSS-REFERENCE INDEX.......................................................... v I. INTRODUCTION ............................................................................................... 1 II. SAFETY........................................................................................................................... 3 A. General Safety Rules...........................................................................................3 B. Fire Protection .................................................................................................. 7 1. On Shore Fire................................................................................................ 7 2. Off Shore Fire ............................................................................................. 9 C. Emergency Shutdown.................................................................................. 10 D. Emergency Names and Numbers............................................................... 12 E. Safety and Personnel Protective Equipment ......................................... 13 F. Chemical Hazards - MSDS.......................................................................... 16 G. Spill Prevention and Response .................................................................. 17 H. Maintenance Procedures ............................................................................ 18 1. Clearing Procedures ............................................................................ 18 2. Lock Procedures.................................................................................... 23 3. Welding, Burning,or Open Flame Procedures................................ 34 4. Ignition Source Permit......................................................................... 41 5. Tank Entry Procedures ....................................................................... 46 I. Communication ............................................................................................ 61 1. Radios....................................................................................................... 61 2. Dock TV Surveillance System............................................................ 61 III. GENERAL PROCESS DESCRIPTION ................................................................. 62 IV. PLANT OPERATION............................................................................................... 65 A. Detailed Process Description...................................................................... 65 1. Liquid Loading ....................................................................................... 65 2. Barge Handling....................................................................................... 66 SL 085476 TABLE OF CONTENTS (continued) Page 3. Ship Handling.......................................................................................... 67 4. Vapor Handling ..................................................................................... 67 5. Liquid and Vapor Loading Shutdown............................................... 68 6. SORBATHENE Unit EDC Recovery.................................................... 71 7. South Terminal Control Room............................................................ 75 8. Oxygen Analyzer Control Building.................................................... 85 B. Equipment Summary..................................................................................... 92 1. Loading and Vapor Handling Equipment......................................... 92 2. Existing Equipment Utilized ............................................................... 92 3. SORBATHENE Vapor RecoverySkid and Equipment .................. 93 4. Electrical.................................................................................................. 99 5. Utilities and Tie-ins............................................................................ 100 C. Startup Procedures.................................................................................... 103 1. SORBATHENE Vapor RecoveryUnit .............................................. 103 2. Pre-loading, Hookup, and Alignment Procedures...................... 104 3. Procedures for EDC Loading.................................................... Ill D. Shutdown Procedures............................................................................... 121 1. SD-1, Loading and Vapor Collection Shutdown......................... 121 2. SD-2, Loading and Normal Vapor Recovery Unit Shutdown ............................................................................................ 122 3. SD-3, Loading and Emergency Vapor Recovery Unit Shutdown ............................................................................................ 123 4. Re-Start After Shutdown................................................................. 123 E. Shutdown Criteria and Response............................................................ 124 1. Level SD-1-Shutdown of Loading, Isolation of Vessel, SVRU Continues Cycling................................................................. 124 2. Level SD-2 - Shutdown of Loading, Isolation of Vessel, SVRU Shut Down and Valved in Under Nitrogen Blanket ... 127 3. Level SD-3 - Shutdown of Loading, Isolation of Vessel, SVRU Shut Down and Purged (Emergency in Recovery Unit)....................................................................................................... 130 SL 085477 TABLE OF CONTENTS (continued) Page F. Marine Vapor Recovery (MVR) Bypass................................................. 133 1. Operation without Marine Vapor Recovery................................. 133 2. Pre-loading, Hookup, and Alignment Procedures without Marine Vapor Recovery.................................................................... 137 3. Procedures for EDO Loading without Marine Vapor Recovery............................................................................................... 140 G. Recovered EDC............................................................................................. 146 1. EDC Recovery Tank Pumpout to Vacuum Truck ...................... 146 2. EDC Recovery Tank Pumpout to ST-1 or ST-2 ......................... 148 H. Marine Vessel Unloading (Vessel to Shore)......................................... 150 I. Routine Operating Procedures................................................................. 152 1. Sampling Procedures.......................................................................... 152 2. Filter Replacement Criteria, Data, and Procedure...................... 152 3. SVRU Sump Pumpout Procedure.................................................... 154 APPENDIX A P&ID'S Liquid Loading and Vapor Handling SORBATHENE Unit Nitrogen System ST-1 and ST-2, EDC Storage Tanks Detailed Analyzer Systems APPENDIX B SAFETY AND EMERGENCY PLOT PLAN APPENDIX C FACILITY PLOT PLAN APPENDIX D MATERIAL BALANCE APPENDIX E APPLICABLE COAST GUARD REGULATIONS APPENDIX F ROUTINE PAPERWORK Logsheets APPENDIX G SVRU OPERATIONS MANUAL SL 085478 TABLE OF CONTENTS (continued) APPENDIX H ALARMS AND OPERATOR RESPONSE APPENDIX I EMERGENCY EVENT RESPONSES Page SL 085479 tv CFR 154.840 CROSS-REFERENCE INDEX 154.840 (Personnel Trainina) (b)(1) Purpose of the Vapor Control System Cross Reference to "A" Dock EDC Operations Manual Section 1 (2) Principles of the Vapor Control System Section III (3) Components of the Vapor Control System Section IV.B and Appendix A (4) Hazards Associated with the Vapor Control Sections II.E, II.F and III System (5) Coast Guard Regulations Appendix E (6) Operating Procedures (i) Testing and Inspection Procedures (ii) Pre-Transfer Procedures (iii) Connection Sequence (iv) Startup Procedures (v) Normal Operations (7) Emergency Procedures Section IV.C.2 Section IV.C.2 Section IV.C.2 Section IV.C.3 Section IV.C.3 Sections II.B, II.C, II.D, II.G, IV.D, and IV.E v SL 085480 SL 085481 SECTION I INTRODUCTION SL 085482 INTRODUCTION In order to comply with EPA's Clean Air Act, which regulates the emission of ethylene dichioride (EDC) to the atmosphere, PPG Industries installed an EDC vapor recovery unit for barge and ship loading at its "A" Dock Facility. PPG Industries chose the SORBATHENE Vapor Recovery Unit (SVRU) for the recovery of EDC vapors. This vapor recovery method is considered by PPG to be Maximum Achievable Control Technology (MACT) as required under the Clean Air Act. This unit will recover greater than 99.9% of the EDC emitted from the marine vessel during loading operation. The SVRU was constructed by AWD Technologies, Inc., a subsidiary of Dow Chemical Company, and the system was designed in accordance with the U. S. Coast Guard Regulations cited in the Federal Register, 33 CFR Part 154. Attached is an operating manual describing the liquid loading, vapor handling, and vapor recovery unit operations at "A" Dock. This operating manual has the following basic purposes: To aid in training personnel with the equipment, chemicals, and safe operating procedures for "A" Dock. To serve as a ready source of reference. To fulfill U. S. Coast Guard requirements. The next section of this manual is the Safety Section. This section contains instructions for emergency situations, chemical information, and safe maintenance procedures. The remaining sections of the manual include a general process description of the dock facilities and operating procedures for the loading of EDC into barges and i SL 085483 ships. Procedures for operating the SVRU which removes EDC vapors released by displacement during barge loading are included. Startup and shutdown procedures are also described. As a reference section, the Appendices contain P&ID's, a plot plan, a material balance, and the applicable Coast Guard Regulations applied in the design of the loading and vapor recovery system. The "Safety First" attitude reflected by management should be the attitude of each of us. The safe, successful operation of the dock area depends on how each one of us performs. 2 SL 085484 SECTION 2.0 SL 085485 SECTION II SAFETY SL 085486 II. SAFETY A. General Safety Rules The following list of general safety rules is applicable to the "A" Dock area. They are to be used in conjunction with the Employee's Manual of Accident Prevention. 1. Personnel entering the South Terminal, where "A" Dock is located, will deposit lighters, matches, regular flashlights, etc., at the entry to this area. 2. No open flames, burning or welding will be permitted in this area, unless absolutely necessary and approved by supervision. Refer to Section II.H.3. 3. The usual safety equipment will be required in the "A" Dock area, which is: a. Safety Hats b. Safety Glasses with Side Shields c. Chemical Goggles (safety glasses under goggles are optional) d. Respirators e. Chemical Resistant Gloves f. Safety Shoes 3 SL 085487 g. Flame Retardant Clothing 4. The established plant tagging procedure will apply to the "A" Dock area. Refer to Section II.H.2. 5. A vehicle permit signed by the Operating Supervisor or Certified Tankerman will be required before any vehicle is allowed to enter a restricted area. 6. The vehicle entry permit must be reissued any time the vehicle leaves the area and returns. 7. Keep all road barricades in place while loading. 8. In case of an emergency warning, all vehicles and equipment in the area on permit will be shut off immediately. 9. Any time there is a substantial vapor release or an emergency situation exists, sound the unit evacuation siren in the control room so that all vehicles and maintenance equipment can be shut down and nonessential personnel evacuated from the area. 10. An equipment permit signed by the Shipping Supervisor will be required before the following equipment may be carried into the "A" Dock area: a. Welding machines b. Cutting torches c. Electrically driven drills 4 SL 085488 d. Any electrical equipment, except explosion-proof flashlights 11. If welding or burning must be done anywhere in the "A" Dock area: a. A complete explosion test must be made which is good only for the immediate area in which the burning is done. b. A fire watch must be present. c. The area should be flooded with water. d. All sewer openings must be sealed. e. All sparks must be hosed out during welding. f. All lines must be blinded from the process and open to the atmosphere. g. Supervision must approve the burning, issue the necessary permits, and see to it that all precautions are taken. 12. The Lead Tankerman or Tankerman must place control points in a safe condition and lock out all lines, equipment, and electrical machinery before Maintenance can work on it. The placement of this lock is certification that the equipment is deactivated and free of any materials or conditions that could cause an accident. The Lead Tankerman must verify all control points and locks and sign the Job Ready Tag. 13. Do not permit air to enter any of the process equipment which contains EDO. SL 085489 5 14. Always purge EDC from a vessel with nitrogen. 15. Always purge air from a vessel with nitrogen until the 02 is less than 2% before allowing EDC back into the vessel. 16. Only explosion-proof flashlights will be permitted in the "A" Dock area. 17. All light circuits outside the control building must be off and tagged out before relamping of the area. 18. Only explosion proof or intrinsically safe equipment will be used in the "A" Dock area. 19. Regular plant utility hoses are not to be used for handling EDC. For EDC, use Teflon-lined hoses. 20. Clothing which has been wet with EDC should be removed immediately and the body thoroughly washed with soap and water. These clothes should be properly laundered before they are used again. SL 8549q 6 B. Fire Protection 1. On Shore Fire If there is a large fire in the area, sound the evacuation horn in the control room and leave the area. Notify the guards of the fire (call 2700). A course of action can then be planned with supervision. TO REPORT A FIRE - CALL 2700 !!!!!!!! If there is a small fire in the area, proceed with the following: Sound the necessary alarms. Report the fire to the guards and stay on the phone until help arrives. Do not attempt to put out the fire, unless otherwise instructed or necessary for personal safety. If safe, isolate the leak source and allow the fire to burn itself out. Try to stay upwind of the fire. This smoke may contain significant quantities of HCI. 7 SL 085491 In the event that a fire extinguisher be used, the following instructions for the dock areas apply: IS# CO, Pull pin. Aim hose at base of fire. Squeeze discharge valve handle. Sweep base of fire with C02 gas. 30# Drv Chemical Pull up hose and break seal. Aim hose at base of fire. Squeeze hose discharge valve handle. Sweep base of fire with dry chemical. 150# and 300# Drv Chemical Wheel Mounted Unwrap hose. Turn Ns cylinder valve counterclockwise to pressurize dry chemical. Aim hose at base of fire. Pull hose discharge valve handle. Sweep base of fire with dry chemical. Stano Monitor Nozzle Point water nozzle in direction of fire. Install water valve handle. Open water valve. Position water nozzle as needed. 8 sl 085492 2. Off Store Fire Rapid Movement of Vessels. Threatened bv Fire Vessels moored at a PPG Industries dock that are threatened by fire or a hazardous condition must be moved to a safe location if possible. Emergency shutdown procedures, detailed in the loading procedure of this manual, should be followed in the event of a fire or hazardous condition. The PPG Industries shift foreman will be responsible for overseeing the movement. The telephone numbers and location of tug companies are listed below and are available to move vessels away from the docks. PPG Industries also has a small tugboat capable of moving barges away from the docks. Telephone Numbers and Tug Company Locations PPG Industries PPG Industries Shipping Shift Foreman (318) 491-4500 (318) 491-4336 Towing Companies Port of Lake Charles 150 Marine Lake Charles, Louisiana Sabine Towing 150 Marine Lake Charles, Louisiana Harbor Docking and Towing 150 Marine Lake Charles, Louisiana (318) 439-3661 (318) 439-8982 (318) 439-3462 SL 085493 9 C. Emergency Shutdown Ethviene Dichloride A stop load button is located on the handrail on the NW side of the dock (HS-1022B) and in the South Terminal Control Room (HS-1022A). Manual shutdowns executed with the stop load button and automatic shutdowns triggered by high and low vapor line pressure, high oxygen content, and high barge level initiate the same shut down procedure. NOTE: A green strobe light remains on while loading is in progress. Either manual or automatic shutdown of loading will: (1) stop the loading pump (P-204/205), (2) close the liquid valve on the EDC line (SDV-1050), and (3) close the valve on the vapor line to the vapor recovery unit (SDV1006). This action also puts the nitrogen flow control valve (FV-1016) on fixed flow control, and the vapor recovery unit continues cycling to clear EDC and remain ready to receive vapor, so that loading can restart without a vapor recovery unit warmup. A high barge level alarm will activate a red strobe light and a high high barge level will activate a red strobe light and horn located at the dock. The trouble or pre-shutdown alarm system, except for high barge level shutdown, will activate an amber-colored strobe light and continuously blasting horn located at the dock. These alarms can be acknowledged by the tankerman at the dock or in the control room. The shutdown alarms will activate both the amber strobe light and a red strobe light located at the dock. The continuously blasting hom will also sound. Lights will remain on after acknowledgement until the alarm situation is cleared. 10 0854?4 si* If operating deviations within the vapor recovery unit cause a shutdown of the vapor recovery unit, shutdown of the loading operations will also be triggered as described above. In this case, the nitrogen flow control valve is closed and a nitrogen blanket is maintained in the vapor line through a bypass valve (PCV-1017). A total restart of both the vapor recovery unit (including warmup) and loading is also required. 11 SL 08549B D. Emergency Names and Numbers EMERGENCY PHONE NUMBERS PPG Industries (318) 491-4500 PPG Shipping Shift Foreman (318) 491-4336 PPG Shipping Dock Foreman (318) 491-4478 PPG Shipping Area Supervisor (318) 491-4260 PPG Customer Service (318) 491-4457 U.S. Coast Guard (318) 433-3765 National Response Center (800) 424-8802 12 SL 085496 E. Safety and Personnel Protective Equipment Respiratory Protection In order to prevent personnel exposure to harmful EDC vapors, proper respiratory protection must be worn at the appropriate times. The short exposure tolerance for EDC is one ppm for 15 minutes. Three types of respiratory protection equipment are provided for personnel in the "A" Dock area: filter-type; self-contained breathing equipment; and air-supplied mask. A standard pocket respirator is to be carried at all times. Besides the standard pocket respirator, a twin cartridge full-face mask filter respirator (Comfo-ll) is provided. The dual cartridge respirator is a light concentration work mask which can be used in situations where self-contained equipment is not necessary and the pocket respirator is insufficient. Good for environments containing combinations of chlorine and organic vapors not exceeding 2% by volume, the use of the dual cartridge mask requires at least 19.5% oxygen in the atmosphere. The mask comes with interchangeable cartridges for different types of gases. A full face Comfo-ll mask must be worn while installing and removing loading hoses. The mask will prevent the employee from inhaling EDC vapors. The self-contained equipment consists of 30-minute Scott Air Packs and 6-minute MSA escape units. The escape unit mask can also be connected to the control room breathing air systems such that a person may continue to operate equipment inside the control room without using up the 6-minute air supply bottle or having to strap on a 30-minute air pack. 13 SL 085497 Hard Hat A hard hat must be worn at all times while in an operating area in the PPG Plant (unless a full face mask is worn). The hat is intended to prevent head injuries caused by falling objects or overhead obstructions. Safety Glasses Safety glasses with side shields must be worn at aH times while in an operating area in the PPG Plant. Safety glasses are intended to prevent foreign objects or chemical splashes from injuring the eyes. Geaotes Goggles are required while installing and removing loading hoses and while taking samples. The goggles are intended to prevent chemical splashes from injuring the eyes. Safety Shoes Steel toed shoes or boots containing thick leather or rubber soles must be worn at all times while in an operating area in the PPG Plant. The shoes/boots are intended to prevent foot injuries from falling objects, to provide proper ankle support while walking on uneven surfaces or climbing ladders, and to prevent slipping on wet or oily surfaces. Gloves Chemical resistant gloves are to be worn while installing and removing loading hoses and while taking samples. The gloves are intended to prevent chemical exposures from burning the skin. 14 SL 85498 Fire Retardant Clothing Operating personnel are required to wear fire retardant clothing while in the "A" Dock area. The clothing is intended to protect personnel from flash fires. A full fire retardant "jump" suit or shirt and pants may be worn. Visitors in the plant will be issued fire retardant lab coats. Q05499 15 Chemical Hazards - MSDS The MSDS's for Ethylene dichloride and Nitrogen are attached. 085500 16 SL ETHYLENE DICHLORIDE UNI184 RQ Clear, colorless liquid; chloroform like odor CAS No. 107-06-02 CARGO TRANSFER - Use authorized personnel only, property protected. WARNING! FLAMMABLE VAPOR HARMFUL POSSIBLE CANCER HAZARD BASEO ON TESTS WITH LABORATORY ANIMALS - OVEREXPOSURE MAY CREATE CANCER RISK HANDLING AND STORAGE Container and system must be electncallv grounded before unloading. Do not allow to collect m poorly ventSated or conhned areas. Ethylene dtdrionde vapors are heavier than a* and vnH collect m low areas Avoid contact with flames. hot swtaces or electnc arcs. May lom tone and commvt turtles of hydrogen chloride and possibly phosgene Adequate venolatron must be mamtamed m storage area to reduce In hazard in the event of a leak. AVOID CONTAMMATING WATER SUPPLIES Handhng, storage and use procedures must be carefully monitored to avoal spdts or leaks. Any spill or leak has the potential to cause underground water eornammSMn winch may. if suhidentty severe, render a drinking water some unht tor human consumption Contamination that does occur cannot be easdy corrected. PRECAUTIONS KEEP AWAY FROM HEAT. SPARKS OR FLAME Ethylene dehtonde vapors are flammable end may be exptare. among below peronttWle txpoiun Imuts. OSHA: t ppm. S-hour TWA (Time Weighted Averegel: 2 ppm 15-mmine STEL Short-Term 'mac and corrosive lumes of hydrogen chlonde and possibly osgtne O uO NOT BREATHE VAPORS. High vapor concentration can cause unconsciousness or death. DO NOT SWALLOW. SwaNowmg may cause ugury or death. Exponas Umid. AVOID CONTACT WITH EYES May cause pam. irritation, and wateretg AVOID PROLONGED OR REPEATED CONTACT WITH SKIN May cause irritation and dermatitis USE WITH ADEQUATE VENTtATUN VenWatwn short) be suHcwnt to kwet employee tmeurr to ethylene tkddanrie WASH THOROUGHLY AFTER HANDLING. IN CASE OF ACCIDENT IF THIS HAPPENS DO THIS O____________________________________;> EXPOSURE INHALATION: Remove to tresh aa. II not breathing, give artificial respiration, preferably moudno mouth It breathmg is dithait gnre oxygen. Call a physician EYE/SKIN CONTACT. Immediately flush eyes and Skin with plenty ot water (soap and water lor skin) for at least 15 minutes, whrie removing contaminated clothing and shoes Call a physician. Wash contaminated caascrept.clothing betare reuse or discard. Discard shoes. SWALLOWING: K give a Quart ot water to drink. 00 NOT induce vomiting. Take immediately to acMlc--s.a hospital or onysician. N or in convulsions, take immediately to a hospital DO NOT induce vomitmg or give anytnmg by mouth to an unconscious person NOTES TO PHYSICIAN NEVER admmnter adrenakne lor swallowing or inhalation overexposure. Increased sensitivity ot the heart to adrenakne may be caused by overexposure to ethylene dicraonde. Saline cathartics should oe consi dered tokowmg Mgh dose mgesnon ; FIRE SPILL OR ^AK FLAMMABLE. Frekghttn weamg NIOSH/MSHA - approved, self-contained breathing aromas shoTOd use dry chtimcstt. loam or carbon dioxide to tight tire Weter spray should be used to keep hr* exposed containers cool. Ethylene dichlonde reacts Mgvourfy vnth oxidizing agents When in contact with flames hot gloneng surface or electnc arcs, the formation ot toxic and corrosive hydrogen chlonde and phosgene is possible saucesEvmuate area prowde maamun wnoiaoan and remove all ot gnsm Only penorwel vroh proper protective eapment should be permmed m area. Oike area to contain spdl. 00 NOT allow ethylene ddtonde to contansiate nesbv vwter soras Colact spied mean*! an sawttat or vemvakro. sweet) up and hold m closed comaawn lor dnposal EMERGENCY Contact PPG Indusmes. Inc. Natnum. WV (304) 843-1300 1L PF*G industries. Inc. One PPG Place NUHP Pittsburgh. PA 15272 SL 085501 L94C-789C PPG INDUSTRIES. INC. ONE PPG PLACE * * * ETHYLENE DICHLORIDE (EDC) MSDS NUMBER: DATE: EDITION: TRADE NAME: CHEMICAL NAME/SYNONYMS: CHEMICAL FAMILY: FORMULA: U. S. DOT SHIPPING NAME: U. S. DOT HAZARD CLASS: SUBSIDIARY RISK: I.D. NUMBER: REPORTABLE QUANTITY: 0094 05/03/89 010 ETHYLENE DICHLORIDE (EDC) 1,2 DICHLOROETHANE CHLORINATED HYDROCARBONS CH2CLCH2CL ETHYLENE DICIILORIDE FLAMMABLE LIQUID N/A UNI184 5000 LBS/2270 KG SECTION 1 * PHYSICAL DATA BOILING POINT @ 760 MM HG: 180 F VAPOR DENSITY (AIR=l): 3.4 SPECIFIC GRAVITY (H20=l): 1.255 @ 20/20 C PH OF SOLU1IONS: APPROX. 7 FREEZING/MELTING POINT: - -32.6 F (-35.3 C) iOLUBILITY (WEIGHT % IN WATER): 0.869 G/100 ML BULK DENSITY: 10. 3 LBS/GAL @ 25 C VOLUME I VOLATILE: 100% VAPOR PRESSURE: 87 MM HG @ 25 C EVAPORATION RATE: (ETHYL ETHER=1): .27 HEAT OF SOLUTION: UNKNOWN APPEARANCE AND ODOR: COLORLESS LIQUID; SWEET CHLOROFORM ODOR PITTSBURGH, PA 15272 CAS NUMBER: 00107 06 2 MATERIAL ETHYLENE DICHLORIDE SECTION 2 * INGREDIENTS PERCENT 100 SECTION 3 * FIRE/EXPLOSION HAZARD DATA FLASH POINT (METHOD USED): 56 F (13.3 C) TAG CLOSED CUP * 24-HOUR EMERGENCY ASSISTANCE: (304) S43-1300 * * Material Safety Data Sheet SL 085502 PPG INDUSTRIES. INC. * * ETHYLENE DICHLORIDE (EDC) ONE PPG PLACE PITTSBURGH. PA 15272 05/03/89 PAGE 2 FLAMMABLE LIMITS IN AIR (Z BY VOLUME) LEL: 6.2% UEL: 15.6% EXTINGUISHING MEDIA: DRY CHEMICALS, FOAM, OR CARBON DIOXIDE SPECIAL FIRE FIGHTING PROCEDURES: FIRE FIGHTERS MUST WEAR NIOSH/MSHA-APPROVED, SELF-CONTAINED BREATHING APPARATUS. WATER SPRAY SHOULD BE USED TO KEEP FIRE EXPOSED CONTAINERS COOL. UNUSUAL FIRE AND EXPLOSION HAZARDS: FIRES WILL FORM TOXIC AND CORROSIVE FUMES OF HYDROGEN CHLORIDE, AND UNDER SOME CONDITIONS MAY FORM TRACE QUANTITIES OF PHOSGENE. REACTS WITH OXIDIZING MATERIALS AND BASES. HYDROLYZES SLOWLY AT ELEVATED TEMPERATURES TO PRODUCE HYDROGEN CHLORIDE. SECTION 4 * HEALTH HAZARD DATA TOXICITY DATA: LC50 INHALATION: LD50 DERMAL: SKIN/EYE IRRITATION: LD50 INGESTION: FISH,LC50-(LETHAL CONCENTRATION) : (RAT) 1000 PPM/7 HOURS (RABBIT) 2890 MG/KG SKIN-MILD/EYE-SEVERE IRRITANT (RAT) 670.MG/KG SEE SECTION 5 CLASSIFICATION: (POISON, IRRITANT, INHALATION: MODERATELY TOXIC SKIN: MODERATELY TOXIC SKIN/EYE: SEE SECTION 5 INGESTION: SLIGHTLY TOXIC AQUATIC: SEE SECTION S ETC.) SECTION 5 * EFFECTS OF OVEREXPOSURE THIS SECTION COVERS EFFECTS OF OVEREXPOSURE FOR INHALATION, EYE/SKIN CONTACT, INGESTION AND OTHER TYPES OF OVEREXPOSURE INFORMATION IN THE ORDER OF THE MOST HAZARDOUS AND THE MOST LIKELY ROUTE OF OVEREXPOSURE. * 24-HOUR EMERGENCY ASSISTANCE: (304) 843-1300 foam*3rr*.j-m Material Safety Data Sheet * 085503 SL PPG INDUSTRIES, INC. * * ETHYLENE DICHLORIDE (EDC) ONE PPG PLACE PITTSBURGH. PA 15272 05/03/89 PAGE 3 IS CHEMICAL LISTED AS A CARCINOGEN OR POTENTIAL CARCINOGEN? NTP - YES IARC - YES OSHA - NO MEDICAL CONDITIONS GENERALLY AGGRAVATED BY EXPOSURE: PROLONGED EXPOSURE TO HIGH CONCENTRATIONS OF ETHYLENE DICHLORIDE MAY COMPLICATE EXISTING LIVER OR KIDNEY DISEASES. PERMISSIBLE EXPOSURE UMITS: OSHA: 1 PPM, 8-HOUR TWA (TIME WEIGHTED AVERAGE); 2 PPM, IS-MINUTE STEL (SHORT-TERM EXPOSURE LIMIT); 29 CFR 1910.1000 (REV. 3/1/89). ACUTE: INHALATION: EXPOSURE TO HIGH CONCENTRATIONS HAVE CAUSED THE FOLLOWING SYMPTOMS IN EXPOSED PEOPLE: HEADACHE, NAUSEA, VOMITING, AND WEAKNESS. THIS MAY BE FOLLOWED BY UNCONSCIOUSNESS AND RESPIRATORY AND CIRCULATORY FAILURE. WHERE DEATHS HAVE OCCURRED, THEY HAVE BEEN ASSOCIATED WITH LIVER AND KIDNEY FAILURE, PULMONARY EDEMA, CELLULAR DEGENERATION, NECROSIS, AND HEMORRHAGIC LESIONS OF INTERNAL ORGANS. EYE CONTACT: ETHYLENE DICHLORIDE IS A SEVERE EYE IRRITANT. IF NOT WASHED OUT IMMEDIATELY, SERIOUS DAMAGE MAY RESULT. LITERATURE REPORTS INDICATE AN IMMEDIATE IRRIGATION OF THE EYE WILL PREVENT SERIOUS INJURY. SKIN CONTACT: WHEN ETHYLENE DICHLORIDE IS HELD UNDER A OCCLUDED PATCH, SEVERE IRRITATION WILL OCCUR. WHEN IT IS NOT HELD TIGHT TO THE SKIN, IT WILL NOT CAUSE SERIOUS IRRITATION. REPEATED OR PROLONGED CONTACT WILL PRODUCE DRYING AND REDDENING OF THE SKIN DUE TO THE EXTRACTION OF FAT. INGESTION: HUMAN CASE REPORTS OF ACCIDENTAL OR INTENTIONAL INGESTION HAVE BEEN REPORTED. INGESTION OF QUANTITIES RANGING FROM 8-200 ML HAVE BEEN REPORTED TO BE LETHAL IN HUMANS. THE PROGRESSION OF SYMPTOMS IS SIMILAR TO THAT FROM OVEREXPOSURE VIA INHALATION. THERE IS TYPirALLY A ONE-HOUR PERIOD AFTEk INGESTION WHERE NO SIGNS OCCUR. THIS IS FOLLOWED BY DIZZINESS, NAUSEA, VOMITING AND UNCONSCIOUSNESS. A RAPID WEAK PULSE, DILATED PUPILS, PULMONARY EDEMA, AND CYANOSIS MAY ALSO OCCUR. DEATH IS USUALLY RELATED TO CIRCULATORY AND RESPIRATORY FAILURE. THE ODOR THRESHOLD (6-110 PPM) OF ETHYLENE DICHLORIDE IS NOT AN ADEQUATE WARNING TO PREVENT OVEREXPOSURE. THE ODOR IS CHARACTERIZED AS BEING SWEET AND NOT UNPLEASANT. GENERAL: ETHYLENE DICHLORIDE CAN BE TAKEN INTO THE BODY BY INGESTION, INHALATION OR SKIN ABSORPTION. BY ANY OF THESE MEANS IT CAN BE HIGHLY TOXIC. ACUTE POISONING MAY CAUSE HEADACHE, DIZZINESS, FEELINGS OF ______________________ * * 24-HOUR EMERGENCY ASSISTANCE: (304) 843-1300 * * Material Safety Data Sheet SL 085504 PPG INDUSTRIES, INC. * * ETHYLENE DICHLORIDE (EDC) ONE PPG PLACE PITTSBURGH. PA 15272 05/03/89 PAGE 4 DRUNKENNESS, LOSS OF CONSCIOUSNESS, INTERNAL BLEEDING, AND DEATH. RE PEATED EXPOSURES CAN BRING ON NAUSEA, VOMITING, STOMACH PAIN, IRRITATED MUCOUS MEMBRANES, LOSS OF APPETITE, LIVER AND KIDNEY FAILURE AND POSSI BLE DEATH. NUMEROUS CASES OF ETHYLENE DICHLORIDE POISONING, BOTH FATAL AND NONFATAL, HAVE BEEN DOCUMENTED BY THE NATIONAL INSTITUTE FOR OCCUPA TIONAL SAFETY AND HEALTH. WITH SKIN ABSORPTION OR INHALATION, THE FIRST EFFECTS ARE HEADACHE, WEAKNESS, EYE IRRITATION, CYANOSIS (BLACKENING OF SKIN) AND NAUSEA. CHRONIC: THE PRIMARY TARGET ORGAN IN BOTH EXPERIMENTAL ANIMALS AND EXPOSED HUMAN POPULATIONS ARE THE LIVER AND KIDNEY. THERE IS ALSO SOME EVIDENCE THAT CHRONIC EXPOSURE TO ETHYLENE DICIILORIDE MAY HAVE ADVERSE EFFECTS ON THE CENTRAL NERVOUS SYSTEM. THE NATIONAL CANCER INSTITUTE CONDUCTED CARCINOGENICITY BIOASSAYS IN OSBORNE-MENDEL RATS AND B6C3F1 MICE. ANIMALS IN THESE STUDIES WERE DOSED ORALLY BY GAVAGE WITH ETHYLENE DICHLORIDE IN CORN OIL. DOSES HAD TO BE ADJUSTED SEVERAL TIMES DURING THE STUDY IN RESPONSE TO SIGNS OF TOXICITY. TIME WEIGHTED AVERAGE DOSES (IN MG/KG/DAY) WERE: 47 OR 95 FOR MALE AND FEMALE RATS; 97 OR 195 FOR MALE MICE AND 149 OR 299 FOR FEMALE MICE. IN THE RAT STUDY, CARCINOMA OF THE FORESTOMACH, HEMANGIOSARCOMA OF THE CIRCULATORY SYSTEM, AND CARCINOMA OF THE MAMMARY GLAND WERE OBSERVED. THERE WAS A HIGH MORTALITY RATE FOR THE RATS DURING- THIS STUDY FROM CAUSES OTHER THAN CANCER. THE MEAN SURVIVAL TIME FOR THE HIGH DOSE ANIMALS WAS ONLY 55 WEEKS WITH 0/50 ALIVE IN WEEK 101. THIS SIGNIFICANT MORTALITY MAY HAVE AFFECTED THE OUTCOME OF THE STUDY. IN THE MOUSE STUDY, HEPATOCELLULAR CARCINOMAS, ALVEOLAR/BRONCHIOLAR ADENOMAS, MAMMARY CARCINOMAS AND ENDOMETRIAL TUMORS WERE OBSERVED. AN INHALATION STUDY IN SPRAGUE-DAWLEY RATS AND SWISS MICE PROVIDED NO EVIDENCE OF CARCINOGENICITY AFTER LIFETIME EXPOSURES. ANIMALS WERE EXPOSED TO 5 PPM, 10 PPM, 50 PPM AND 150 PPM FOR 78 WEEKS. AT THE END OF THE STUDY NO EXPOSURE RELATED CANCER WAS FOUND AT ANY TARGET ORGANS IN EITHER SPECIES. PHARMACOKINETIC ANALYSIS OF THE KNOWN METABOLIC PATHWAYS OF ETHYLENE DICHLORIDE IN MICE, RATS AND HUMANS HAVE BEEN CONDUCTED. SUCH COMPARI SONS SUGGEST THAT THE CONFLICTING OUTCOME OF THE BIOASSAYS WITH REGARD TO CARCINOGENICITY ARE DUE TO ROUTE OF EXPOSURE DEPENDENT DIFFERENCES IN METABOLISM AND THAT THE ANIMAL BIOASSAYS SIGNIFICANTLY OVERESTIMATE HUMAN CANCER RISK. THE RESULTS OF REPRODUCTIVE AND TERATOGENICITY STUDIES IN ANIMALS 24-HOUR EMERGENCY ASSISTANCE: (304) 843-1300 * * to** tin j.m Material Safety Data Sheet SL 085505 PPG INDUSTRIES, INC. * * ETHYLENE DICHLORIDE (EDC) ONE PPG PLACE PITTSBURGH. PA 15272 05/03/89 PAGE 5 INDICATES THAT ETHYLENE DICHLORIDE HAS LITTLE POTENTIAL FOR PRODUCING ADVERSE REPRODUCTIVE AFFECTS OR FOR ADVERSELY AFFECTING THE DEVELOPING CONCEPTUS, EXCEPT WHEN THE MOTHER IS EXPOSED TO DOSES HIGH ENOUGH TO PRODUCE MATERNAL TOXICITY. ETHYLENE DICHLORIDE IS LISTED BY NTF IN GROUP II (SUBSTANCE THAT MAY REASONABLY BE ANTICIPATED TO BE CARCINOGEN) AND IS AN IARC 2B CARCINOGEN FISH, LC50 (LETHAL CONCENTRATIONS): DAPHNIA MAGNA - 48-HOUR - 218,000 BLUEGILL - 96-HOUR - 550,000 FATHEAD MINNOW - 96-HOUR - 118,000 MICROGRAM/L MICROGRAM/L MICROGRAM/L * EMERGENCY AND FIRST AID PROCEDURES INHALATION: REMOVE PATIENT TO FRESH AIR. IF NOT BREATHING, GIVE ARTIFICIAL RESPIRATION, .PREFERABLY MOUTH-TO-MOUTH. IF BREATHING IS DIFFICULT, GIVE OXYGEN. CALL A PHYSICIAN. EYE OR SKIN CONTACT: IMMEDIATELY FLUSH EYES AND SKIN WITH WATER (SOAP AND WATER FOR SKIN) FOR AT LEAST 15 MINUTES WHILE REMOVING CONTAMINATED CLOTHING AND SHOES. .CALL A PHYSICIAN. WASH CONTAMINATED CLOTHING BEFORE REUSE OR DISCARD. DISCARD SHOES. INGESTION: IF CONSCIOUS, DRINK LARGE QUANTITIES OF WATER. DO NOT INDUCE VOMITING. TAKE IMMEDIATELY TO A HOSPITAL OR PHYSICIAN. IF UNCONSCIOUS, OR IN CONVULSIONS, TAKE IMMEDIATELY TO A HOSPITAL. DO NOT ATTEMPT TO INDUCE VOMITING OR GIVE ANYTHING BY MOUTH TO AN UNCONSCIOUS PERSON. NOTES TO PHYSICIAN (INCLUDING ANTIDOTES): NEVER ADMINISTER ADRENALINE FOR SWALLOWING OR INHALATION OVEREXPOSURE. IN CREASED SENSITIVITY OF THE HEART TO ADRENALINE MAY BE CAUSED BY OVEREXPOSURE TO ETHYLENE DICHLORIDE. SALINE CATHARTICS SHOULD BE CONSIDERED FOLLOWING HIGH DOSE INGESTION. OVEREXPOSURES MAY CAUSE VOMITING AND PROTRACTED RETCHING VIA CNS MECHANISMS. STABILITY: STABLE SECTION 6 * REACTIVITY DATA 24-HOUR EMERGENCY ASSISTANCE: (304) 843-1300 ---Material Safety Data Sheet SL 085506 PPG INDUSTRIES. INC. * * ETHYLENE DICHLORIDE (EDC) ONE PPG PLACE PITTSBURGH. PA 15272 05/03/89 PAGE 6 CONDITIONS TO AVOID: FLAMES, INTENSE HEAT SOURCES, ELECTRIC ARCS HAZARDOUS POLYMERIZATION: WILL NOT OCCUR CONDITIONS TO AVOID: ELEVATED TEMPERATURES INCOMPATIBILITY (MATERIALS TO AVOID): REACTS WITH OXIDIZING MATERIALS AND BASES OR WATER AT ELEVATED TEMPERATURES. WILL CORRODE ALUMINUM AT ELEVATED TEMPERATURES. HAZARDOUS DECOMPOSITION PRODUCTS: DECOMPOSES UPON CONTACT WITH FLAME, HOT SURFACES OR ELECTRIC ARCS EMITTING TOXIC FUMES OF HYDROGEN CHLORIDE AND POSSIBLE TRACES OF PHOSGENE. SECTION 7 * SPILL OR LEAK PROCEDURES STEPS TO BE TAKEN IF MATERIAL IS SPILLED OR RELEASED: EVACUATE AREA, PROVIDE MAXIMUM VENTILATION, AND REMOVE ALL SOURCES OF IGNITION. ONLY PERSONNEL EQUIPPED WITH NIOSH/MSHA APPROVED, SELF-CONTAINED BREATHING APPARATUS OR FULL FACEPIECE AIRLINE RESPIRATORS WITH AUXILIARY SCBA'S OPERATED IN THE PRESSURE DEMAND MODE SHOULD BE PERMITTED IN AREA. DIKE AREA TO CONTAIN SPILL AND PUMP SPILLED MATERIAL INTO METAL CONTAINERS FOR DISPOSAL OR RECLAIMING. RECOVER ANY REMAINING MATERIAL ON ADSORBENTS SUCH AS SAWDUST OR VERMICULITE, AND PUCE IN METAL CONTAINERS FOR DISPOSAL. AFTER ALL VISIBLE TRACES AND ALL VAPORS HAVE BEEN REMOVED, THOROUGHLY WET VACUUM-THE AREA OF SPILL. IF AREA OF SPILL IS POROUS, REMOVE AS MUCH CONTAMINATED EARTH, GRAVEL, ETC. AS NECESSARY AND PUCE IN CLOSED CONTAINERS FOR DISPOSAL. WASTE DISPOSAL METHOD: CONTAMINATED SAWDUST, VERMICULITE, OR POROUS SURFACE MUST BE DISPOSED OF IN A PERMITTED HAZARDOUS WASTE MANAGEMENT FACILITY. RECOVERED LIQUIDS MAY BE REPROCESSED OR INCINERATED OR MUST BE TREATED IN A PERMITTED HAZARDOUS WASTE MANAGEMENT FACILITY. CARE MUST BE TAKEN WHEN USING OR DISPOSING OF CHEMICAL MATERIALS AND/OR THEIR CONTAINERS TO PREVENT ENVIRONMENTAL CONTAMINATION. IT IS YOUR DUTY TO DISPOSE-OF THE CHEMICAL MATERIALS AND/OR THEIR CONTAINERS IN ACCORDANCE WITH THE CLEAN AIR ACT, THE CLEAN WATER ACT, THE RESOURCE CONSERVATION AND RECOVERY ACT, AS WELL AS ANY OTHER RELEVANT FEDERAL, STATE, OR LOCAL UWS/REGUUTIONS REGARDING DISPOSAL. SECTION 8 * SPECIAL PROTECTION INFORMATION RESPIRATORY PROTECTION: USE NIOSH/MSHA-APPROVED ORGANIC RESPIRATOR OR USE AIR-SUPPLIED RESPIRATORY _ 24-HOUR EMERGENCY ASSISTANCE: (304) 843-1300 * -- Material Safety Data Sheet SL 085507 PPG INDUSTRIES. INC. * * ETHYLENE DICHLORIDE (EDC) ONE PPG PLACE PITTSBURGH. PA 15272 05/03/89 PAGE 7 PROTECTION WHEN CONCENTRATIONS EXCEED THE PERMISSIBLE EXPOSURE LIMITS. SEE SECTION 7 FOR RESPIRATORY PROTECTION IN THE EVENT OF SPILLS OR LEAKS. . THE RESPIRATOR USE LIMITATIONS MADE BY NIOSH/MSHA OR THE MANUFACTURER MUST BE OBSERVED. RESPIRATORY PROTECTION PROGRAMS MUST BE IN ACCORDANCE WITH 29 CFR 1910.134. VENTIUMION(TYPE): USE GENERAL OR LOCAL EXHAUST VENTILATION SUFFICIENT TO LIMIT EMPLOYEE EXPOSURE TO ETHYLENE DICHLORIDE BELOW PERMISSIBLE LIMIT. EYE PROTECTION: SPLASHPROOF CHEMICAL SAFETY GOGGLES GLOVES: POLYVINYL ALCOHOL. VITON(R). OTHER PROTECTIVE EQUIPMENT: BOOTS, APRONS, OR CHEMICAL SUITS SHOULD BE USED WHEN NECESSARY TO PREVENT SKIN CONTACT. PERSONAL PROTECTIVE CLOTHING AND USE OF EQUIPMENT MUST BE IN ACCORDANCE WITH 29 CFR 1910.132 AND 29 CFR 1910. 133. SECTION 9 * SPECIAL PRECAUTIONS PRECAUTIONS TO BE TAKEN DURING HANDLING AND STORING: * POSSIBLE CANCER HAZARD BASED ON TESTS WITH LABORATORY ANIMALS -- OVER EXPOSURE MAY CREATE CANCER RISK. * CONTAINER AND SYSTEM MUST BE ELECTRICALLY GROUNDED BEFORE UNLOADING. * DO NOT USE IN POORLY VENTILATED OR CONFINED AREAS. * ADEQUATE VENTILATION MUST BE MAINTAINED IN STORAGE AREAS TO REDUCE FIRE HAZARD IN THE EVENT OF A LEAK. * ETHYLENE DICllLORIDE VAPORS ARE HEAVIER THAN AIR AND WILL COLLECT IN LOW AREAS. * STORE ONLY IN CLOSED, PROPERLY LABELED CONTAINERS. * KEEP AWAY FROM HEAT, SPARKS, OR FLAME. ETHYLENE DICHLORIDE VAPORS ARE FLAMMABLE AND MAY BE EXPLOSIVE. * AVOH CONTAMINATION WITH WATER SUPPLIES! HANDLING, STORAGE AND USE PROCE DURES MUST BE CAREFULLY MONITORED TO AVOID SPILLS OR LEAKS. ANY SPILL OR LEAK HAS THE POTENTIAL TO CAUSE UNDERGROUND WATER CONTAMINATION WHICH MAY, IF SUFFICIENTLY SEVERE, RENDER A DRINXING WATER SOURCE UNFIT FOR HUMAN CONSUMPTION. CONTAMINATION THAT DOES OCCUR CANNOT BE EASILY CORRECTED. * AVOID CONTACT WITH FLAMES, HOT SURFACES OR ELECTRIC ARCS. MAY FORM TOXIC AND CORROSIVE FUMES. OTHER PRECAUTIONS: * DO NOT BREATHE VAPORS. HIGH VAPOR CONCENTRATIONS CAN CAUSE UNCONSCIOUSNESS * * 24-HOUR EMERGENCY ASSISTANCE: 1304) 843-1300 ----- Material Safety Data Sheet + SL 085508 PPG INDUSTRIES. INC. * * ETHYLENE DICHLORIDE (EDC) ONE PPG PLACE PITTSBURGH. PA 15272 05/03/89 PAGE 3 OR DEATH. * USE WITH ADEQUATE VENTILATION. VENTILATION MUST BE SUFFICIENT TO LIMIT EMPLOYEE EXPOSURE TO ETHYLENE DICHLORIDE BELOW THE PERMISSIBLE EXPOSURE LIMITS. OBSERVANCE OF LOWER LIMITS (SEE SECTION 5) IS ADVISABLE. * AVOID CONTACT WITH EYES. MAY CAUSE PAIN, IRRITATION AND WATERING. * AVOID PROLONGED OR REPEATED CONTACT WITH SKIN. MAY CAUSE IRRITATION AND DERMATITIS. * DO NOT SWALLOW. SWALLOWING MAY CAUSE INJURY OR DEATH. * WASH THOROUGHLY AFTER HANDLING. * DO NOT EAT, DRINK OR SMOKE IN WORK AREAS. COMMENTS: TSCA - ETHYLENE DICHLORIDE IS ON THE TSCA INVENTORY UNDER CAS NO. 107-06-2 SARA TITLE III - A) LISTED IN 311/312 CATEGORIES AS FLAMMABLE. ACUTE AND CHRONIC, B) LISTED IN SECTION 313 AS 1,2-DICHLOROETHANE, C) NOT LISTED IN SECTION 302. CERCLA - LISTED IN TABLE 302.4 AS A HAZARDOUS SUBSTANCE WITH A REPORTABLE QUANTITY OF 5000 POUNDS. RELEASES TO AIR, LAND, OR WATER WHICH EXCEED THE RQ MUST BE REPORTED TO THE NATIONAL RESPONSE CENTER, 800-424-8802. RCRA - WASTE ETHYLENE DICHLORIDE AND CONTAMINATED SOILS/MATERIALS FROM SPILL CLEANUP ARE UQ77 HAZARDOUS WASTE AS PER 40 CFR 261.33 AND MUST BE DISPOSED OF ACCORDINGLY UNDER RCRA. SEE 40 CFR 261.33(C) AND 261.7(B)(3) / FOR CLEANING REQUIREMENTS FOR EMPTY CONTAINERS. CALIFORNIA PROP. 65 - THIS PRODUCT IS A CHEMICAL KNOWN TO THE STATE OF CALIFORNIA TO CAUSE CANCER. R. KENNETH LEE MANAGER, PRODUCT SAFETY * * * 24-HOUR EMERGENCY ASSISTANCE: (304) 843-1300 Matarial Safsty Data Shsat * SL 085509 NAME: Nitrogen OCCURRENCE: Purging and padding equip. FORMULA: N2 MOLECULAR WEIGHT: 28.02 BOILING POINT: -320.4F MELTING POINT: n/a VAPOR PRESSURE: n/a FREEZING POINT: n/a SOLID DENSITY: n/a VAPOR DENSITY: n/a AUTOIGNITION: n/a FLASH POINT: r\/a EXPLOSIVE LIMITS: n/a MAXIMUM ALLOWABLE CONC: n/a DETECTABLE ODOR CONC: Odorless PHYSICAL APPEARANCE: Colorless, odorless, inert gas SPECIFIC GRAVITY: 1.0 with relation to air (Air is 78% Nj) 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, flammable organics 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, EVERY VESSEL THAT IS ENTERED, MUST BE CHECKED FOR FLAMMABILITY AND SUFFICIENT OXYGEN. NITROGEN LINES, AS WELL AS TOXIC LINES MUST BE ISOLATED FROM THE VESSEL BEFORE ENTRY AND A CLEAN AIR SWEEP PROVIDED. TREATMENT: Inhalation: Remove person from the oxygen deficient area. Administ r artificial respiration and oxygen if necessary. SL 085510 G. Spill Prevention and Response If an EDC spill occurs, this general procedure should be followed: Activate required warning devices (road signs, warning lights, etc.). Put on a Scott Air Pack. Isolate leak. Notify supervision. If an EDC spill is collected in a drip pan, the tankerman will notify the Shipping Shift foreman who will call for the vacuum truck service for removal of the collected liquid. 17 SL 085511 H. Maintenance Procedures The following safety procedures directly apply to the "A" Dock area. Refer to the PPG Safety Procedures and Bulletins manual for the following safety procedures: Scaffold Guidelines; Asbestos Work Practices; Blue Flag, Derail, and Rail Car Storage; Opening Vessels to Atmosphere; Vehicle Entry Permit; Roof Work Permit; Structural Change, Drilling and Evacuation Permit; Respiratory Protection Program; and the Lake Charles Hazard Communication Program. 1. Clearing Procedures One of the responsibilities of the Lead Tankerman or Tankerman is to clear equipment and piping for maintenance work. There are a few general rules that apply no matter what is being cleared. The main thing is that the equipment or piping must be cleared so that maintenance workers are not subjected to unsafe working conditions. It must be remembered that the maintenance workers are not as aware as Tankermen are of how to treat various chemicals. They also do not have a complete understanding of plant operating procedures and piping systems. Another very important consideration is locking of equipment and piping by the Lead Tankerman. The Lead Tankerman has the same responsibility toward locking as a supervisor does when the supervisor issues a welding or vessel entry permit. He is saying in writing (hanging a signed tag), that the maintenance mechanics can work safely on equipment. One other thing that should be done when extensive piping systems are locked is to trace out the piping carefully for ail locking locations. Do not depend on remembering ail the block 18 SL 085512 valve locations. It is recommended that someone (another Tankerman) double check the locking of a complex piping system. A third factor that must be considered in all cases is to make sure that it is possible to purge completely through a cleared piece of equipment or piping. Also, purges at low points must be possible to make sure these drains are not plugged. The above discussion covers general considerations for clearing. However, there must be detailed written instructions covering the clearing of equipment and piping for EDC. The instructions must contain specific information about the hazard potential of the chemical. More complete information about EDC is given on the page that follows. 19 sx* 085513 Clearing Procedures for Equipment ContaininaMon-Volatile Organics (EDC1 Hazards nf Ngn-volatile Organics (EDO: Flammable. Vapors are toxic. Strong irritant to skin and eyes. Will cause severe skin dryness. Treatment if Contact with Body: Wash thoroughly and remove contaminated clothing. If shoes, belts, billfolds, or any other leather goods are soaked with EDC, they should be thoroughly washed and allowed to dry before being used again. Apply skin cream to the affected area. Protective Clothing Required: Fire retardant clothing. Other Safety Precautions: Clearing should not be done when maintenance workers are in the area if at all possible. Only organic hoses in good condition should be used. 20 SL 085514 Clearing Procedures: Isolate equipment or line. Push (with hi,,) all liquid into other process equipment if possible. Use Teflon-lined hoses. Drain to a liquid dump box if the liquid cannot be pushed into other process equipment. Do not drain any quantities of EDC or contaminated water to the sewer. Check all bleeds and drains to make sure a purge is coming out. Tag out. Special Maintenance Worker Precautions: Break loose bolts of a flange first on the side away from the worker. 21 SL 085515 General Procedures: The tank or vessel will be emptied and all valves will be locked and tagged. The vapor contents of the tank will be purged with an inert gas. Blinds win be inserted in all connecting lines. The equipment will be steam purged where possible to vaporize and remove all flammable materials. If steam cannot be utilized, an inert gas will be used. After ail flammables are gone, purge the equipment with plenty of air. The equipment will then be checked with an explosion meter before work is begun. The necessary welding and burning permits must be issued. See the Employee's Manual of Accident Prevention for complete rules. If entry into the vessel is required, the vessel must be also checked with an oxygen meter and a vessel entry permit issued. Refer to the Employee's Manual of Accident Prevention for complete rules to be followed for vessel entry. Safety belts and safety lines will be required in top exit tanks. A manway watch is required while someone is in the vessel. 22 SL 085516 2. Lock Procedures a. Purpose To protect employees from injury caused by the uncontrolled release of energy. b. Scope This procedure covers the servicing and/or maintenance of machines and equipment in which the unexpected energization or start up of the machines or equipment, or release of stored energy could cause injury to employees. c. Application This procedure applies to the control of energy during servicing and/or maintenance of machines and equipment. Normal production operations are not covered by this procedure but are covered by unit standard operating procedures. Non-routine operation activities are covered by this procedure. d. Procedure The basic principle of this procedure is the requirement that all energy sources that could adversely affect employees doing a job will be locked in a safe position by the affected employees. (1) When empk>yee(s) are working on or around equipment that normally falls under their control, all energy control points which, if opened or activated, could result in harm to 23 SL 085517 employees) must be locked out by the affected employees) with personal locks. This shall be done in accordance with a written standard operating procedure. Where a standard operating procedure does not exist for a specific Job, the employee(s) performing the work shall list the energy control points associated with the job on a "Job Ready" tag, sign and date the tag, and attach the tag to a prominent control point associated with the job. (2) All other work performed on or around equipment that has the potential for an uncontrolled release of energy will be done in accordance with the following: (a) The equipment owner shall: i) Ensure equipment has been shut down, isolated, blocked, cleared, cleaned, etc. ii) List the energy control points associated with the job on a "Job Ready" tag. iii) Control all job related energy sources by placing them in a safe condition and locking with an Owner Lock (i.e., valves, breakers, blinds used as isolation points, etc.). NOTE: All Owner Lock(s) isolating electrical energy sources shall have a "Do Not Operate" tag attached. The tag shall be signed and dated by the Equipment Owner. 24 SL 085518 (V) Place the key(s) to the Owner Lock(s) used to isolate energy sources in a Lockout Box. (A Lockout Box will not be used if the Equipment Owner chooses to have all employees working on the job place a Personal Lock on each control point.) v) Verify that the equipment will not operate (push start button, etc.). NOTE: Anyone that could be affected by this action shall be notified in advance. vi) Sign, date and attach the "Job Ready" tag to the Lockout Box. If a Lockout Box is not used, the "Job Ready" tag shall be attached to a prominent control point associated with the job. (b) The supervisor of the employee(s) performing the work (e.g., Maintenance Supervisor/Field Engineer) shall provide appropriate Job Safety Instruction (i.e., use of personal protective equipment, scaffolding, etc.) and sign and date the "Job Ready" tag indicating acceptance of the job. (c) All employees working on the job that are protected by a controlled energy source (including Supervision and Staff Personnel) are required to: i) Review the "Job Ready" tag and personally check each control point. 25 SL 085519 ii) Place their Personal Lock on the Lockout Box. if the Equipment Owner has chosen to not use a Lockout Box, the Personal Locks will be placed on each control point. NOTE: All Personal Lock(s) isolating electrical energy sources shall have a "Do Not Operate" tag attached. The tag shall be signed and dated by the employee applying the Personal Lock. iii) Verify that the equipment will not operate (push start button, etc.). NOTE: Anyone that could be affected by this action shall be notified in advance. (d) When the equipment repairs, adjustments, etc. are completed, the supervisor of the employee(s) performing the work shall initial the job complete box and enter the date and time on the "Job Ready" tag and notify the Equipment Owner. (e) The Equipment Owner shall verify completion of work. (0 At the completion of the job, all locks will be removed. 26 SL 085520 SL 085521 Figure 3.b - Bed Desorption System IMPELLER BLADES SUCTION PORT PUMP CASE LIQUID FULL POINT SHAFT DISCHARGE PORT ------ SERVICE LIQUID SERVICE QUID INLET VAPOR VAPOR FULL POINT SECTION "A-A" DISCHARGE (QUID AND VAPOR) SHAFT SERVICE LIQUID INLET A SUCTION INLET Figure 3.b.1.1 - Vacuum Pump (56-599) Level Detail SL 085522 SL 085523 SL 085524 the suction port. The pump level is correct when the pressure at the service liquid inlet is at a vacuum. Addition of service liquid increases the pressure to 0 psig. If too much is added, that area will become pressurized as the area is sealed and the volume is fixed. If too little service liquid is added, the area will remain under a vacuum. (2) EDC/Oil Separator (60-2677) The EDC vapor and the vacuum pump seal oil are separated in the EDC/Oil Separator. This separator is equipped with a coalescer for oil recovery. Oil is knocked out in the separator and returned to the vacuum pump. The EDC vapor and back-purge nitrogen gas flow through the coalescer and enter the vapor condensing and storage system. The oil coalescer removes greater than 99% of any oil droplets that could be carried over in the vapor stream leaving the knock-out section of the EDC/Oil Separator. See Figure 3.b.2. (3) Oil Cooler (71-2640) An oil cooler removes the heat of compression generated in the vacuum pump. This air-cooled exchanger is controlled by bypass so that the operating temperature of the vacuum pump is above the temperature of condensation for EDC and below the temperature of EDC fractionation. An RTD (TE-1568) is located downstream 96 SL 085525 of the oil-cooler bypass valve and ahead of the liquid supply port on the vacuum pump. This RTD provides feedback to the bypass valve. The oil cooler is carbon steel. A 3 HP motor drives the cooling fan. (4) Oil Circulation Pump (55-6049) An oil circulation pump provides constant oil flow through the vacuum pump to maintain a liquid-ring seal required for compression in the liquid-ring vacuum pump. An oil filter is provided at the outlet of the pump to remove solid particles which might accumulate in the oil. The oil circulation pump is ductile iron. The filter at its outlet is carbon steel. The filtering material is polyester for 10 micron filtration. Vapor Condensing and Storage System The vapor condensing and storage system recovers the EDC from the adsorption regeneration system. The EDC is condensed in an air-cooled exchanger and the condensed EDC is stored in a recovery tank until it is pumped out by plant operating personnel. See Figure 3.c. (1) EDC Recovery Cooler (71-2641) The EDC recovery cooler is an air-cooled heat exchanger. A concentrated stream of EDC and nitrogen from the vacuum regeneration system enters the cooler where SL 085526 97 SL 085527 Figure 3.c Vanor Condensing and Stored System condensation of the EOC occurs. The two phase flow of liquid EDO and EDC-saturated nitrogen discharge from the condenser and flow to the EDC recovery tank. The EDC recovery cooler is carbon steel with a 7.5 HP motor. (2) EDC Recovery Tank (60-2678) Recovered EDC liquid is stored in the 1000 gallon EDC recovery tank. The vapor stream of EDC-saturated nitrogen leaves the EDC recovery tank and is returned to the on-line adsorber. Plant operators may pump-out the tank when vessel loading is not in progress. The tank is equipped with a level transmitter to measure level and alarm at 90% and shut down operation of the SVRU and barge unloading at 95%. A high level switch also indicates high high level in the tank and causes a shut down. A low level sensor in the pump-out line at the bottom of the tank disables the EDC transfer pump to stop unloading operations and prevent the running of this pump. (3) EDC Transfer Pump (55-6050) A mag-drive EDC transfer pump is used for return of the recovered EDC liquid to an EDC storage facility located in the dock area. Also, this pump will be used to pump the EDC to a truck if the EDC is contaminated. This pump is operated by the tankerman when product discharge is desired. A recycle line on the outlet of the pump returns a fraction of the EDC liquid to the EDC recovery tank so that the recovered EDC may be sampled. The pump is SL 085528 98 shut off when the level in the recovery tank is reduced to less than the low low level alarm. Additionally, the pump is equipped with a temperature sensor (TE-1550) to shut off the pump if it is run dry. Electrical a. Power and control for the following SVRU motors are provided via MCC 34000 which is located in the Control Room: MCC Ckt Equipment # Equipment Name 34002 50-7752 EDC Recovery Tank Pump Driver 34026 50-7754 EDC Recovery Cooler Driver 34027 50-7752 Oil Circulation Pump Driver 34028 50-7753 Oil Cooler Driver 34029 50-7751 Vacuum Pump Driver The starter for MCC Ckt 34002 is located in the Telemacanique section of MCC 34000. Starters for circuits 34026 through 34029 are located in the General Electric 8000 line section of MCC 34002. b. Self Regulating heat tracing wiring is provided for freeze protection of the Knock-Out Pot 60-2698. SL 085529 99 c. Lighting for the SVRU and Analyzer building area is individually photocell controlled. d. Panel LBA (100A main, 120/208V, 3 phase) is located in the Analyzer Building. It provides power for the camera receivers, heat tracing system and local area lighting. Utilities and Tie-ins a. Nitrogen The following use Nitrogen from the 80# plant header when loading (the 80 psi N2 is let-down to the needed pressures): Nitrogen is supplied to control at 8% oxygen in the vapor loading line. Nitrogen is used in the SVRU for purging the adsorption bed after it cycles. (This is intermittent during the period that the SVRU is on line.) During loading, if nitrogen is not used for inerting, a small purge is maintained through FT-1016. When in the shutdown mode, a 4-inch water pressure is maintained on the vent recovery header and the adsorber beds through PCV-1017. Nitrogen is supplied to ST-1 and ST-2 as pad gas for the liquid displaced during loading. 100 SL 085530 The nitrogen supply from the plant's 6-inch main header line contains a 4-inch take-off which contains a new flow meter (FE-6003). The 4-inch line connects to an existing 4-inch line to the dock area. The 4-inch line contains a 2-inch take-off line that connects to an existing 2-inch line supplying the dock area. This nitrogen system has piping options (jumpovers) for equalization of the nitrogen system between the 4-inch and 2inch headers. The new tie-ins are installed to supply the SVRU and inertion system in addition to the existing lines supplying ST-1 and ST-2 and other small vessels. Refer to drawings 27A-10043, 11A-10029, and 11A-10030 in Appendix A. b. Instrument Air Instrument air is used for operation of automated control valves and purging of junction boxes. Instrument air is supplied to the following control valves (not contained on the SVRU skid): FV-1051, SDV-1006, SDV1050, SDV-1028, and FV-1016. A 1.5-inch instrument air line supplies control valves on the SVRU skid. If the instrument air supply is lost, barge/ship loading will stop and the SVRU will be shutdown. c. Water Potable water is used for safety showers and eye washes. This is also used for hose connections. d. Steam SL 085531 101 Steam is not used at "A" Dock. e. Electricity Electricity is used for motor drivers, lighting, heat tracing, and electrical instrumentation. See Section IV.B.4 for a detailed description of electrical users. f SL 085532 102 C. Startup Procedures The SVRU and loading and vapor handling pre-startup procedures consists of the following: Loading and vapor collection pre-startup which consists of testing shutdown valves, oxygen analyzers, and Coast Guard required alarms. Testing must be completed within 24 hours of startup. Marine vessel inspection and piping alignment. Warm-up of the SVRU. Cycling of the SVRU. The TEST MODE, which includes oxygen analyzer calibration and instrument testing, must be done before warmup of the SVRU. Instruments that are not calibrated and/or tested during the TEST MODE will be subject to periodic calibration and testing. The schedule for this testing/calibration shall be one year for valves and six months for transmitters, gages and other instruments. The oxygen analyzers must be calibrated within 24 hours of startup. Warmup and cycling of the SVRU will follow the TEST MODE. The SVRU must cycle at least one time prior to loading the barge. The following sections describe the pre-startup and startup procedures in detail. 1. SORBATHENE Vapor Recovery Unit The SVRU has been designed for an automated start-up. The SVRU Program will perform shutdowns related to process control or the SVRU can be shut-down on request of the tankerman as part of the SL 085533 103 normal operating sequence or in response to an emergency. The automated start-up will consist of several steps initiated by the tankerman. The program will then run through the sequences required to complete each step and then continue on the next step. Should the step be unsuccessful, the program will inform the tankerman of the problem and shut-down. See Appendix G for a complete SVRU operational procedure and system detail. Pre-loading, Hookup, and Alignment Procedures The following steps shall be performed by the Certified Tankerman or by the Tankerman under the direction of the Certified Tankerman. Certified Tankerman/Tankerman: a. Within 24 hours prior to each barge/ship loading, system tests are to be conducted as follows: (1) The following steps must be taken to test the liquid loading shutdown valve (SDV-1050), the vapor recovery shutdown valve (SDV-1006), and critical shutdown alarms as mandated by Coast Guard regulations: (a) Fully close the manual valve on the dock (MV- 1052) located upstream of SDV-1050. This valve is equipped with open and closed limit switches and must be fully closed in order to begin the TEST MODE sequence. To run the TEST MODE, the LOADING MODE switch (HS-1034) must be in the LOAD MODE. Also, the SHIPPING MODE switch (HS-1021) must be in the barge mode. The SL 085534 104 electrical level switch to the barge must be disconnected to run the TEST MODE. HS-1022A and HS-1022B must be reset to run the TEST MODE. The SVRU must not be in operation to run the TEST MODE. (b) Place the TEST MODE keylock switch in the control room (HS-1035) in the ON position. This will automatically close the EDO liquid flow control valve (FV-1051). At the same time, a high high level shutdown alarm (LAHI-M001) will be generated and the green strobe light at the dock will turn on. NOTE: In order for this alarm to be generated, the level switch plug cannot be attached to the receptacle on a barge. That is, there must be an open circuit for this alarm to be generated. The alarm can be acknowledged from the CRT screen. This will silence the horn located at the dock, but the strobe light will remain ON until the TEST MODE keylock switch is placed in the OFF position. (c) Press the START EDC LOADING pushbutton (HS-1022C) located in the control room. SDV1006 and then SDV-1050 will be automatically opened in sequence. SL 085535 105 (d) A watchdog timer will generate an alarm if positive indication of opened status (ZSO) is not received within 10 seconds. (e) If the shutdown valves opened successfully, the test solenoids at PIT-1004 will then be automatically positioned to simulate a high high pressure alarm. (f) It will be verified that a high high alarm was received and that the valves SDV-1050 and SDV1006 closed completely within 10 seconds. (g) The following shutdown alarms will then be consecutively tested in similar fashion: f PALL-1004 Low low dock vapor line pressure PAHH-1005 High high dock vapor line pressure PALL-1005 Low low dock vapor line pressure LAHH-1013 High high knockout pot level If at any time the alarm cannot be successfully generated, an alarm message will appear on the CRT. The TEST MODE sequence will proceed to the next alarm. However, actual loading will not be allowed until a successful completion of the TEST MODE sequence is made. (h) After successful completion of the TEST MODE sequence, the TEST MODE keylock switch (HS1035) should be placed into the OFF position. The SL 085536 106 manual valve on the dock (HV-1052) must be fully opened before loading can begin, after the loading hose is connected. (2) The oxygen analyzer will be automatically calibrated in the TEST MODE. The flashing light indicates the duration of the automatic calibration. Failure of the analyzer system to calibrate properly is indicated by failure lights (steadily off) and an alarm at the CRT and prevents startup until corrected. The light will stay steadily lit if the calibration is successful. NOTE: When the STOP EDC OPERATION switch (HS1022A or HS-1022B) is pressed, this signals the end of the loading operation. If loading must be restarted after either HS-1022A or HS-1002B are pressed, the TEST MODE must be rerun. Normally, HS-1022A or HS-1022B should not be pressed until loading has been completed and hoses are purged. During loading, HS-1022A or HS-1002B should only be used for emergency stop. b. Spot the barge that is to be loaded or unloaded (normally this is performed by contract tug). c. Obtain the shore tank number from the Shift or Day Foreman. Check with the Shipping Shift Foreman if a surveyor is needed to sample the EDC from the tank prior to filling a ship or customer barge. SL 085537 107 NOTE: Samples are not normally required for PPG terminal destinations; sampling of shore tanks, when necessary, is usually done before arrival of the barge or ship. d. Determine the vessel pressure allowable, vessel PSV setting, and vessel vapor piping pressure drop for the intended flows. Confirm the corresponding vapor recovery control and PSV set points based on applicable charts and log sheets (see attached). The loading rate must be limited to no more than the rate which results in a pressure at the vessel of 80% of the lowest pressure relief valve setting. e. Place the gangplank on the barge and secure. f. Complete preloading conference with person in charge (PIC) of ship. g. Complete preloading inspection of barge (refer to 46 CFR 151.45-5). Close the sea cock valve and pump stern rake if necessary. Call the VC-II Vinyl Storage Operator to obtain tank availability and for sample clearance; then tag the appropriate valves. h. Complete the Declaration of Inspection form for barges. In the case of ships, complete the Declaration of Inspection with the PIC before hooking up. i. For barges, check and apply all warning signs and signals (see 46 CFR 151.45-2 and 151.45-9). Using the Certificate of Inspection found in the document tube on the barge, determine 108 SL 085538 PRELOADING SETTING OF ALLOWABLE FACILITY VAPOR CONNECTION PRESSURE (REF 33 CFR 154.814(c)) EXAMPLE WORK SHEET: VALUE DATA (EXAMPLE) SOURCE MAXIMUM ALLOWABLE LOADING RATE FOR VESSEL TPH VESSEL PSV SETTING, PSIG PRESSURE SHUTDOWN SWITCH CALCULATION: (A) VESSEL PSV SETTING X 80%, PSIG (B) VESSEL VAPOR PIPING PRESSURE DROP, PSI (C) VAPOR HOSE & CONNECTIONS PRESSURE DROP UP TO SHUTDOWN PRESSURE SWITCH, PSI NET VALUE OF (A) LESS (B) LESS (C), PSIG CONFIRM THAT NET VALUE IS GREATER THAN SHUTDOWN SET POINT OF 0.7 PSIG; OTHERWISE, LOADING CANNOT PROCEED UNTIL SUPERVISION IS NOTIFIED & SHUTDOWN SET POINT IS RESET LOWER. 600 (D 1.50 (1) 1.20 0.08 (2) 0.02 1.10 (3) DATA SOURCES: (1) FROM VESSEL INFORMATION FROM PRELOADING CONFERENCE. EXAMPLE VALUES ARE FOR TYPICAL BARGES. (2) FROM PRESSURE DROP VS FLOW GRAPH OR EQUIVALENT DATA FROM VESSEL INFORMATION FROM PRELOADING CONFERENCE. EXAMPLE DATA IS FROM ATTACHED GRAPH. (3) FROM ATTACHED GRAPH OF PRESSURE DROP VS FLOW FOR VAPOR HOSE & CONNECTIONS UP TO PRESSURE SWITCH. SL 085539 PRELOADING SETTING OF ALLOWABLE FACILITY VAPOR CONNECTION PRESSURE (REF 33 CFR 154.814(c)) WORK SHEET: VALUE DATA SOURCE MAXIMUM ALLOWABLE LOADING RATE FOR VESSEL, TPH VESSEL PSV SETTING, PSIG PRESSURE SHUTDOWN SWITCH CALCULATION: (A) VESSEL PSV SETTING X 80%, PSIG (B) VESSEL VAPOR PIPING PRESSURE DROP, PSI (C) VAPOR HOSE & CONNECTIONS PRESSURE DROP UP TO SHUTDOWN PRESSURE SWITCH, PSI NET VALUE OF (A) LESS (B) LESS (C), PSIG CONFIRM THAT NET VALUE IS GREATER THAN SHUTDOWN SET POINT OF 0.7 PSIG; OTHERWISE, LOADING CANNOT PROCEED UNTIL SUPERVISION IS NOTIFIED & SHUTDOWN SET POINT IS RESET LOWER. (1) (D (2) (3) DATA SOURCES: (1) FROM VESSEL INFORMATION FROM PRELOADING CONFERENCE. (2) FROM PRESSURE DROP VS FLOW GRAPH OR EQUIVALENT DATA FROM VESSEL INFORMATION FROM PRELOADING CONFERENCE. (3) FROM ATTACHED GRAPH OF PRESSURE DROP VS FLOW FOR VAPOR HOSE & CONNECTIONS UP TO PRESSURE SWITCH. SL 085540 i LIQUID TRANSFER RATE KS. PRESSURE DROP ALL TANKS AT A TIME PR ESSU R E DROP (PSI> i------------- P----------1------------1--------- 1----------- 1---------- 1-----------1----------1----------- 1----------- 1------------1----------- 1--------- 1 0 50 too ifo ico xo uo w W0 HSO $ce? 550 (.SO (TtfN5/H#0 LIQUID TRANSFER RATE VS. PRESSURE DROP MOST REMOTE TWO TANKS (3P AS) AT A TIME PRESSURE DROP (PSO I------------- )----------- 1------------- 1-----------1------------- 1----------- ----------- f----------- 1------------- *------------ ------------h------------1------------ ( 0 SO 100 150 Zoo ISO Soo tfoo 0 5 o $0o 55a ^00 6$0 dTOHS/HR) N^ 3*^ ^5 unS ;K \U Hydrant calcuk*;*5. \ l /QUID TRANSFER RATE VS. VAPOR PRESSURE ORO P //V HOST and PJFE CONNEC T/OA/G pa ess va tr o r o f (p $ 0 EDC LOADING - VAPOR UNE HYDRAULICS: SEGMENT--------- -- 10-11 11-12 12-13 13-14 14-15 BARGE CONNECT HOSE PIPE PIPE --FLUID DATA-GAS/VAPOR- VAPOR>>>>>>>>>>>>>>>>>> VAP+N2 FLOWRATE lOOOb/hr 2.03 2.03 2.03 2.03 3.70 TEMPERATURE dag F 90 90 90 90 90 MOLECULAR WEIGHT 38.66 38.66 38.66 38.66 33.01 VISCOSITY @TP cp 0.01687 0.01687 0.01687 0.01687 0.01687 K, Cp/Cv @T 1.4 1.4 1.4 1.4 1.4 Z,COMPRESSIBILITY 1.0 1.0 1.0 1.0 1.0 ---------SYSTEM DATA -- COMPRESSOR DP psi (NOT APPLICABLE) CONTROL VALVE DP psi EQUIPMENT DP psi 0.01 HOSE LENGTH feet 40 FACTOR TO PIPE 1.0 PIPE LENGTH feet 2 40 21 91 PIPE I.D. inches 7.981 6.00 7.981 7.981 s, ROUGHNESS feet 0.00015 0.00015 0.00015 0.00015 FITTINGS FLO THRU TEE no. 1 BRANCH TEE no. 1 45' ELBOW no. 1 90' ELBOW no. 26 L/D 0 0 0 0 GATE VALVE no. 11 GLOBE VALVE no. CHECK VALVE L/D OTHER, (SUM) L/D REDUCTION,I.D. inches 6.00 ENLARGEMENT,I.D. inches 7.981 ENTRANCE,K value EXITS,K value OTHER,SUM K value ------ CALCULATIONS- -- SPEC GRAV (vs air) 1.33 1.33 1.33 1.14 FLOW RATE mmscfd 0.47847 0.47847 0.47847 1.02031 DENSITY TP lb/113 0.10 0.10 0.10 0.08 VELOCITY ft/sec 16.3 28.9 16.4 34.9 MACH NUMBER 0.02 0.03 0.02 0.03 REYNOLDS NUMBER 95162 126581 95162 173269 (FACTOR 1) 0.09205 0.08989 0.09205 0.08750 (FACTOR 2) 0.14454 0.14202 0.14454 0.13717 FRICTION FACTOR 0.01914 0.01870 0.01914 0.01751 (L/D SUMMATION) 8.00 16.00 48.00 200.00 (K SUMMATION) 0.57 0.19 0.00 0.00 EQUIVALENT LENGTI feet 27 53 53 224 PIPING DELTA P *** psi 0.080 0.002 0.018 0.004 0.066 SEGMENT DELTA P psi 0.080 0.002 0.018 0.004 0.076 PIPING PRESSURE: UPSTREAM DOWNSTREAM PSIA PSIA 15.24 15.16 15.16 15.16 15.16 15.14 15.14 15.14 15.14 15.06 MIN @ RECOVERY UNIT = 10" W.C. = 15.06 PSIA MAX @ BARGE = 1.0(MIN)*80% = 0.8 PSIG = 15.50 PSIA > 15.24 PSIA SHUTDOWN SET PT - 0.8 PSIG - (DP,10-14) = 0.70 PSIG NOTE: DELTA P IS FOR REMOTE BARGE PIPING PER TYPICAL BARGE DATA. REV 6/1/93 SL 085544 the number and type of fire extinguishers to be used on the barge. (1) Ensure that the barge is certified to carry EDC per the Certificate of Inspection. (a) Verify the U. S. Coast Guard (USCG) expiration date on the certificate. The barge cannot be loaded if the expiration date has passed. (b) In the case of ships, the ship's PIC is responsible for vessel compliance. j. General procedure for barge hose connects is below. A full face Comfo II or Airline mask must be worn while installing and removing hoses. (1) Remove blind flanges off the ends of both the liquid and vapor hoses. (2) Hook up both hoses to the barge. Verify that the insulating flanges are not shorted. k. Before a barge's overfill system is connected to the shore system, the total connected inductance and capacitance of the barge overfill system must be determined. In many cases, these values will be marked on the fixed male connector for the barge's overfill system. If these values are not marked, they must be determined by measurement. Once the barge overfill system inductance and capacitance are known, they should be compared to the maximum allowable values marked on the high SL 085545 109 level system junction box located on the dock (EJB-0657). This junction box will have a nameplate indicating the maximum allowable inductance and capacitance for the barge's overfill system. If the actual vessel values exceed the allowable values marked on the nameplate, the barge's overfill system should not be connected and loading should not proceed. If the vessel values are less than the allowable, proceed to hook up the electrical cable for the tank high level switches on the barge. (This is not required for ships.) NOTE: Per Coast Guard Regulation 154.810(g), no ground cable hookup is to be made. l. The high level switch in each barge vessel compartment must be tested after the electrical cable is connected. To do this, the Certified Tankerman must pull up the rod on each switch until an alarm and shutdown is obtained. The Tankerman will acknowledge the alarms. If any level switch does not work, barge loading cannot begin. m. Locate the STOP EDC LOADING OPERATION pushbutton (HS1022B) on the handrail of the walkway between the dock and shore. Make sure the "mushroom" type pushbutton is pulled out. NOTE: An additional STOP EDC LOADING OPERATION pushbutton (HS-1022A) is located in the control room. n. Line up the barge piping. The PIC on the ship will line up the ship's piping. SL 085546 110 o. Make sure the dock loading valve and vents on the loading hoses and piping are closed. p. Line up the shore tank piping from the dock to the tank for both ships and barges. Check to be sure the tank has been gauged; then record the tank temperature. When loading a barge, be sure the stern rake is pumped out before transfer begins, if applicable. NOTE: There may be input into ST-1 or ST-2 during loading. Procedures for EDC loading In general, the Certified Tankerman should remain on the barge or dock during EDC loading. The Tankerman should proceed with offbarge control activities at the direction of the Certified Tankerman. Certified Tankerman/Tankerman: a. Confirm that there is an oil level in the EDC/Oil Separator and Seal Oil Pots and that EDC Recovery Tank is at an acceptably low level. b. Turn the SVRU motor hand switches to AUTO. c. To start the recovery unit, first push the vapor recovery unit START PERMISSIVE pushbutton (HS-1009) in the control room. d. Put the SHIPPING MODE switch (HS-1021) in the control room in either the "BARGE" or "SHIP" mode, depending on which is to be loaded. For loading barges or ships, place the LOADING SL 085547 MODE switch (HS-1034) in the control room the "LOADING" mode. The "UNLOADING" mode is to be used only when a ship barge or ship is to be unloaded back into the plant. Place the EDC STORAGE TANK SELECT switch (HS-1019) on the tank being pumped from. NOTE: Before pushing the master control switch (HS-1570) the oil must be drained from the vacuum pump case. This must be done to insure that the oil level is not high in the pump before start up. e. Go to the SVRU and turn the master control switch (HS-1570) ON. This will align the valves for warm-up of the unit and will start the vacuum pump motor, oil recirculation pump, EDC recovery cooler fan, and oil cooler fan. The nitrogen blanketing valve (SDV-1028) will close and nitrogen flow control valve (FV-1016) will begin fixed flow control of 25 cfm. This will also start the analyzer sample pumps. Make certain that the sample line temperatures are at 150 F. These line heaters are to be left on at all times. f. When the oil temperature has heated up to the control point of 210 F, the vapor recovery beds will begin cycling. g. When the vapor recovery unit has regenerated each bed at least once (about 20-30 minutes) and TV monitoring of dock is confirmed, barge loading is ready to start. NOTE: To monitor the loading dock area, there are two identical Panasonic camera surveillance systems. The SL 085548 112 systems are independent of each other. Each system comprises of the following major components: B/W Camera Receiver Controller B/W Monitor (model #WV-BL204) (model #WV-RC150) (model #WV-CU101) (model # TR-930B) Monitors and controllers for both systems are housed in Control Panel CP-100 which is located In the South Terminal control building. The controller enables remote control of pan and tilt, zoom lens and receiver functions. Tankerman: (1) Before beginning loading, gauge and record the shore tank level. Certified Tankerman: (2) Verify all valve positions in the vapor line from the vessel tanks to facility vapor collection system (per 33 CFR 154.850 [c]) to assure a clear vapor path. Open header valve on barge and manual valve at loading hose. Make sure the liquid manual valve (MV-1052) is closed. (3) Check pressure of barge and vapor hose/line at vapor line gauge PI-1003 at the dock. If less than -0.1 psig (vacuum) is measured, a nitrogen hose is to be hooked up to the barge at the nitrogen header (through PCV on 113 SL 085549 barge) and pressure raised to approximately 0 psig before proceeding. Barge loading cannot begin if less than -0.1 psig is measured. If more than the allowable positive pressure (approximately 0.75 psig) is measured, supervision is to be notified to arrange for manual venting to an acceptable range. Manual venting will be by a special procedure through the SVRU. NOTE: Refer to Section 2.d for determination of flow limits. Tankerman: (4) Proceed to the control room and set the mass flow meter to deliver the required total amount of EDC to the barge/ship. (5) Push the START EDC LOADING button (HS-1022C) located in the control room. The following will occur: (a) The valve in the vapor line to the vapor recovery unit (SDV-1006) will automatically open subject to the following limitation: if pressure in the vapor line is greater than 0.1 psig, SDV-1006 will open to a throttle limit until pressure is bled down below 0.1 psig. At that point, the valve will open fully. (b) The valve for the EDC liquid to the barge or ship (SDV-1050) will automatically open. This occurs only after the valve in the vapor line (SDV-1006) is fully open. SL 085550 114 (c) The nitrogen flow control valve (FV-1016) will automatically switch from "FIXED FLOW CONTROL" to "FLOW CONTROL" cascaded with oxygen concentration. NOTE: Normally, this results in a minimum controlled flow of nitrogen to the barge vapor line since the barges typically will have less than set point oxygen in them; if oxygen is greater than set point, nitrogen will be flow-controlled to reduce it to set point. The minimum controlled nitrogen flow is intended to be maintained even if the liquid EDC flow to the barge goes to zero, in order to keep a positive flow to vapor recovery. (6) Set the flow controller (FIC-1051) on the liquid EDC at the target loading rates. (a) Do not lower the loading rate set point below 250 tons per hour (TPH) with two pumps or 125 TPH with one pump in operation due to the pumping turndown limits. (b) Do not set the loading rates above 600 TPH; there is a high flow alarm at 650 TPH. Tankerman: SL 085551 115 e. Proceed to the EDC loading pump and open the discharge valve. Certified Tankerman: f. Open the liquid manual valve (MV-1052) on the dock. Check the hose and dock area for leaks. Radio the Tankerman when the gravity flow is established and when it is time to turn on the pump. Tankerman: g. Start the EDC loading pump at the storage tank. If 125 tph is not achieved within 30 seconds, the pump will shut down. After the pump start, then check the pump for leaks and walk the pipeline checking for leaks. If leaks are detected, take appropriate shutdown action and notify supervision. The EDC loading pump can only be turned on at the pump. h. Return to the control room and monitor the loading operation. (1) Record the required operating data from the vapor recovery unit. (2) Inspect the EDC storage tank pump system hourly for pump leaks, gauge and record the tank level, and record the tank temperature. (3) Inspect the SVRU skid hourly for the following: knock out pot level; EDC/oil separator oil level; seal oil pot oil SL 085552 116 levels; and EDC Recovery Tank level. Note any excess noise from either of the fans or the vacuum pump. Certified Tankerman: i. Control flow to the tanks on the barge with on-board valves to keep the barge level. The person in charge (PIC) on board the ship is responsible for monitoring and controlling fill levels in ship tanks. j. Adjust mooring lines on the barge during loading as needed. Continue checking dry (double hull) compartments for leaks throughout product transfer. k. When the loading nears completion, instruct the Tankerman to reduce the flow to the barge/ship to minimum flow or stop the pump. The pump can be turned off either at the pump or in the control room by pressing HS-1030.. l. Top off the barge tanks evenly, using reduced flow and on board valves. m. Instruct the Tankerman to turn off the pump (if not already off). Close MV-1052. Certified Tankerman and Tankerman: n. Hook up the nitrogen hose to the liquid loading line (connection between SDV-1050 and MV-1052) and blow the EDC liquid line into the barge or ship. Close the flow control valve (FV-1051) by putting the controller (FIC-1051) on "MANUAL" from the 117 SL 085553 CRT in the control room, then close the liquid valve on the barge/ship and then close the valve on the end of the hose. o. Close the barge/ship vapor valve. Hook up a nitrogen hose to the vapor line and purge the vapor line with nitrogen to the vapor recovery unit. Close the 6-inch valve on the end of the hose. p. After clearing both lines, press the STOP EDC LOADING OPERATION button at the dock (HS-1022B). The STOP EDC LOADING OPERATION button (HS-1022A) in the control room may also be used. The stop button at the dock (HS-10222A) should be pulled out, while the control room stop button (HS 1022B) should be left pushed in (1) This action will close the valve in the liquid line (SDV1050) to the barge or ship and the vapor line (SDV-1006) to the vapor recovery unit. (2) The nitrogen controller (FIC-1016) will be automatically converted back to a fixed flow controller, and nitrogen flow to the vapor recovery unit will be controlled at a fixed set point. q. Disconnect the loading and vapor recovery hoses from the barge. Install blinds on the ends of each of the hoses. Disconnect electrical cables to barge level elements from barge. SL 085554 118 r. When loading is complete, open MV-1052 and add a small amount of nitrogen to the liquid line upstream of SDV-1050 for liquid expansion purposes. s. Close the discharge valve on the pump. Gauge and record barge tank levels. t. Ensure that all barge cargo hatches, ullage hatches and dry compartment hatches are closed and secured for shipment. u. Remove the gangway. Tankerman: v. Cycle the vapor recovery unit at least once to regenerate the beds after each barge loading . This should take approximately 30 minutes. For loading ships, it may be necessary to cycle the beds two more times to regenerate them. This will be determined experimentally after operations begin. w. Shut off the vapor recovery unit by pressing the VAPOR RECOVERY SYSTEM SHUTDOWN button (HS-1024) in the control room or the master control switch (HS-1570) at the skid. This action will: (1) Automatically shut off the nitrogen flow and turn off the four motors on the vapor recovery unit. (2) Automatically open a nitrogen valve (SDV-1028), keeping 4 inches water pressure on the pipeline to the vapor recovery unit and on the vapor recovery unit itself. 119 SL 0S5555 (3) Automatically position the valves to the absorbers to be open and the vent valves from the absorbers to be closed. (4) Automatically stop the three analyzer sample pumps. x. Before leaving the dock area, gauge the shore tank and record the levels. Turn off all strobe lights on the dock by activating idle button on computer. Complete the Solvent Barge Loading and Inspection Report. Send the top copy to the laboratory and the remaining two copies to the Plant A Shipping Office. Send the Declaration of Inspection form to the Plant A Shipping Office. y. Secure the boom line to the dock, police the dock and lock the gate. SL 85556 120 D. Shutdown Procedures 1. SD-1, Loading and Vapor Collection Shutdown A stop load button is located on the handrail on the NW side of the dock (HS-1022B) and in the control room (HS-1022A). Manual shutdowns executed with the stop load button and automatic shutdowns triggered by high and low vapor line pressure, high oxygen content, and high barge level initiate the same shut down procedure. Either manual or automatic shutdown of loading will: (1) stop the loading pump (P`204/205), (2) close the liquid valve on the EDC line (SDV-1050), and (3) close the valve on the vapor line to the vapor recovery unit (SDV-1006). This action also puts the nitrogen flow control valve (FV-1016) on fixed flow control, and the vapor recovery unit continues cycling to clear EDC and remain ready to receive vapor, so that loading can restart without a vapor recovery unit warmup. NOTE: There are two horn-strobe light systems on the dock with two acknowledge push buttons at the dock and a horn acknowledge for both systems at the computer terminal. One system only works for the barge level alarms and the other system works with all other system alarms and shutdowns including the barge levels. The barge high levels will activate a horn in the control room and two horns on the dock (LA-1001A and UA1037A). A red strobe light (LA-1001B) and an amber strobe light on the dock (UA-1037B) will be lit. Both 121 Sh 085557 horns will have to be acknowledged. The barge high high levels will activate a horn in the control room and two horns on the dock (LA-1001A and UA-1037A). A red strobe light (LA-1001B) and a red strobe light on the dock (UA-1037C) will be lit. The barge high high level will shutdown barge loading. All non-shutdown alarms on the system including the SVRU will activate the amber strobe light (UA-1037B) and a horn (UA-1037A) at the dock. Any shutdown systems (SD-1, SD-2 or SD-3) will activate the red strobe light (UA-1037C) and the horn (UA-1037A) at the dock. The green strobe light at the dock will be on when the START EDO LOADING button (HS-1022C) is pushed and will go off when the STOP EDO LOADING OPERATION button (HS-1022A in the control room or HS-1022B at the dock) is pushed or when EDO loading is shutdown by system interlocks. The red strobe lights (LA-1001 B and/or UA-1037C) must be turned off using the computer when the loading personnel leave the dock area. 2. SD-2. Loading and Normal Vapor Recovery Unit Shutdown If operating deviations within the vapor recovery unit cause a shutdown of the vapor recovery unit, shutdown of the loading operations will also be triggered as described above. In this case, the nitrogen flow control valve is closed and a nitrogen blanket is maintained in the vapor line through a bypass valve (PCV 1017). A 122 SL 085558 total restart of both the vapor recovery unit (including warmup) and loading is also required. 3. SD-3. Loading and Emergency Vapor Recovery Unit Shutdown An SD-3 level shutdown assumes that there is a possible fire in the adsorber beds. Shutdown of the vapor recovery unit and the loading operations will be triggered as described above. In this case, the automated block valves (FBV-1502, FBV-1511) to the adsorber beds will both close and the vent valves (FBV-1518, FBV1519) will both open. FBV-1547 and FBV-1548 will open and introduce nitrogen to the beds. All other valves on the SVRU will return to their fail positions. 4. Re-Start After Shutdown a. SD-1 Recheck valve alignment and mass flow meter setting. Re enter the start-up procedure at Section C.3.f.(5). b. SD-2 Re-enter the start-up procedure at Section C.3. c. SD-3 A re-start after an SD-3 shutdown will be only with the approval and under the direction of supervision. SXj 085559 123 E. Shutdown Criteria and Response There are three (3) levels of shutdown for the EDC Closed Dome Loading system: 1. A level SD-1 shutdown shuts down the barge/ship loading operation, but keeps the SVRU in operation. 2. A level SD-2 shutdown shuts down loading operations and shuts off the SVRU. 3. A level SD-3 shutdown shuts down loading, shuts off the SVRU, and purges nitrogen through the adsorber beds with the vent valves open. The following section details the shutdown sequences and the alarms/events that cause these shutdown sequences: 1. Level SD-1 - Shutdown of Loading. Isolation of Vessel. SVRU Continues Cycling A level SD-1 shutdown will terminate loading operations and isolate the vessel. The SVRU and the analyzer sample pumps will remain in operation. The following events will occur as a result of an SD-1 shutdown: EDC Vapor Line Shutdown Valve (SDV-1006) will close. EDC Liquid Line Shutdown Valve (SDV-1050) will close. EDC loading pumps (P-204 and P-205) will be turned off. SL 085560 124  The control of nitrogen to the vapor line (FIC-1016) will switch from cascade control based on oxygen concentration to fixed flow control of 25 scfm. The following alarms will cause an SD-1 shutdown to occur: PAH-102 EDC Storage Tank ST-1 high pressure (set point 3 inches W.C.) PAL-102 EDC Storage Tank ST-1 low pressure (set point 1 inch W.C.) PAH-175 EDC Storage Tank ST-2 high pressure (set point 2 psig) PAL-175 EDC Storage Tank ST-2 low pressure (set point 1 psig) LAL-101 EDC Storage Tank ST-1 low level (set point 3 feet) LAL-111 EDC Storage Tank ST-2 low level (set point 3 feet) LAHH-1001 High high barge tank level PALL-1004 Low low vapor line pressure (set point -0.1 psig) PALL-1005 Low low vapor line pressure (set point -0.1 psig) PAHH-1004 High high vapor line pressure (set point 0.75 psig) PAHH-1005 High high vapor line pressure (set point 0.75 psig) SL 085561 125 AAHH-1011A High high oxygen concentration on vapor line (set point 11.2%) AAHH-1011B High high oxygen concentration on vapor line (set point 11.2%) FSL-1011A Low sample flow on oxygen analyzer AT-1011 A* FSL-101 IB Low sample flow on oxygen analyzer AT-1011B* AAX-1011A Loss of signal from oxygen analyzer AT-1011 A* AAX-101 IB Loss of signal from oxygen analyzer AT-1011B# XA-1011A Malfunction alarm on oxygen analyzer AT-1011A* XA-1011B Malfunction alarm on oxygen analyzer AT-101 IB* LAHH-1013 High high knockout pot level (set point 95%) FAHH-1501 TAL-1027 High high vapor flow on recovery unit (set point 750 acfm) Low sample temperature for EDC recovery tank oxygen analyzer (set point 135F) TAL-1029 FQAH-1051 Low sample temperature for vapor recovery line oxygen analyzers (set point 110F) High mass flow meter totalized reading SL 085562 126 PAL-1002 Low nitrogen pressure (set point 75 psig) XA-1013 Knock-out pot level transmitter loss of signal FSL-1031 Low sample flow on EDC recovery tank oxygen analyzer TALL-1524 Low low oil temperature (set point 200F) * These alarms will only result in an SD-1 shutdown provided that the redundant oxygen analyzer has already malfunctioned. For example, low sample flow on oxygen analyzer AT-1011A (FSL-1011A) would only result in an SD-1 shutdown if oxygen analyzer AT-101 IB had already produced a failure alarm (FSL101 IB, XA-1011B, or AAX-101 IB). Also note that both analyzers must be functioning properly without any alarms in order to begin loading. In addition to the alarms listed above, an SD-1 shutdown can be initiated by operating personnel in response to an emergency or as part of the normal loading sequence. There are two pushbuttons, one on the control panel in the control room (HS-1022A) and one at the dock (HS-1022B), either of which may be used to shutdown loading. If the SD-1 shutdown pushbutton on the dock (HS-1022B) is used, there will be an indication (HL-1022A) on the CRT in the control room. This will alert the tankerman in the control room that the SD-1 shutdown occurred as a result of operator action instead of a process alarm. 2. Level SD-2 - Shutdown of Loading. Isolation of Vessel. SVRU Shut Down and Valved in under Nitrogen Blanket SL 085563 127 An SD-2 level shutdown will result in a simultaneous shutdown of the SVRU and loading operations. The following events will occur as a result of an SD-2 shutdown: EDC Vapor Line Shutdown Valve (SDV-1006) will close. EDC Liquid Line Shutdown Valve (SDV-1050) will close. EDC loading pumps (P-204 and P-205) will be turned off. Nitrogen Inerting Flow Control Valve (FV-1016) will close. Nitrogen Blanketing Shutdown Valve (SDV-1028) will open. This will place a nitrogen blanket of 4 inches of water all the way through to the adsorbers. This nitrogen pad is to prevent air from getting into the system during shutdown. All motors on the skid will be turned off. Analyzer sample pumps will be turned off. All valves on the SVRU will return to their fail positions. The following alarms will cause an SD-2 shutdown occur: PAL-1533 Low instrument air pressure (set point 60 psig) VAH-1527 High fan vibration on oil cooler VAH-1531 High fan vibration on EDC recovery cooler SI, 085564 128 PDAHH-1546 High high differential pressure on EDC/oit separator (set point 5 psid) LSL-1562 Low oil level - EDC/oil separator LSH-1561 High oil level - EDC/oil separator FAHH-1016 High high inerting nitrogen flow (set point 450 scfm) PALL-1527 Low low oil pressure (set point 13.7 psia, 10 sec. delay) PAHH-1527 High high oil pressure (set point 15.7 psia, 10 sec. delay) TAHH-1524 High high oil temperature (set point 250F) TAHH-1544 High high vapor temperature (set point 140SF) LAHH-1535 High high EDC recovery tank level LAHH-1534 High high EDC recovery tank level (setpoint 95%) AAHH-1031 High high oxygen content in the EDC recovery tank (set point 11.2%) AAX-1031 Loss of signal from EDC recovery tank oxygen analyzer SL 085565 129 XA-1031 Malfunction alarm on EDC recovery tank oxygen analyzer PAH-1503 High adsorber (60-2676) pressure (setpoint 18.0 psia) PAH-1507 High adsorber (60-2675) pressure (set point 18.0 psia) An SD-2 level shutdown will also occur when any valve fails to move into the position commanded by the sequence or when any of the following four motors stops running: Vacuum pump motor (50-7751) Oil circulation pump motor (50-7752) Oil cooler fan motor (50-7753) EDC recovery cooler fan motor (50-7754) In addition to the alarms and events listed above, an SD-2 level shutdown can be initiated by operating personnel in response to an emergency or as part of the normal operating sequence. A master stop pushbutton at the SVRU (HS-1570) and one on the control panel in the control room (HS-1024) may be used to shutdown the SVRU. 3. Level SD-3 - Shutdown of Loading. Isolation of Vessel. SVRU Shut Down and Purged (Emergency in Recovery Unit) 130 SL 085566 An SD-3 level shutdown assumes that there is a fire in the adsorber beds. The following actions will be taken as a result: EDO Vapor Line Shutdown Valve (SDV-1006) will close. EDC Liquid Line Shutdown Valve (SDV-1050) will close. EDC loading pumps (P-204 and P-205) will shutdown. Nitrogen Inerting Flow Control Valve (FV-1016) will close. Nitrogen Blanketing Shutdown Valve (SDV-1028) will open. This will place a nitrogen blanket of 4 inches of water all the way through to the adsorbers. This nitrogen pad is to prevent air from getting into the system during shutdown. All motors on the skid will be turned off. Analyzer sample pumps will be turned off. FBV-1502 and FBV-1511, automated block valves to the adsorber beds, will both close. FBV-1518 and FBV-1519, vent valves from the adsorber beds, will both open. FBV-1547 and FBV-1548 will open and introduce nitrogen to the beds. All other valves on the SVRU will return to their fail positions. SL 085567 131 The following alarms will result in an SD-3 level shutdown: TAHH-1504 High high temperature in Adsorber 60-2676 (set point 150F) TAHH-1505 High high temperature in Adsorber 60-2676 (set point 150F) TAHH-1506 High high temperature in Adsorber 60-2676 (set point 150F) TAHH-1508 High high temperature in Adsorber 60-2675 (set point 150F) TAHH-1509 High high temperature in Adsorber 60-2675 (set point 150F) TAHH-1510 High high temperature in Adsorber 60-2675 (set point 150F) SVRU Shutdown of SVRU for any reason NOTE: To restart the SVRU after a SD-3 shutdown, the vapor recovery system shutdown button (HS-1024) must be pushed. SL 085568 132 F. Marine Vapor Recovery (MVR) Bypass 1. Operation Without Marine Vapor Recovery There are 2 modes for EDC barge/ship loading operations. The modes of operation are as follows: Normal Operation - This mode of operation is with the vapor recovery unit in operation. This mode of operation should be used essentially all of the time. PPG will be required by regulation to run the vapor recovery unit so EDC vapors will not be emitted to the atmosphere. Operation in this mode is as described in Section C of this manual. Non Routine Operation - This mode of operation will be without the vapor recovery unit in operation, and the EDC vapors will be emitted to the atmosphere. This mode of operation cannot commence without the approval of the shift superintendent. The shift superintendent will request from the environmental representative who in turn will request from the Louisiana Department of Environmental Quality (LDEQ) a variance to emit the vapors. It would be a violation of applicable air permits and LDEQ regulations to emit vapors without an approved variance. Since the vapor recovery unit needs to operate only during EDC loading, there should be ample time to repair the unit between barge/ship loadings. If the vapor recovery unit malfunctions, resulting in shutdown of the loading process, the unit must be repaired before loading is completed. In the event of a major disruption of loading operations due to the vapor recovery unit being SL 085569 133 out of service and if there are compelling reasons to proceed with loading, it may be possible to obtain a variance and load a barge/ship without the vapor recovery unit in operation. The following discussion explains how the system is to operate if this is done. The shift superintendent is to authorize the shipping shift supervisor to go to the south terminal control room and put the EDC barge loading control system in the non-routine operating mode. This can only be done with a security access code. This will allow loading of a barge/ship without the vapor recovery unit in operation. Once in the non-routine loading mode, all the shutdown interlock functions associated with the vapor recovery system will be bypassed. All the interlocks associated with the liquid loading system will still be activated. The procedure for preloading and inspection and procedures for EDC loading are to be followed with the following comments/exceptions: The TEST MODE switch (HS-1035) must be in the OFF position. The TEST MODE sequence does not have to be followed. The oxygen analyzers do not have to be calibrated. The vapor hose should not be attached to the barge/ship. Make certain that there is a barge/ship vent valve open for vapor displacement out of the tanks. The electrical cable for the tank high level switches on the barge must be attached. The barge high high levels (LAHH1001) will stop loading. The high level switch in dock barg vessel compartment must be tested after the electrical cable is SL 085570 134 connected. To do this, the Certified Tankerman must pull up the rod on each switch until an alarm is obtained. The tankerman will acknowledge the alarms. If any level switch does not work, barge loading cannot begin. All the checks on the vapor recovery unit will not be required. The following steps are similar to those for normal loading with Marine Vapor Recovery: The SHIPPING MODE switch (HS-1021) in the control room must be in either the barge or ship mode, depending on which is to be loaded. The LOADING MODE switch (HS-1034) must be in the loading mode for loading barges or ships. Place the EDC STORAGE TANK SELECT switch (HS-1019) on the tank being pumped from. The dock camera system must be in operation. The flow meter (FQ-1051) in the control room must be set to deliver the required total amount of EDC to the barge/ship. When barge/ship loading is to commence, the START EDC LOADING switch (HS-1022C) in the control room must be pushed. This will open SDV-1050. To stop loading, push the STOP EDC LOADING OPERATION button in the control room (HS-1022A) or at the dock (HS- 135 SL 085571 1022B). This will stop the pumps (P-204 and/or P-205) and close SDV-1050. NOTE: Pushing the STOP EDO LOADING OPERATION button in the control room or at the dock will take the system out of the Marine Vapor Bypass Mode. The permissives to start barge/ship loading when the vapor recovery unit is not used are: The barge vapor valve SDV-1006 must be closed (ZSC-1006 must be satisfied) for loading to begin. The ST-1 or ST-2 (depending on which tank is being pumped from) level and pressure must be in the proper operating range. The interlocks for ST-1 are LALL-0101, PAH-0102, and PAL0102. The interlocks for ST-2 are LALL-0111, PAH-0175, and PAL-0175. The barge must not have a high high level (LAHH-1001). The shutdown of the barge/ship loading will be done by stopping the EDC ship loading pumps (P-204, P-205) and closing the liquid EDC fill valve to the barge (SDV-1050). The interlocks that will stop barge/ship loading when the vapor recovery unit is not used are as follows: High or low storage tank pressure on the EDC storage tank being pumped from (ST-1 or ST-2). The interlocks for ST-1 are PAH-0102 and PAL-0102. The interlocks for ST-2 are PAH-0175 and PAL-0175. SL 085572 136  A low low liquid level in the EDC storage tank (ST-1 and ST-2). The interlock for ST-1 is LALL-0101, and for ST-2 is LALL0111. High high barge tank levels (LAHH-1001) The STOP EDC LOADING OPERATION button in the control room (HS-1022A) or at the dock (HS-1022B). High mass flow meter totalized reading (FQAH-1051). 2. Pre-loading. Hookup, and Alignment Procedures without Marine Vapor Recovery The following steps shall be performed by the Certified Tankerman or by the Tankerman under the direction of the Certified Tankerman. Certified Tankerman/Tankerman: a. Spot the barge that is to be loaded or unloaded (normally this is performed by contract tug). b. Obtain the shore tank number from the Shift or Day Foreman. Check with the Shipping Shift Foreman if a surveyor is needed to sample the EDC from the tank prior to filling a ship or customer barge. NOTE: Samples are not normally required for PPG terminal destinations; sampling is usually done before arrival of the barge or ship. SL 085573 137 c. Place the gangplank on the barge and secure. d. Complete preloading conference with person in charge (PIC) of ship. e. Complete preloading inspection of barge (refer to 46 CFR 151.45-5). Close the sea cock valve and pump stern rake if necessary. Call the VC-II Vinyl Storage Operator to obtain tank availability and for sample clearance; then tag the appropriate valves. f. Complete the Declaration of Inspection form for barges. In the case of ships, complete the Declaration of Inspection with the PIC before hooking up. g. For barges, check and apply all warning signs and signals (see 46 CFR 151.45-2 and 151.45-9). Using the Certificate of inspection found in the document tube on the barge, determine the number and type of fire extinguishers to be used on the barge. (1) Ensure that the barge is certified to carry EDC per the Certificate of Inspection. (a) Verify the U. S. Coast Guard (USCG) expiration date on the certificate. The barge cannot be loaded if the expiration date has passed. (b) In the case of ships, the ship's PIC is responsible for vessel compliance. 138 h. General procedure for making the hose connection is below. A full face Comfo II or Airline mask must be worn while installing and removing the hose. (1) Make sure liquid loading valve (HV 1052) is closed. Remove the blind flange off the end of the liquid hose. (2) Hook up the liquid fill hose to the barge or ship using the appropriate gaskets. i. Hook up the electrical cable for the tank high level switches on the barge. (This is not required for ships.) NOTE: Per Coast Guard Regulation 154.810(g), no ground cable hookup is to be made. j. Locate the STOP EDC LOADING OPERATION pushbutton (HS-1022B) on the handrail of the walkway between the dock and shore. Make sure pushbutton is pulled out. NOTE: An additional STOP EDC LOADING OPERATION pushbutton (HS-1022A) is located in the control room. k. Line up the barge piping. The PIC on the ship will line up the ship's piping. l. Make sure the vents on the loading line are closed. m. Line up the shore tank piping from the dock to the tank for both ships and barges. Check to be sure the tank has been gauged; then record the tank temperature. When loading a barge, be SL 085575 139 sure the stern rake is pumped out before transfer begins, if applicable. NOTE: There may be input into ST-1 or ST-2 during loading. 3. Procedures for EDC Loading without Marine Vapor Recovery In general, the Certified Tankerman should remain on the barge or dock during EDC loading. The Tankerman should proceed with offbarge control activities at the direction of the Certified Tankerman. Certified Tankerman/Tankerman: a. Put the SHIPPING MODE switch (HS-1021) in the control room in either the "BARGE" or "SHIP" mode, depending on which is to be loaded. For loading barges or ships, place the LOADING MODE switch (HS-1034) in the control room in the "LOADING" mode. The "UNLOADING" mode is to be used only when a barge or ship is to be unloaded back into the plant. Place the EDC STORAGE TANK SELECT Switch (HS-1019) on the tank being pumped from. b. When TV monitoring of dock is confirmed, barge loading is ready to start. NOTE: To monitor the loading dock area, there are two identical Panasonic camera surveillance systems. The systems are independent of each other. Each system comprises of the following major components: B/W Camera (model #WV-BL204) 140 SL 085576 Receiver Controller B/W Monitor (model #WV-RC150) (model #WV-CU101) (model it TR-930B) Monitors and controllers for both systems are housed in Control Panel CP-100 which is located in the South Terminal control building. The controller enables remote control of pan and tilt, zoom lens and receiver functions. Tankerman: (1) Before beginning loading, gauge and record the shore tank level. Certified Tankerman: (2) Open header valve on barge and manual valve at loading hose. Make certain that the barge tank vent line is open. Tankerman: (3) Proceed to the control room and set the mass flow meter to deliver the required total amount of EDC to the barge/ship. (4) Push the START EDC LOADING button (HS-1022C) located in the control room. The following will occur: (a) The valve for the EDC liquid to the barge or ship (SDV-1050) will automatically open. SL 085577 141 (5) Set the flow controller (FIC-1051) on the liquid EDC at the target loading rates. (a) Do not lower the loading rate set point below 250 tons per hour (TPH) with two pumps or 125 TPH with one pump in operation due to the pumping turndown limits. (b) Do not set the loading rates above 600 TPH; there is a high flow alarm at 650 TPH. Tankerman: c. Proceed to the EDC loading pump and open the discharge valve. Certified Tankerman: d. Open manual liquid loading valve (HV 1052) and check for leaks at the hose and dock area. Radio the Tankerman when the gravity flow is established and when it is time to turn on the pump. Tankerman: e. Start the EDC loading pump at the storage tank. Then check the pump for leaks and walk the pipeline checking for leaks. If leaks are detected, take appropriate shutdown action and notify supervision. The EDC loading pump can only be turned on at the pump. SL 085578 142 f. Return to the control room and monitor the loading operation. (1) Inspect the EDC storage tank pump system hourly for pump leaks, gauge and record the tank level, and record the tank temperature. Certified Tankerman: g. Control flow to the tanks on the barge with on-board valves to keep the barge level. The person in charge (PIC) on board the ship is responsible for monitoring and controlling fill levels in ship tanks. h. Adjust mooring lines on the barge during loading as needed. Continue checking dry (double hull) compartments for leaks throughout product transfer. i. When the loading nears completion, instruct the Tankerman to reduce the flow to the barge/ship to minimum flow or stop the pump. The pump can be turned off either at the pump or in the control room. j. Top off the barge tanks evenly, using reduced flow and on board valves. k. Instruct the Tankerman to turn off the pump (if not already off). Close MV-1052. Certified Tankerman and Tankerman: SL S5S79 143 l. Hook up the nitrogen hose to the liquid loading line and blow the EDO liquid line into the barge or ship. Close the flow control valve (FV-1051) by putting the controller (FIC-1051) on "MANUAL" from the CRT in the control room, then close the liquid valve on the barge/ship and then close the valve on the end of the hose. m. After clearing the liquid hose, press the STOP EDC LOADING OPERATION button at the dock (HS-1022B). There will also be a STOP EDC LOADING OPERATION button (HS-1022A) in the control room that may be used. (1) This action will close the valve in the liquid line (SDV1050) to the barge or ship. n. Disconnect the loading hose from the barge. Install a blind on the end of the hose. o. When loading is complete, open MV-1052 and add a small amount of nitrogen to the liquid line upstream of SDV-1050 for liquid expansion purposes. p. Close the discharge valve on the pump. Gauge and record barge tank levels. q. Ensure that all barge cargo hatches, ullage hatches and dry compartment hatches are closed and secured for shipment. r. Remove all fire extinguishers from the barge and remove the gangway. Sh 085580 144 Tankerman: s. Before leaving the dock area, gauge the shore tank and record the levels. Complete the Solvent Barge Loading and inspection Report. Send the top copy to the laboratory and the remaining two copies to the Plant A Shipping Office. Send the Declaration of Inspection form to the Plant A Shipping Office. t. Secure the boom line to the dock, police the dock and lock the gate. SL 085581 145 G. Recovered EDC Liquid EDC recovered from the barge vapors by the SVRU is intermediately stored in EDC Recovery Tank 60-2678. Off-spec EDC is normally transferred to the EDC plant in a vacuum truck. In-spec recovered EDC can be pumped to the EDC storage tanks through the loading line. NOTE: ST-1 can only be filled to a level of 38 feet and ST-2 can only be filled to a level of 42 feet. 1. EDC Recovery Tank Pumpout to Vacuum Truck Tankerman Recognize that the level in the EDC Recovery Tank is sufficient for transfer. Circulate the recovered EDC using pump 55-6050. Take a sample of the EDC. Send the sample to the main laboratory for analysis. If the EDC quality is not acceptable for shipment, notify the Shipping Shift Foreman that a vacuum truck is needed. Tankerman and Vacuum Truck Operator: A clean, dry, empty, nitrogen purged, one compartment truck is to be ordered. Check the truck vapors with an oxygen meter. The oxygen concentration must be less than 10% to proceed. 146 SL 085582 Before proceeding with the EDO transfer, be sure that the SVRU is cycling, but not while vessel loading is in progress. This allows the displaced truck vapors to be processed to recover any EDC. It is not necessary to run the TEST MODE to pump out the tank. Make a hose hookup of the EDC Recovery Tank Pump discharge connections to the vacuum truck. Also, hook up a vapor return line from the truck to the EDC Recovery Tank. The Vacuum Truck Operator will align truck values. The Truck Operator will not use the vacuum pump on the truck during this EDC transfer. The Tankerman will open the liquid valve to the vacuum truck by using the switch at the skid. This valve can be closed by using the manual switch or by an automatic shutdown. He will also open the valve in the vapor return line. The recirculation line valve to the tank can be closed or pinched back if necessary to divert sufficient flow to the truck. Allow the EDC to be pumped into the vacuum truck using pump 55-6050. The vapors displaced in the vacuum truck will return to the EDC Recovery Tank through the vapor return hose. When the tank is emptied sufficiently, as indicated by low level alarm, the Tankerman will shut down pump 55-6050. It should take approximately 30 minutes to pump out the tank. The Tankerman will notify the Truck Operator. SL 085583  The Tankerman will purge the liquid contents of the transfer hose into the truck using nitrogen. The Tankerman and Truck Operator will close the appropriate valves and disconnect the liquid loading line and vapor return line. The SVRU can then be shut down according to normal procedure. The Vacuum Truck Operator will transport the EDO to the EDC Plant or the Waste Treatment Unit. The interlocks that will shutdown the EDC recovery tank pump and liquid transfer valve (FBV-1549) are as follows: a. Low low EDC recovery tank level (LALL-1534). (set point 5%) b. Low EDC recovery tank level (LSL-1514). c. High EDC transfer pump temperature (TAH-1550). (set point 200F) 2. EDC Recovery Tank Pumoout to ST-1 or ST-2 Tankerman: Recognize that the level in the EDC Recovery Tank is sufficient for transfer. Circulate the recovered EDC using pump 55-6050. 148 SL 085584 Take a sample of the EDC. Send the sample to the main laboratory for analysis. If the EDC quality is acceptable, then proceed to pump the liquid to either ST-1 or ST-2. NOTE: Since the VC-II plant is responsible for the product quality in the EDC storage tanks, they must be involved with the transfer of liquids back into the tanks. Notify the VC-II operator to come down so a transfer back to the storage tanks can be done. The VC-II operator will align the valves at the storage tanks that he wants the EDC to be transferred back into. Align the valves to pump the liquid back into the line to the storage tanks. Turn on the switch to open FBV-1549. NOTE: The SVRU does not need to be in operation for this transfer operation. The EDC Recovery Tank pressure will be maintained during the pumpout by the pressure regulator control system on the tank. The EDC Loading Pumps (P-204 and P-205) must not be in operation during this transfer. When P-204 and P-205 are in operation, the liquid transfer valve (FBV-1549) will not open. When the tank is sufficiently empty, as indicated by a low level alarm, the Tankerman will close FBV-1549 and turn off the EDC Recovery Tank pump. SL 085585 U9 H. Marine Vessel Unloading (Vessel to Shore) Unloading of barges or ships back to the shore storage tank system will be very infrequent. This unloading must be coordinated with VC-II operations. The SVRU will not be in operation during this procedure. A nitrogen line will have to be connected to the vessel. The new control system is designed to accommodate this event. Supervision will provide specific instructions of how this is to be done. In addition, the vessel contains cargo transfer procedures. Information specific to our new on-shore facilities are as follows: The LOADING MODE switch (HS-1034) in the South Terminal Control Room will be put in the UNLOAD MODE when a vessel is to be unloaded. The EDC STORAGE TANK SELECT switch (HS-1019) should be placed in the proper tank position. In the unload position, the interlocks that will close the automatic liquid valve (SDV-1050) are as follows: 1. High or low storage tank pressure on the EDC tank being pumped into (PAL-0102 and PAH-0102 on ST-1; PAL-0175 and PAH-0175 on ST-2). 2. High high EDC storage tank level on the tank being pumped into (LAHH-0101 on ST-1 or LAHH-0111 on ST-2). In the UNLOAD MODE, SDV-1050 will be opened by pressing the START EDC LOADING switch (HS-1022C) in the control room. Also, in the UNLOAD MODE, pressing the STOP EDC LOADING OPERATION button (HS-1022A or HS-1022B) will close SDV-1050. The EDC storage tank level and pressure should be closely monitored during unloading to make certain the tank is not overfilled or overpressured. The unloading rate will 150 SL 085586 be controlled at a rate not to increase the pressure in ST-1 or ST-2. The unloading flow rate will also be controlled with FIC-1051 in the control room. There are high level alarms on ST-1 and ST-2. SL 085587 151 I. Routine Operating Procedures 1. Sampling Procedures The EDC Recovery Tank sample is caught using a sample bomb obtained from the laboratory. This sample is taken prior to unloading the tank. Samples containing EDC are taken under pressure using pressure rated steel bombs that allow safe handling of the material. The sample collection procedure is as follows: a. The sample bomb is to be connected to the sampling connections on the EDC Recovery Tank recirculation line. Open the needle valves on the sample bomb and check for leaks. b. Let the sample flow through the bomb for about five minutes. c. Close the needle valves on the sample bomb and remove it from the line. d. Send the sample to the main laboratory. 2. Filter Replacement Criteria. Data, and Procedure The dust filter (72-821) on the SVRU contains a bag type filter using a 100 micron polypropylene bag. A differential pressure is measured across the filter by PDT-1500 and will alarm at 0.5-inch W.C. SL 085588 152 When a differential pressure of 0.5-inch W.C. has been reached, the filter bag must be removed and replaced. After the pressure differential alarm is obtained, barge or ship loading can proceed as long as the differential pressure does not exceed 2 inches W.C. To remove and replace the bag, perform the following steps: Close the inlet and outlet valves to the dust filter. Apply a small nitrogen purge to the top of the dust filter using a hose. The filter should already be full of nitrogen. Open the 1.5-inch drain valve on the bottom of the dust filter. Collect any liquid in a drip pan. (The drip pan will be emptied using a vacuum truck). Normally, there should be no liquid or EDC vapors. Close the nitrogen purge valve. Once the dust filter has been cleared, lock the filter for maintenance. Maintenance personnel or a tankerman can remove and replace the bag. A Comfo-ll must be worn while the dust filter is opened. Maintenance personnel will contact the RCRA drum coordinator to have the filter bag put in a blue RCRA drum with the proper label. The waste code will be F025/DQ01. SL 085589 153  Once the filter bag is replaced and the dust filter is buttoned up, the tankerman can unlock the dust filter and realign the valves. 3. SVRU Sump Pumpout Procedure The SVRU contains collection sumps in the southwest corner of the skid and beneath the knockout pot. The exit valves from the sumps are car-sealed-closed (CSC) to prevent uncontrolled drainage from the sump. The tankerman is to inspect the sumps and proceed to have them emptied when they are nearly full. If an oil sheen is observed on the water, the Tankerman should contact the Shipping Shift Foreman who will contact the oiler to remove the oil from the water. The oil will be removed by pumping and/or soaking the oil in oil pads. These oil pads will be put in roll off box number 525.25 in the South Terminal area. The tankerman must fill out a Dike Water Handling Log Sheet (in Environment SOPs) and take two samples of the water from each sump and send them to the main laboratory for analysis. If the lab does not clear the samples, the tankerman will have the Shipping Shift Foreman call for the vacuum truck service who will empty the sump and transport the contaminated material to the Waste Treatment Unit. If the lab clears the sample, the CSC sump valve must be administratively approved for opening so that the sump can be drained to the surface run-off ditch. SL 085590 154 The tankerman must enter all appropriate data on the log sheet, including analysis. The log sheets must be sent to the Plant B Environmental Coordinator. SL 085591 155 APPENDICES SL 085592 APPENDIX A P&ID'S SL 085594 Liquid Loading and Vapor Handling SL 085595 SORBATHENE Unit SL 085598 009580 'IS CHEMICALS LAKE CHARLES. LOUISIANA WQTTS. 1 ) V*lVt MX LOW PONT Oft**rS 2) Ptoc au t*ch powt vtxrs 3 ) SAMPLE BOU0 COW<CTKJNS * ) OtSACLE 0PCTAT1CN Cf 51-SOW. COMPUTER GENERATED DRAWING BY EAKE CHARLES CHEMICALS CAD REVISE WIT AYTD TECHNOLOGIES, INC. 5.) SWITCH KS-1009 MUST BE ST BEFORE HS-ISTO(KS-15TtJ stajttsatcps PLC PROOTaM ) JOB NUMBER: 6A01 6.) FCR A CCTAJU33 P A 0T TK S*HPV SrSIEW. RtTTH TO DPAWMC T1A-1O027. iDRAWING NUMBER: 6 ACM-F-102 i DOCK AREA-SIXJTH P fc K> PPC CLOSED DOME LOADING-EDC _____ VACUUM PUMP AMO CONDENSER SORBATHENE UNIT frfttn rr JL " - l TMr 1 1 A-10*036.0 Nitrogen System SL 085602 09580 7S ST-1 and ST-2 (EDC Storage Tanks) SL 085604 r 99S80 SIOHUKTDCOMWRNATOR srsTrw J 7*-76031 TO MCNCRA1CK <j7A-loooa~^ J^h-joos-phs _ON_0 5 PSK| orr (o j psci \wu +- 30 PStC T wjpruwt Drsc 6 ~-PI 34- ?QOJ -Pt*s | ajciiQH gQTti: 11 .s' * S' T/T (M-W) \r f-- ' [ 2" oo-- 0 i'a* > *-- Is1?7'-PTW-200*-Pl vy i 'itAwTr I3xo- -7043PS1cCrw , RSEfLfMECATOrrRcSomlp7rl>efssor j i^WT COMPRESSORS CORKCM wooci 0*490 T*4 rBA-IOJ. 7Jo I MOTOR SIZE 7 3 M> iJ/V2T2*-VJl8 \' -vjie -HtXJHT 1 *E --r ysu FLTCR*--1 Vi*-1**'' A0ANOCMCD w PLACE / l 1 X X **-TM X U4^>TA L r-V27* SSV VALMCS 04A*I> OPEN rv-w ]' Y -VM4 CDC STORACC TAM( 9o r-o* (60-TOM) r\ ft -i3oa-pii RCCWQJLA1ICN LPC PirtRIRg PWH 37A-10OJA - OPERATIONS n.O DIAGRAM SOUTH TERVPCAt. - CTKJ STORAGE REVISIONS _ REDRAWN ft *CCD <** COW**. 0*0- o-4rrso C r. BROW 5/rs/B* (XTt vjr A ^A-m *x> aoccd ir.R-m ro UO.CR-'W<7O8-1^n9t7o0?ts C r brow e/ft/M C*T> VJri XX___*tv 'as ut.r CMC I90O-CO-6322J on>C- F-. BROW A CMC RES-7W9 o 0 KATWCS i/2/1? A.PP- A;REVTSEO as suit CMC res-?*o BT o 8LANOHARO 0*H 6-26-M /K"RTVT5CO TCR fDCKCL1O0S*E0DP*C CMC- A*S-7tO* BT DATE. A*AM) LAADHOCHD-01lA<1M-- 0111 CMC. RTS-7609 A Btt.S 0* >E 6-10-93 APPRO D JO-NSON COMPUTER GENERATED DRAWING BY lake CHARLES CHEMICALS CAP REVISE OWLY phj-phj-11 GX UNLOAD**: l PC ' FBtX OOCXS ft sue non TO PUU^S >2 7A-MOOT '] CHEMICALS LAKE CHARLES LOUISIANA SOUTH TERMINAL FACILITIES SOUTH TERMINAL FACILITIES MECHANICAL FLOW SHEET - P&JD .- rr-O i/IQ /4 1 -C \3 T fl6 2 0 \5 7 4 tti Detailed Analyzer Systems SL 085607 809S80 7S y* ^/s t*u s/s nje*c ow tun pout) oYt*"*uuioi.crer*r*y-. .y.'nnjejeiHFGC v*>/ | Yr b*u v*4^ *-- {oo "or acra i*c cm v*t*u ~r TO KMOC*OUT por ",7 1 5 SAMPLE LINES FOR OXYCEN ANALYZERS 1011A ANO 10119 ARE ROUTED TOGETHER W TV. SAME ELECTRKAUY HEAT TRACED BUNDLE. A SEPARATE TEMPERATURE CONTROL PANEL WILL MONITOR ANO CONTROL THE TEMPERA IURE Of THE SAMPLE LINES the control PANEL IS EQUIPPED WITH REDUNDANT CONTROLLERS. 1 NQTS.INSULATE FROM AOJ SAMPLE PUMP TO ANALYZER2 SIGNAL SELECTION BASED ON HIGH SICNAL OR NON-MALFUNCTIONINC ANALYZER 3 CONTROLLER FIC-10T6 IS SHOWN ON OWC. 11 A-10029. OFF-AUTO HAND SWITCH IS USED TO DISCONNECT TEST CAS SOLENOID (54) FROM PIC CONTROL FOR MAINTENANCE PURPOSES. A too C 103 jo ho PRELEASED FOR CONSTRUCTION > **.erXasIeM* hoMtr 1/n/* WA(JCt HAYOEt 4 ASSOCIATES, C. ethJmcers NCt CRUJVfS Jwii BATON WUCC WHAAICWC MO. I7-13- liS CHEMICALS LAKE CHARLES. LOUISIANA DOCK AREA P k 10 CLOSED POME LOADING VAPOR RECOVERY OXYGEN ANALYZER occms *t M. 0*rt oak 1I22/0/W9/9AZ2 CKct "ESJ 0 0*n 1/21y>3 M ---------- OWG. 11 A-- 1 0026.2 609580 5S powi ecvuco two OCTHNSTRCAU REVISIONS A CHANCE R^SIRIJKHI WMCRS A*pf w wioomr sju*\ fur ouisoc 9 WMtrnnt tuu*c *x> n> CHAKt km cr mu c *ubm ruesc OKcnot OC: Kl-not NOTI t rrsuLjUT tuqhc ntcu *or saic>lc pvjv TO AMAlTTDt 1 SAWPU AH3 ACnjRM lS ARC ROJITD TOCCTKH ti IK SAK tLCCmtCAIXT HEAT TRACO ftMXL A SEPARATE COHmOL PAHCL cru.twkosranmcppleamaomoecautrmuRoHt tukcsrtwtEkPAcrounmtrol PA>d ts COUFPED 11H RCBLHOANI CCHTPOttrwS. A 100 C 103 RELEASED FDR CONSTRUCTION bcwso* m> *1 ST * ---tfl* _c*n . WAU, HATOfL ft ASSOCIATES. WC. o*dKnes CW CPLEAM5 JoetA ftATOH ROUCC JTMM IHU OPC. MO . M-Ol* CHEMICALS LAKE CHARLES. LOUISIANA POCK AREA CLOSED DOUE LOADING EDC RECOVERY TANK oxygen analyzer MIC 12/09/97 sc*u . rt 12/P9/gJ ch*c* PCS# ?W Duirt T/23/93 DWG. 1 1 A-10027.2 APPENDIX B SAFETY AND EMERGENCY PLOT PLAN SL 0856H ~9 0 m* 60' f*!L CLUSTBU X DOCK ____________ ____________ Vvwwww g3QvVVVNA>,VvVVV^ s Fire EytinGuioHi^G- Equipment Location ^ ~aa/JX OF DOCK. 6 33S3J6 e e/a.z'f N(JM&K A A TypE ' AThhlQr MOA/troK yi/ATER hJo22-L 'Bsc4 w/Hel Mowtzl Eer CtiEmicz-i30* bpy CffEmtcAL < 330* WPEEL Mouy/TEt E>RT CHELICAL ao 41 Bo* i> r Ci-iemi 'a l JOry Caemical , A APPENDIX C FACILITY PLOT PLAN SL 085614 1 D SL 085616 APPENDIX D MATERIAL BALANCE SL 085617 VtSSEL I ooo 1~ --CXH <--OO- --Cx>--l t--to- ---o- -t&-- UuQnUaIDn SHUT - OFF VALVE ^ HOSE ~--------^STREAM DATA ^--L__ TOTAL FLOW - LB/HR - L9M0L/NR - ACEH TEMPERATURE - F PRESSURE - PSJG DENSTY - LB/CUFT AW VOL WT COUPOtCNTS - LB/HR EDC NITROGEN OXYGEN H20 COMPONENTS - LSUCLjAT* EDC NITROGEN OXYGEN H20 cctroNENrs - ucl fr eoc NITROGEN OXYGEN *20 COMPONENTS - ACFH EOC NrTROCEN OYYCEh H20 1 1300000 13137 16027 90.0 0 77.28 9*96 1JOOOOO 00 OO 00 13137 00 00 00 1.0 0.0 00 D0 16822 00 00 oo VAPOR. SHUT - CFF VALVE 2 2031 32.5 21078 fiO.O 0 0 0968 38 66 76t 943 287 39 7.7 33 7 90 21 0146 06*2 0 111 0041 3076 13503 3589 850 ---- -- WLWE MIXER 667 39.3 23831 90.0 0 0.0669 28.01 0.0 1M7 CLC 0.0 00 39 3 00 00 GO 10 00 00 00 23631 0.0 00 4 3698 1120 44*59 88.97 0 0.0625 33.01 76T 2612 287 39 77 93 2 90 21 0.069 0832 0 080 Q 010 3077 37331 3591 B60 <r~J V----------------------------- 5 760 77 9.5 58.97 0 77 53 90.96 760 0.0 ao OO 77 OO 00 00 1o 00 00 00 06 00 00 0.0 6 2930 104 4 41700 88 97 0 0.0703 28 15 0.2 2612 287 39 00 93 2 90 2.1 OO 0 693 0 056 0 021 08 37326 3591 860 REVISIONS SL 085618 1a ioo ]c ici ] ^rLtASEl) FOS CONSTRUCTION RfVSiON so ?_ ST _ _wrt. WALK. HAYOEt k ASSOCIATES. fNC ENGINEERS NEW ORLEANS wC*01LET BATON RC\.Gf 37 ?Q . *HS> ~J*Z fi CHEMICALS '.JSKE CHARLES, LOUISIANA DOCK ARE A PPG CLOSED DOME LOADrNG SOUTH TERMINAL - DCC-CS * BARGE S SHEET 1 OF } PFf) HSA4M flT -L* n*TT 12/09/9? v.,r ChECxLD fir C nfctt 17/09/92 iwrc* *ESf 7609 APPoCvtp g> __ d* t sue___ 0 - owe 1 1 A- 1 0028.0 E crn* iidn 0o3 cn APPENDIX E APPLICABLE COAST GUARD REGULATIONS SL 085620 Thursday Juna 21, 1990 Part II Department of Transportation Coast Guard 33 CFR Part 154 et at. 49 CFR Part 30 et at Marine Vapor Control Systems; Baal Rule SL 085621 28428 Federal Register / Vol SS, No. 120- / Thuraday, jane 21, 1990 / Rule* and Regulations Assessment. it should bMeted that the Coast Guard has also determined that regulations for the safe design, installation, and operation of vapor control systems, as described in this rulemaking, can only be effectively implemented at the national level. Once a state requires vapor control, the discretion available to that state to modify requirements concerning design, installation, and operation of vapor control systems, as they pertain to shoreside facilities, will be limited. For example, all flexible hoses used in vapor control systems ahjfthe last one meter (3.3 feet) of fixed piping leading to the facility vapor connection must be color coded with three bands painted red/ yellow/red of specified width! The vapor connection flange is also of unique design to prevent improper crossconnection. These requirements, and others like them, could not be modified. Some standardization of equipment and operational procedures is necessary since affected vessels move from port to port in the natkmalmarketpiace and excessive modification of the requirements would be burdensome and potentially unsafe. List of Subjects 33 CFR Part 154 Incorporation by reference. Oil pollution. Reporting and recordkeeping requirements. Vapor control 33 Cm Part 155 Oil pollution. Reporting and recordkeeping requirements. 33 Cm Part 158 Hazardous materials transportation. Oil pollution. Reporting and recordkeeping requirements, Water pollution control. 48 Cm Part 30 Cargo vessels. Foreign relations. Hazardous materials transportation. Penalties. Reporting and recordkeeping requirements. 46 CFR Part 32 Cargo vessels. Fire prevention. Marine safety. Navigation (water). Occupational safety and health. Reporting and recordkeeping requirements. Seamen. 46 Cm Part 35 Cargo vessels. Fire prevention. Marine safety. Navigation (water). Occupational safety and health. Reporting and recordkeeping requirements. Seamen. 46 Cm Part 39 Cargo vessels. Hazardous materials transportation, incorporation by reference. Marine safety, Occupational safety and health. Reporting and ANSI mtlTI limine Pip* ------ recordkeeping requirements. Vapor antral Flanges and Flanged Fit tings. Class 150 and 305 For the reasons set out in the preamble, the Coast Guard amends title 33. chapter L Subchapter O', parts 184, 1979 ............... fr ..... ANSI B31.3--Chemical Plant and ' Petroleum Refinery 154605 1H 806 155. and 158. and title 46. chapter L parts Piping. 1987 (including 3a 32. and 35 and adds a new part 39 to B31234-1988. B31.3b~1985 46 CFR. Chapter L as set forth below. and B31.3c-1986 addenda)154.515 TTTLE 33--(AMENDED) - i *- International ' Electrotechnical 154608 PART 154--(AMENDED) _ Commission ([ECU Bureau Central de la Commission 1, The authority citation for part 154 is revised to read as follows: ' * 11 - Elactrotechniqua IntarnaOo- ale. L rue da .. .Yapambd. Geneva. Switzerland Authority; 33 U.5.C. 1231.1321(|)(1)(C); sac. IEC 309-1--Plugs, Socket- 2. E.0.11735 38 FR 21243. 3 CFR. 1071-1975 Outiati and Couplers for Comp., p. 703; 40 CFR 1.45 *` - Industrial Purpoeesr Pert i. 2. Section 154.106 is revised to read as follows: ''General Requirement*. 1975----------------------------154612 IEC 309-2--Plug*. Socket. 154.106 Incorporation by reference. Outlets and Coupler* for Industrial Purposes: Part 2. (a) Certain materials are incorporated Dimensional Interchange by reference into this part with the ability Requirements for approval of the Director of the Federal Register in accordance with 5 U.S.G 552(a). To enforce any edition other than the one listed in paragraph (b) of this section, notice of change must be Pin and Contact-tube Ac cessories. 1981 --'.,7._____ 184612 National Electrical Manufactur ers Association (NEMA/, 2101 LwmSsL NW. Washington, fDC published in the Federal Register and the material made eveilable to the ANSI/NEMA WD8--Wiring Devices. Dimensional Re public. All approved material is on file quirements. 1088--154612 at the Office of the Federal Register. National Fire Protection Asso- 1100 L Street NW,, Washington. DC and at the U.S. Coast Guard. Marine Technical and Hazardous Materials Division (G-MTH). 2100 Second Street SW.. Washington. DC 20593-0001, and is available from the sources indicated in paragraph (b) of this section. (b) The material approved for incorporation by reference in part and action (NFPA), Batteiymarch Park. Quincy. MA 02209,. NFPA 70--National Electri cal Coda. 1987____ !!_____ Oil Companies International Marine Forum (OCIMFU Bib Floor, Portland House. Stag Place. London SWIE SBH. Eng 154.731 154605 154612 the sections affected are: land International Safety Guide American Petroleum Institute (API), 1220 L Street NW.. Washington. DC 20005 for Oil Tanker* and Ter minals. Third Edition. 1988.. 154.733: 154610 API Standard 2000. Venting Atmospheric and LowPressure Storage Tanks (Nonrefrigeratad and Re frigerated). Third Edition, tannery 1982 (reaffirmed 3. Section 154.310 is amended by redesignating existing paragraphs (b) and (c) as (c) and (d). respectively, adding new paragraph (b). and adding a parenthetical at the end of the section to December 1987)__________ 154.814 read as follows: API Recommended Practice 555 Manuel on Installa 154.310 Operations manual: Contents. tion of Refinery Instru ***** ments and. Control Sys tems. Psrt II--Process Stream Analyzen. Section (b) If a facility collects vapors emitted from vessel cargo tanka for recovery, 1--Analyzers. Fourth Edi destruction, or dispersion, the tion. February 1985_______ 154.824 operations manual must contain a American National Standards In stitute (ANSI), 1430 Broadway. New York. NY 10018 ANSI B155 Steel Pipe Flanges snd Flanged Fit tings. 1981................. 154.505 154.805 description of the vapor collection system at the facility which includes: (1) A line diagram or simplified piping and instrumentation diagram (PAID) of the facility's vapor control system piping, including the locauon of each 154.810 valve, control device, pressure-vacuum l> 085622 Federal Register / Vol. 55. No. 120 / Thnndgy. }una ZL 1990 / Rules and Regulation! ww relief valve, preen-- toficator. Sim arrester, and detonation aircstan and (2) A description of the vapor control system's design and operation including the: (i) Vapor line connection: (ii) Startup and shutdown procedures: (iii) Steady state operating procedures; (iv) Provisions for dealing with pyrophoric sulfide (for facilities which handle inerted vapors of cargoes containing sulfur); (v) Alarms and shutdown devices: and (vi) Pre-transfer equipment inspection requirements. ; *** (Approved by the Office of Management and Budget under control number 2115-0078) 4. Section 154.740 is amended by deleting the word ``and" at the end of paragraph (e). by replacing the period at the end of paragraph (f) with a semicolon, adding new paragraphs (g). (h). and (i), and adding a parenthetical at the end of the section to read as follows: } 164.740 Records. at (g) A record of ell repairs made within the last three years involving any component of the facility'* vapor control system required by eubpart E of this part (h) A record of all automatic shut downs of the facility's vapor control system within the last 9 years; and (i) Plans, calculations, and specifications of the facility's vapor control system certified under 1154.804 of this part. (Approved by the Office of Management end Budget under control number 2115-0096) 5. A new subpart E is added to part 154 to read as follows: Subpaft E--Vapor Control Systems 154*00 Applicability. 154.802 Definitions. 154*04 Review, certification, and initial inspection. 154.806 Application for acceptance a* a certifying entity. 154*06 Vapor control system, general. 154*10 Vapor line connections. 154*12 Facility requirement* for vessel liquid overfill protection. 154.814 Facility requirements forvesiel vapor overpressure end vacuum protection. 154.820 Fire, explosion, and detonation protection. 154.822 Detonation arresters, flame arresters, and flam* screen*. 154.824 Inerting, enriching, and diluting syttema. 154*26 Vapor compresaor* and blower*. 151.828 Vapor recovery and vapor destruction units. 154410 Personnel training. , 154*50 Operational requirement*. Subpart E--Vapor Control Systems J 154*00 ApptaMMy. (a) Except as specified by paragraph (c) of this section, this subpart applies to: (1) Each facility which collects vapors of crude oil. gasoline blends, or benzene i emitted from vessel cargo tanka: (2) A vassal which is not a tank vassal that has a vapor processing unit located on board far recovery, destruction, or dispersion of and* oil gasoline blends, or benzene vapors from a tank vessel; and (3) Certifying entities which review, inspect, test and certify facility vapor control systems. (b) A facility which collects vapors of flammable or combustible cargoes other than crude oiL gasoline blends, or benzene, most meet the requirements prescribed by the Commandant (GMTH). (c) A facility with an existing Coast Guard approved vapor control system which was operating prior to July 23, 1990 is subject tmly to 1154*50 of this subpart as long as it receive* cargo vapor only from the specific vessels for which it was approved. (d) This subpart does not apply to the collection of vapors of liquefied flammable gases as defined in 46 CFR 30.10-39. (a) When a facility vapor control system which receives cargo vapor from a vessel is connected to a facility vapor control system that serves tank storage areas and other refinery processes, the specific requirements of this subpart apply between the vassal vapor connection and the point where the vapor control system connects to the facility's main vapor control system. {154*02 Definitions. As used in this subpart Certifying entity means an individual or organization accepted by the Commandant (G-MTH) to review plans and calculations for vapor control system designs, and to conduct initial inspections and witness tests of vapor control aystem installations. Existing vapor control system means a vapor control system which was operating prior to July 23,1990. Factiity vapor connection means the point in e facility's vapor collection system where it connects to a vapor collection hose or the base of e vapor collection arm. Inerted means the oxygen content of the vapor space in a tank vessel's cargo tank is reduced to 8 percent by volume or less in accordance with the inert gas requirement* of 46 CFR 32*3 or 46 CFR 153.500. Liquid knockout vessel a device to separate liquid from vapor. Maximum allowable transferrate meana the maximum volumetric rate at which a vessel may receive cargo or ballast -. New vapor control system means a vapor control system which ia not an existing vapor control aystem. Vapor balancing means the transfer of vapor displaced by tnrnmtwj cargo from the tank of a vessalTeceivingcargo into a tank of the vessel or facility delivering cargo via a vapor collection system. Vapor collection system moans an arrangement of piping and hoses used to collect vapor emitted from a vessel's cargo tanks and transport the vapor to a vapor processing unit Vapor control system means an arrangement of piping end equipment used to control vapor emissions collected from a vessel and twdudas the vapor collection system and the vapor processing unit Vapor destruction unit means a vapor processing unit that destroys cargo vapor by a means such as incineration. Vapor dispersion system means a vapor processing unit which releases cargo vapor to the atmosphere through e venting system not located on the vessel being loaded or ballasted. Vaporprocessing unit means the components of a vapor control system that recovers, destroys, or disperses vapor collected from a vessel Vapor recovery unit meana a vapor processing unit that recovers cargo vapor by a non-destructive means such as lean oil absorbtion. carbon bed adsorption. or refrigeration. Vessel vaporconnection maans the point in a vessel's fixed vapor collection system where it connects to a vapor collection hose or arm. } 154*04 Review, certification, and Initial inspection. (a) A new vapor control system installation must be certified by s certifying entity as meeting the requirements of this subpart prior to operating. (b) An existing vapor control system installation not exempted by 154.600(c) of this subpart must be certified by a certifying entity by July 23, 1992. Plana, calculations, and specifications for the installation must be submitted to a certifying entity for review by January 23,1991. (c) An existing vapor control system installation that ha* been Coast Guard approved for operation with specific SL 085623 &D0 Fedfcal / VoL 55. No.-l2D / ThufttUy. lune' 21. 1980 / Rules dfid'Rfeguidtifthi vessels most be certifiedbye certifying for the vapor control system must be entity prior to receiving vajmn from maintained at the facility. other vmmIi. (i) A certifying entity accepted under (d) Plena and informationwhnittad to 1154408 of this subpart may not certify the certifying entity must inctode a. a facility vapor control system if it was qualitative failure analyefo Theanalyaia involved is the design or installation of must demonstrate tha followmy the system. (1) Tha vapor control system is (Approved by the Office of Management and designed to permit the system to Budget under control number 2115-0581) coatmuousiy operate safelywhen receiving cargo vapors from tankships and barges over the full range of VfiMJM Aspicalton tar acceptance aa a CmraTyl^ VnOIjr* transfer rates expected at the facility (a) An individual or organization (2) The vapor control system is seeking acceptance as a certifying entity provided withtha inoper alarms and automatic control systems to prevent must apply in writing to ths Commandant (G-MTH). Each unsafe operation: application must be signed end certified (S) The vapor control system is equipped with sufficient automatic or passive devices to minimi damage to personnel property- end the environment if an accident were to occur and to be correct by the applicant or, if the applicant is an organization, by an authorized officer or official representative of the organization, and must include a letter of intent from e facility owner or operator to use the (4) If a quantitative failure analysis is also conducted, the level of safety attained is at least one-order of magnitude greater than-that calculated for operating without a vapor control system. . Now: Ths AmancaB Liahtatt of Chtauaal Fnfin-- puhliMtaw . I-- services of the individual or organization to certify a vapor control system installation. Any false stetement or misrepresentation, or the knowing and willful concealment of a material fact may subfect tha applicant to prosecation under the provisions of 18 U-S.C. 1001. and denial or termination of Hasatd Evaluation Prooodoras" may be ased a* guidancewhan preparing a qualitative acceptance aa a certifying entity. (b) The applicant must possess the failure sualyti* MilUary Standard VflL-STD- following minimum qualifications, and taa may be used is guidance when be able to demonstrate these inpnitng e quantitative failart analysis. qualifications to the satisfaction of the (e) The certifying entity must conduct all initial inspections and witness all tests required to demonstrate that the facility: (1) Conforms to certified plans and specifications; (2) Meets tha requirements of this subpart; and (3) Is operating properly. (0 Upon receipt of written certification from the certifying entity that a facility's vapor control systsm complies with the requirements of *! part the COTP shall endorse the letter of adequacy required by 1154425 of this part to indicate that thafecility is acceptable for coliecttnfVapors of erode oil gasoline blende. beamAne. or any other vapors for which it ts certified. (g) Any design or configuration alteration involving a certified vapor control system must be reviewed by e certifying entity. After conducting any inspections and witnessing tests necessary to verify that tha modified vapor control lystam meets the requirements of this subpart the certifying entity must recertify the installation. Commandant (G-MTH): (1) The ability to review and evaluate design drawings and failure analyses; (2) A knowledge of the applicable regulations of this subpart including the standards incorporated by reference in these regulations; (3) The ability to monitor end evaluate test procedures and results; (4) The ability to perform inspections and witness testa of bulk liquid cargo handling systems: (5) That it is not controlled by an owner or operator of a vessel or facility engaged in controlling vapor emissions; end (S) That it is not dependent upon Coast Guard acceptance under this section to remain in business. (e) Each application for acceptance must contain the following: (1) The name end address of the applicant including subsidiaries and divisions if applicable: (2) A statement that the applicant is not controlled by an owner or operator of vessel or facility engaged in controlling vapor emissions, or a full disclosure of any ownership or controlling interest held by such owners (h) Certifications issued in accordance or operators; with this section and a copy of the (3) A description of the experience plans, calculations, and specifications and qualifications of the person(s) who would be reviewing or testing the systems; '" (4f A stetement that the person(s) who would be reviewing or testing the systems is/are familiar with the regulations In this subpart and (3>A statement that tin Coast Guard may verify the information submitted in the application and may examine the personfs) who would be reviewing or totting the systems to determine their qualifications. (d)The acceptance of a certifying entity may be terminated by the Commandant (G-MTH) if the entity fails to properly review, inspect or test a system in accordance with this subpart. Neta A Bat of entities aecsmsd to cartify fadttty vapor control system installations is available from tha Commaadam(G-MlH|. (Approved by tha Office ofManapnmit and --*--` iiiimlm nill Wir| 11S4JM Vapor control eyeWeq general (a) A vapor control system design and installation must eliminate potential overfill hazards, overpressure and vacuum hazards, and sources of ignition to the maximum practical extent Each remaining hazard source which is not eliminated must be spedfically addressed in tha protection system design and operational raqoinments. (b) Vapor collection system piping and fittings must be in accordance with ANSI B314 and designed for a maximum allowable working pressure of at least 150 pstg- Valves and flanges must be in accordance with ANSI B18.5 or B1&24.150 pound class. (c) All electrical equipment used in a vapor control system must comply with NEPA70. (d) Any pressure, flow, or concentration indication required by this part must provide a remote indicator on the facility where the cargo transfer and vapor control systems are controlled. (e) Any alarm condition specified in this part must activate an audible and visible alarm where the cargo transfer and vapor control systems are controlled. (f) The vapor control system must be separated or insulated from external heat sources to limit vapor control system piping surface temperature to not more than 177 *C. (350 *F.) during normal operation. (g) A means must be provided to eliminate any liquid condensate from the vapor collection system which carries over from the vessel or condenses as a result of an enrichment process. (h) If a liquid knockout vessel is installed it must have; SL 085624 . Ftdwi / VoL SS> .No> 120 ( Thursday, lune 21. 1990 / Rules and Regulattom 25131 (l) A means to inriteote the level of liquid in the device: - (Z) A high liquid level sensor that activates an alarm: and (3) A high high level tensor that closes the remotely operated cargo vapor shutoff valve required by 1154.810(a) of this subpan and shuts down any compressors or blowers prior to liquid carrying over from the vessel to the compressor or blower.- (i) Vapor collection piping must be electrically grounded and electrically continuous. - - ,,r 0) If the facility handles ineried vapors of cargoes containing sulfur, provisions must be made to control heating from pyrophoric iron sulfide deposits in the vapor collection line. 5154.110 Vapor tine connections. (a) A remotely operated'Cargo vapor shutoff valve must be installed in the vapor collection line between the facility vapor connection end the nearest point where any inerting, enriching, or diluting gas is introduced into the vapor collection line or where a detonation arrester is fitted. The valve must (1) Close within thirty (30) seconds after detection of a shutdown condition by a component required by this subpart (Z) Close automatically if the control signal is lost 0) Activate en alarm when e signal to shut down is received: (4) Be capable of manual operation or manual activation: (5) Have a local valve position indicator or be designed so that the valve position can be readily determined from the valve handle or valve stem position: and (6) If the valve seat ia fitted with resilient material not allow appreciable leakage when the resilient material is damaged or destroyed. (b) Except when a vapor collection arm is used, the last ID meter (3J feet) of vapor piping before the facility vapor connection must be: (1) Painted red/yellow/red with: (1) The red bands 0.1 meter (0.33 feet) wide, and (li) The middle yeilow band 0.8 meter (2.84 feet) wide; and (2) Labeled "VAPOR" in black letters at least 50 millimeters (2 inches) high. (c) Each facility vapor connection flange must have a permanently attached 0.5 inch diameter stud at least 1.0 inch long projecting outward from the flange face. The stud must be located at the top of the flange, midway between bolt holes, and in line with the bolt hole pattern. (d) Each hoae used for transferring vapors must (1) Have a design burst pressure of at least 25 psig; (2) Have a maximum allowable working pressure of at least 5 psig; (3) Be capable of withstanding at least 2D psi vacuum without collapsing or constricting; (4) Be electrically continuous with a maximum resistance of ten thousand (10.000) ohms: (5) Have flanges with: (!) A bolt hole arrangement complying with the requirements for 150 pound class ANSI BIAS flanges, and '1 (II) One or more 0.825 inch diameter holes in the flange located midway between bolt holes and in line with the bolt hole pattern: (6) Be abrasion resistant and resistant to kinking; and (7) Have the last 1.0 meter (3.3 feet) of each end of the vapor hoae marked in accordance with paragraph (b) of this section. (a) Vapor hose handling equipment must be provided with hose saddles which provide adequate support to prevent kinking or collapse of hoses. (f) Fixed vapor collection arms must: (1) Meet the requirements of paragraphs (d)(1) through (d)(5) of this section: (2) Have the last 1.0 meter (3D feet) of the aim marked in accordance with paragraph (b) of this section. (g) The facility vapor connection must be electrically insulated from the vessel vapor connection in accordance with section 8.10 of the OCIMF International Safety Guide for Oil Tankers and Terminals. (b) A vapor collection system fitted with an enriching system that operates at a positive gauge pressure at the facility vapor connection must be fitted with: (1) A manual isolation valve between each facility vapor connection and the remotely operated cargo vapor shutoff valve required by paragraph (a) of this section: and (2) A means to prevent backflow of enriched vepor to the vessel's vapor collection system. $ 154.112 Faculty requirements tor vessel liquid ovcrtw protection. (a) Each facility which receives cargo vapor from a tank barge which is fitted with overfill protection in accordance with 48 CFR 39.20-9(a) as its only means of overfill protection must provide a 120 volt. 20 amp explosion proof receptacle which meets; (1) ANSI/NEMA WD6; (2) NFPA 70. Articles 410-57 and 50112; and (.3) 48 CFR 111.108-0. o (b) Each facility that raceme cargo vapor from a tank barge fitted with an intrinsically safe cargo tank level sensor system complying with 46 CFR 39.20- 9(b) as its only means of ovetfiff " protection must have an overfill control panel on the dock capable of powering and receiving an alarm and shutdown signal from the cargo ii< level sensor system that (1) Closes the remotely operated cargo vapor shutoff valve required by. , _ 1154D10(a) of this aubpartactivates the emergency shutdown system ^ required by 1154DS0 of this part when: (1) A tank overfill signal la received from the barge, or >. (if) Electrical continuity of the cargo tank level sensor system ia lost (2) Activates an alarm wfctafcis audible and visible to barge personnel and facility personnel whim a tank overfill signal or an optionalUgh-level signal corresponding to a liquid lerfei lower than the tank averfiilsansor setting, ia received from the:beige; (3) Has a means to electrically and mechanically teat the alarms and automatic shutdown systems prior to transferring cargo to or ballasting the tank barge: it .. (4) Has suitable maana, sudr'aa approved Intrinsic safety barrier* able to accept passive devices, to asm that the overfill and optional alarm circuits on the barge side of the overfill control panel, including cabling, normally closed switches, and pin and sleeve connectors, are intrinsically safe: (5) Is labeled with the maximum allowable inductance and capacitance to be connected to the panel as specified by the equipment manufacturer and (6) Has a female connecting plug for the tank barge level sensor system with a 5 wire. 18 amp connector body meeting IEC 309-1/309-2 which is; (i) Configured with pins S2 and R1 for the tank overfill sensor circuit pin G connected to the cabling shield, and pins N and T3 reserved for an optional high level alarm connection: (ii) Labeled "Connector for Barge Overflow Control System"; and tiii) Connected to the overfill control panel by a shielded flexible cable. 154.114 Faculty requirement* for vessel vapor overpressure end vecuum protection. (a) A facility's vapor collection system must have the capacity for collecting cargo vapor at a rate of not less than 1.25 times the facility's maximum liquid transfer'rate for cargo for which vapor collection is required plus any inerting, SL 085625 25432 Fedwsl Kugistnr / VoL 55. .No. 120 / Thursday. June 21. 1900-/ Rules and Reguiationi- diluting. or enriching ggawhich may be added to the eysf. ja-- the vapor growth far turbulent Hiding of the mast volatile liquid handled by the facility is lest than 25 percent (b) A facility vapor collection system must maintain the pressure in a vessel's cargo tanks between 80 percent of the highest setting of any of the vessel's vacuum relief valves and 80 percent of the lowest setting of eny of the vessel's pressure relief velvet for e non-tnerted tank vessel and between 0-2 psig and 80 percent of the lowest setting of any of the vessel's pressure relief valves for an inerted tank veeaeL The system must be capable of maintaining the pressure in the vessel's cargo tanks within this range at any cargo transfer rate less than or equal to the maximum transfer rate determined at the pre-transfer conference required by 1158.l20(w) of this chanter. (c) The pressure measured at the facility vapor connection must be corrected for pressure drops tcross the vessel's vapor collection system end the vapor collection hose or arm. (d) A pressure sensing device must be provided which activates an alarm when the pressure at the facility vapor connection exceeds either the pressure corresponding to the upper pressure determined in paragraph (b) of this section or a lower pressure agreed upon at ths pre-transfer conference required by f 158.L20(w) of this chapter. (e) A pressure --"g device must be provided which activates an alarm when the pressure at the facility vapor connection falls below either the pressure corresponding to the lower pressure determined in paragraph (b) of this section or a higher pressure agreed upon at the pre-transfer conference required by ( 156.120(w) of this chapter. (f) A pressure sensing device must be provided which activates the emergency shutdown system required by 1154.550 of this part and doses the remotely operated cargo vapor shutoff valve required by { 154.810(a) of this subpart when the pressure at the facility vapor connection exceeds 2J) psi. or a lower pressure agreed upon at the pre-transfer conference required by 1156.120(w) of this chapter. The sensing device must be independent of the device used to activate the alarm required by paragraph (d) of this section. (g) A pressure sensing device must be provided which doses the remotely operated cargo vapor shutoff valve required by $ 154.810(a) of this subpart when the vacuum at the facility vapor connection is more than 1.0 psi, or a lesser vacuum set at the pre-transfer conference required by 1 158.120fw) of :his chapter. The sensing device must be independent of the device used to activate the alarm required by paragraph (e) of this section. (h) The pressure sensing devices required by paragraphs (e) and (f) of this section must be located in the vapor collection line between the facility vapor connection and the manual isolation valve, if required by S 154.810(h) of this subpart unless an interlock is provided which prevents operation of the system when the isolation valve ia dosed. (i) A pressure indicating device must be provided which indicates the pressure in the vapor collection line. (j) If e compressor, blower, or eductor capable of drawing more than 1.0 pai vacuum la used to draw vapor from the vessel, a vacuum relief valve must be installed in the vapor collection line between the compressor, blower, or eductor and the faahty vapor connection, which: (1) Relieves at a pressure such that the pressure in the vapor collection system at the facility vapor connection does not exceed 1.0 pm vacuum: (2) Has a relieving capacity equal to or greater than the capacity of the compressor, blower, or eductor; (3) Has s flame screen fitted at the vacuum relief opening; and (4) Has been tested for relieving capacity in accordance with paragraph 1.5.1 J of API 2000 with a flame soeen fitted. (k) When a facility collects cargo vapor through an undersea pipeline from a vessel moored offshore, the vacuum relief valve may be set at a vacuum greater than 1.0 psi vacuum provided the pressure controls take into account the pressure drop across the vessel's vapor collection system, any vapor collection hose*, and the undersea pipeline as a function of the actual transfer rate. (l) If the pressure m the vapor collection system can exceed 2.0 psig due to e malfunction m an inerting, enriching, or diluting system a pressure relief valve must (1) Be installed between the point where inerting, enriching, or diluting gas is introduced into the vapor collection system and the facility vapor connection; (2) Relieve at a pressure such that the pressure m the vapor collection system at the facility vapor connection does not exceed 2.0 psig; (3) Have a relieving capacity equal to or greater than the maximum capacity of the facility inerting, enriching, or diluting gas source: (4) If not designed to insure a minimum vaoor discharge velocity of 30 meters (98.4 ft.) per second, have a flame screen fitted at the discharge opening: and (5) Have been tested for relieving capacity in accordance with paragraph 1.5.1.3 of AH 2000. (m) The relieving capacity test required by paragraph (1)(5) must be carried out with a flanw soeen fitted at the discharge opening if the pressure relief valve is not designed to insure a minimum vapor discharge velocity of 30 meters (98.4 ft) per second. 1184428 Bra. esplasinn, and detonation protection. (e) A vapor control system with a single facility vapor connection that receives vapor only from a vessel with inerted cargo tanks and processes vapor with a vapor recovery unit must (1) Be capable of inerting the vapor collection line in accordance with } 154424(a) of this subpart prior to receiving vapors from the vassal: (2) Have at least one oxygen analyzer that samples the vapor concentration continuously at a point not more than 6 meters (1R7 ft) from the facility vapor connection: end (3) Meet 1154424 (f)(1). (f)(2). (g). (h)(2), and (h)(3) of this subpart (b) A vapor control system with a single fatality vapor connection that receives vapor only from a vessel with inerted cargo tanks and processes vapor with a vapor destruction unit must (1) Have a detonation arrester located not more than 8 meters (19J ft) from the facility vapor connection: or (21 Have an inerting system that meets the requirements of S 154.824 of this subpart (c) A vapor control system with a single facility vapor connection that receives vapor from a vessel with cargo tanks that are not inerted and processes vapor with a vapor recovery unit must: (1) Have a detonation arrester located not more than 8 meters (19.7 ft.) from the facility vapor connection: or (2) Have an inerting, enriching, or diluting system that meets the requirements of { 154.824 of this subpart (d) A vapor control system with a single facility vapor connection that receives vapor from a vessel with cargo tanks that are not inerted and processes the vapor with a vapor destruction unit must: (1) Have a detonation arrester located not more than A meters (19.7 ft) from tne facility vapor connection: and (2) Have an inerting, enriching, or diluting aystem that meeta the requirements of i 154.824 of this subpart. 0856^6 Sli Eaderalfagietat. / Vol 55.- Na12Q:/ Tlraradiy; junemiMO / 'fade* and JtegulatiaMvt;V25433 (e) A vapor control swtun with millimeters (Vi in.) or more than 75 multipla fadlity vaporSlacttana that millimeters (1ft in.>spart - tvs: id ~ processes vapor with avapor recovery unit must haw a detonation arrester 154824 tnerttng, erwlefttno, snd eHfcjhnq located not more than 6 metera (19.? ft.) from each facility vapor mnnartion. (f) A vapor control syetam with multiple facility vapor connections that proceaaea vapor with a vapor destruction unit must *: (1) Haw a detonation arrester located not more than 8 meters (19.7 ft) from each facility vapor connection: and (2) Haw an inerting, enriching, or diluting system that meets the requirements of f 154824 of this subpart. - ...... (g) A vapor control system that uses a vapor balancmg system In which cargo vapor from a vessel is transferred through the facility vapor collection system to facility storage tanks must (1) Haw a detonation arrester located not more than 8 meters (19.7 ft) from each facility vapor connection: (2) Have a detonation arrester located within the stsvsgv HwiMiiimmt area as close as practical to the vapor return connection of each fadlity storage tank; and . (3) Have facility storage tank high level alarm systems and facility storage tank overfill control eystams arranged to prevent cargo from entering the vapor return line. (h) Except for a discharge vent from a vapor destruction unit each outlet of a vapor control system that wnta to atmosphere and is not Isolated with a pressure-vacuum relief wlw must have a flame arrester located at the outlet. 154822 Detonation arresters, flame arresters, and flame screens. (a) A vapor control system which uses inerting, enriching or diluting gas must be capable of inerting, enriching, or diluting the vapor collection line and the vapor collection hose or arm prior to receiving cargo vapor. . . (b) Except as permitted by {154.820(a) of thla subpart a vapor control system which uses an inerting, enriching, or diluting system must be equipped with e gas Injection and mixing arrangement located as doss as practical but not more than 10 meters (328 ft) from the facility vapor connection that ensures complete mixing of die gases within 20 pipe diameters of ths injection point (c) A vapor control system that uses an inerting or enriching system may not be operated at a vacuum after the injection point unless: (1) There ere no sleeve-type pipe couplings, vacuum relief valves, or other devices which could allow air into the vapor collection system downstream of the injection point or i (2) An additional analyzer is used to monitor the downstream vapor concentration end a means is provided to inject additional inerting or Bundling 8"- (d) A vapor control system that uses analyzers to control the amount of inerting, enriching, or diluting gas injected into the vapor collection line must be equipped with at least 2 analyzers. The analyzers must be connected so that: (1) Whan oxygen analyzers are used, (a) Each detonation arrester required the higher oxygen concentration reading by this part must: controls the inerting or enriching system (1) Be capable of arresting a and activates the alarm and automatic detonation from either side of the shutdown system required by paragraph device: and (h). (j) or (k)(2) of this section: (2) Be acceptable to the Commandant (2) Whan hydrocarbon analyzers are (G-MTH). A detonation arrester used, the lower hydrocarbon designed, built and tested in concentration reading controls the accordance with appendix A of this part enriching system and activates the will be acceptable to die Commandant alarm and automatic shutdown system (G-MTH). required by paragraph (i) or (k)(l) of this (b) Each flame arrester required by section: and 'his pan must be acceptable to the (3) When hydrocarbon analyzers are Commandant (G-MTH). A flame used, the higher hydrocarbon arrester designed, built and teated in concentration reading controls the accordance with appendix B of this part diluting system and activates the alarm will be acceptable to the Commandant and automatic shutdown system (G-MTH). required by paragraph (1) of this section. (c) Each flame screen required by this (e) A vapor control system that uses part must be either a single screen of volumetric measurements to control the corrosion resistant wire of at least 30 by . amount of inerting, enriching, or diluting 30 mesh, or two screens, both of gas injected into the.vapor collection corrosion resistant wire, of at least 20 by line must be equipped with at least one 2D mesh, spaced not less than 25 analyzer to activate the alarms and automatic shutdown systems required by this section. it (f) Each oxygen or hydrocarbon analyzer required by this must: (1) Be installed in accordance with API Recommended Practiced (2) Haw a response time otaotmore so seconds from the time the vapor is sampled; and .: -satu.-wv:: (3) Sample the vapor coocanlraboo continuously not more than80 pipe diameters from the gee tnjedionpoint. (g) Oxygen analyzers which operate at elevated temperatures (Ls. zirnama oxide or thcnnomagnetic) mem eot be used.- ` doiortt voower. (h) An inerting system must.:: (1) Supply sufficient hurt gss to the vapor stream to ensure that throxygen concentration throughout thevapor collection system is maintained below 8j0 percent by volume:. ': tiroqev . (2) Activate an alarm wimntbe oxygen concentration In the vapor collection line exceeds 88 pmumit by volume: (3) Close the remotely operated cargo vapor shutoff vahre mtiisd by { 154.810(a) of this part whra the oxygen concentration in the vapor ooBectfam line exceeds 9.0 percent by volume, end (4) If a combustion device is used to produce the inert gss. haw e hydraulic seal end non-return vulw between the combustion device and the vapor collection line. '. . (0 An enriching system meat (1) Supply sufficient compatible hydrocarbon vapor to the vapor stream to ensure that the hydrocarbon concentration throughout the vapor collection system is maintained above 170 percent by volume of the upper flammable limit: (2) Activate an alarm when the hydrocarbon concentration in the vapor collection line falls below 170 percent by volume of the upper flammable limit: and (3) Close the remotely operated cargo vapor shutoff valve required by $ 154810(a) of this subpart when the hydrocarbon concentration in the vapor collection line falls below 150 percent by volume of the upper flammable limit (j)Oxygen analyzers may be used in heu of hydrocarbon analyzers in an enriching system at a fadlity that receives cargo vapor only from a vessel with non-inerted cargo tanks, provided that the analyzers: (1) Activate an alarm when tha oxygen concentration in the vapor collection line exceeds 155 percent by volume; snd (2) Close the remotely operated cargo vapor shutoff valve required by 154810(a) of this subpart when the SL 085627 '23434 Fodut-mglofi / VoU 53/No. *120 / ninreduyv june 21. 1990 /' Rules and Regulatfraw oxygen concentration inthe vepor collection line exceedS ttApnreeiit by volume, ev^tor (k) An enriching system may be used in a vapor collection systemthat receives cargo vapor frdnra vessel with inerted cargo tanks Ifc - `" a * * (l) Hydrocarbon analyzers are used to comply with paragraph (i)(2) and (i}(3) of this section: or (2) If oxygen analyzers an used, the analyzers activate an alarm when the oxygen concentration in the vapor collection line exceeds percent by volume, and close the remotely operated cargo vapor shutoff valve required by 1154.810(a) of this subpart when the oxygen concentration exceeds 0 percent by volume. , r.n.. w .. . (1) An air dilution system must (1) Supply sufficient additional air to the vapor stream to ensure that the hydrocarbon concentration throughout the vapor collection system is maintained below 30 percent by volume of the lower flammable limit (2) Activate an alarm when the hydrocarbon concentration in the vapor collection line exceeds 30 percent by volume of the lower flammable limit and - (3) Close the remotely operated cargo vapor shutoff valve required by 1154.810(a) of this subpart when the hydrocarbon concentration in the vapor collection line exceeds 50 percent by volume of the lower flammable limit 8184436 Vapor compressors end Mowers. (a) Each inlet and outlet to a compressor or blower which handles vapor that has not been inerted, enriched, or diluted in accordance with 8 154.824 of this subpart must be fitted with: (1) A detonation arrester: (2) A flame arrester: or (3) An explosion suppression system acceptable to the Commandant (GKfTH). (b) If a reciprocating or screw-type compressor handles vapor in the vapor collection system, it must be provided with indicators and audible end visible alarms to warn against the following conditions: (1) Excessive discharge gas temperature at each compressor chamber or cylinder (2) Excessive cooling water temperature; (3) Excessive vibration; (4) Low lube oil level: (5) Low lube oil pressure: and (sj Excessive shaft bearing temperatures. (c) If a liquid ring-type compressor handles vapor in the vapor collection system, it must be provided with indicators and audible and.visible alarms to warn against the following conditions: .- (1) Low level of liquid sealing medium: . (2) Lack of flow of liquid sealing medium: "!' (3) Excessive temperature of the liquid seeling medium: (4) Low lube oil level: (5) Low lube oil prasaure, if pressurized lubricating system: and (8) Excessive shaft bearing temperature. (d) If e centrifugal compressor, fan. or lobe blower handlea vapor in the vapor collection system, conetruction of the blades and/or housing must meet one of the following: (1) Bledea or housing of nonmetallic construction: (2) Blades and housing of nonferrous material: (3) Bladea and housing of corrosion resistant steel: (4) Ferrous blades and housing with one-half inch or more design tip clearance: or (5) Blades of aluminum or magnesium alloy and a ferrous housing with a nonferrous insert sleeve at the periphery of the impeller. 1154428 Vapor recovery end vepor destruction units. (a) The inlet to a vapor recovery unit which receives cargo vapor that has not been inerted, enriched, or diluted in accordance with 8154424 of thia subpart must be fitted with one of the following: (1) A detonation arrester (2) A flame arrester or (3) An explosion suppression system acceptable to the Commandant (G- MTH). (b) The inlet to a vapor destruction unit must: (1) Have a liquid seal; and (2) Have two quick-closing stop valves installed in the vapor line. (c) A vapor destruction unit must: (1) Not be within 30 meters (984 ft.) of any tank vessel berth or mooring at the facility: (2) Have a flame arrester or detonation arrester fitted in the vapor line: and (3) Alarm and shut down when a flame is detected on the flame arrester or detonation arrester. (d) When a vapor destruction unit shuts down or has a flame-out condition the vapor destruction unit control system must: (1) Close the quick-closing stop valves required by paragraph (b)(2) of this section: and (2) Close the remotely operated cargo vapor shutoff valve required by 8154410(a) of this subpart. ' 8154440 Peraonnat training () A person in charge of e transfer operation utilizing a vaporcontrol system must have completed a training program covering the particular system installed at the facility. Training must iwtiiH* drills or demonstrations using the installed vapor control system covering normal operations and emergency procedures.- .-s. fb) The training program required by paragraph (a) of this section must caver th following subjects: (1) Purpose of e vapor control system; (2) Principles of the vapor control' system: (3) Components of the vapor control system: -- (4> Hazards associated with the vapor control system: (5) Coast Guardregulations in this subpart () Operating procedures, including: (i) Testing end inspection requirements, (Li) Pre-transfer procedures. (ill) Connection sequence. (iv) Start-up procedures, and (v) Normal operations: and (7) Emergency procedures. 8154450 Operational requUamawra. (a) A facility must receive vapors only from e vessel which has its certificate of inspection or certificate of compliance endorsed in accordance with 45 CFR 39.10-13(e). (b) The following must be performed not more than 24 hours prior to each transfer operation: (1) All alarms and automatic shutdown systems required by this part must be tested: and (2) The analyzers required by 8 154.820(a). 8 154.824 (d) and (e) of th subpart must be checked for calibretby use of a span gas. (c) The position of all valves in th vapor line between the vessel's ta: and the facility vapor collection t m must be verified prior to the star the transfer operation. (d) A tank barge overfill con* system that meets the requirer nts of 46 CFR 39.20-9(b) must not be .onnected to an overfill sensor circuit t; jt exceeds the system's rated cable len in. inductance, and capacitanr (e) When vapor is beinr received from a vessel with inerted carvo tanka, the remotely operated cargo vapor shutoff valve required by 8 154 810(a) of this subpart must not be opened until the pressure at the facility vapor connection SL 085628 Ffctoral ltogUttt / Vbl. 55. No; 120't TUtimtoy. M* 'arlWO / Uti-- hbtMteMttafr exceeds the pressure on tba downstream side of tha remotely op*tmicaifD _ vapor lhutoff valve. (I) The initial cargo, transfer rate must not exceed the rate egreed upon at the pre-transfer conference required by S 156.120(w) of this chapter and 46 CFR 39.30-1(h). (g) The cargo transfer rate must not exceed the maximum allowable transfer rate aa determined by the lesser of the following; (1) A transfer rate corresponding to the maximum vapor processing rate for the vapor control system, as specified in the facility operations manual required by 1154.300 of this chapter; or (2) The veaael's maximum transfer rate determined in accordance with 46 CTR 39.30-1(d). (h) While transferring cargo to a vessel connected to a vapor control system, compressed air or gas may be used to clear cargo hoses and loading anna, but must cot be used to clear cargo lines. (i) If one of the two analyzers required by 1154.624(d) of this subpart becomes inoperable during a transfer operation, the operation may TMHmw provided the remaining analyzer remains operational; however, no further transfer operations may be started until the inoperable anatyznr la replaced or repaired. 0) Whenever a condition results in a shutdown of the vapor control system, the person in charge shall immediately terminate cargo loading. (k) If it is suspected that a flare in the vapor control system has had a flareback. or if a flame ia detected on the flame arrester required by i 154.828(c)(2) of this subpart the transfer operation must be stopped end not be restarted until ths I1m arrester has been inspected and found to be in satisfactory condition. 5a. Appendices A and B are added to part 154 to read aa fallows: Appendix A to Part 186 OuktoUnei for Datamation Flame Arraatara This appendix contains the draft ASTM standard for detonauon lUw* amnion. Device* meeting this standard will be accepted by the Commandant (C-MTH). 1 Scope 1.1 This standard provides the minimum requirements for design, construction, performance end testing of detonation flame arresters. 1 Intent 2.1 This standard is intended for detonation flame arresters protecting systems containing vapors of flammable or combustible liquids where vapor temperatures do not exceed SO *C For all teats, ths test madia defioad ia 14.1.1 can be mod except whan detonation flame arrester* prated systems handling vapors with a maximum experimental safe gap (MESG) below OS millimeters. Detonation flame arresters protecting such systems must bo tested with appropriate madia (the same vapor or a media having a MESG no greeter then the vapor). Varione gueae and their respective MESG are listed in 22 Tba teats in thia atandard are mtanded to qualify detonadon flama arresters for ell inline Tp1*TM*"TM independent of piping uaiflrareUoo provided the tesrating preeeure is equal tt> or less tI*h--a*n* the asdstmnatko. perating preseura rertificsttoa and the dtamomr of the piping system in which the detonation arrester is to be Installed ia equal to or less than the piping diameter used in the testing. Note Detonation flame arresters meeting thia standard as Type I devices, which are cerdflod to be effective below 0 *C and which can sustain three stable detonaboos without being damaged or permanently deformed, also comply with the mtwiamm requirements of the internabonel Maritime Organization. Maritime Safety Committee Circular No. 373 (MSC/Circ. 373/Rev.U. 3. Applicable Document! 3.1 ASTM Standard* (1) A385 Ferritic Ductile iron PressureRetaining Castings For Use At Elevated Temperatures. F722 Welded (aims fur Shipboard Piping Systems F115S Standard Practice for Selection and Application of Piping System Materials 32 ANSI Standards (2) B16J Pipe Flanges and Flanged Fittings. 32 Other Documents 3.3.1 ASME Boiler and Pressure Vessel Cod* (2) Section VUL Division L Pressure Vessels Section IX Welding and Brazing Qualifications. 3.3.2 International Maritime Organization. Mantime Safety Committee (3) MSC/Circ. 373/Rev. l--Revised Standards for the Design. Testing and locating of Device* to Prevent the Passage of Flame into Cargo Tanka in Tankers. 3.3.3 tnternauonal Electrotechnical Commission (4) Publication 79-1--Electrical Apparatus for Explosive Gas Atmosphere*. 4. Terminology ' Footnote* appear at the end of thi* article. 4.1 AP/Pg--'The dimenairmlea. tSXiO, for any daflagatton and detonation test of 1U m.yinmw pressure minua the initial preswim), a* measured in ih* piping systam oo the side of tha arretter where ignition begins by the devka deambed in paragraph 1422, to tha initial absolute preseura in tha piping system. The lnitiel preeeure should be greater then or equei to tha tuaxhnnwi operating pressure specified in paragraph ttU. 42 Deflagration A combustion wavs that properte* euhannlcaUy (ae maaaured at the pteeeure and temperature of the flame boot) by the taaafar afhaat and active chemical epedaa In the unhumed gaa ahead af tha flam* front..,r* 42 Detonation A reaction in a combustion wavs propagating at sonic orsupersonic (as maaaured at tba pra--uw and temperature of tha flam* front)velocity. A detonation ie stabia when it ha* * veiodty uquai to the speed af rated in the burnt gee or may hi table (overdriven) with a higher velocity and pressure. 4.4 Detonation flame ameSer--A device which prevents tha nensmleeinu of a detonation and a deflamattam 42 Flam* speed 'The ip sad at which a flama propagate* along a pipe or other syutM. 4.4 Flama Peieege The trapamieeiim of a flame through a device. 4.7 Gasoline Vapors A --| --1 petroleum distillate -"wtf essentially of AUphfttic hytfcomfaoQ oonponwis with a boiling range "HTM`iMW"g 8S*C/74`C .. . ^ . 5. Classification 5.1 Tba turn types of detonation flam* anasm* covered in this specification are classified ae followe: 5.1.1 Type I--Detonation flama arresters acceptable for applications where stationary flame* may rest on tba device. 5.12 Type U--DetonaHon flame arresters acceptable for applications where stationary flama* are unlikely to rest on the device. and further method* are provided to provent flame passage when a stationary flame occurs. One example of "further methods" 1* a temperature monitor and an automatic shutoff valve. 6. Ordering Information 5.1 Order* for detonation flama arrester* under this specification shall include the following information a* applicable: 6.12 Type (I or II). 6.12 Nominal pip* size. 6 1.3 Each gas or vapor in the system and the corresponding MESG. 6.1.4 Inspection and testa other than specified by thi* standard. 6.1.5 Anticipated ambient air temperature range. 6.1.6 Purchaser s inspection requirements (seeeeetioalO.il. 6.1.7 Description of insinuation. SL 085629 APPENDIX F ROUTINE PAPERWORK SL 085631 Logsheets 0856^2 ATTACHMENT #1 DIKE WATER HANDLING ! r v. 2/93 Send Completed shs&i la. EotIrgnmintal Foreman The following information on the dikes listed below must be filled out each time these dikes are drained and kept for three years. Date Dike No. Disch/Treat Area No. Analyses c>f Water CiHC's pH Estimated Volume. Gal. -- t Dike No. Description Disch/Treat Volume Control Rm. Area No. Gal/inch Responsible .1 EDO MMC Tank 1 11000 2. EDC North Dock #1 2 4500 3. EDO North Dock #2 2 4500 4. EDC Blend ST-1 3 38000 5. EDC ST-2 3 39000 6A. ST EDC Peis Beds Outfall 3 500 6B. ST EDC Peis Beds Pad (Transfer to WTU only) 500 .7. VC-2 DH Bottoms Tanks 8 VC-2 EDC Crude Tanks 3 2000 3 5000 9. VC-2 Purnaoe Peed Tanks 3 7500 .10. VC-2 DH Peed Tanks 11 Per, Tri, MC North Dock 3 1500 2 16000 12. MC #3 North Dock Tank 2 15000 13. 6301,6362,6303 Tanks 3 8000 14. South Terminal Drum Stg. (N) 2 20 15. South Terminal Drum Stg. (S) 2 20 16. No. 2 Hazardous Drum Storage 4 50 16. South Terminal Marine Vapor Rec. 3 EDC VC-2 VC-2 WTU VC-2 VC-2 VC-2 VC-2 VC-2 VC-2 VC-2 P/T TE-2 WTU Envir Aast Envir Asst Envir Asst Shipping Dlscharae/Treatment Sp rtsman Lake Calcasieu River PPG Canal WTU Area Usu. 1 2 3' 4 A GC is located at VC-2 to run ail non-WTU water analyses. Bring your samples there. ANY CONCENTRATION >1 ppm or a PH <6 or >9 must be transferred to treatm nt. SL 08s 633 SL 085634 APPENDIX G SVRU OPERATIONS MANUAL SL 085635 OPERATIONS MANUAL EDC VAPOR ABATEMENT BARGE LOADING PREPARED BY: t A WD Technologies, Inc. FOR: PPG INDUSTRIES, INC. Lake Charles, Louisiana October 1992 AWD TECHNOLOGIES SL 085636 _____________________________________Item___________ __ _______ Page 1 Introduction _________________ _____________________________________ -3 II System Description III Equipment Description and Process Control_7 A. Vapor Adsorption System....................................................... ............ ........J B Bed Desorption System________________________________________________ ___ __ 9 C. Vapor Condensing and Storage System_______________________________________ _14 IV Operational Procedure.............................................................................................. 16 A. Operational Steps_______________________________________________ 16 1. Step 1 - Process Wait_16 2. Step 1A- Emergency Shut-Down________ _18 3. Step 2 -Warm-up_____________________________________ 20 4. Step 3 - Start Bed Cycle_________________________________ 21 5. Step 4 - Run________________________________________ 23 V. Abnormal Operating Conditions________________________________________________ _____ 22 A. Vapor Adsorption System_____ . _____ 24 B. Bed Desorption System30 C. Vapor Condensing and Storage System______________________________________ 35 VI Shut-Downs A. Normal_________ B. Operator Request. C. Emergency______ _______ ,,__________________________________38 VH. English Language Operating Program39 A. Operational Steps 1. Step 1 -ProcessWait 39 2. Step 1A- Emergency Shut-Down 3. Step 2 - Warm-up 4. Step 3 - Start Bed Cycle ______ 5. Step 4 -Run48 B. Digital Output Summary49 C. Controller Summary_______________________________________________________ D. Analog Alarm Summary _______ E. Digital Alarm Summary52 F. Indicator Summary53 G. Digital Input Summary54 H. Notes to Programmer55 39 41 43 46 _50 51 VUI. Process Control Diagrams56 A. Piping and Instrument Diagrams;____________________________________ AWD Confidential 56 SL 085637 I. Introduction The purpose of this project is to recover 1,2-dichloroethane (EDC) vapor during the loading of EDC barges at the PPG Industries, Inc. barge dock in Lake Charles, Louisiana A SORBATHENE* Solvent Vapor Recovery Unit, constructed by AWD Technologies, Inc. (AWD) removes the EDC vapor released by displacement during loading. The adsorbed EDC is regenerated under vacuum and condensed and collected. The SORBATHENE unit described below reduces the inlet concentration of EDC from approximately 139,000 pans per million (ppm) to less than 20 ppm. The patented SORBATHENE process was developed in 1988 by The Dow Chemical Company and in 1992 a license was granted to AWD Technologies, the environmental services subsidiary of Dow Chemical. Currently, seventeen SORBATHENE units are installed at operating sites to control vent emissions from process plants and distribution facilities. * Trademark of The Dow Chemical Company AWD Confidential SL 085638 II. System Description The PPG-Lake Charles barge loading SORBATHENE unit is a vapor abatement device to separate 1,2-dichloroethane (ethylene dichloride, EDC) vapor from the vent stream during barge loading of liquid EDC. The nitrogen atmosphere in the vapor space of the barge is displaced during the loading of EDC. This stream becomes increasingly saturated with EDC vapor as the liquid EDC is loaded and mixing of nitrogen and EDC vapor occurs. The mixing of EDC with nitrogen is driven by two mechanisms: 1) Stirring of nitrogen gas due to displacement by liquid and 2) diffusion of EDC vapor into the displaced nitrogen vent stream. The concentration of EDC increases from 0% prior to loading to a saturated concentration once loading is well underway. This SORBATHENE unit is designed to recover the EDC in the vent stream and release less than 20 ppm EDC in the cleaned nitrogen effluent stream. The displaced stream of nitrogen and EDC vapor from the barge enter either of two identical adsorption beds (60-2675 and 60-2676) after passing through an inlet filter and a series of control valves. The EDC selectively adsorbs on the surface of the solid adsorbent in the bed while the nitrogen passes through the bed and vents to atmosphere. The adsorption is exothermic and the heat released during adsorption accumulates in the adsorber. This accumulation of thermal energy raises the temperature in the adsorber by 5 to 15 F in a 10 to 30 minute adsorption period. The temperature rise over the programmed period of adsorption is a function of the capacity of the adsorbent for the component, the heat of adsorption released by a specific component and the concentration of the component in the vent stream. The temperature rise in the adsorber is a primary design parameter for the dimensions of the adsorber and the determination of cycle time. The adsorbers in a typical SORBATHENE unit are sized such that only 25 to 30% of the total adsorption capacity is consumed in ten minutes. At the end of the ten minute adsorption step, the bed is switched to a regeneration mode to restore adsorption capacity. In this unit, designed for a very low pressure drop, the adsorbers have been oversized in diameter to reduce the velocity of the stream being treated. Cycle time may be increased once the adsorption system is satifactorily demonstrated at shorter cycle times. Cycle time is often tuned and reset in the field after the thermal effects of common venting scenerios are determined. While one bed is in the adsorption mode, the second bed is regenerated. Following each adsorption period, the adsorbers are regenerated by vacuum desorption of the EDC. A vacuum is drawn from the bottom of the bed while a small fraction of the clean nitrogen stream leaving the adsorber back-sweeps through the bed and purges the bed of the adsorbed EDC. The two beds are continously alternated duringlhe entire period of product loading. AWD Confidential SL 085639 The EDC in the backpurge stream is drawn into the inlet of the liquid ring vacuum pump (56-599) During start-up of the SORBATHENE unit, the vacuum pump, which is sealed with a low vapor pressure oil, is heated to a temperature above the condensation temperature of EDC. In operation, as the EDC vapor flows through and is re-compressed in the hot oil-sealed vacuum pump, the EDC vapor does not condense. A two-phase outlet stream of the EDC saturated nitrogen and hot oil liquid is discharged from the vacuum pump. This two phase stream is separated in a liquid knock-out vessel equipped with an oil-coalescer for oil recovery. The warm back-purge nitrogen and desorbed EDC vapor stream enters an air-cooled exchanger (71-2641) where the temperature of the stream is reduced and the EDC condenses. Liquid EDC is collected in the EDC recovery tank (60-2678). The EDC saturated non-condensable nitrogen stream is recycled to the inlet feed to the on-line adsorber. The SORBATHENE unit recovers the EDC in the inlet stream regardless of its relative saturation. Since the stream is not nearly saturated in the beginning of a loading cycle, condensation may not begin immediately. During regeneration, the quantity of adsorbed EDC vapor is purged by a nitrogen stream of only 10%-20% of the inlet quantity of nitrogen. If condensation does not occur, the entire quantity of EDC adsorbed in the regenerating bed is returned to the on-line bed. t Subsequent adsorption and regeneration steps gradually increase the concentration to a level necessary for condensation to occur. The condensed EDC is stored in the recovery tank until it is pumped out by operating personnel There are three systems required to achieve the goals of EDC Vapor abatement. AWD Confidential s1j 0S5&40 1. Vapor Adsorption System a. Dust Filter This operation assures no solids larger than 100 microns will enter into the Adsorbent Beds. b. Adsorbent Beds This operation adsorbs Organic vapors in the vent gas from the Barge, 2. Bed Desorption System a. Vacuum Pump This operation maintains a constant vacuum pressure on the Beds during desorption cycle. b. EDC/Oil Separator This operation separates the EDC vapors from the vacuum pump seal oil. c. Oil Cooler This operation prevents the vacuum pump seal oil from getting too hot. 3. Vapor Condensing and Storage System a. EDC Recovery Cooler This operation condenses the EDC vapors from the EDC/Oil Separator. b. EDC Recovery Tank This operation stores the condensed EDC vapors until it can be pumped elsewhere. AWD Confidential SL o85641 III. Equipment Description and Process Control The following is a discussion of Equipment Descriptions and Process control ot variables for each of the systems in the unit. HLA Vapor Adsorption System This system removes the EDC from the barge vents by adsorption. III.A.1. Dust Filter (72-821) This is a bag type filter using a 100 micron polypropylene bag. A differential pressure is measured across the filters and will alarm at 0.5" WC. AWD Confidential SL 085642 HI.A.2. Adsorbent Beds (60-2675 & 60-2676) Two adsorbent beds are cycled in adsorption and regeneration. The adsorbent in this SORBATHENE unit is granular activated carbon. Each bed contains approximately 200 cubic feet of adsorbent. Wedgewire screens hold the adsorbent at top and bottom. The adsorbers are made of carbon steel and rated for full-vacuum and 150 psig. Three RTD's in each bed measure the temperature rise accompanying adsorption and will alarm at 130 F and result in an SD-3 level shutdown at 150 F. The adsorption system is controlled by time. Dual beds alternate in adsorption and desorption based on programmed time settings that limit the time each bed is in adsorption prior to regeneration. The adsorption takes place for a short enough time to assure that breakthrough of the adsorbent does not occur, heat is not appreciably lost to the surroundings or carried out of the bed in the clean stream, and the temperature rise in the adsorber is not too high. The cycle time is sufficiently long such that complete regeneration of the adsorbent in the off-line bed will occur while the on-line bed is adsorbing. The optimal cycle time is often tuned in the field over a range of 10 to 30 minutes. Larger beds are usually cycled over longer times because the longer times needed to repressurize and evacuate become significant f when the cycle times are shorter. AWD Confidential SL 085643 IILB. Bed Desorption System This system desorbs the EDC from the adsorbent beds. The EDC is desorbed by vacuum. Off-line regeneration of the adsorbent permits the unit to operate continuously in adsorption by continuously restoring adsorption capacity. ni.B.l. Vacuum Pump (56-599) This is a Siemens liquid ring vacuum pump (model 2BE1253) with a capacity of 1340 ACFM at 1.93 psia. The case and shaft are made of carbon steel, the impeller is made of ductile iron. It requires a 1800 rpm motor at 100 HP The vacuum pump level is actually controlled by pressure. The vacuum pump has a shaft (Fig HI.B. l.-l) with impeller blades on it. The shaft is mounted off-center with regard to the pump case. This creates more clearance at the bottom of the pump impeller blades than at the top. To work efficiently, the liquid level in the pump should just touch the bottom impeller blade. Section A-A shows that the impellers on the top are full of liquid. As the pump turns counter-clockwise, the area between the impeller blades and the pump case increases. This pulls a vacuum in the part AWD Confidential S1 88e44 of the pump where the area (volume) between the impeller and the case is increasing. This is where the suction port is located. On the other side of the pump, the area (volume) is decreasing between the impeller and the pump case. Since the service liquid (oil in this case) is noncompressible, the vapor in the chamber is compressed. This is where the discharge port is located There is a suction port on one side of the impeller and a discharge port on the other side of the impeller. The service liquid inlet is located just past the suction port. The pump level is correct when the pressure at the service liquid inlet point is held at 0 psig. The area between the impeller blades as they pass the service liquid inlet is at a vacuum. Addition of service liquid increases the pressure to 0 psig. If too much is added, that area will become pressurized as the area is sealed and the volume is fixed. If too little service liquid is added, the area will remain under a vacuum. r AWD Confidential Si 8564S IMPELLER BLADES SUCTION PORT PUMP CASE -- -- LIQUID / FULL POINT SHAFT DISCHARGE PORT SERVICE LIQUID SERVICE LIQUID INLET VAPOR VAPOR FULL POINT SECTION "A-A" DISCHARGE -- (UQUID AND VAPOR) SHAFT SERVICE UQUID INLET A SUCTION INLET Figure m.B. 1.1 - Vacuum Pump (56-599) Level Detail AWD Confidential SL 085646 m.B.2. EDC/Oil Separator (60*2677) The EDC vapor and the vacuum pump seal oil are separated in the EDC/Oil Separator. This separator is equipped with a coalescer for oil recovery. Oil is knocked out in the separator and returned to the vacuum pump. The EDC vapor and back-purge nitrogen gas flow through the coalescer and enter the vapor condensing and storage system. The oil coalescer removes greater than 99% of any oil droplets that could be carried over in the vapor stream leaving the knock-out section of the EDC/oil separator. AWD Confidential SXj 085647 Figure HI.B.2. - Oil Coalescer m.B.3. Oil Cooler (71-2640) An oil cooler removes the heat of compression generated in the vacuum pump. This air-cooled exchanger is controlled by bypass so that the operating temperature of the vacuum pump is above the temperature of condensation for EDC and below the temperature of EDC fractionation. An RTD (TE 1568) is located downstream of the oil-cooler bypass valve and ahead of the liquid supply port on the vacuum pump. This RTD provides feedback to the bypass valve. The oil cooler is carbon steel. A 3 HP motor drives the cooling fan. m.B.4. Oil Circulation Pump (55-6049) An oil circulation pump provides constant oil flow through the vacuum pump to maintain a liquid ring seal required for compression in the liquid-ring vacuum pump. An oil filter is provided at the outlet of the pump to remove solid particles which might accumulate in the oil. The oil circulation pump is ductile iron. The filter at its outlet is carbon steel. The filtering material is polyester for 10 micron filtration. AWD Confidential SL 085648 mX. Vapor Condensing and Storage System The vapor condensing and storage system recovers the EDC from the adsorption regeneration system. The EDC is condensed in an air-cooled exchanger and the condesed EDC is stored in a recovery tank until it is pumped out by plant operating personnel. m.F. 1. EDC Recovery Cooler (71 -2641) The EDC recovery cooler is an air-cooled heat exchanger A concentrated stream of EDC and nitrogen from the vacuum regeneration system enters the cooler where condensation of the EDC occurs. The two phase flow of liquid EDC and EDC-saturated nitrogen discharge from the condenser and flow to the EDC recovery tank. The EDC recovery cooler is carbon steel with a 7.5 HP motor. AWD Confidential SL 085649 [II.F 2. EDC Recovery Tank (60-2678) Recovered EDC liquid is stored in the 1000 gallon EDC recovery tank. The vapor stream of EDC-saturated nitrogen leaves the EDC recovery tank and is returned to the on-line adsorber Plant operators may pump-out the tank when the unit is in a process wait step. The tank is equipped with a level transmitter to measure level and alarm at 90% and shut down operation of the SORBATHENE unit and barge unloading if the recovered EDC level is 95%. A high level switch also indicates high high level in the tank and causes a shut-down. A low level sensor in the pump-out line at the bottom of the tank disables the EDC transfer pump to stop unloading operations and prevent the running of this pump. m.F.3. EDC Transfer Pump (55-6050) A mag-drive EDC transfer pump is used for return of the recovered EDC liquid to an EDC storage facility located in the dock area. This pump is operated by plant personnel when product discharge is desired. A recycle line on the outlet of the pump returns a fraction of the EDC liquid to the EDC Recovery Tank so that the recovered EDC may be sampled. The pump is shut off when the level in the recovery tank is reduced to less than the low-low-level alarm. Additionally, the pump is equipped with a temperature sensor (TE-1550) to shut off the pump if it is run dry. AWD Confidential SL 085650 Date : OMUl Author*: L Brandstetter Revicion: 1 Page : 16 of 56 IV. Operational Procedure The SORBATHENE Skid has been designed for an automated start-up. The SORBATHENE Skid Program will perform Shut-Downs related to process control or the SORBATHENE Skid can be Shut-Down on request of the Operator as part of the normal operating sequence or in response to an emergency. The automated start-up will consist of several Steps initiated by an Operator. The Program will then run through the sequences required to complete each Step and then continue on to the next Step. Should the Step be unsuccessful, the Program will inform the Operator of the problem and Shut-Down. IV.A. Operational Steps IV.A.l.A Step 1 - Process Wait a Step Description This Step is the initial Program Step. This Step will be used for plant maintenance which requires line openings. The Skid will be in this Step when not in use, and the Skid will come to this Step after an operator-initiated Shut-Down or an SD-2 Level Shut-Down. b. Conditions Required to Enter Step 1) System power up will begin at this Step. 2) Operator may enter this Step with Shut-Down request. 3) Program will enter this Step in reponse to an SD-2 Level Shut-Down c. Program Actions Taken During Step 1) All automated motors are disabled. 50-7751, 50-7752, 50-7753, and 50-7754 2) All controllers are put in manual and outputs put to 0% Controllers: TIC-1568 PIC-1527 PIC-1545 Valve: TV-1568 PV-1527 PV-1545 Fail Position Open Open Closed 3) All automated actuated valves Disabled. Actuated Valve Valve Fail Position FBV-1502 Open FBV-1511 Open FBV-1512 Closed AWD Confidential SL 085651 FBV-1515 FBV-1516 FBV-1518 FBV-1519 FBV-1523 FBV-1547 FBV-1548 FBV-1536 LBV-1563 FBV-1549 Closed Closed Closed Closed Closed Closed Closed Closed Open Closed 4) Enable 55-6050 (DO-1532). 5) LSL-1514 will disable 55-6050 (DO-1532) when in disabled (open) state. 6) TE-1550 (TAH-1550) will disable 55-6050 (DO-1532) when at 200 F. 7) Enable EV-1549 (DO-1549) when 55-6050 (DI-1532) is enabled (closed) and motor is running and disable EV-1549 (DO-1549) when 55-6050 (DI-1532) is disabled (open) or motor is stopped. 8) Vapor Recovery System Start Permissive pushbutton HS-1009 located on the EDC loading control panel in the South Terminal Control Room must be enabled before Master control Switch HS-1570 is enabled to start Skid. d. Operator Actions Taken During Step 1) The Operator must open the Nitrogen supply header to the Skid 2) The Operator must open the Instrument Air header supply to the Skid. 3) The Operator should lower the EDC liquid in 60-2678 before starting Skid. 4) The Operator should check the oil level of 60-2677 for proper level. 5) The Operator must enable the Vapor Recovery Sysem Start Permissive pushbutton HS-1009. This switch is in the control room. 6) The Operator must press the "START" pushbutton on the Master Control Station HS1570 located at the skid. This will start the Skid. 7) The HS-1009 and HS-1570 pushbuttons must be enabled in the correct order. If the HS-1570 pushbutton is enabled before the HS-1009 pushbutton, the Skid will not Start. e. Conditions Required to Exit Step 1) Nitrogen supply header open. 2) Instrument Air supply header open. 3) Vapor Recovery System Shut-Down pushbutton HS-1024 (SD-2) enabled (closed). 4) Vapor Recovery System Start Permissive pushbutton HS-1009 enabled. 5) Master Control Station HS-1570 "START" pushbutton enabled. AWD Confidential SL 085652 IV.A.l.B Step 1A - Emergency Shut-Down Step a. Step Description This Step is the Emergency Shut-Down Step. This Step is entered on a High-High temperature alarm from a RTD in either bed. Both beds are purged with nitrogen. The Skid will stay in this step until the operator initiates an advance to Step 1. b. Conditions Required to Enter Step 1) High-High Temperature Alarm from RTD in bed. c. Program Actions Taken Purine Step 1) All automated motors are disabled 50-7751, 50-7752, 50-7753, and 50-7754 2) All controllers are put in manual and outputs put to 0%. Controllers. TIC-1568 PIC-1527 PIC-1545 Valve. TV-1568 PV-1527 PV-1545 Fail Position Open Open Closed automated actuated valves are positioned as follows Actuated Valve FBV-1502 FBV-1511 FBV-1512 FBV-1515 FBV-1516 FBV-1518 FBV-1519 FBV-1523 FBV-1547 FBV-1548 FBV-1536 LBV-1563 FBV-1549 Valve Fail Position Closed Closed Closed Closed Closed Open Open Closed Open Open Closed Closed Closed AWD Confidential SL 085653 d Operator Actions Taken During Step 1) The Operator must initiate Shut-Down to go to Step 1 (Process Wait), e Conditions Required to Exit Step 1) Operator must request Step 1 AWD Confidential SL 085654 IV A. 2. Step 2 - Warm-up a Step Description In this Step the Vacuum Pump, 56-599, is warming the liquid seal oil. The adsorption beds are purged with nitrogen. b Conditions Required to Enter Step 1) Nitrogen supply header open. 2) Instrument Air supply header open. 3) Vapor Recovery System Shut-Down pushbutton HS-1024 (SD-2) enabled (closed). 4) Vapor Recovery System Start Permissive pushbutton HS-1009 enabled. 5) Master Control Station HS-1570 "START" pushbutton enabled. c. Program Actions Taken During Step 1) Enable controller PIC-1527 and put set-point to 0.0 psig. 2) Enable EDC/Oil Separator (60-2677) level switches LSL-1522 and LSH-1521, and level block valve LBV-1563. 3) Enable the following actuated valves; FBV-1518, FBV-1519, andFBV-1536. 4) Enable EDC Recovery Cooler motor 50-7754. 5) Enable Vacuum Pump motor 50-7751. 6) Enable Oil Circulation Pump motor 50-7752. 7) Enable Oil Cooler motor 50-7753. 8) Enable controller TIC-1568 and put set-point to 210 F. d. Operator Actions Taken During Step 1) The Operator should observe all equipment on the Skid is operating properly. e. Conditions Required to Exit Step 1) Program will advance to Step 3 when TIC-1568 is equal to or greater than 210 F. 2) Vapor Recovery System Shut-Down pushbutton HS-1024 is disabled (opened) indicating an operator request for a Shut-Down 3) Program will Shut-Down Skid on SD-2 alarm. AWD Confidential SL 085655 IV.A.3. Step 3- Start Bed Cycle a. Step Description This Step will start the Adsorption and Desorption Bed cycle. b. Conditions Required to Enter Step 1) Program will advance to Step 3 when TIC-1568 is equal to or greater than 210 F. c. Program Actions Taken During Step 1) Enable (close) FBV-1511 and Disable (close) FBV-1519. 2) Enable (open) FBV-1523. 3) Enable controller PIC-1545 and put set-point 6 psia. 4) Wait here until PIC-1545 is 1.9 psia or Shut-Down IF in this sequence for more than 3 minutes. 5) Enable (open) FBV-1516 and wait here for 10 minutes. 6) Disable (close) FBV-1516. 7) Put controller PIC-1545 set point to 0 psia. 8) Disable (close) FBV-1523. 9) Enable (open) FBV-1548 until Pressure indicator PIT-1507 is equal to or greater than 14.7 psia, then disable (close) FBV-1548. 10) Enable (open) FBV-1519 and Disable (open) FBV-1511. 11) Advance Program to Step 4, but continue these sequence. 12) Enable (close) FBV-1502 and Disable (close) FBV-1518. 13) Enable (open) FBV-1512. 14) Enable controller PIC-1545 and put set-point 6 psia. 15) Wait here until PIC-1545 is 1.9 psia or Shut-Down IF in this sequence for more than 3 minutes. 16) Enable (open) FBV-1515 and wait here for 10 minutes. 17) Disable (close) FBV-1515. 18) Put controller PIC-1545 set point to 0 psia. 19) Disable (close) FBV-1512. 20) Enable (open) FBV-1547 until Pressure indicator PIT-1503 is equal to or greater than 14.7 psia, then disable (close) FBV-1547. 21) Enable (open) FBV-1518 and Disable (open) FBV-1502. 22) Enable (close) FBV-1511 and Disable (close) FBV-1519. 23) Enable (open) FBV-1523. 24) Enable controller PIC-1545 and put set-point 6 psia. 25) Wait here until PIC-1545 is 1.9 psia or Shut-Down IF in this sequence for more than 3 minutes. 26) Enable (open) FBV-1516 and wait here for 10 minutes. 27) Disable (close) FBV-1516. 28) Put controller PIC-1545 set point to 0 psia. AWD Confidential SL 085656 29) Disable (close) FBV-1523. 30) Enable (open) FBV-1548 until Pressure indicator PIT-1507 is equal to or greater than 14.7 psia, then disable (close) FBV-1548, 31) Enable (open) FBV-1519 and Disable (open) FBV-1511. 32) Return to sequence 12 and repeat until Skid is Shut-Down, d. Operator Actions Taken During Step 1) The Operator should observe all equipment on the Skid is operating properly. e. Conditions Required to Exit Step 1) Program will advance to Step 4 after adsorption Bed 60-2675 has been desorbed. 2) Operator request for Shut-Down. 3) Program will Shut-Down Skid on SD-2 alarm. AWD Confidential SL 085657 IV A.4. Step 4 - Run a Step Description This Step the Skid is in full operation and unloading of the barge can begin. b Conditions Required to Enter Step 1) Program will advance to Step 4 after adsorption Bed 60*2675 has been desorbed. c. Program Actions Taken During Step 1) Continue Adsorption and Desorption Bed cycle. d Operator Actions Taken During Step 1) The Operator should observe ail equipment on the Skid is operating properly. e. Conditions Required to Exit Step 1) Operator request for Shut-Down. 2) Program will Shut-Down Skid on SD-2 alarm. AWD Confidential SL 085658 V. Abnormal Operating Conditions V.A. Vapor Adsorption System Alarm: PDAH-1500 Description: 72-821 High Differential Pressure Instrument of comparison: PROBABLE CAUSES Plugged Filter Bag Line blocked Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Replace filter bag. Check all manual block valves for proper position, filter maybe plugged. Repair instrument PDT-1500 Alarm. FAH-1501H Description: High Inlet Flow Instrument of comparison: FIT-1501 PROBABLE CAUSES Loading barge or ship too fast. Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Slow down loading or continue loading rate. May emit vapors to atmosphere. Repair instrument FIT-] 501. Alarm: FAHH-1501H Description: High High Inlet Flow Instrument of comparison: PROBABLE CAUSES Loading barge or ship too fast. Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Slow down loading or continue loading rate. May emit vapors to atmosphere. Repair instrument FIT-1501H. AWD Confidential Alarm: TAH-1S04 Description: High Temperature 60-2676 Instrument of comparison: PROBABLE CAUSES Adsorption rate too high due to concentration or flow rate. Exothermic chemical reaction. Adsorption Bed on fire Bad instrument ! ALARM CORRECTION - OPERATOR ACTION TO: Slow down flow rate. Stop loading of barge or ship, purge bed with Nitrogen. Stop loading of barge or ship, purge bed with Nitrogen. Repair instrument TE-1504. Alarm: TAHH-1504 Description: High-High Temperature 60-2676 Instrument of comparison: PROBABLE CAUSES Adsorption rate too high due to concentration or flow rate. Exothermic chemical reaction. Adsorption Bed on fire Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Lower concentration or slow down flow rate. Stop loading of barge or ship, purge bed with Nitrogen. Stop loading of barge or ship, purge bed with Nitrogen. Repair instrument TE-1504. Alarm: TAH-1505 Description: High Temperature 60-2676 Instrument of comparison: PROBABLE CAUSES Adsorption rate too high due to concentration or flow rate. Exothermic chemical reaction. Adsorption Bed on fire Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Lower concentration or slow down flow rate. Stop loading of barge or ship, purge bed with Nitrogen. Stop loading of barge or ship, purge bed with Nitrogen. Repair instrument TE-1505. AWD Confidential SL 085660 Alarm: TAHH-1505 Description: High-High Temperature 60-2676 Instrument of comparison1 PROBABLE CAUSES Adsorption rate too high due to concentration or flow rate. Exothermic chemical reaction Adsorption Bed on fire Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Lower concentration or slow down flow rate. Stop loading of barge or ship, purge bed with Nitrogen. Stop loading of barge or ship, purge bed with Nitrogen. Repair instrument TE-1505. Alarm: TAH-I506 Description: High Temperature 60-2676 Instrument of comparison: PROBABLE CAUSES Adsorption rate too high due to concentration or flow rate. Exothermic chemical reaction. Adsorption Bed on fire Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Lower concentration or slow down flow rate. Stop loading of barge or ship, purge bed with Nitrogen. j Stop loading of barge or ship, purge bed with Nitrogen. Repair instrument TE-1506. Alarm: TAHH-1506 Description: High-High Temperature 60-2676 Instrument of comparison; PROBABLE CAUSES Adsorption rate too high due to concentration or flow rate. Exothermic chemical reaction. Adsorption Bed on fire Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Lower concentration or slow down flow rate. Stop loading of barge or ship, purge bed with Nitrogen. Stop loading of barge or ship, purge bed with Nitrogen. Repair instrument TE-1506 AWD Confidential Si 1S6S1 Alarm; TAH-1508 Description: High Temperature 60-2675 Instrument of comparison: PROBABLE CAUSES Adsorption rate too high due to concentration or flow rate. Exothermic chemical reaction. Adsorption Bed on fire Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Lower concentration or slow down flow rate. Stop loading of barge or ship, purge bed with Nitrogen. Stop loading of barge or ship, purge bed with Nitrogen. Repair instrument TE-1508. Alarm: TAHH-1508 Description: High-High Temperature 60-2675 Instrument of comparison: PROBABLE CAUSES Adsorption rate too high due to concentration or flow rate. Exothermic chemical reaction. Adsorption Bed on fire Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Lower concentration or slow down flow rate. Stop loading of barge or ship, purge bed with Nitrogen. Stop loading of barge or ship, purge bed with Nitrogen. Repair instrument TE-1508 Alarm: TAH-1509 Description: High Temperature 60-2675 Instrument of comparison: PROBABLE CAUSES Adsorption rate too high due to concentration or flow rate. Exothermic chemical reaction. Adsorption Bed on fire Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Lower concentration or slow down flow rate. Stop loading of barge or ship, purge bed with Nitrogen. Stop loading of barge or ship, purge bed with Nitrogen. Repair instrument TE-1509. AWD Confidential SL 085662 Alarm: TAHH-1509 Description: High-High Temperature 60-2675 Instrument of comparison: PROBABLE CAUSES Adsorption rate too high due to concentration or flow rate. Exothermic chemical reaction. Adsorption Bed on fire Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Lower concentration or slow down flow rate. Stop loading of barge or ship, purge bed with Nitrogen. Stop loading of barge or ship, purge bed with Nitrogen. Repair instrument TE-1509. Alarm: TAH-1510 Description: High Temperature 60-2675 Instrument of comparison: PROBABLE CAUSES Adsorption rate too high due to concentration or flow rate. Exothermic chemical reaction. Adsorption Bed on fire Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Lower concentration or slow down flow rate. Stop loading of barge or ship, purge bed with Nitrogen. Stop loading of barge or ship, purge bed with Nitrogen. Repair instrument TE-1510 Alarm: TAHH-1510 Description: High-High Temperature 60-2675 Instrument of comparison: PROBABLE CAUSES Adsorption rate too high due to concentration or flow rate. Exothermic chemical reaction. Adsorption Bed on fire Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Lower concentration or slow down flow rate. Stop loading of barge or ship, purge bed with Nitrogen. Stop loading of barge or ship, purge bed with Nitrogen. Repair instrument TE-1510. AWD Confidential SL 085663 Alarm: FAH-1S17 Description: Desorption Sweep Gas High Flow Instrument of comparison PROBABLE CAUSES HCV-1567 open. Leak or open vent/drain Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Adjust HCV-1567 to correct flow rate. Check and fix leaks, close vents or drains. Repair instrument FIT-1517. Alarm: PSL-1533 Description: Instrument Air Low Pressure Instrument of comparison: PROBABLE CAUSES Line blocked Leak or open vent/drain Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Check all manual valves for proper position. Check and fix leaks, close vents or drains. Repair instrument PSL-1533. The following valves will alarm and Shut-Down the Skid if they are not in the position the Program expects them to be in. The Program will scan valve positions with each sequence of the Program: FBV-1502, FBV-1511, FBV-1512, FBV-1515, FBV-1516, FBV-1518, FBV-1519, FBV-1523, FBV-1547, andFBV-1548. Listed below are some causes that may have prevented the valve from going to the correct position. PROBABLE CAUSES Stuck valve Instrument air off Solenoid valve bad Bad actuator Bad position switch ALARM CORRECTION - OPERATOR ACTION TO: Try to manually open or close valve, repair valve. Turn on instrument air. Repair or replace solenoid valve. Repair or replace actuator. Repair instrument ZSO or ZSC switch. AWD Confidential SL 085664 V.B. Bed Desorption System Alarm: TAH-1524 Description: 56-599 Discharge High Temperature Instrument of comparison: PROBABLE CAUSES TV-1568 not working TV-1568 in manual. 71 -2640 not working. Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Instrument air off, I/P not working, or control valve stuck. Make repairs as needed. Put control valve TV-1568 in AUTO.. Check 71-2640 to find cause for not cooling, air way blocked, drive belt broken, etc. j Repair instrument TH-1524. Alarm: TAHH-1524 Description: 56-599 Discharge High-High Temperature Instrument of comparison; PROBABLE CAUSES TV-1568 not working TV-1568 in manual. 71-2640 not working. Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Instrument air off, I/P not working, or control valve stuck. Make repairs as needed. Put control valve TV-1568 in AUTO.. Check 71-2640 to find cause for not cooling, air way blocked, drive belt broken, etc. Repair instrument TE-1524, Alarm: TAL-1524 Description: 56-599 Discharge Low Temperature Instrument of comparison: PROBABLE CAUSES TV-1568 not working TV-1568 in manual. ALARM CORRECTION - OPERATOR ACTION TO: Instrument air off, I/P not working, or control valve stuck. Make repairs as needed. Put control valve TV-1568 in AUTO.. Bad instrument Repair instrument TE-1524. AWD Confidential SL 085665 Alarm: TALL-1524 Description, 56-599 Discharge Low-Low Temperature Instrument of comparison: PROBABLE CAUSES TV-1568 not working TV-1568 in manual. ALARM CORRECTION - OPERATOR ACTION TO: Instrument air oflf, I/P not working, or control valve stuck. Make repairs as needed. Put control valve TV-1568 in AUTO.. Bad instrument Repair instrument TE-1524, Alarm: PAH-1527 Description: 56-599 Seal Oil High Pressure Instrument of comparison: PROBABLE CAUSES PV-1527 open PV-1527 in manual Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Instrument air off, I/P not working, or control valve stuck. Make repairs as needed. Put PV-1527 in AUTO. Repair instrument PIT-1527. Alarm: PAHH-1527 Description; 56-599 Seal Oil High-High Pressure Instrument of comparison: PROBABLE CAUSES PV-1527 open PV-1527 in manual Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Instrument air oflf, I/P not working, or control valve stuck. Make repairs as needed. Put PV-1527 in AUTO Repair instrument PIT-1527. AWD Confidential SL 085666 Alarm: PAL-1527 Description: 56-599 Seal Oil Low Pressure Instrument of comparison PROBABLE CAUSES PV-1527 closed PV-1527 in manual Line blocked Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: I/P not working, or control valve stuck. Make repairs as needed. Put PV-1527 in AUTO. Check all manual valves for proper position. Repair instrument PIT-1527 Alarm: PALL-1527 Description: 56-599 Seal Oil Low-Low Pressure Instrument of comparison: PROBABLE CAUSES PV-1527 closed PV-1527 in manual Line blocked Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: I/P not working, or control valve stuck. Make repairs as needed. Put PV-1527 in AUTO. Check all manual valves for proper position. Repair instrument PIT-1527. Alarm: VAH-1569 Description: 71-2640 Vibration Instrument of comparison: PROBABLE CAUSES Bad bearing Loose mounting Foreign object Fan blade balance Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Check bearings. Check mountings. Check for foreign objects. Check balance of fan blades. Repair instrument VBS-1569. Alarm: LAL-1528 Description: V-125A Seal Pot Low Level Instrument of comparison: PROBABLE CAUSES Bad seal Vessel or line leak Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Check 56-599 seals for leak. Check for leaks. Repair instrument LSL-1528. AWD Confidential SL 085667 Alarm LAH529 Description, V-125B Seal Pot Low Level Instrument of comparison PROBABLE CAUSES Bad seal Vessel or line leak Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Check 56-599 seals for leak. Check for leaks. Repair instrument LSL-1529. Alarm: PDAH-1546 Description: 60-2677 High Differential Pressure Instrument of comparison: PROBABLE CAUSES Oil demister plugged Oil level in demister section too high Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Check oil demister. Check oil level in demister section. Check valve LBV-1563 for proper operation. Repair instrument PDT-1546. Alarm: PDAHH-1546 Description: 60-2677 High-High Differential Pressure Instrument of comparison: PROBABLE CAUSES Oil demister plugged Oil level in demister section too high Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Check oil demister. Check oil level in demister section. Check valve LBV-1563 for proper operation. Repair instrument PDT-1546 Alarm: LAH-I561 Description: 60-2677 High Oil Level Instrument of comparison: PROBABLE CAUSES Low seal oil Temp. Foreign liquid intrusion Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Check seal oil temperature, TE-1523 may be bad. Check seal oil for intrusion of other liquids. Repair instrument LSH-1561. AWD Confidential SL 085668 Alarm: LAL-1562 Description: 60-2677 Low Oil Level Instrument of comparison: PROBABLE CAUSES Oil in demister section of 60-2677 Vessel or line leak Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Check valve LBV-1563, may not have opened to drain seal oil back into vacuum pump. Check for leaks. Repair instrument LSL-1562. The following equipment will shut-down the SORBATHENE Unit if it fails when the PLC program expects it to be running. The PLC program will scan equipment with each sequence of the program and alarm if it fails: 56-599, 55-6049, and 50-7753. Listed below are some causes that may have made the equipment fail. PROBABLE CAUSES Motor starter Failed coupling Bad motor Equipment fail ALARM CORRECTION - OPERATOR ACTION TO: Check motor starter breaker, fuses, and over loads. Check and/or repair coupling. Repair or replace motor. Check manufactures booklet for repair. AWD Confidential SL 85669 V.C. Vapor Condensing and Storage System Alarm: VAH-1531 Description: 71-2641 Vibration Instrument of comparison: PROBABLE CAUSES Bad bearing Loose mounting Foreign object Fan blade balance Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Check bearings. Check mountings. Check for foreign objects. Check balance of fan blades. Repair instrument VBS-1531. Alarm: LAH-1534 Description: 60-2678 High Level Instrument of comparison: PROBABLE CAUSES Operations Error Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Operator should transfer product. Repair instrument LIT-1534. Alarm: LAHH-1534 Description: 60-2678 High-High Level Instrument of comparison: PROBABLE CAUSES Operations Error Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Operator should transfer product. Repair instrument LIT-1534. Alarm: LAHH-1535 Description: 60-2678 High-High Level Instrument of comparison: PROBABLE CAUSES Operations Error Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Operator should transfer product Repair instrument LSH-1535. AWD Confidential Alarm: TAH-1544 Description: 71-2641 High Outlet Temperature Instrument of comparison: PROBABLE CAUSES Broken drive belt Seal oil too hot Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Check and/or repair drive belt. Check seal oil temperature and try to lower if above its normal temperature (210 F into 56-599). Repair instrument TE-1544. Alarm: TAHH-1544 Description: 71-2641 High-High Outlet Temperature Instrument of comparison: PROBABLE CAUSES Broken drive belt Seal oil too hot Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Check and/or repair drive belt. Check seal oil temperature and try to lower if above its normal temperature (210 F into 56-599). Repair instrument TE-1544. Alarm: TAH-1550 Description: 55-6050 High Temperature Instrument of comparison: PROBABLE CAUSES Line blocked FBV-1549 failed to open Bad instrument ALARM CORRECTION - OPERATOR ACTION TO: Check all manual valves for proper position. Check FBV-1549 to see if it opens when 55-6050 start. Check for blocked instrument air or stuck valve Repair instrument TE-1550, AWD Confidential SL 085671 The following valves will alarm and Shut-Down the Skid if they are not in the position the Program expects them to be in. The Program will scan valve positions with each sequence of the Program: FBV-1536 Listed below are some causes that may have prevented the valve from going to the correct position. PROBABLE CAUSES Stuck valve Instrument air off Solenoid valve bad Bad actuator Bad position switch ALARM CORRECTION - OPERATOR ACTION TO: Trv to manually open or close valve, repair valve. Turn on instrument air. Repair or replace solenoid valve. Repair or replace actuator. Repair instrument ZSO or ZSC switch The following equipment will shut-down the SORBATHENE Unit if it fails when the PLC program expects it to be running. The PLC program will scan equipment with each sequence of the program and alarm if it fails: 50-7754. Listed below are some causes that may have made the equipment fail. PROBABLE CAUSES Motor starter Failed coupling Bad motor Equipment fail ALARM CORRECTION - OPERATOR ACTION TO: Check motor starter breaker, fuses, and over loads. Check and/or repair coupling. Repair or replace motor. Check manufactures booklet for repair. AWD Confidential SL 085672 VI. Shut-Downs VI.A. Normal There are several Shut-Downs built into the Program. The Program will automatically shut-down the SORBATHENE Unit if any of these alarms are activated while the Skid is Running. The Program will Shut-down the Skid to Step I and turn off all equipment. VLB. Operator Request The Operator may Shut-Down the Skid at any time in any of the Steps by means of the Vapor Recovery System Shut-Down pushbutton HS-1024(SD-2) in the control room. The Operator can Shut-Down the Skid in the Field by pressing the "STOP" pushbutton on the Master Control Station, HS-1570, or by turning off any of the four motors that run continuously Shut-Downs on the Skid in most cases will be done by the program, but the Operator can ShutDown the Skid in an emergency in the same manner as a Normal Shut-down. An SD-2 level ShutDown and a Normal Shut-Down will take the Skid to Step I. VLC. Emergency Shut-Down The skid will go to an SD-3 Emenrgency Shut-Down on High-High Temperature Alarm from an RTD in either beds. The Skid will stay in Step 1A, Emergency Shut-Down SD-3, until the operator requests advance to Step 1, Process Wait. AWD Confidential 085673 SL VII. English Language Operating Program The SORBATHENE Skid has been designed for an automated start-up. The SORBATHENE Skid Program will perform Shut-Downs related to process control or the SORBATHENE Skid can be Shut-Down on request of the Operator as part of the normal operating sequence or in response to an emergency. The automated start-up will consist of several Steps initiated by an Operator. The Program will then run through the sequences required to complete each Step and then continue on to the next Step. Should the Step be unsuccessful, the Program will inform the Operator of the problem and Shut-Down. VILA. Operational Steps VII. A. 1. Step 1 - Process Wait a. Step Description This Step is the initial Program Step. This Step will be used for plant maintenance which requires line openings. The Skid will be in this Step when not in use, and the Skid will come to this Step after an operator-initiated Shut-Down or an SD-2 Level Shut-Down. b. Conditions Required to Enter Step 1) System power up will begin at this Step. 2) Operator may enter this Step with Shut-Down request. 3) Program will enter this Step in response to an SD-2 Level Shut-Down c. Actions Taken Purine Step 1) All automated motors are disabled. 50-7751, 50-7752, 50-7753, and 50-7754 2) All controllers are put in manual and outputs put to 0%. Controllers: TIC-1568 PIC-1527 PIC-1545 Valve' TV-1568 PV-1527 PV-1545 Fail Position Open Open Closed 3) All automated actuated valves Disabled. Actuated Valve Valve Fail Position FBV-1502 Open FBV-1511 Open FBV-1512 Closed AWD Confidential SL 085674 FBV-1515 FBV-1516 FBV-1518 FBV-1519 FBV-1523 FBV-1547 FBV-1548 FBV-1536 LBV-1563 FBV-1549 Closed Closed Closed Closed Closed Closed Closed Closed Open Closed 4) Enable 55-6050 (DO-1532). 5) LSL-1514 will disable 55-6050 (DO-1532) when in disabled (open) state 6) TE-1550 (TAH-1550) will disable 55-6050 (DO-1532) when at 200 F. 7) Enable EV-1549 (DO-1549) when 55-6050 (DI-1532) is enabled (closed) and disable EV-1549 (DO-1549) when 55-6050 (DI-1532) is disabled (open). 8) Vapor Recovery System Start Permissive switch HS-1009 must be enable before Master control Switch HS-1570 is enabled to start Skid. d. Conditions Required to Exit Step 1) Nitrogen supply header open 2) Instrument Air supply header open. 3) Vapor Recovery System Shut-Down switch HS-1024 (SD-2) enabled (closed) 4) Vapor Recovery System Start Permissive switch HS-1009 enabled 5) Master Control Switch HS-1570 enabled. e. Summary of Software Alarms Enabled Purine Step 1) LAH-1534 , 60-2678 High Level. 2) LAL-1534 , 60-2678 Low Level. 3) LALL-1534 , 60-2678 Low-Low Level, f. Summary of Software Shutdowns Enabled During Step 1) LAHH-1534 , 60-2678 High-High Liquid Level, 2) LAHH-1535 , 60-2678 High-High Liquid Level. 3) TAH-1550 , 55-6050 High Temperature. Disable (DO-1532) pump 55-6050 only. 4) LSL-1514 , 60-2678 Low Level. Disable (DO-1532) pump 55-6050 only. AWD Confidential SL 085675 VILA. 1 .B Step 1A - Emergency Shut-Down Step a Step Description This Step is the Emergency Shut-Down Step. This Step is entered on a High-High temperature aiarm from a RTD in either bed. Both beds are purged with nitrogen The Skid will stay in this step until the operator initiates an advance to Step 1. b Conditions Required to Enter Step 1) High-High Temperature Alarm from RTD in bed. c. Program Actions Taken During Step 1) All automated motors are disabled. 50-7751, 50-7752, 50-7753, and 50-7754. 2) All controllers are put in manual and outputs put to 0%. Controllers: TIC-1568 PIC-1527 PIC-1545 Valve: TV-1568 PV-1527 PV-1545 Fail Position Open Open Closed All automated actuated valves are positioned as follows Actuated Valve FBV-1502 FBV-1511 FBV-1512 FBV-1515 FBV-1516 FBV-1518 FBV-1519 FBV-1523 FBV-1547 FBV-1548 FBV-1536 LBV-1563 FBV-1549 Valve Fail Position Closed Closed Closed Closed Closed Open Open Closed Open Open Closed Closed Closed AWD Confidential SL 085676 d. Conditions Required to Exit Step 1) Operator must request Step 1 e. Summary of Software Aiarms Enabled During Step none f Summary of Software Shut-Downs Enabled During Step none AWD Confidential SL 085677 VILA.2. Step 2 - Warm-up a. Step Description In this Step the Vacuum Pump, 56-599, is warming the liquid seal oil. The adsorption beds are purged with nitrogen b. Conditions Required to Enter Step 1) Nitrogen supply header open. 2) Instrument Air supply header open. 3) Vapor Recovery System Shut-Down pushbutton HS-1024 (SD-2) enabled (closed). 4) Vapor Recovery System Start Permissive pushbutton HS-1009 enabled. 5) Master Control Station HS-1570 "START" pushbutton enabled. c Actions Taken Purine Step 1) Enable controller PIC-1527 and put set-point to 0.0 psig. 2) Enable EDC/Oil Separator (60-2677) level switches LSL-1522 and LSH-1521, and level block valve LBV-1563. 3) Enable the following actuated valves; FBV-1518, FBV-1519, andFBV-1536. 4) Enable EDC Recovery Cooler motor 50-7754. 5) Enable Vacuum Pump motor 50-7751. 6) Enable Oil Circulation Pump motor 50-7752. 7) Enable Oil Cooler motor 50-7753. 8) Enable controller TIC-1568 and put set-point to 210 F d. Conditions Required to Exit Step 1) Program will advance to Step 3 when TIC-1568 is equal to or greater than 210 F. 2) Vapor Recovery System Shut-Down pushbutton HS-1024 is disabled (opened) indicating an operator request for Shut-Down 3) Program will Shut-Down Skid on SD-2 alarm. e. Summary of Software Alarms Enabled Purine Step 1) PDAH-1500 , 72-821 High Differential Pressure. 2) FAH-1501H , High Inlet Flow. 3) FAHH-1501H, High-High Inlet Flow. 4) TAH-1504 , 60-2676 High Temperature. 5) TAH-1505 , 60-2676 High Temperature. 6) TAH-1506 , 60-2676 High Temperature. 7) TAH-1508 , 60-2675 High Temperature. 8) TAH-1509 , 60-2675 High Temperature. 9) TAH-1510 , 60-2675 High Temperature. 10)TAH-1524 , 56-599 Discharge High Temperature. 11) PAL-1527 , 56-599 Seal Oil Low Pressure. AWD Confidential SL 085678 12) PAH-1527 13) LAL-1528 14) LAL-1529 15) PDAH-1546 16) TAH-1544 17) FAH-1517 56-599 Seal Oil High Pressure. V-125A Seal Pot Low Level, V-125B Seal Pot Low Level. 60-2677 High Differential Pressure. 71-2641 High Outlet Temperature. Desorption Sweep Gas High Flow f. Summary of Software Shutdowns Enabled During Step 1) TAHH-1504 60-2676 High-High Temperature, Goes to Step 1A. 2) TAHH-1505 60-2676 High-High Temperature, Goes to Step 1A. 3) TAHH-1506 60-2676 High-High Temperature, Goes to Step 1A. 4) TAHH-1508 60-2675 High-High Temperature, Goes to Step 1 A. 5) TAHH-1509 60-2675 High-High Temperature, Goes to Step 1A. 6) TAHH-1510 60-2675 High-High Temperature, Goes to Step 1A. 7) PAHH-1527 56-599 Seal Oil High-High Pressure. 8) PALL-1527 56-599 Seal Oil Low-Low Pressure. 9) TAHH-1524 56-599 Discharge High-High Temperature. 10) LAHH-1534 60-2678 High-High Liquid Level. 11) LAHH-1535 60-2678 High-High Liquid Level 12) PDAHH-1546 , 60-2677 High-High Differential Pressure, 13) LAL-1562 60-2677 Low Oil Level. 14) VAH-1531 71-2641 High Vibration. 15) VAH-1569 71-2640 High Vibration. 16) TAHH-1544 71-2641 High-High Outlet Temperature. 17) PAL-1533 Instrument Air Low Pressure 18) ZIO-1502 FBV-1502 Failed To Open. 19) ZIC-1502 FBV-1502 Failed To Close 20) ZIO-1511 FBV-1511 Failed To Open 21) ZIC-1511 FBV-1511 Failed To Close. 22) ZIO-1512 FBV-1512 Failed To Open. 23) ZIC-1512 FBV-1512 Failed To Close. 24) ZIO-1515 FBV-1515 Failed To Open 25) ZIC-1515 FBV-1515 Failed To Close. 26) ZIO-1516 FBV-1516 Failed To Open. 27) ZIC-1516 FBV-1516 Failed To Close. 28) ZIO-1518 FBV-1518 Failed To Open. 29) ZIC-1518 FBV-1518 Failed To Close. 30) ZIO-1519 FBV-1519 Failed To Open. 31) ZIC-1519 FBV-1519 Failed To Close. 32) ZIO-1523 FBV-1523 Failed To Open. 33) ZIC-1523 FBV-1523 Failed To Close. 34) ZIO-1536 FBV-1536 Failed To Open. AWD Confidential SL >85679 35) ZIC-1536 36) ZIO-1547 37) ZIC-1547 38) ZIO-1548 39) ZIC-1548 40) ZI-1520 41) ZI-1525 42) ZI-1526 43) ZI-1530 44) PAH-1503 45) PAH-1507 , FBV-1536 Failed To Close. , FBV-1547 Failed To Open. , FBV-1547 Failed To Close. . FBV-1548 Failed To Open. , FBV-1548 Failed To Close. , 50-7751 Failed. , 50-7752 Failed . 50-7753 Failed. , 50-7754 Failed. , 60-2676 High Pressure. 60-2675 High Pressure. AWD Confidential SL 0856S0 VII. A.3. Step 3-Start Bed Cycle a. Step Description This Step will start the Adsorption and Desorption Bed cycle. b Conditions Required to Enter Step 1) Program will advance to Step 3 when TIC-1568 is equal to or greater than 210 F c Actions Taken During Step 1) Enable (close) FBV-1511 and Disable (close) FBV-1519. 2) Enable (open) FBV-1523. 3) Enable controller PIC-1545 and put set-point 6 psia. 4) Wait here until PIC-1545 is 1.9 psia or Shut-Down IF in this sequence for more than 3 minutes. 5) Enable (open) FBV-1516 and wait here for 10 minutes, 6) Disable (close) FBV-1516. 7) Disable (close) FBV-1523 and put controller PIC-1545 set point to 0 psia. 8) Enable (open) FBV-1548 until Pressure indicator PIT-1507 is equal to or greater than 14.7 psia, then disable (close) FBV-1548. 9) Enable (open) FBV-1519 and Disable (open) FBV-1511. 10) Advance Program to Step 4, but continue these sequence. 11) Enable (close) FBV-1502 and Disable (close) FBV-1518. 12) Enable (open) FBV-1512. 13) Enable controller PIC-1545 and put set-point 6 psia. 14) Wait here until PIC-1545 is 1.9 psia or Shut-Down IF in this sequence for more than 3 minutes. 15) Enable (open) FBV-1515 and wait here for 10 minutes 16) Disable (close) FBV-1515. 17) Disable (close) FBV-1512 and put controller PIC-1545 set point to 0 psia. 18) Enable (open) FBV-1547 until Pressure indicator PIT-1503 is equal to or greater than 14.7 psia, then disable (close) FBV-1547. 19) Enable (open) FBV-1518 and Disable (open) FBV-1502 20) Enable (close) FBV-1511 and Disable (close) FBV-1519 21) Enable (open) FBV-1523. 22) Enable controller PIC-1545 and put set-point 6 psia. 23) Wait here until PIC-1545 is 1.9 psia or Shut-Down IF in this sequence for more than 3 minutes. 24) Enable (open) FBV-1516 and wait here for 10 minutes. 25) Disable (close) FBV-1516. 26) Disable (close) FBV-1523 and put controller PIC-1545 set point to 0 psia. 27) Enable (open) FBV-1548 until Pressure indicator PIT-1507 is equal to or greater than 14.7 psia, then disable (close) FBV-1548. AWD Confidential SL 085681 28) Enable (open) FBV-1519 and Disable (open) FBV-1511. 29) Return to sequence i 1 and repeat until Skid is Shut-Down d. Conditions Required to Exit Step 1) Program will advance to Step 4 after adsorption Bed 60-2675 has been desorbed 2) Operator request for Shut-Down 3) Program will Shut-Down Skid on ESD alarm. e. Summary of Software Alarms Enabled During Step 1) TAL-1524 , 56-599 Low Discharge Temperature. f. Summary of Software Shutdowns Enabled During Step 1) TALL-1524 , 56-599 Low-Low Discharge Temperature. 2) LAH-1561 , 60-2677 High Oil Level. AWD Confidential si 85682 iL m toe vapor ABATEMENT barge loading AWD WSJHSRSIH Date : 04/08/93 Authors : L. Brandetetter Revision: 1 Pape : 48 of 66 VTI. A.4 Step 4 - Run a. Step Description This Step the Skid is in full operation and unloading of the barge can begin b Conditions Required to Enter Step 1) Program will advance to Step 4 after adsorption Bed 60-2675 has been desorbed c. Actions Taken During Step 1) Continue Adsorption and Desorption Bed cycle. d Conditions Required to Exit Step 1) Operator request for Shut-Down. 2) Program will Shut-Down Skid on ESD alarm. e. Summary of Software Alarms Enabled Purine Step 1) None by Program this Step 2) Announce on screen and print, "Skid Operational". f. Summary of Software Shutdowns Enabled Purine Step None by Program this Step. AWD Confidential SL 085683 VII.B. Digital Output Summary DO No. DO-1502 DO-1511 DO-1512 DO-1515 DO-1516 DO-1518 DO-1519 DO-1520 DO-1523 DO-1525 DO-1526 DO-1530 DO-1532 DO-1536 DO-1547 DO-1548 DO-1549 DO-1563 Description FBV-1502 Close FBV-1511 Close FBV-1512 Open FBV-1515 Open FBV-1516 Open FBV-1518 Open FBV-1519 Open 50-7751 Start FBV-1523 Open 50-7752 Start 50-7753 Start 50-7754 Start 55-6050 Start FBV-1536 Open FBV-1547 Open FBV-1548 Open FBV-1549 Open FBV-1563 Open Enable Permissive Selected by Program Selected by Program Selected by Program Selected by Program Selected by Program Selected by Program Selected by Program Selected by Program Selected by Program Selected by Program Selected by Program Selected by Program Selected by Program Selected by Program Selected by Program Selected by Program Selected by Program Selected by Program AWD Confidential SL SS684 MI *ABATEMENT BARGE LOADING VII.C. Controller Summary Tag No. TIC-1568 PIC-1527 PIC-1545 Description 56-599 Seal Oil Temp. Controller 56-599 Seal Oil Pressure Controller 56-599 Inlet Pressure Controller Range 50-300 F 12-17 psia 0-15 psia AWD Date : OAK)8/93 Authors : L. Branditetter Revision: 1 Page : 60 of 56 Set-Point 210 F 0.0 psig 6.0 psia Action Direct Reverse Reverse AWD Confidential 3L o 85685 VTLD. Analog Alarm Summary Tag No. Description PDAH-1500 72-821 High Differential Pressure FAH-1501H High Inlet Flow FAHH-1501H High-High Inlet Flow TAH-1504 60-2676 High Temperature TAHH-1504 60-2676 High-High Temperature TAH-1505 60-2676 High Temperature TAHH-1505 60-2676 High-High Temperature TAH-1506 TAHH-1506 TAH-1508 TAHH-1508 60-2676 High Temperature 60-2676 High-High Temperature 60-2675 High Temperature 60-2675 High-High Temperature TAH-1509 60-2675 High Temperature TAHH-1509 60-2675 High-High Temperature TAH-1510 60-2675 High Temperature TAHH-1510 FAH-1517 TAH-1524 60-2675 High-High Temperature Desorption Sweep Gas High Flow 56-599 Discharge High Temperature TAHH-1524 56-599 Discharge High-High Temp. TAL-1524 56-599 Discharge Low Temperature TALL-1524 PAH-1527 PAHH-1527 56-599 Discharge Low-Low Temp. 56-599 Seal Oil High Pressure 56-599 Seal Oil High-High Pressure PAL-1527 56-599 Seal Oil Low Pressure PALL-1527 LAH-1534 LAHH-1534 LAL-1534 LALL-1534 TAH-1544 TAHH-1544 PDAH-1546 PDAHH-1546 TAH-1550 VAH-1503 VAH-1507 56-599 Seal Oil Low-Low Pressure 60-2678 High Level 60-2678 High-High Level 60-2678 Low Level 60-2678 Low-LOw Level 71-2641 High Outlet Temperature 71-2641 High-High Outlet Temp. 60-2677 High Differential Pressure 60-2677 High-High Differential Press. 55-6050 High Temperature 60-2676 High Pressure 60-2675 High Pressure AWD Confidential Controller Indicator Tag PDI-1500 FI-1501H FI-1501H TI-1504 TI-1504 TI-1505 TI-1505 TI-1506 TI-1506 TI-1508 TI-1508 TI-1509 TI-1509 TI-1510 TI-1510 FI-1517 TI-1524 TI-1524 TI-1524 TI-1524 PIC-1527 PIC-1527 PIC-1527 PIC-1527 LIC-1534 LIC-1534 LIC-1534 LIC-1534 TI-1544 TI-1544 PDI-1546 PDI-1546 TI-1550 LI-1503 LI-1507 Set-Point 0.5" WC 800 CFM 900 CFM 130 F 150 F 130 F 150 F 130 F 150 F 130 F 150 F 130 F 150 F 130 F 150 F 225 CFM 240 F 250 F 210 F 200 F 0.5 psig 1.0 psig -0.5 psig -1.0 psig 90% 95% 10% 5% 130 F 140 F 3,0 psig 5.0 psig 200 F 16.7 psia 16.7 psia Type High High High-High High High-High High High-High High High-High High High-High High High-High High High-High High High ....._... High-High Low Low-Low High High-High Low Low-Low High High-High Low Low-Low High High-High High High-High High High High 085686 SL VII.E. Digital Alarm Summary Tag No. Description VBS-1569 VBS-1531 PSL-1533 LSL-1528 LSL-1529 LSH-1535 LSH-1561 LSL-1562 71-2640 Vibration 71-2641 Vibration Instrument Air Low Pressure V-125A Seal Pot Low Level V-125B Seal Pot Low Level 60-2678 High-High Level 60-2677 High Oil Level 60-2677 Low Oil Level Set-Point N/A N/A 60 psig N/A N/A N/A N/A N/A Type High High Low Low Low High-Hieh Jjigh______ High Contact Position Open Open Open Open Open Open Open Open AWD Confidential SL 085687 Vn.F. Indicator Summary Tag No. PDI-1500 FI-1501L FI-1501H PI-1503 PI-1507 TI-1504 TI-1505 TI-1506 TI-1508 TI-1509 TI-1510 FI-1517 TI-1524 LI-1534 TI-1544 PDI-1546 Description 72-821 Differential Pressure Inlet Flow Inlet Flow 60-2676 Pressure 60-2675 Pressure 60-2676 Temperature 60-2676 Temperature 60-2676 Temperature 60-2675 Temperature 60-2675 Temperature 60-2675 Temperature Desorption Sweep Gas 56-599 Discharge Temperature 60-2678 Level 71-2641 Outlet Temperature 60-2677 Differential Pressure Range 0-2" WC 0-400 ACFM 0-1,000 ACFM 0-20 psia 0-20 psia 0-200 F 0-200 F 0-200 F 0-200 F 0-200 F 0-200 F 0-300 ACFM 50-300 F 0-100% 0-250 F ~15Psig_________ AWD Confidential Slj 085688 VTI.G. Digital Input Summary Tag No. ZSO-1502A ZSC-1502B ZSO-1511A ZSC-15UB ZSO-1512A ZSC-1512B ZSO-1515A ZSC-I515B ZSO-1516A ZSC-1516B ZSO-1518A ZSC-1S18B ZSO-1519A ZSC-1519B ZSO-1523A ZSC-1523B ZSO-1536A ZSC-1536B ZSO-1547A ZSC-1547B ZSO-1548A ZSC-1548B ZSO-1549A ZSC-1549B ZSO-1563A ZSC-1563B DI-1520 DI-I525 DI-1526 DI-1530 DI-1532 LSL-1514 LSH-1521 LSL-1522 Instrument or Equipment Location and Description FBV-1502 Open FBV-1502 Closed FBV-1511 Open FBV-1511 Closed FBV-1512 Open FBV-1512 Closed FBV-1515 Open FBV-1515 Closed FBV-1516 Open FBV-1516 Closed FBV-1518 Open FBV-1518 Closed FBV-1519 Open FBV-1519 Closed FBV-1523 Open FBV-1523 Closed FBV-1536 Open FBV-1536 Closed FBV-1547 Open FBV-1547 Closed FBV-1548 Open FBV-1548 Closed FBV-1549 Open FBV-1549 Closed FBV-1563 Open FBV-1563 Closed 56-599 Start 55-6049 Start 71-2640 Start 71-2741 Start 55-6050 Start 55-6050 Stop FBV-1563 Open FBV-1563 Close Contact Position Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Closed Open Open Open AWD Confidential Si S5689 VIII Notes to Programmer 1. The Vapor Recovery System Shut-Down switch HS-1024(SD-2) will return the Program to Step 1 from any higher Step at any time. The Vapor Recovery System Start Permissive switch HS-1009 must be enabled before the Master Control switch is enabled to start the Skid, when this two swiches are enabled in the correct order the Skid will start. 2. Shut-Down alarms in the Program will return the Program to Step 1 from any Step at any time. 3. An enabled controller does not enable the alarms on the controller. Alarms are enabled as noted in the English Language Operating Program. 4. Controllers disabled by the program are disabled only in auto and put in manual, they should not be locked out in the manual mode. 5 Actuated block valves position switches will be on a make contact basis. If a block valve does not go to the position the Program expects it to be, the Program will alarm the valve failed to make the correct position. A block valve enabled will have output, and a block valve disabled will not have an output, from the Program. Position switches on block valves will have a 8 second delay (time-out) before they alarm positioned failed. Some valves failing to make their proper position will Shut-Down the Skid, for the listing of these valves see the Abnormal Operating Conditions section. 6. An alarm enabled in a Step of the Program will remain enabled throughout the program, unless noted otherwise in Program. 7. All digital input alarms and analog alarms will have a 3 second delay (time-out), unless noted otherwise in the English language procedure. AWD Confidential 085690 SL E83 VAPOR ABATOMNT BAROE LOADING VIII. Process Control Diagrams WHlATK^lilANUAi. SECTIONVItl AWD TfSTOBSfS Date : M/Ot/93 Authors : L Brandstetter Revision: 1 Page : 86 of 66_______ AWD Confidential SL 085691 PPG Imdustri Lake Charles, Louisiana Sorbathene Unit AWD TECHNOLOGIES, INC AWD TECHNOLOGIES HOUSTON. TEXAS i ! I SL 085^92 <mD- 60-2676 60-2675 (60-2675) ---------------- ------------------------------------------------------- ------------ (7TM>(5^9) PROCESS DIAGRAM CONFIDENTIAL - PROPRIETARY! THIS DRAWING AND AU. INFORMATION CONTAINED HEREIN ARE THE PROPERrr CF AWQ TECHNOLOGIES. INCORPORATED. REPRODUCTION OR TRANSMITTAL IS PROHlSITEO 56-599 ~1 71-2641 L- __ .1 Tfi60-7677 60-2678 STEP BES V-IM(C-2SK) 1- 2 3 4 5 7 t to SYSTEM STEPS D ! * ; t ' VALVE POSITIONS HUEfUW) SIMULATION CASE FBV-15CJ fBV-ISlI irBv-ISI RBi --1519 FBV-1SI2 fBV-1513 FBV-ISlS FBV-IS16 FBV-154 FBV-154T FB--1436 -- -- - - - - ---- t 1 ! J 1 1 ! ILK {*/* * iroffl roo pffTtoJU. OT* AWD TECHNOLOGIES, INC. AWD PROCESS FLOW/CONTROL DIAGRAM SORBATHENE UNIT CUSTCUEP PPG INDUSTRIES. INC * HLAiBEH 6AQ1 SL 085693 ] general equipment ROTARY fMM>. CLAft Pump. LOBE pump Oft POSITIVE displace**:*! An-OPCRAlED OMMtAO< PUMP positive-lwspocemen r PISTON PUMP suup pu**> ccntrfxcal sueucRsetE blower on Fan (crNrarucAL) VACUUM PUMP pr-oc vchtk>l gentrfucal pump HORIZONTAL CCNTRFUG*L PUMP o{a]< S**CLE (HAPHRACU PUMP ^O positive displacement PRESSURE VESSEL ATUOSPtCRfC TAWt STORAGE Tank 1 BAG OR CARTROCE FLIER -0" w-tMC luenicATOft MOOULE BREAK 'Y* TYPE STRAHER CCNICA1. START -UP STRAINER rn st AM r=l AP (aBBREviaiui fORu of 0*FV3JPATK>* BELOW) fOJlPMfKS PACXACt ouivue INSTRUMENTS electrical, signal SOFTWARE'Da.'A <,** pneumatic skxal hydraulic sjcnal CapllaRy MSTOLMCNT ANALOG SCmai PfSTRUMEffT OICITal Signal INSTRUMENT fLXTMISKO fly EOUPmEhT PAOCAGC VEtSCR HSTRLROfT FOR SMGLC MEASURED VARIABLE AMO AMT NUMBER of FUNCTIONS. MSTRUMCNT IS LOCALLY MOUNTED. frcmt or maim panel mounted MSTCftjUCNT. MOUNTED N LOCAL PAfCL (FCLD) MOUNTED * CONTROL ROOM, REAR or PANEL WPUT TO OR OUTPUT FROM PLC computer function LOCAL KSTRUhCNTS FOR TWO MEASLKCD VARIABLES SWAftHC COMMON HQUSMG, OR MORE THAN OE FUNCTION FACE OF PANEL OR CONSOLE MOUNTED ttSIRUMCNT TWO MEASURED VARMOLES OR MORE THAN <X FUNCTION. CRT OtSPLAT X - E - FLO* ELEMENT ORriCE PLATE X - O - FLOW ELEMENT INSTRUMENTS PRESSURE RELCF OR SAFETY ValvE PRESSURE/VAQJUW RftCF valve RUPTURE OCSK OR SAFETY KaO FOR PRESSURE RELIEF JP RUPTURE DISK OR SAFETY KAO FOR VACUUM RCLCF JJ? pressure /vacuum relief uanhqlF COVER ABBREVIATIONS a| - analog txptir AO - analog output AS - AIR SUPPLY Oi - CWGITAL MHIT DO - OICITAL OUTPUT ES - Electrical supply HS - hano swrroi 1A - MSTRUMCNT AJt CSC - Car SEAL CLOSE (LC) CSO - CAR SEAL open (L O ) fC - FA* CLOSED ECS - Fal CLOSED- manual RESET FO - FA* OPEN FOR - FA*. OPEN - MANUALRESET NO nC MU. M.L LU SC SO SP (0) (V) - normally open - NORMALLY CLOSED - MO* LIQUID LEVEL - NORMAL LKXTK) LEVEL - LOW LKJUD LEvCL - SAA*>LE COMCCTIOH - STEAM OUT - SET POPTT - ORAN - VENT FA>. POSITHXS FA*JUR MOOC FC - FA*. CLOSED (ASSUMED) fo - FAI FB open ri - fa*, mx.tochma.te fl - fa*, loozd solEnoc valve ELECTRIC ANALOG SIGNAL JO PKUUATIC VALVE MTH r/P CONnEHTOR AND P0SITKRC8 'GHE8AL PIPING SPEC BREAK PttUAAY PROCESS FLOW SECONDARY PROCESS. FLO* FAEHATKW OR SONIC SIGNAL (WITHOUT WM4C OR TUBHC) FIXED CAPRXARY TUBIMC ELECTRIC ANALOG SKMAL TO PKUMATK VALVE MTH i/P CONVERTER DWCCTKN OF FLO* HYDRAULIC PPM (TOP Of V NDICATES FLOW WRECTICW) ESPAKSAX JOPTT PIPING SPECIFICATION iXGENO P - 12" - 106 - 6C (3" C) T T^^ 1 TPACPC Pipe -INSULATION TYPE ' COLD h - MOT PP - PERSONNEL PROTECTION fT> . FREEZE PROTECTION FLANCE RAlMC a - ISO/ amSI R f. a joo/ ansi nr C - 00# ANSI RF 0 - 000/ aatso n r FUIO TYPE u - pistrukni ar FC - FUEL CAS A - ACD p - voc S - STEAM w - WfATER C - CONOEMSATV PW - POTABLE WATER V - VAPOR AA - ATMOSPKCE AJR insulation ThocK.SS AlTRTAt SPECIFICATION C - CARBON Situ 0 - OCRAKJWC E - HOPE r > rep duct wow 1 - CAiVANttCD CARBON STEEL L - POLYPROPYLOC LMEO CARBON STEEL H < pmqF (TKAR)w p > pvc R - CP>C s - MICH TEMP CAR8CH STCtL 6 - Jl ST*P*SS STEEL N-UE NSTHIACNT (FLOW} AMRI6AR FLOW SENSOR | UML-H1ERNAL BALL FLOAT PtCUMATC OLKXJC posmcw. FOR ELECTRIC WITH SOJENOO VALVC. ACTUM 10 FAR. NOIMTIC FAftJJRE 3 .--<> RESET (OPTIONAL} SOLENOC VALVE QLHQC OQHMECT/tKSCONHECT COLPLMSAXEXiaLE HOSE SAMPLE POUT X s> ^5) BATTERY LIMIT MEASURED OR MJ11ATMG VARIABLE JOENirnCATION LETTERS mootc* READOUT OR palSstve fvpctkm SUCCEEDMC LETTERS OUTPUT FUNCTION MoartR A ANALYSIS ALARM 9 BURNER FLAME CONOUCTTVTFY C (ElXCmiCAO 1 DENSITY (MASS) 0 OR SPECS1C GRAVITY OrFCRENTUf. c VOLTAGE (CUT) USERS O40KC USERS (HOKE CONTROL SCHSO* (PRIMARY ELEKHTJ USERS CHOKE aostD PRESSURE DtRECT--CONNECTED 1 WITH DIRECT--CONFCCTED DUPMRAU SEAL TTCAaOCOuPLE and nCMOWELL u - ultrasonic C - CAPACITANCE 5 RTO ANO THERMOWELL MAOCTIC FLOWT mEIER Jg PRESSURE REDUCING REGULATOR TIT CONTAFED ( - SET PRESSURE) BACKPRESSURE REGULATOR SELF COHTAMD ( - SET PRESSURE) <LAM ARRESTOR AS - MSTRUUCMT AJR SPLY G/S - GAS SUPPLY HNSTS//SSM----HSYKRDTEANRTMOAEUCI*LESSINCULPPfSPPUJLLPfYYfK) Y VALVES CxJ CJ r-j * CATE VALVE D1APHRAM VALVE CKCX VALVE NEEDLE VALVE R/SLEED ca tea o*o GLOBE VALVE BALL VALVE PLUG VALVE t-o r^j 4 PNCH VALVE BUTTERFLY VALVE ANCLE VALVE BARE STOCK MULDPORT VALVE *P 4 WAY VALVE (SOLENOID OPERATED) (B-^3 3 WAY SOLENOD T PNEUMATIC OR HYWAULIOlAt OPERATED SUX GATE. nB (H7771 MAMJAL SLUE CATE. LOUVERED DAJJPCR MTH OPERATOR 17771 LOUKRED OAjiR J> 03NTMJATKM SYMBOL |--txn-<0 UNE DRAM WITH VALVE AND SCRCYCS CAP OR PLUG. PPC REDUCER A SPRAY WOZILE /ms. s Nome OCSIOATVX (X - NUMBER) (Y - SIZE) PPC MSULATION 2 r -------- R--------- coupkkt msulation ATM09KTTTC VENT HPE FLANGE ------------------- -------------------[J %JNO FLANGE tELCED CAP [3--{hose connectton ----------------- K] SCREWED PLUG OR Cap ------------------------- hA.T TRACR4G (FOR TYPE see p**fc sPtciric*noN leccnc> r IUN RAX RAUD (FRACTION) G CACMC (OHENSKMAL} KMO (WHMIT H PdHated) GLASS 1 CURRENT (EXECTRSCAL) M31CATE J POWER IVX on TRE- K schoxju: L LEVEL MOISTURE CR M HUMomr SCAM TIE RATE OF CHAMCCI 1 MOMCNT|AftY LKHT (PtUOT) M USERS CHOICE o USERS CHOICE PRESSURE OR p VACUUM QUANITY OR o EVENT R FLMMOACTIVirr SPEED CH S FREOUCKCY MTCGRATE OR TOTALIZE SAFETY USERS CMCMCE ORFICE ' (RESTRICTION) PORfT (TEST COHtCCTTON) RECORO OR PflXT T TEUPCRATliRE u uuLTCVARJaA_ V VSRAnOH WEIGHT OR . FORCE ___________ j_______- mul i mjnchon WELL X UNOAlSSTTED EVEN T.STATE V OR PRESENCE X ASS ' T AXES UNCLAssrai z POSITION Z AXIS HICM CONTROL STATION USERS CHOKE LOwr WDCCC OR intermediate USERS CHOICE OPEN SWITCH TRANSMIT UULUFUMCDON VALVE DAMPER OR LOUVER MULTIFUNCTION unclassrto RELAY OR COM+vn, CONVERT DRIVE ACTUAL OR LtNCLASStFED FINAL con ran nruiNi UMCLASSJFED CONFiDENTiAt - PROPRIETARY THIS DRAWING ANO AU. INFORMATION CONTAINED HEREIN ARE THE PROPERTY OF AM) TECHNOLOGIES, (NCCWPORATIO. REPRODUCTION OR TRANSMITTAL tS PROHIBITED REFERENCE DRAWINGS AWD TECHNOLOGIES. INC. AWD TECHNOLOGIES P&10 SYMBOL & LEGEND SHEET SORBATHENE UNIT cusroues PPC industries. Inc joe rruueen 6A01 NONE DRAW1NC NUK3CP 6A01 - F-100 085694 cn r CONFIDENTIAL - PROPRIETARY1 THIS DRAWING AND ALL ]Nf ORVI ATION C0N7AJNE0 HEREIN ARE THE PROPERTY CT AWD TECHNOLOGIES, INCORPORATED. REPRODUCTION OR TTJANSinAL tS PRCHIBETTD *< KMO MamC nv REFERENCE DRAWINGS i SL 085695 aa fi n*/x i Mt-OKCHKS "OBEH MWtOV oTS ATS Dn/H qsjcd ro DMnjcnw *vatNT APP'D CRA'W oestcH 0Y 0V o*ro o*cs fl^VTStD W-U-fl W-O-1] 0*T ! AWD TECHNOLOGIES, iNC, AWD TECHNOLOGIES EQUIPMENT LOCATION PLAN SORBATHENE MODULE CUStOuCR PPG INDUSTRIES. INC -* WJwSfft 6A01 SCALE _ V? =1-0 1 ORAWMC NUV9D? ,,,s, | pTv 6A01 -r>- ? elevation *c - c~ CONFIDENTIAL - PROPRIETARY! THIS DRAWING AND ALL INFORMATION CONTAINED HEREIN ARE THE PROPERTY OF AWO TECHNOLOGIES. INCORPORATED, REPRODUCTION OR TRANSMITTAL IS PROHIBITED muwc wca REFERENCE DRAWINGS WMM ITU in WT. IM/tl CLENT *PP0 DRAW Br aesiOf er CH*0 CNOt a REV fw omwchoi PCASED 'O--<B--*3 0J.TC A TO TECHNOLOGIES AWD technologies ! INC EQUIPMENT LOCATION ELEVATION SORBATHENE MODULE CUSTOMER ppG HOUSTBITS INC. joa MUfcafB 6*oi vr=f~o" OftAMIHC NUM00J 6A0I-P-TOO 085697 CONFIDENTIAL - PROPRIETARY! THIS DRAWING ANO ALL INFORMATION CONTAINEO HEREIN ARE THE PROPERTY OF AWO TECHNOLOGIES. INCORPORATED, REPRODUCTION OR TRANSMITTAL IS PROHBITEO. REEERENCE DRAWTNCS plan Pt-am I'W nc in rrmc r-iv-.K\ SL 085698 HO IE: i raniCAioR to mcmx Hio poini VN rs AMO low ^OfHT OHAMS (see pphc spccrw>nc5) AWD TECHNOLOGIES, INC TECH NOLOG TES' I PIPING PLAN SORBATHENE MODULE CUSTCJUEB PPQ INOUSmiES. INC I xe N-jrnecft 6A01 "l~0O, SAO'-P-^P 1 "tV I i ELEVATION "E - E" NOTES i *'Ca6ntsica*hio> to low pflcMoc high powi mams point {SEC PPIHC SPEOFtCATKXSJ 60-7678 CONFIDENTIAL - PROPRIETARY THIS DRAWING AND ALL INFORMATION CONTAINED HEREIN ARE THE PROPERTY OT AWO TECHNOLOGIES, INCORPORATED. reproduction or TRANSMITTAL ES PROHIBITED Mn otiinc mu REFERENCE DRAWINGS SL 085700 so ft m rt (X> m CLIENT AJ3P0 DUm BY cesec* BY 0*^0 Ou cm Ou {NCR 3 MB tf gi*g * um MB HXfR ham Aa 1 w *iaa m3' Ti-ijx 1 iQ/a/s O tssxs fo* onsmjcTm n/ea/n "tv ptvtscd 0*te AWD TECHNOLOGIES, INC TECHNOLOGIES MODULE PIPING elevation "B-B". "D-D", "E-E". & "F- F'' __________________________ SORE A THE NT UNIT___________________ CUSIOUEF PPG INDUSTRIES. INC rn UP0tR 6AO! scaal _ _ V; = i -0 I >:>.'**"*' mpleboi ,, [ GAOl -P- 510 CENTRAL motes i occrRicAi AREA cLASsnouicN - class i DtvtswN a. crop xr r5Lici*iwirer/27iT*mr&!^^ ui *u *o*t sh*i cofn w fn u*.rtsT etnn> of ik utunh elecn?cal mx_ L OOCK SLAB W*U. flt KSUU1D * C LETT OFR to A `AIAIIX :BUK9HUMuC is kim rap or cmxii 4 ALL COKMT AW fTTIMS WALL BC M6R0Y BCD' (UNlSS OfhCJWtS W3IQ) i ALL Flit CCKRJIT 9UU BE tWlEY. (LKCSS OMMS M3IED) t cooir amrr axes skai be yobaot me ram e sercs. I ANT CMCSTDNS fOnAHMC 10 NSTALLATOt Of NOW CX TK5E MaKS SHALL ec orcccd iq k ac nao coxomkr d ewiuefOR io (ja au pakls r tjc cn tamon tooncM onuk i oowsucrafl w njsww mo ksuu au ukplaies cm au Etienne*. courmifT per ewes, io. con hactqa io njwsi ao ktni ml nmciacs on au mcs. 1^^ uaieiim WAU BE BRACT HA.T-3*WC SjOXI IT CALVAffUED OR VOtCAMC C COAIED SLITICES GARACED BT CR&LX CSWWC. 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Sltt Apr CROAC *30 CKXPC cu [ IPCHCATES s -0- CROUrO CABLE SlUB-Oui ABtHE CRAOC OR C0t<JTC T FQR FUTURE CONNECT ION TO COLT I Pi~0< T OR STRUCTURE SIZE *S NOTED. chopo c*ai iaa cn cokciion ___ ^0 (KUOK la HSUAIED <SStl caLimorT oopowc ELECTRICAL PLAN SYMBOLS POWER AND CONTROL CD o OCTAL MJW8CR - REFERENCE: APPLICABLE OKS. JUNCTICH 90* TnwyORwOL panel - START/5T0P EhCLOSL^E: AUEN-BRaOLCY NCMa 7 Otv IE explosion Pftoar. mra thru connection MOMENTARY `STAnr BUTTON. *CUA 7, OIV. II. I N.0./1 N.C CONTACT UANUKD "STOP" BUTFO, NCU* 7. OFV (L 1 NO./I N.C. OfTACT 0. PUT BUTTON ENCLOSURE; AUEM-BAAOLEY. NEVA 7 OTV EXPLOSION PROOF - MOMENTARY PUS* BUTTCM UNIT NCUA 7 CIV. U. 1 N.O./1 N.C CONTACT HL - HANG--OFT-AUTO ENCLOSURE. AlLEN-BRADlEY. NEVA 7 OTV EXPLOSION PROOF, mn thru CONNECTION 3 POSITION SELECTOR S11CH UNIT. NEMA 7. OfV IL SPRING RETURN FROM LEFT POSincH; I H.O./S N.C CONTACT U 151 NAND-OfT-AuTO ENCLOSURE alLEN-BRAOL-TY. N[UA ? oiv n EXPLOSION PROOF, rrtD THRU CONNECTION PocincN stucciow s~-,:o -^ir new* i oiv MAINTAINED POSinCM 1 AT O./l WC CONTACT CONFIDENTIAL - PROPRIETARY* THIS DRAWING ANO ALL. INFORMATION CONTAINED HEREIN ARE THE PROPERTY Of* AMD TECHNOLOGIES, INCORPORATED. REPRODUCTION OR TRANSMITTAL IS PROFITED OB it-- K MMO RETFCRENCC DRAWINGS wine m/ TJG rx MAW MAW CLCM ORANN OCSICN APPT> BY BY OW'D rnc i 0 REV REVISED C SWTCh REVISED SL 085701 -1/93 *rt AWD TECHNOLOGIEjS, INC. AWD TECHNOLOGIES 1 electrical SYMBOLS ANO LEGEND SORBATHENE UNIT CUSTOMER ppc INDUS TT?CS. INC. JOB NUVfeCR 6A01 none: OQamxnC MUU9CR 6aoi -r-00* NOIfS 1 CP"Oj[l 0 *H> su CD~fO^ <D CCK*M WJKi w 1 OKL T If* *C00* *D DJO*S < OSSBX. r> lCu SCO! *0 B DMUCM OOATX. 3 OXUf C rfTIMC Oa*<XC 1K>U. CD^O*. H3 CTK** '5TT II (tac U-(-*h COO Ml SIZE 1 7* l _fc_ * 6 -I- QpQjfT soromf n*au d c*W D Wrr W) cafetv 9ct"kr Acs rn M-WH TQ ' 50-7T5J - VACUUM PUM> HOIOft sa-?T - vacuum njw> Waco* 50-77SJ - os cwatAncM am> mojor 50-i?S5 - toe (tcD'orr tamc wofan 50-7W - coc NECoerr cocun a own hotoh SO-77M - OA COOLER 010*01 WOTCR ~ EASIER COKMOL AW 0UT7OH ROMMKS 4M PeCR 0ov *o*ca/ijov cnMOta CONFIDENTIAL - PROPRIETARY1 THIS DRAWING AND ALL INFORMATION CONTAINED HEREIN ARE THE PROPER TV OF AWO TECHNOLOGIES. INCORPORATED. REPRODUCTION OR TRANSMITTAL IS PROHIBITED 6AOI-E-0CI 6AOt---100 srueots amo leceno Out--LHE QLAdtAU 6AOl--7tO IMSTAUAIKM OE1ALS 6AOI-C-600 Mimic ium ELECTRICAL SECTIONS nuwc imr REFERENCE DRAWINGS TX TX OOAWH aPP'0 er TX TX BY HAW HAW UAV UAW O*K0 EMC*? 2 1 O REV REVISED VC' SWITCH ft CONDUIT REVISIONS FCA CLASF1CATK> ROWED n/92 10/16/9? 0*1E I SL 085702 TECHNOLOGIES, INC AWD TECHNOLOGIES ELECTRICAL OVERALL SKID PLAN SORBATHENE UNIT {NCcustoner ppc industries. scau 1/2 = 1-0 DRammc WM9ER J06 MjWaCR 6 AO! ,. 6 aOt -- E 1 - MOTOR CONTROL CENTER (RY OTHERS <8QV- 30. 60 H? \ NOTES * m*no switch surims shall be installed *S Show Oh ORawmc *0i-E-O40 amo ORMNC 6A01-C-3IO 2 AOIVOuw. HANO SWTCKS SHAU. 8f SPtCWCO Of NamnC (ACt-E-OOl. i "wjn H*at' oicrtAL output n>o< nc shau QC wWCD TO ENABLE OUNNINC of kOUMS h T*C "AUTO* POSITION. CONFIDENTIAL - PROPRIETARY! THIS DRAWING and AU INFORMATION CONTAINED HEREIN ARE THE PROPERTY Of AW3 TECHNOLOGIES, INCORPORATED. REPROOOCnON OR TRANSMITTAL IS PROHI8ITED 6A01 -- --001 SYUSOLS AND LECOCI SAO1-E-030 <X-LNE OIACRAM 6*01---210 EN**K MMO jkstallatxiw oeiAtLS RAwe nvr REFERENCE OR aWINGS SL 085703 UAff TjC MAW TJC CLENT APPtk 0RAVN err CCSor er o*nj UAW UAW ENCTT RCuO'nCD WASTER CCHT. Sw A NOTE 1 CEfCRAL 400riCATI0NS 0 rev revised 11/92 OatI j AWD TECHNOLOGIES. INC. AWD TECHNOLOGIES 480V ELECTRICAL ONE-LINE DIAGRAM SORBATHENE UNIT customer ppc ENOOSTRSES. INC SCALE NONE DRAWING NUMBER JC 6*01 ,, _ [ *tv 6 AQ1 - T - 100 r -> NORMAL operating SEQUENCE (shuioowns woi smown> CONFIDENTIAL - PROPRIETARY* THIS ORAWNG ANO ALL INFORMATION CONTAINED HEREIN ARE THE PROPERTY OF AM3 TECHNOLOGIES. INCORPORATED. REPRODUCTION OR TRANSMITTAL IS PROHISITEO NOTES ANO ALOCX VA!.\t LBV-1363 085704 Sli AWD TECHNOLOGIES, INC technologies PROCESS CONTROL VALVE SEQUENCE LOGIC _______ ______________ SORBATHENE UNI customer ppG INDUSTRIES, INC jce number 6 AOI SCALE NONE DRAWING MJU0CR K>16AQ1- I rv LEGEND - CLCC'&KX. [MSrauufNT - LLCCTHICAt ICuCKflATURlCUuEnI Cxi - automatic CQHmoL/atoot vaivc ^ - coouir njttNNC com CONFIDENTIAL - PROPRIETARY* THIS 0RAW1NG ANO ALL INFORMATION CONTAINED HEREIN AR THE PROPERTY OF AW3 TECHNOLOGIES. WCCftPORATEO. REPRODUCTION Ofi TRANSMITTAL is PROHIBITED REFERENCE DRAWINGS OB/m; mil REFERENCE DRAWINGS 6A01-I-4OO 6A01 -l-*OI 6AOI-I-402 6A0l-1-*03 mstruwckt junction bo* ue-ioo IR>4C DIACRAM ClTCTRICAt. JUNCTION BOX CJB-lOO WIRMG OlAGRAM rtLD MRHC OISIRBUTIOH OIACHW r(u) wifljktc otsnajTxw diacnw SL 085705 A.AM KAJJ KAM KAM KAM KM* TjF TS TS IS IS TX arHT APPO URAWN 0V OCSJGH 0V CNtCO OCH 3 CHANCED TAC NO A AOOCD SWITCH U/0*/M 1 REVISED AS NOTED 10/22/93 0 FOR CONSTRUCTS^ lO/S/92 FEY RCWSEa OATE j AWD TECHNOLOGIES, INC AWD TECHNOLOGIES INSTRUMENT LOCATION/ CONDUIT PLAN sorbathcne unit CUSTOMER ppC fNDOS TRIES. INC. JO0 MUM0ER $a01 Va" = C-0" l ORawInG wjwBCS GA01 - -200 IJ6--100 \I 1ff^in2 I II I 1 NOTES: CONFIDENTIAL - PROPRIETARY 3THIS DRAWING ANO AU. INfORWATTON CONTA|N0 HEREIN are ive pROPEfirr of a m technologies, incorporated REPRODUCTION OR TRANSUlTTAL IS PRCHBITEO RHTPfNCE DRAWINGS SCC owe. WH-I-4Q3 set Owe *MS\-V-4C2 REVISED AS NOTED ran cxxsTRjcnaN REFERENCE DRAWINGS 6A01-1-200 ISTRUUWT LCCATW/CCMXIII P"LAM 6A01-I-300 U6-100 ASST OCTAL eAOi-i-4o? held MRtNc orsmourK* oeacaav AWD TECHNOLOGIES, INC TECHNOLOGIES SL 085706 INSTRUMENT JUCT10N SOX IJB- 100 wiring diagram SORBAIHENE UNIT PPG INDUSTRIES INC. 6xfi wjwacw A,ot NONE { ooawinC ia/90* 6A01-3-4QO CONFIDENTIAL - PROPRIETARY! DRAWING AHO AU. CONTAINEDTHtS ARE O A IES.THE PROPERTY INFORMATION WO TECHNOLOC HERE IN WCOPPORATEO. REPRODUCTION OR TRANSMITTAL IS PROHIBITED imar* RfTTRTNCE DRAWINGS ou< mi NOTES: SL 085707 i REFERENCE DRAWINGS | 6*01-1-mo nsmjuCNt ux>.TiaN/conduit 6*01-1-310 E.JB-IQ0 ASST DETaK 6*01 -1- *0J HELD WWHC OJSniBUTlOW DIAGRAM K U. K.IL IB. KJ4. KM ta T^r. TJf tot I.J.F. I.JJ7 IJ.F. ORaw ock> CMK'li twca APP"D IJT er 2 8CVT5E0 TAC NO k AOOCD KS-1570 "A>*f92 flFWSCD AS NOTED >0/?6/92 0 FOR COrSIRuCTIOK 'O/S/92 RtviSCO D*rt I AWD TECHNOLOGIES AWD TECHNOLOG ICS ;NC ELECTRICAL JUCTION BOX LJB-100 WIRING DIAGRAM SORBATHENE UNIT Customer ppG INDUSTRIES INC wwaffi 5*01 scajx NONE DRAWING NUMBER 1 6A01-l-*0i 1 - FOR COHHNUaTICH SEC owe. 6*01 -1-400 ron CCrwTINUAJIGN SEE 0"*C 6*01 -- I --*00 NOTES: t. COL * TAPE ALL SHCLDS AT f CLO OfVICE. DO HPT CROUfgL CONFIDENTIAL - PROPRIETARY1 THIS DRAWING ANO AIL INFORMATION CONTAINED HEREIN ARC THE PROPERTY OF AWO TECHNOLOGIES. INCORPORATED. REPRODUCTION OR TRANSMITTAL IS PROHIBITED *< HMn crrrprNrr np awtncs REfERENCE DRAWINGS 6*01-1-TOO Aoi-i-*oo INSTRUMENT tOCATTOH/COMCMJTT Pl>N instrument junction eat ue-ioo wtfTMC OlACft*** \ e.cKU fl-C. t-lf. ecK.U B.C. T.af. 0 atNT OftAVM ccsicn CHATO EHOR RTV wo er ef fiEVtSB AS NOTED for a>*sTRucnian REVISED SL 085708 *0/22/82 10/5/92 DATE | AWD TECHNOLOGIES, INC. AWD TECHNOLOGIES FIELD WIRING DISTRIBUTION DIAGRAM SORBaTHCNE UNIT CUSTOMER ppC INDUSTRIES INC. FD6 huuR gACI SCALE NONE 1 DRATNG MUU0ER | ] <?tv 6AQ1~1-ir? 1 i FO0 CONlIMJATIQH SCC 0n moi ~i-*01 FOR COJISOATIOM SEE 0G. 6*01-1-401 |g)|0|0i o C Me LSH-1521 SET TAB, SVE SWI1CH HK V-i563 i0|0l0| ; i 21 4 S6 ZSC-1S49 I ZSO-1549 I<2>l0l0l c c LSL-1522 SO FAIL SAFE SWITCH LOW : 10|0|0( . LSH-1561 SO TAIL SAFE SWITCH HICH |0|0|0| LSL-1562 SlT Fa*. SAFE SWITCH LOW I0I0I0I : NO c w * PSL-1533 J EV-1523 CV-IS1* --<- > ZSC-1519 1010101 1CHO ISL-1514 so Fa*, safe SWITCH LOW 1010101 W C NC LSH-1535 so fail safe SWITCH H(GH -- L-1S35 EV--1519 EV-1SI6 --I j ZSC-ISI* EV-1516 1010101 -1516 mmm EV-1549 EV-1511 EV-1547 EV--1502 EV--1515 1010101 t 23 ZSC-1515 EV-1518 i 10' 1021031 ZSC-1518 -ISIS NOTES: AU. UNIT SWITCH CONTACTS AflC SHOW WITH VALVE IN ITS FAA. POSITION, I0l0i0i : CONFIDENTIAL - PROPRIETARY1. W S ANO CONTAINED1 DRAWING AU INFORMATION HEREIN ARE THE PROPERTY Of AWO TECHNOLOGIES. WCORPORATEO, REPRODUCTION OR TRANSMITTAL IS PROHIBITED I0I010I KO C KC V0S-1531 CJKANKC KMOX REFERENCE DRAWINGS 1RMK ITU EV--1546 |0|01^ EV-1512 ' 2S ZSC-1512 *S6 ZSO-1512 REFERENCE DRAWINGS *AOr-l-200 6AOI-I-L01 TrSTnuuOri IOCAUON/CONDUIT PLAN I: ! CmC*L JUNCTION BOX Jl K; WtrC DIACRrur EV-1536 1010101 NO C NC LSI-1529 I0i0l0l HO C NC LSI-1528 | 1 1 KM. K.M. e.c. 0.C. 0.C. T-JLF. j0.C. T^if. 2 1 REVtSED AS NO TEE n/04/92 W;*4C RVTSiOTS/CLAR FCA rK>-S S0/7I/92 K. a.c 8.C. ] TJ.F. O FOR CONSTWJCIt '0/5/92 ORAM OESOl 0*15 | OCR APR 0 er 0r RTvraro OAlt ! AWD TECHNOLOGIES, INC. mas Uf ITCHNOLOG if 5 SL 085709 FIELD WIRING DISTRIBUTION DIAGRAM SORB ATHENE UN fT PPG INDUSTRIES INC. J06 NUUBtfl 6A0T NONE DRAWING NUUBOI EA01 - 5- <0 5 I 0 CONIJNUCO Om 0*C 6ACH-J-60* LEGEND COC.M. CCWlWOL TCFurlNATIOl f tLD TEPMINATKX XXI xxxx CXIERkaE DEVICE W1ERWAE TO PIC O0O TM" O Jf O MC CONTACT HO CCH1AC1 o-cyTTMi MOTcw/cot. NOTES: i. urn s*ttch contacis are 940m wrrw vj*avc h rrs r*t posttoh CONTINUED ASOVt RIOT CONFIDENTIAL - PRnPRTFTa p yt THIS ORAttlNG ANO AU, INFORMATION CONTAINED KRtN ARC THE PROPEUrr Of AWO TECHNOLOGIES. INCORPORATED, RtPROOUCTTCw OR TRANSMITTAL IS PROHIBITED HJWIC hmu REFERENCE DRAWINGS CMMWC TnLT REFERENCE DRAWINGS AOT-h-101 **01-1-600 IAOt-l-601 **01-1--601 vaj.ic scoucno; lock: LOGIC LACOER DIAGRAM LOGIC LAOCCR DIAGRAM LOGIC LAOCCR DIAGRAM I.OCIC 1WVTB ntACPMJ SL 085710 CM. ICU. ac 0C CALPEpN-DT DRAW BY BY TJJ1 a.c TJLf. ac CHAT) CHCH 1 0 REV REVISED LOGIC FOR CONSTRUCTION REMSCD U/M/92 10/2/93 oate | ATO TECHNOLOGIES. INC. AWD TECHNOLOGIES INSTRUMENT LOGIC LADDER DIAGRAM SORB A THEME UNIT CUSIEUER PPG TNDUSTRES INC. job wjwecfl 6aoi SCALE nonc CRAVING NuuBCR 6A01 -1-604 cmnwco on Dwc 6*01 -- 1--60? LSH-1561 1 - o- tf o - -O- 0^16^0-^- VSH-1S64 -O - o K 0-0- CONTINUED BELOW LEFT TR170 HH FROM 50-7754 JUJXUART CONTACTS t-O - O---11---O- - -Q-* -O-^^------------------------------ ------- --|------ <k^x--j--o^aL oxthuco ecLOw left LEGEND ------------------- - SOFTWARE --------------------- M7EROOM4CCT O LOCAL CONTROL TCFWJNaTTOh FIELD TCRWRunON XXX ItXXX EXTERNAL DEVICE XTERKAL TO FLC RELAY ' TT? ^X. FfcCfi O-----Jf-- ^ CONTACT O----- 1|----- O NO CONTACT O-nmn-O UOTOR/COt V91-1UI --Q - o if o--0- ------ TR17Q HI--( FROM 50-7751 MIXHJART CONTACTS *-0 --O------- o--cH TP1TO >--II--C FROM SO-7752 AUXUAKY 0X1ACTS O - -o--II--o - -CM -fh ^r LfROU 50-7751 njxiiary ctXTAcrs > - HH - O-1 a sec ---1 171.I75177.1J9 iu -0^171^0" -o^7^o^- CONTINUED ASCM RIGHT CONFIDENTIAL - PROPRIETARY1. THIS DRAViONG AND ALL INFORMATION CONTAINfO HEREIN ARE THE PROPERTY CP AMD TECHNOLOGIES. INCORPORATED. REPRODUCTION OR TRANSMITTAL IS PROHIBITED W*"< 4** rui.wc mu 1 1---------- *s]xh<^^>o-------------- <x^^o- -0^0^" ------- NOTES: 1. Um SWITCH CONTACTS AAE SOW WETH val\c m ns fax PosmoH amw -<^JM7>0------------ REFERENCE DRAWINGS CADI-1-101 6A01-I-600 6IAtZJ7'I -1:-6K01? 6AQ1-I-604 VALXE SEQUENCE LOCJC LCCIC LA00CR DIAGRAM lock: iadccr diagram ^ock. laodcp d:acra*. LOGIC lADCE.fi DIAGRAM CONTXUCO A&OVE RIGHT CONTXUED on O'WG 6401-1-604 SL 0&5T11 K.U. K.U. &C B.C. n riti raw rrsxx rjr. TJT. . __ e.c _B.C 0 REVISED LOCK FOR CONSTRUCntX 11/11/92 10/7/9? AWD TECHNOLOGIES, INC. INSTRUMENT LOGIC LADDER DIAGRAM ________________________ SORBATHENE UNET___________ CUSTOMER ppc INDUSTRIES INC. ^ ****&* 6A01 r^r TRIJ6 >--!i--< CONTINUOI Aficvt RIGHT CONFIDENTIAL - PROPRIETARY! THIS DRAWING ANO ALL INFORMATION CON TAWED HEREIN ARE the PROPERTY CP AM} TECHNOLOGIES. INCORPORATED REPRODUCTION OR transmittal is Prqh&CTEO. ccmtmjco ecLOw ixn cohtmxd eeicw icrr LEGEND HTtRCOH^CT LOCAL CONTROL TDUW*TK3N rcui icrumtiok CxtlRnal Device NTITNA TO PtC (?) " o---- Jf --O HC CONTACT o-omrv) wotorao*- NOTES: 1. IWfT SWITCH CONTACTS ARE valvl * ns r#4L position OXT1MJEI] ABGve RKXI Thip. REFERENCE DRAWINGS 6*01-1-101 6*01-1-600 SADI-1-601 *A*mGi--iJ-6-*0043 VLVC SCOUCNCE COCK LOCTC LAOOCR OlACRAU LOCK LAOOCR DIAGRAM LOCK LAOU.A DLaCmam LOGIC LAOOCR DIAGRAM CONT1HULD on DVC 6*01-1-603 SL 085712 REVISED LOCK FOR COfSTROCTTON 10/23/93 AWD TECHNOLOGIES, INC Atfifufli INSTRUMENT LOGIC LADDER DIAGRAM SORBATHENE UNIT OJSTOUCR ppG INDUSTRIES INC * nuukr 6A0i CONTMUCO ON o*c 6*Ol --t--600 r -------------------------- %___________________________________________________.A,_____________________ conukuco above Riot CONFIDENTIAL - PROPRIETARY! THIS DRAWING ANO ALL INrORWATlON CONTAINED HEREIN ARE THE PROPERTY Cf ANO TECHNOLOGIES. INCORPORATED. REPRODUCTION OR TRANSMITTAL IS PROHIBITED continue!) etucrw left _____________ a_____________ CCSNTINUCO BtlOv* LETT I t tii ! i I i ! r~~' LEGEND ------------- SOTTnr*flt ------------- interconnect O LOOL CONTROL ROO* TUhJMAllON Q ECU) ICRUInaTIOK CCTTRHAJ. OEVtCE INTERNAL TO PIC RCLAr rTR TCR v. x O--Jf--O NC CONTACT O------||----- O NO CONTACT O-'TTP-O NOTOR/COl NOTES: 1. LMfT SWITCH CONTACTS ARC SHOWN WITH VALVE ** tTS TAB. POSmOH REFERENCE DRAWINGS 6AD1-K10I <Art-l--600 6AG1 --1--60? tAC)-l--6Ui 6AOT--I--604 VALVE SEOUCNCE LOGIC eocic laoocr diagram LOGIC LAOOCR DIAGRAM luck: lalihXH CiALHam LOGIC LADDER DIAGRAM CCKTINUCO ABOVE KXT CONTINUED OH Owe 6A01--T--60J SL 085713 ji. KM. DC BC TJJL TOf. ec et 0 REVT5ID LOGIC FOR CCHSTRuCmx 11/11/92 10/72/92 AWD TECHNOLOGIES. INC AWD INSTRUMENT LOGIC LADDER DIAGRAM SORBafhenE unit CUSTOMER ppc INDUSTRIES INC. 300 6A01 H in T--I oino o co APPENDIX H ALARMS AND OPERATOR RESPONSE si S57iq TAG NO. I 11A-LAH-1001 11A-LAHH-1001 11A-PAL-1002 UA-PAH-1054 11A-PAHH-1004 11A-PAL-1004 11A-PALL-1004 11A-XAH-1004 11A-PAH-100S 11A-PAHH-1005 | 11A-PAL-100S | 11A-PALL-1005 11A-AAH-1011A 11A-AAH-1011B PPG CHEMICALS LAKE CHARLES, LA PROJECT: CLOSED DOME LOADING Page 1 ] 1 | ALARMS AND OPERATOR RESPONSE | SERVICE BARGE HIGH LEVEL ALARM BARGE HIGH/HIGH LEVEL ALARM AND SHUTDOWN NITROGEN SUPPLY LOW PRESSURE ALARM AND SHUTDOWN OPERATOR RESPONSE: f DECREASE LOADING RATE OR STOP LOADING. RE-DIRECT FLOW TO ANOTHER COMPARTMENT. | STOP LOADING. IF VESSEL NOT FULL, EQUALIZE TANK LEVELS AND RESTART LOADING. CHECK VALVE ALIGNMENT ON N2 HEADER CHECK FOR EXCESSIVE NZJSAGE ELSEWHERE ON HEADER NOTIFY SUPERVISION. EDC VAPOR PRESSURE ALARM HIGH EDC VAPOR HIGH/HIGH PRESSURE ALARM Si S/D EDC VAPOR LOW PRESSURE ALARM EDC VAPOR LOW/LOW PRESSURE ALARM & S/D EDC VAPOR LINE PRESSURE TRANSMITTERS DEVIATION ALARM EDC VAPOR HIGH PRESSURE ALARM EDC VAPOR HIGH/HIGH PRESSURE ALARM Si S/D EDC VAPOR LOW PRESSURE ALARM EDC VAPOR LOW/LOW PRESSURE ALARM ic S/D EDC VAPOR HIGH OXYGEN CONTENT ALARM EDC VAPOR HIGH OXYGEN CONTENT ALARM DECREASE LOADING RATE NOTIFY SUPERVISION. NOTIFY SUPERVISION. MANUALLY VENT VESSEL. THROUGH VAPOR CONTROL SYSTEM. RESTART LOADING. NOTIFY SUPERVISION OF POSSIBLE BARGE N2 FAILURE IF DIRECTED TO SHUT DOWN, MANUALLY ADD N^TO BARGE BEFORE RESTART. NOTIFY SUPERVISION OF POSSIBLE BARGE N2 FAILURE MANUALLY ADD N2TO BARGE BEFORE RESTART. REPORT TO INST. GROUP FOR RE-CALIBRATION AND REPAIR. DECREASE LOADING RATE NOTIFY SUPERVISION. NOTIFY SUPERVISION. MANUALLY VENT VESSEL THROUGH VAPOR CONTROL SYSTEM. RESTART LOADING. NOTIFY SUPERVISION OF POSSIBLE BARGE N2 FAILURE IF DIRECTED TO SHUT DOWN, MANUALLY ADD N2TO BARGE BEFORE RESTART. NOTIFY SUPERVISION OF POSSIBLE BARGE N2 FAILURE. MANUALLY ADD N2TO BARGE BEFORE RESTART. CHECK N2 FLOW. VERIFY THAT 02 ANALYZERS ARE FUNCTIONING AND THAT CONTROLLER IS FUNCTIONING. CHECK N2 FLOW. VERIFY THAT 02 ANALYZERS ARE FUNCTIONING AND THAT CONTROLLER IS FUNCTIONING. SL 085717 I TAG NO. 11A-AAHH-1011A HA-AAHH-1011B 11A-AAX-1011A 11A-AAX-1011B | 11A-FAL-1011A 1 11A-FAL-1011B 1 11A-XAH-1011 11A-LAH-1013 1LA-LAHH-1013 1 11A-XA-1013 HA-FAH-1016 11A-FAHH-1016 11A-PAH-1025 11A-PAL-102S PPG CHEMICALS LAKE CHARLES, LA PROJECT: CLOSED DOME LOADING Page 2 ALARMS AND OPERATOR RESPONSE SERVICE OPERATOR RESPONSE: EDC VAPOR HIGH/HIGH 02 CONTENT ALARM Si S/D CHECK N2 FLOW. VERIFY THAT 02 ANALYZERS ARE FUNCTIONING. PURGE AND RESTART. EDC VAPOR HIGH/HIGH 02 CONTENT ALARM & S/D CHECK N2 FLOW. VERIFY THAT 02 ANALYZERS ARE FUNCTIONING. PURGE AND RESTART. OXYGEN ANALYZER A LOSS OF SIGNAL ALARM Sl S/D REPORT TO THE ANALYZER REPAIR GROUP FOR RE-CALIBRATION AND REPAIR. OXYGEN ANALYZER B LOSS OF SIGNAL ALARM Sc S/D 02 ANALYZER A LOW FLOW ALARM AND SHUTDOWN 02 ANALYZER B LOW FLOW ALARM AND SHUTDOWN EDC VAPOR LINE OXYGEN ANALYZERS DEVIATION ALARM REPORT TO THE ANALYZER REPAIR GROUP FOR RE-CALIBRATION AND REPAIR. CHECK THAT SAMPLE PUMP IS OPERATING CORRECTLY. CHECK ALIGNMENT OF VALVES. REPORT RESPONSE TO ANALYZER GROUP. CHECK THAT SAMPLE PUMP IS OPERATING CORRECTLY. CHECK ALIGNMENT OF VALVES. REPORT RESPONSE TO ANALYZER GROUP. REPORT TO THE ANALYZER REPAIR GROUP FOR RE-CALIBRATION AND REPAIR. EDC VAPOR LINE KNOCKOUT POT HIGH LEVEL ALARM FIELD CHECK THE LEVEL IF HIGH, DRAIN VESSEL IF LEVEL NOT HIGH NOTIFY INSTR GROUP FOR REPAIR. IF LEVEL HAS RISEN RAPIDLY OR IF HIGH LEVEL PERSISTS, NOTIFY SUPERVISION OF POSSIBLE LIQUID CARRYOVER. 1 KNOCKOUT POT HIGH/HIGH LEVEL ALARM AND S/D HELD CHECK THE LEVEL IF HIGH, DRAIN VESSEL IF LEVEL NOT HIGH NOTIFY INSTR. GROUP FOR REPAIR. IF LEVEL HAS RISEN RAPIDLY OR IF HIGH LEVEL PERSISTS, NOTIFY SUPERVISION OF POSSIBLE LIQUID CARRYOVER. K.O. POT LEVEL XMTR LOSS OF SIGNAL ALARM Sc S/D NITROGEN INERTING HIGH FLOW ALARM NITROGEN INERTING HIGH HIGH FLOW ALARM Sl S/D EDC VAPOR TO SORBATHENE UNIT HIGH PR$$ ALARM EDC VAPOR TO SORBATHENE UNIT LOW PRESS ALARM REPORT TO THE INSTRUMENTATION GROUP FOR REPAIR FIELD CHECK LEVELS. CHECK VALVE POSITION OF FV-1016. VERIFY SETPOINT. CHECK 02ANALYZERS FOR 02 CONTENT. NOTIFY SUPERVISION AND INSTRUMENT GROUP FOR REPAIR CHECK VALVE POSITION OF FV-1016. VERIFY SETPOINT. CHECK 02ANALYZERS FOR 02 CONTENT. NOTIFY SUPERVISION AND INSTRUMENT GROUP FOR REPAIR RESTART AFTER SYSTEM OK. CHECK FOR SVRU BLOCKAGE OR VALVE MALFUNCTION. SHUT DOWN AND NOTIFY SUPERVISION AND INSTRUMENT GROUP IF NOT IMMEDIATELY CORRECTED. CHECK FOR SVRU BLOCKAGE OR VALVE MALFUNCTION. SHUT DOWN AND NOTIFY SUPERVISION AND INSTRUMENT GROUP IF NOT IMMEDIATELY CORRECTED. 1 SL 085718 | TAG NO. 11A-TAH-1027 11A-TAL-1027 HA-TAH-1029 I 11A-TAL-1Q29 j 11A-AAH-1031 11A-AAHH-1031 UA-AAX-1031 11A-FAL-1Q31 11A-FAH-1051 11A-FAL-1051 11A-FQAH-1051 | 11A-PDAH-1S00 | 11A-FAH-1501H | 11A-FAHH-1501H PPG CHEMICALS LAKE CHARLES, LA PROJECT: CLOSED DOME LOADING ALARMS AND OPERATOR RESPONSE SERVICE OPERATOR RESPONSE: | HEAT TRACING HIGH TEMPERATURE ALARM SWITCH TO REDUNDANT SYSTEM AND I MONITOR. CHECK CONTROLLER AND TRACING FOR MALFUNCTION. CALL FOR REPAIR. HEAT TRACING LOW TEMPERATURE ALARM Si S/D HEAT TRACING HIGH TEMPERATURE ALARM SWITCH TO REDUNDANT SYSTEM AND MONITOR. CHECK CONTROLLER AND TRACING FOR MALFUNCTION. CALL FOR REPAIR. SWITCH TO REDUNDANT SYSTEM AND J MONITOR- CHECK CONTROLLER AND TRACING FOR MALFUNCTION. CALL FOR REPAIR. HEAT TRACING LOW TEMPERATURE ALARM Si S/D SWITCH TO REDUNDANT SYSTEM AND MONITOR- CHECK CONTROLLER AND TRACING FOR MALFUNCTION. CALL FOR REPAIR. EDC RECOVERY TANK OXYGEN CONTENT HIGH ALARM VERIFY THAT 02 ANALYZER IS FUNCTIONING. CHECK FOR VACUUM PUMP OR SAMPLE PUMP FAILURE. CHECK N2 PAD INPUT. NOTIFY INSTRUMENT GROUP IF FAULT IS CONTROL FAILURE EDC RECOVERY TANK OXYGEN CONTENT HIGH HIGH ALARM VERIFY THAT 02 ANALYZER IS FUNCTIONING. CHECK FOR VACUUM PUMP OR SAMPLE PUMP FAILURE CHECK N2 PAD INPUT. NOTIFY INSTRUMENT GROUP IF FAULT IS CONTROL FAILURE EDC RECOVERY TANK OXYGEN ANALYZER NOTIFY INSTRUMENT GROUP FOR REPAIR. LOSS OF SIGNAL EDC RECOVERY TANK 02 ANALYZER LOW SAMPLE FLOW CHECK THAT SAMPLE PUMP IS OPERATING CORRECTLY. CHECK ALIGNMENT OF VALVES. REPORT RESPONSE TO ANALYZER GROUP. PRODUCT LINE HIGH FLOW RATE ALARM CHECK MEASURED FLOW AT FIC-1Q51 VS FIC1051 SET POINT. NOTIFY INSTRUMENT GROUP OF CONTROL FAILURE PRODUCT LINE LOW FLOW RATE ALARM CHECK MEASURED FLOW AT FIC-1QS1 VS FIC1051 SET POINT. NOTIFY INSTRUMENT GROUP OF CONTROL FAILURE. PRODUCT LINE HIGH TOTALIZED FLOW ALARM CHECK TOTALIZER SET POINT VS INTENDED LOADING RESET IF NECESSARY. CHECK SET POINT VS TOTAL LOADED SO FAR. IF INSTRUMENT/ALARM MALFUNCTION IS THE CAUSE NOTIFY INSTRUMENT GROUP. EDC DUST FILTER HIGH DIFFERENTIAL PRESSURE ALARM CHECK ALL MANUAL BLOCK VALVES FOR PROPER POSITION. FILTER MAY BE PLUGGED. REPLACE FILTER BAG. EDC VAPORS/N2 FROM VESSEL HIGH FLOW CHECK N2 FLOW RATE (FIC-1016) AND 02 ALARM ANALYSIS (AI-M22A/B). EDC VAPORS/N2 FROM VESSEL HIGH HIGH FLOW ALARM CHECK MEASURED FLOW RATE (FIC-1Q51X STOP LOADING. NOTIFY INSTRUMENT GROUP IF INSTRUMENTATION IS MALFUNCTIONING. RESTART AFTER REPAIR. SL 085719 | TAG NO. 11A-PAH-1503 11A-TAH-1504 11A-TAHH-LS04 11A-TAH-LS05 11A-TAHH-1505 11A-TAH-1506 11A-TAHH-L506 11A-PAH-1507 11A-TAH-1508 11A-TAHH-1508 11A-TAH-LS09 11A-TAHH-1509 11A-TAH-1510 1 11A-TAHH-1510 1 11A-FAH-15I7 11A-TAH-1524 11A-TAHH-1524 11A-TAL-1524 PPG CHEMICALS LAKE CHARLES, LA PROJECT: CLOSED DOME LOADING Page 4 ALARMS AND OPERATOR RESPONSE SERVICE OPERATOR RESPONSE: EDC ADSORBER 60-2676 HIGH PRESSURE ALARM EDC ADSORBER 60-2676 HIGH TEMPERATURE ALARM CHECK MEASURED FLOW RATE (FIC-1051). STOP LOADING. NOTIFY INSTRUMENT GROUP IF INSTRUMENTATION IS MALFUNCTIONING. RESTART AFTER REPAIR. STOP LOADING. NOTIFY SUPERVISION. CHECK I SVRU BLOCKAGE OR MALFUNCTION. RESTART I AFTER CORRECTION. | EDC ADSORBER 60-2676 HIGH/HIGH TEMPERATURE ALARM STOP LOADING. PURGE SVRU BED WITH N2NOTIFY SUPERVISION. EDC ADSORBER 60-2676 HIGH TEMPERATURE ALARM STOP LOADING. PURGE SVRU BED WITH N2NOTIFY SUPERVISION. EDC ADSORBER 60-2676 HIGH/HIGH TEMPERATURE ALARM EDC ADSORBER 60-2676 HIGH TEMPERATURE ALARM STOP LOADING. PURGE SVRU BED WITH N2NOTIFY SUPERVISION. STOP LOADING. PURGE SVRU BED WITH N2NOTIFY SUPERVISION. EDC ADSORBER 60-2676 HIGH/HIGH TEMPERATURE ALARM STOP LOADING. PURGE SVRU BED WITH N2NOTIFY SUPERVISION. EDC ADSORBER 60-2675 HIGH PRESSURE ALARM STOP LOADING. PURGE SVRU BED WITH N2NOTIFY SUPERVISION. EDC ADSORBER 60-2675 HIGH TEMPERATURE ALARM STOP LOADING. NOTIFY SUPERVISION. CHECK FOR SVRU BLOCKAGE OR MALFUNCTION. RESTART AFTER CORRECTION. EDC ADSORBER 60-2675 HIGH/HIGH TEMPERATURE ALARM STOP LOADING. PURGE SVRU BED WITH N2NOTIFY SUPERVISION. EDC ADSORBER 60-2675 HIGH TEMPERATURE ALARM STOP LOADING. PURGE SVRU BED WITH N2NOTIFY SUPERVISION. EDC ADSORBER 60-2675 HIGH/HIGH TEMPERATURE ALARM EDC ADSORBER 60-2675 HIGH TEMPERATURE ALARM EDC ADSORBER 60-2675 HIGH/HIGH TEMPERATURE ALARM STOP LOADING. PURGE SVRU BED WITH N2NOTIFY SUPERVISION. STOP LOADING. PURGE SVRU BED WITH N2NOTIFY SUPERVISION. STOP LOADING. PURGE SVRU BED WITH N2NOTIFY SUPERVISION. AIR TO ADSORBERS HIGH FLOW ALARM VACUUM PUMP DISCHARGE HIGH TEMPERATURE ALARM VACUUM PUMP DISCHARGE HIGH/HIGH TEMPERATURE ALARM VACUUM PUMP DISCHARGE LOW TEMPERATURE ALARM ADJUST HCV-1567 TO CORRECT FLOWRATE. CHECK AND FIX LEAKS, CLOSE VENTS OR DRAINS. CHECK VACUUM PUMP FOR MECHANICAL OR CONTROL MALFUNCTION. CALL FOR REPAIR IF NEEDED. PUT TV-1568 IN AUTO. CHECK VACUUM PUMP FOR MECHANICAL OR CONTROL MALFUNCTION. CALL FOR REPAIR IF NEEDED. PUT TV-1568 IN AUTO. CHECK VACUUM PUMP FOR MECHANICAL OR CONTROL MALFUNCTION. CALL FOR REPAIR IF NEEDED. PUT TV-1568 IN AUTO. SL 085720 TAG NO. 1 11A-TALL-1524 11A-PAH-L527 11A-PAHH-1S27 11A-PAL-IS27 11A-PALL-1527 11A-LAL-1S28 1LA-LAL-1529 11A-VAH-153I UA-PAL-1533 UA-LAH-I534 11A-LAHH-LS34 I 11A-LAL-15J4 | 11A-LALL-1534 11A-LAHH-1535 11A-TAH-1544 -- j 11A-TAHH-1544 PPG CHEMICALS LAKE CHARLES, LA PROJECT: CLOSED DOME LOADING Page 5 ALARMS AND OPERATOR RESPONSE SERVICE OPERATOR RESPONSE: I VACUUM PUMP DISCHARGE LOW/LOW TEMPERATURE ALARM VACUUM PUMP OIL PRESSURE ALARM HIGH CHECK VACUUM PUMP FOR MECHANICAL OR | CONTROL MALFUNCTION. CALL FOR REPAIR IF I NEEDED. PUT TV-1568 IN AUTO. [ CHECK VACUUM PUMP FOR MECHANICAL OR CONTROL MALFUNCTION. PUT TV-1527 IN I AUTO. VACUUM PUMP OIL PRESSURE ALARM HIGH HIGH CHECK VACUUM PUMP FOR MECHANICAL OR CONTROL MALFUNCTION. PUT TV-1527 IN AUTO. | I VACUUM PUMP OIL PRESSURE ALARM LOW CHECK VACUUM PUMP FOR MECHANICAL OR CONTROL MALFUNCTION. PUT TV-1527 IN AUTO. VACUUM PUMP OIL PRESSURE ALARM LOW LOW CHECK VACUUM PUMP FOR MECHANICAL OR CONTROL MALFUNCTION. PUT TV-1527 IN AUTO. SEAL OIL POT A LEVEL ALARM LOW CHECK VACUUM PUMP SEALS AND LINES FOR LEAKS. CALL FOR REPAIR IF NEEDED. ADD OIL AS NEEDED. SEAL OIL POT B LEVEL ALARM LOW CHECK VACUUM PUMP SEALS AND LINES FOR LEAKS. CALL FOR REPAIR IF NEEDED. ADD OIL AS NEEDED. EDC RECOVERY COOLER FAN HIGH VIBRATION ALARM CALL FOR REPAIR NOTIFY SUPERVISION. INSTRUMENT AIR LOW PRESSURE ALARM LOW PRESSURE ALARM CHECK MANUAL VALVES FOR PROPER POSmON. NOTIFY SUPERVISION. EDC RECOVERY TANK LEVEL ALARM HIGH MONITOR LEVEL THROUGH CURRENT LOADING. TRANSFER EDC AFTER LOADING CYCLE PER PROCEDURES. EDC RECOVERY TANK LEVEL ALARM HIGH HIGH MONITOR LEVEL THROUGH CURRENT LOADING. TRANSFER EDC AFTER LOADING CYCLE PER PROCEDURES. EDC RECOVERY TANK LEVEL ALARM LOW STOP TRANSFER TO TRUCK. EDC RECOVERY TANK LEVEL ALARM HIGH CONFIRM HIGH LEVEL VIA RECOVERY TANK LEVEL INDICATOR. MONITOR LEVEL CAREFULLY THROUGH REMAINDER OF LOADING. AFTER LOADING COMPLETION, ARRANGE FOR RECOVERED EDC TRANSFER. EDC RECOVERY TANK LEVEL ALARM HIGH HIGH CONFIRM HIGH LEVEL VIA RECOVERY TANK LEVEL INDICATOR. IF NECESSARY SHUT DOWN LOADING IF NOT DONE AUTOMATICALLY TO AVOID OVERFILL ARRANGE FOR RECOVERED EDC TRANSFER BEFORE RESUMING LOADING. EDC RECOVERY COOLER OUTLET TEMPERATURE HIGH ALARM CHECK AND/OR REPAIR DRIVE BELT. CHECK SEAL OIL TEMP. AND LOWER IF ABOVE 210 F. EDC RECOVERY COOLER OUTLET TEMPERATURE HIGH HIGH ALARM CHECK AND/OR REPAIR DRIVE BELT. CHECK SEAL OIL TEMP. AND LOWER IF ABOVE 210 F. SL 085721 I TAG NO. I 1IA-PDAH-1546 UA-PDAHH-1546 11A-TAH-1550 I 11A-LAH-1561 11A-LAL-L562 1" PPG CHEMICALS LAKE CHARLES, LA PROJECT: CLOSED DOME LOADING Page 6 ALARMS AND OPERATOR RESPONSE SERVICE OPERATOR RESPONSE: GDC/OIL SEPARATOR DIFFERENTIAL PRESSURE ALARM HIGH EDC/OIL SEPARATOR DIFFERENTIAL PRESSURE ALARM HIGH HIGH CHECK OIL DEMISTER, OIL LEVEL AND LBV-1563 FOR PROPER OPERATION. NOTIFY SUPERVISION. CHECK OIL DEMISTER, OIL LEVEL AND LBV-1563 1 FOR PROPER OPERATION. NOTIFY | SUPERVISION. | RECOVERY OIL TANK PUMP BEARING TEMPERATURE ALARM HIGH NOTIFY SUPERVISION. EDC/OIL SEPARATOR LEVEL ALARM HIGH CHECK SEAL OIL TEMP. CHECK SEAL OIL FOR INTRUSION OF OTHER LIQUIDS. NOTIFY SUPERVISION. EDC/OIL SEPARATOR LEVEL ALARM LOW CHECK VALVE LBV-1563, MAY NOT HAVE OPENED TO DRAIN SEAL OIL BACK TO VAC PUMP. CHECK FOR LEAKS. ADD (ML NOTIFY SUPERVISION IF LOW LEVEL RECURS FREQUENT. OIL COOLER FAN VIBRATION ALARM HIGH CHECK BEARINGS, MOUNTING. FOR FOREIGN OBJECTS AND FOR BALANCE OF FAN BLADES. NOTIFY SUPERVISION. SL 085723 APPENDIX I EMERGENCY EVENT RESPONSES SL 085724 EMERGENCY EVENT RESPONSES I PPG CHEMICALS LAKE CHARLES, LA PROJECT: CLOSED DOME LOADING EMERGENCY EVENTS AND OPERATOR RESPONSE | EMERGENCY EVENT Hose breaks or leaks Bad weather; i.e. lightning Fire Equipment Failure OPERATOR RESPONSE Press the "STOP EDO LOADING OPERATION" button; activate required warning devices; put on Scott air pack, isolate leak; notify supervision. If spill is collected in drip pan, notify shipping shift foreman who will call for the vacuum truck service for removal of the collected liquid. Press the "STOP EDO LOADING OPERATION" button, resume loading when weather clears. Do not load while lightning is occurring. Press the "STOP EDO LOADING OPERATION" button. On shore: If the fire is large, sound the evacuation hom in the control room and leave the area. Notify the guards (call 2700). If the fire is small, proceed as follows: sound the necessary alarms; report fire to guards; do not attempt to put out the fire unless otherwise instructed or necessary for personal safety; if safe, isolate leak source and allow fire to bum itself out; try to stay upwind f the fire since this smoke may contain HCI. In the event that a fire extinguisher is used, refer to Section II.B. Offshore: Refer to Section II.B.2, "Rapid Movement of Vessels Threatened by Fire". Press the "STOP EDO LOADING OPERATION" button, call maintenance for equipment repair. If SVRU fails, follow the emergency bypass procedure (Section IV.F). Water level change caused by Press the "STOP EDO LOADING OPERATION" passing vessel button. If spill occurs, follow above procedure. SL 085725