Document XRX8bMj3L4aQqk7O9M6pVK2qB

CEA 1430 & 1800 Date: August 28, 1967 TABLE OF CONTENTS 1.1 Title 1.2 Summary 1.3 Process Technology 1.31 1.32 1.33 1.34 1.35 Process Description Raw Materials Products and By-Products Waste Streams Personnel, Property and Public Hazard 1.4 Manufacturing Facilities 1.41 1.42 1.43 1.44 1.45 1.46 Description Design Capacity Flexibility Requirements Future Expansion Physical Appearance Storage and Shipping Requirements 1.5 Utilities and Services 1.51 Utility and Service Requirements 1.52 Utility and Service Facilities Page No. 1 1 2 2 3 5 7 8 9 9 13 16 17 18 19 20 20 20 APPENDICES A. Equipment Flow Sheet B. Suggested Equipment Layout C. Equipment List D. Scope of Work, Anniston Storage Tank Farm E. Scope of Work, Anniston Drumming and Flaking F. Scope of Work, WGK, New 40M Pound Plant G. Scope of Work, WGK, Storage Tank Farm H. Preliminary Schedule I. Project Loss Prevention Report (9 pages) (2 pages) (13 pages) (9 pages) (6 pages) (11 pages) (7 pages) (2 pages) (5 pages) 0356800 TOWOLDMON0044713 CEA 1430 & 1800 Date: August 28, By: R. S. Yates Page 1 1967 1.1TITLE Aroclors - Increase Aroclor Capacity - Organic Division At Anniston Plant - CEA 1430 At WGK Plant - CEA 1800 1.2 SUMMARY ' The objectives of this project are to, a) Provide adequate finished goods storage facilities at Anniston and WGK to assure a minimum inventory of the various Aroclors and Aroclor blends so that bulk shipments can be made on demand. b) Provide at Anniston for blending and drumming of the several Aroclors with other components without interferring with primary production facilities. c) Minimize potential for cross contamination of products. d) Provide loading facilities for tank trucks and tank cars and unloading facilities for raw mater ials in tank cars. e) Provide additional raw material storage at WGK for biphenyl and at Anniston for TCB and TTCB. f) Provide at Anniston new expanded facilities for flaking and bagging biphenyl and solid Aroclors. g) Provide new facilities at WGK to increase plant capacity from 29.5M lbs./year to 69.5M lbs./year. h) Provide an overall production capacity for liquid Aroclors of up to 30% more than indicated in the latest Sales forecasts. i) Provide for an orderly expansion of the WGK and Anniston Aroclor facilities. Addition of these facilities will result in capacity increases over the present standard'^-' capacity as follows: 0365809 TOWOLDMONOQ44714 3 1.31 . CEA 1430 & 1800 Date: August 28, 1967 Page 2 At WGK, Liquid 40.0M lbs./year At Anniston, Liquid 5.7M lbs./year Solid 1.0M lbs./year (1) Note - Standard capacities at present are: At WGK, Liquid 29.5M lbs./year At Anniston, Liquid 48.071 lbs./year . Solid 10.02M lbs./year The installation at Anniston will include finished storage and blending tanks, two flakers for solid Aroclors and biphenyl, a drumming station, tank car spur and loading facilities and bagging station for solid Aroclors and biphenyl. The installation at WGK will include a new continuous chlorination line, blow tank, intermediate storage, distillation equipment, continuous clay treatment facilities, finished storage tanks, and a biphenyl storage tank with additional rail spur and unloading docks. Desired completion dates: Tank farm at WGK Tank farm at Anniston Flaking facilities at Anniston New production facilities at WGK July 1, 1968 August 1, 1968 September 1, 1968 December 1, 1968 PROCESS TECHNOLOGY Process Description Aroclors are the reaction products formed by the chlorination of biphenyl and/or terphenyls using an iron catalyst. The by-product HC1 gas produced is absorbed in water to produce muriatic acid. Crude Aroclors are produced in chlorinator reaction vessels, air blown and distilled. Liquid Aroclors are earth treated, filtered and loaded for shipment. Solid Aroclors are drummed, flaked or flaked and milled and packaged for shipment. Distillation residues are discarded as waste or sold as Montars. A numerical system of nomenclature is used for iden tifying the various Aroclors. 0355810 TOWOLDMONOQ4471 1.32 i*JU 6( XOUU Date: August 28, 1967 Page 3 Product yields are calculated on both chlorine and biphenyl and are different for each plant and for each Aroclor produced. They are recorded in the respective plant cost standards. Process documents: "Standard Operating Instructions for Aroclors Anniston Plant" - April 1966 - M. J. Williams "Standard Manufacturing Process for Aroclors Anniston Plant" - 'September 1966 - M. J. Williams "Process Description for the Manufacture of Aroclors - Department 246 - WGK Plant" - October 1966 D. E. Harris "Process Description for the Manufacture of Pyranols and Inerteens - Department A246 - WGK Plant" October 1966 - D. E. Harris "Standard Manufacturing Process for Pydraul A-200 Department B-246 - WGK Plant" - October 1966 D. E. Harris "Operating Instructions - Aroclor and Pyranols Departments 246 and A246 - WGK Plant" - August 1966 - V. Brawley "Final Report on the Continuous Chlorination of Biphenyl" - June 4, 1957 - R. A. Simone "Tentative Process for Continuous Chlorination of Biphenyl" - March 23, 1956 - R. A. Simone "Final Report on the Continuous Chlorination of Aroclors - Plant Demonstration" - May 7, 1958 R. A. Simone Raw Materials 1.321 Specifications Reference is made to the respective standard process manuals for raw material specifications. Raw materials at Anniston, for this project, are the Aroclors and additives used in blends and mixes and at the flakers. Raw materials at WGK are the materials used for the manufac ture of Aroclors. A list of materials follows: 0355811 TOWOLDMONOQ44716 CEA 1430 & 1800 Date: August 28, 1967 Page 4 Material Plant Code Date Material WGK (246) 82601 33500 38800 19409 43099 81059 12/8/64 1/7/66 7/21/66 1/21/66 2/18/65 6/29/66 Diphenyl Ferric chloride, Anhydride Lime, Hydrated Attapulgus Earth 200/UP Nitrogen Gas Chlorine, Liquid Anniston (27) 82612 81102 82641 82613 82613 82614 82614 82615 36100 60200 58500 61320 - 64010 6/17/66 1/10/64 7/5/64 6/28/64 7/15/64 2/7/62 7/15/64 3/2/66 5/26/66 6/3/65 8/29/63 12/23/63 - 12/18/64 Aroclor 1242 Electrical Grade Aroclor 1248 Electrical Grade Aroclor 1248 Non-Electrical Grade Aroclor 1254 Electrical Grade Aroclor 1254 Non-Electrical Grade Aroclor 1260 Electrical Grade Aroclor 1260 Non-Electrical Grade Aroclor 1262 Glycidyl Phenyl Ether (1) Trichlorobenzene (1) Tetrachlorobenzene (1) Epoxide 201 Toluene Xylene (1) WGK Specification 1.322 Sources WGK Biphenyl Received from the Anniston Plant in 20,000 gallon unlined steel, steam heated tank cars. Transferred to an existing 25,000 gallon storage tank. Chlorine ' Received direct from WGK's Department 232 in a 4" transfer line. This line is being replaced by a 6" transfer line in the third quarter of 1967. Ferric Chloride Received from the warehouse in 2 lb. glass containers. Lime, Hydrated Received from the warehouse in 100 lb. bags. TOWOLDMONOQ44717 1.33 Attapulqus Earth CEA 1430 & 1800 Date: August 28, 1967 Page 5 Received from the warehouse in 50 lb. bags. Nitrogen Gas Supplied by a bulk station located in the tank farm area. Anniston Aroclors are transferred by pipeline direct from department to storage and from storage tanks to mix tanks, to drumming station and to flakers. Glycidyl Phenyl Ether Received from the warehouse in 55 gallon drums. Trichlorobenzene Received from Hooker Chemical Company in 8,000 gallon steel tank cars. Tetrachlorobenzene Received from Hooker Chemical in 8,000 gallon tank cars. Epoxide 221 ' Received from warehouse in 55 gallon drums. Toluene Received from warehouse in 55 gallon drums. Xylene Received from warehouse in 55 gallon drums. Products and By-Products 1.331 Quality Considerations Marketing stresses that quality protection is the most effective means of protecting our present sales position of electrical grade Aroclors. Plant studies have shown that the use of aluminum tanks and aluminum transfer piping systems coupled with inert blanking of in-process and finished goods storage tanks will give us maximum protection. 0355B13 TOWOLDMON0044718 C,rt JL-*OU 6< J.OUU Date: August 28, 1967 Page 6 1.332 Specifications Reference is made to the respective standard process manuals for finished goods specifi cations. Finished products at Anniston, for this project, are the completed blends from mix tanks and solids from the flakers. At WGK, finished products, are the liquid Aroclors and Montars. A list of products follows: Product Code Anniston Date Product Code WGK Date Product 82611 82612 82612 81102 82641 82613 82613 82614 82614 82615 -- -- 82622 82621 82620 82619 82618 82616 82601 82649 82658 82681 82659 82661 82685 82664 10/28/63 6/17/66 7/15/64 1/10/64 7/15/64 6/28/65 7/15/64 5/25/66 6/15/64 3/2/66 7/15/64 7/15/64 3/11/66 3/15/66 3/11/66 3/11/66 3/11/66 3/11/66 7/8/65 4/18/66 4/18/66 5/3/67 3/11/66 3/15/66 3/9/66 4/17/58 8115 81101 81101 81102 81102 81103 81103 81105 81105 81107 82868 82868 4/7/64 6/17/66 7/15/64 1/10/64 7/15/64 6/28/65 7/15/64 5/25/66 6/15/64 3/2/66 7/15/64 7/15/64 Aroclor 1232 Aroclor 1242 Electrical Grade Aroclor 1242 Non-Electrical Grade Aroclor 1248 Electrical Grade Aroclor 1248 Non-Electrical Grade Aroclor 1254 Electrical Grade Aroclor 1254 Non-Electrical Grade Aroclor 1260 Electrical Grade Aroclor 1260 Non-Electrical Grade Aroclor 1262 Non-Electrical Grade Montars 1, 2 Montars 314 Aroclor 5460 Aroclor 5442 Aroclor 5060 Aroclor 4465 Aroclor 2565 Aroclor 1268 Biphenyl Inerteen PPO A13B3B Inerteen 54201 KA Aroclor 1260 - 10% Toluene Aroclor 1262 - 10% Toluene Therminol FRO Aroclor 1254 - 10% Toluene 1.333 Packaging and Shipping Liquid Aroclors At both Anniston and WGK, liquid Aroclors are shipped in the following manner: Tank Trucks Size - 4,000 gallon Materials of Construction - All electrical grade Aroclors are loaded into SS trailers. Non-electrical grade Aroclors may be shipped in steel trailer tanks. 0366814 TOWOLDMONOQ44719 CEA 1430 & 1800 Date: August 28, 1967' Page 7 Tank Cars Size - 4,000 or 8,000 gallon Materials of Construction - All electrical grade Aroclors are loaded into solid aluminum cars or in tin, zinc or aluminum spray-lined cars. Non-electrical grade Aroclors may be shipped in steel cars. Drums and Cars Size - 5, 30 or 55 gallon Materials of Construction - Lacquer-lined containers. Solid Aroclors At Anniston, solid Aroclors are packaged in 5 and 40 gallon galvanized steel drums as a solid and in 41 gallon fibre drums as flakes. Biphenyl and Aroclor 5460 are packaged in bags as follows (major part of the production): Bags Aroclor 5460 Net weight - 100 lbs., St. Regis No. PCBG-32A. Size - 18" X 6" X 34" with a 5" valve. Type - Sewn Valve (SV). Biphenyl Net weight - 50 lbs., St. Regis No. PCBG-145A. Size - 16-3/4" X 5" X 33" with 5-1/2" valve. Type - Sewn Valve (SV). HB-40 At Anniston, HB-40 is packaged in 5 and 55 gallon steel drums. 1.34 Waste Streams WGK 1,250 lbs./day of HC1 gas absorbed in a 50 GPM water stream (0.21%) will be discharged from the continuous blow tank into the plant sewer. Other process losses are of a minor nature. 0355815 TOWOLDMONOQ44720 CEA 1430 & 1800 Dates August 28, 1967 . Page 8 Anniston No change is expected in waste discharges as a result of this project. A dust collector will be installed to control Aroclor dusts from the milling operation . of Aroclor 1268. 1.35 Personnel, Property and Public Hazards Chlorine Gas ' Causes eye, skin and mucous membrane irritation. In strong concentrations canister gas masks, Scott Air Paks, or oxygen breathing apparatus are required. Biphenyl Solid at normal temperatures. Fumes are toxic over a prolonged period of exposure. The flash point is 235 F. HC1 Gas Fumes are very toxic and hazardous to teeth, skin, eyes and mucous membranes. In strong concentrations, rubber protective equipment and approved pack or cannister gas masks are required. Ferric Chloride Solid at normal temperatures. Material is not toxic but presents an eye hazard. Xylene Fumes are very toxic. Limiting explosion concentra tion is 1-27 to 7.0% by volume in air. The flash point is 40F. Trichlorobenzene Solid at normal temperatures. Fumes are medium toxic. Fire point is above 210F. Crude Aroclors During processing,Aroclors are generally hot, 100C or above, and can cause serious thermal burns. Con tinuous or repeated skin contact must be avoided. Vapors at room temperatures should not be breathed in a confined space. At elevated temperatures, fumes are quite toxic. Continuous or repeated skin contact with Aroclor must be avoided by the use of gloves and protective garments. 0355lb TOWOLDMON0044721 CEA 1430 & 1800 Date: August 28, 1967 Page 9 1.4MANUFACTURING FACILITIES 1.41 Description 1.411 General The following information is included in the Appendix of this report: Equipment F16w Sheets Suggested Equipment Layout Equipment Lists Scopes of Work Preliminary Schedule Project Loss Prevention Report 1.412 For Anniston New storage and blending tanks to be added: Aroclor 1242 " M 1248 1254 " 1260 h 1262 ti 1221/1232 Inerteen PPO and A13B TCB TTCB 54,000 gallon 18,000 II 54,000 II 18,000 It 18,000 II 18,000 II 30,000 12,000 12,000 II II II (2 - 27,000 gallon) (2 - 27,000 gallon) (1 - 12,000 gallon) (1 - 18,000 gallon) An existing 2,000 gallon mixing tank will be relocated. One covered loading dock for tank cars. One covered loading dock for tank cars and trailers. A new railroad spur. Four existing 12,000 gallon storage tanks with submerged pumps will be dismantled and scrapped. New drumming facilities to be added include a high speed drumming scale and a conveyor system to bring empty drums to the scale and take filled drums away from the scale. New flaking and bagging facilities to be added: Storage for Aroclor 5460, 1268 and biphenyl Flaker for solid Aroclors 0355817 I TOWOLDMONOQ44722 CEA 1430 & 1800 Date: August 28, 1967 Page 10 Flaker for biphenyl Mill for Aroclor 1268 . High speed bagging machines for Aroclor 5460 flakes and biphenyl flakes Conveyor system to take filled bags away from bagging machines Fume control system for Aroclor 1268 1 ! I | I ' [ iSf; * | ( f | The existing Aroclor and biphenyl flakers will be dismantled together with the present Aroclor feed tank. A suitable building (1201 X 60') to house the drumming and flaking operations. Pipelines from Department 27 to tank farm as follows: One line for Aroclor 1242 from existing 12,000 gallon day tank One line for Aroclor 1248 and 1221 One line for Aroclor 1254 from existing 12,000 gallon day tank One line for Aroclor 1260 One line for Aroclor 1262 Pipelines from tank farm to mix tanks: One line for Aroclor 1242 One line for Aroclor 1254 One line for Aroclor 1260 One line for Aroclor 1248 and 1262 Pipelines from tank farm to loading spots and drum filling: One line for A13B One line for KA and PPO One line for Xylene and Toluene blends (drum filling only) 0355818 : TOWOLDMONOQ44723 CEA 1430 & 1800 Date: August 28, 1967 Page 11 One line for HB-40 (drum filling only) One line for Aroclor 1242 One line for Aroclor 1254 One line for Aroclor 1221, 1232, 1248, 1262 One line for Aroclor 1260 Pumps will be providedas follows: One for Aroclor 1242 transfer at tank farm One for Aroclor 1254 transfer at tank farm One for Aroclor 1248/1221, 1232/1262 trans fer at tank farm One for Aroclor 1260 transfer at tank farm One for Mix tank and PPO tank transfer One for Xylene Mix tank transfer One for TCB, TTCB tank car unloading One for TCB, TTCB transfer to Mix tank Three to transfer Aroclors from Building 27 to storage 1.413 For W. G. Krummrich New storage tanks to be added: Aroclor 1242 Aroclor 1248 Aroclor 1254 Aroclor 1260 Biphenyl 44,000 gallon (2 - 22,000 gallon) 22,000 gallon 22,000 gallon 22,000 gallon 100,000 gallon A new railroad spur Two unloading docks for biphenyl cars Three existing 15,000 gallon storage tanks with submerged pumps will be dismantled. Pipelines from day tanks to tank farm as follows: 0355814 TOWOLDMONOQ44724 CEA 1430 & 1800 Date: August 28, 1967 Page 12 One line for Aroclor 1242 One line for Aroclor 1248 One line for Aroclor 1254 One line for Aroclor 1260 Pipelines from tank farm to drum filling: One line for Aroclor 1242 One line for Aroclor 1248 One line for Aroclor 1254 One line for Aroclor 1260 Pumps will be added as follows: One for Aroclor 1248 transfer One for Aroclor 1254 transfer One for Aroclor 1260 transfer One for Aroclor 1242 transfer Facilities to produce 40M lbs./year of Aroclor 1242: A continuous chlorinator chain consisting of biphenyl mix and continuous feed tank, four chlorination tanks, four mass circulating pumps and four external air coolers. A continuous blow tank and intermediate storage tank. Two semi-continuous distillation systems consisting of still pot, external circulat ing system with therminol heating, entrain ment separator, vapor condenser, receiver and vacuum steam ejector. Two continuous porocel treatment systems consisting of feed tank, absorber, cleanup filter and product receivers. One train will have two absorbers to provide flexi bility. 03^820 TOWOLDMONOQ44725 1.42 CEA 1430 & 1800 Date: August 28, 1967 Page 13 A complete therminol heating, storage and circulating system. Additions to the existing control room to provide space for a foreman and motor con trol center. Design Capacity 1.421 Anniston Finished Product Storag e Recommended ^ Provided Future Need Product ___ (gai-) (gai.) (gal.) (1970) 1221 1232 1242 1248 1254 1260 1262 TOTAL 13,0507 14,000J 97,500 20,800 51,500 20,900 5,550 223,300 18,000 66,000 18,000 66,000 '2' 18,000 18,000 204,000 27,000 27,000 Increased flexibility in the sto_rage area will allow a capacity .increase of 5.7M lbs./year (from 48M to 53.7M). Estimated tank car shipments for 1971: Estimated tank trailer shipments for 1971: Estimated drum shipments for 1971: Estimated can shipments for 1971: 372 66 25,610 2, 030 (3) (3) (3) (3) (1) Letter from HJD to RSY 5/18/67. (2) Includes 12,000 gallon of day storage. (3) Anniston Job No. 370-720 (1) by R. H. Taylor Mixing and Drumming Area A new 12,000 gallon mix tank, a relocated 2,000 gallon mix tank and an 18,000 gallon mix tank to provide for: Estimated tank car shipments for 1971: Estimated tank truck shipments for 1971: Estimated drum shipments for 1971: Estimated can shipments for 1971: 55 (3) 1 (3) 5,764 (3) 1,312 (3) A new drumming station with associated conveyors to handle 150 drums/day. (Basis: 8 hrs./day, 260 days/year, .75% OST) 0365821 TOWOLDMONOQ44726 CEA 1430 & 1800 Date: August 28, 1967 Page 14 Flawing and. Bagging ' ----. Aroclor flaking capacity (Aroclor 5460) 41,500 lbs./day (Basis: 8 hrs./day, 365 days/year, 75% OST) ...... .._ Aroclor bagging capacity 2 bags/min. Biphenyl flaking capacity 18,300 lbs./day (Basis: 8 hrs./day, 365 days/year, 75% OST) Biphenyl bagging capacity 2 bags/min. Flaking and bagging design will allow these operations to be carried out on a one-shift basis, seven days a week. Exception is Aroclor 1268 which will be flaked and packaged on a three-shift basis, seven days a week (3% of production). Raw Material Storage Raw Material Provided (gal.) TTCB TCB 12,000 12,000 1.422 WGK Finished Product Storag e Recommended ^ Provided Future Need Product (gal.) (gal.) (gal.) (1970) 1242 1248 1254 1260 TOTAL 132,000 25.200 34,400 20.200 211,800 84.000 42.000 ^ 42,000`4' 22.000 190,000 66,000 66,000 Estimated tank car shipments for 1971: Estimated tank trailer shipments for 1971: Estimated drum shipments for 1971: Estimated can shipments for 1971: 112 306 12, 200 765 (1) Letter from HJD to RSY 5/18/67. (2) Includes 40M gallons on hand storage. (3) Includes 20M gallons on hand storage. Extra storage required for operating flexibility. (4) Include 20M gallons on hand storage. 0355822 TOWOLDMONOQ44727 CEA 1430 & 1800 Date: August 28, 1967 Page 15 Raw Material Storage Raw Material Biphenyl Provided (gal.) 125,000(5) (5) Includes 25M gallons on hand storage. Provides capacity for 4 - 20,000 gallon cars and six days' supply at increased rate. New unloading track and docks provide four days turnaround time at increased rate. New Manufacturing Facilities Continuous chlorination: Basis: Producing Aroclor 1142 OST: 7,950 hrs./year Rate: 43M lbs./year Semicontinuous distillation and earth treatment Basis: OST: Rate: Producing Aroclor 1242 7,950 hrs./year 40M lbs./year For the overall product group, after these additions are completed, Anniston and WGK plant capacity will be as follows, H lbs./ year: Present Capacity New Capacity Increase in Capacity Anniston WGK 48.0 29.5 TOTAL CAPACITY 77.5 53.7 69.5 123.2 5.7 40.0 45.7 Based on 1971 requirements for both plants (July 1967 Sales Forecast), excess capacity at that time will be: New Capacity Required in' 1971 Excess Capacity 123.2M lbs./year 99.2M lbs./year 24.0TI lbs ./year Excess Capacity 24.2% 0355823 TOWOLDMONOQ44728 CEA 1430 & 1800 Date; August28, 1967 Page 16 < ! | j 1.43 Flexibility Requirements 't 1.431 Anniston Increased storage capacity and blending facilities will allow for better utilization of present still capacity. This will be accomplished by longer runs on the same product and result in increased pro duction capacity. 1.432 WGK ' Based on the sales forecast of July 1967 for the Aroclor product group, batch units will produce Aroclors 1248, 1254 and 1260. The maximum capacity of these units is as follows for each Aroclor: , Aroclor 1248 8,750 hrs. X 7,200 lb./ba. X 5 chlor X 92% OST = 34.4 M lbs. 8.5 hrs./ba. Aroclor 1254 8,750 hrs. X 8,040 lb./ba. X 5 chlor X 92% OST = 30.8 M lbs. 10.5 hrs./ba. Aroclor 1260 8,750 hrs. X 9,100 lb./ba. X 5 chlor X 92% OST = 29.2 M lbs. 12.5 hrs./ba. For the year 1971, the maximum batch capacity will be: For Aroclor 1248: 34.4 M lbs. X 21%^= 7.25 M lbs.. For Aroclor 1254: 30.8 M lbs. X 35%*1)= 10.80 M lbs. For Aroclor 1260: 29.2 M lbs. X 43%^= 12.60 M lbs. Total Batch Capacity on this basis = 30.65 M lbs. (1) From the July 1967 Sales Forecast for 1971. 0355824 TOWOLDMON0044729 1.44 .. . CEA 1430 & 1800 Date: August 28, 1967 Page 17 Requirements for 1971 are 20.3M lbs., leaving an excess capacity of 51% at WGK. For 1971, the continuous system capacity utili zation will be 25.6M lbs., leaving an excess capacity of 56% at WGK. Flexibility will be designed into the WGK disfiliation systems to allow for the following operations: Still No. 1 (existing) Aroclor 1260, 1262 Still No. 2 (existing) Boil down still to separate Montars (residues) from all products, Aroclors 1242, 1248, 1254, 1260 and 1262. Still No. 3 (New) Aroclor 1242 or 1254 Still No. 4 (New) Aroclor 1242 or 1254 Future Expansion 1.441 Anniston At the completion of this expansion, space will be available to the north of Building 27 for the addition of a complete new solid Aroclor line. Space is avail able in the tank farm area for additional tankage. Flaking and drumming capacity can be increased by adding additional personnel and operating on a 2 or 3 shift basis. 1.442 WGK One of the objectives of this expansion is to provide 25-30% excess production capacity for Aroclors. As we use up the excess capacity provided in this project we must consider the next step in department expansion. If we assume the product split will increase propor tionally according to the latest sales forecasts,we can postulate an operation diagrammed as follows: TOWOLDMONOQ44730 CEA 1430 & 1800 Dates August 28, 1967 Page 18 Aroclor 1142 Continuous Operation 4 Chlorinator Units 1.45 The layout of the new chlorination-distillation facili ties at WGK will allow space for the addition of another chlorination unit, intermediate storage tanks and two additional distillation chains. Aroclor 1248 and 1262, because of the smaller requirements, would continue to be made in the batch units. On this basis, we can postulate productive capacity as follows for liquid Aroclors, M lbs./year: Anniston WGK batch units Cont. 1242 unit Cont. 1254 unit Cont. 1260 unit 53.7 29.5 40.0 15.0 15.0 TOTAL CAPACITY 153.2 Physical Appearance 1.451 Anniston Tanks of different heights will be grouped together to provide standardization. In the flaking and drumming area, provision will be made for moving finished products directly into a new warehouse facility (when built)' 0355826 TOWOLDMONOQ44731 1.46 CEA 1430 & 1800 Date: August 28, 1967 Page 19 1.452 WGK Tanks will be grouped together as an exten sion of the present tank farm. The new facilities will be a separate structure to the south of the existing unit. Storage and Shipping Requirements 1.461 Anniston Facilities provided are noted in greater detail in other parts of this report. Provision is being made for: Raw material storage of TTCB and TCB. Finished product storage for all liquid Aroclors. Loading docks for tank car and tank trailer loading of products. Moving filled bags of solid Aroclors and biphenyl to palette loading station, then to warehouse storage. Moving drums and cans to palette loading station, then to warehouse storage. Storage in the drumming area of the new manufacturing facility for empty drums and containers. 1.462 WGK Provision is being made for: Raw material storage of biphenyl. Finished product storage for all liquid Aroclors. Unloading docks for tank cars. Making an existing unloading dock a loading dock for tank cars of Aroclors. No extensions or additions are being made to the present blending and drumming facilities. WGK technical service is modifying an existing storage tank to a blend tank and revamping piping in the drumming area. 0355827 TOWOLDMONOQ44732  CEA 1430 & 1800 . Date: August 28, 1967 Page 20 UTILITIES AND SERVICES 1.51 Utility and Service Requirements 1.511 Anniston Additions Steam - 100 psiq-For Storage Tanks 2,000 lbs./hr -For Process Purchased Water- For Process (Cleanup) Compressed Air - For Storage Tanks Plant Water - For Process (Flakers) Nitrogen - For Storage Tanks Electric - Connected 500 lbs./hr 150 GPM 20 GPM 300 GPM 50 SCFM 300 HP - Operating 200 HP WGK Additions Steam - 80 psiq - For Storage Tanks 5,000 lbs./hr. - For Process 3,000 lbs./hr, 200 psig-For Process Natural Gas - For Process Purchased Water- For Process Compressed Air - For Process 600 lbs./hr. 1,800 SCFH 150 GPM 100 SCFM Electric - For Instruments - Connected - Operating 75 SCFM 315 HP 250 HP Plant Water - None Required Nitrogen - None Required 1.52 Utility and Service Facilities 1.521 Anniston A new spur track from main track at north of plant to 5th Street, 1700 ft. long. TOWOLDMONQ044733 CEA 1430 & 1800 Date: August 28, 1967 Page 21 A new 300 KVA pole line transformer to supply tank farm and warehouse requirements. A new sewerage lift station to replace existing field which is in the proposed manufacturing area. The lift station will tie into an exist ing city sewerage line. Relocating a 24" IPS VC acid sewer. Installation of a steel frame prefab-type building, 120' long X 60' wide to house the flaking, drumming and bagging facilities. This building will be designed so that it can be attached to a new warehouse building which will be 120' wide X 240' long. A 15' wide X 80' long tank truck loading sta tion. Relocation of existing plant parking facilities 70' wide X 120' long. 1.522 WGK Extension of existing track 10A for 110 feet and installation of a turnover to tie existing track 10a into track 10. Replace existing gas meter with a larger capa city meter. Install new pump at department city water break tank with associated piping. Install new 600 amp breaker in Sub #17. Install fans in Sub #17 transformer. Transfer feeder 8-1 from Sub #8 to Sub #17. Install an overhead feeder from Sub #17 to Building CF. Install feeder cables from breaker 8-1 to Department 246. 0355829 TOWOLDMONOQ44734 CEA 1430 Date: August 28, 1967 By: H. D. Gabelman SCOPE OF WORK Aroclor Expansion at Anniston Storage Tank Farm and Mixing Station Appendix "D" 0365830 TOWOLDMON0044735 Appendix D CEA 1430 Date: August 28, 1967 By: H. D. Gabelman Page 1 General: The facilities included in this project are intended to: 1. Assure storage capacity for minimum inventories of the various Arodors and blends so that bulk shipments can be made on demand. 2. Provide for blending of several Aroclors with other components without holding up primary production facilities. 3. Minimize the potential for cross contamination of products. 4. provide loading facilities for tank cars, tank trucks and unload ing facilities for raw materials in tank cars. Major Equipment Includes 2 - 27,000 gallon Aluminum Storage Tanks for 1242. 2 - 27,000 gallon Aluminum Storage Tanks for 1254. 1 - 18,000 gallon Aluminum Storage Tank for 1248. 1 - 18,000 gallon Aluminum Storage Tank for 1221/1232. 1 - 18,000 gallon Aluminum Storage Tank for 1260. 1 - 18,000 gallon Aluminum Storage Tank for 1262. 1 - 12,000 gallon Steel Storage Tank for TCB. 1 - 12,000 gallon Steel Storage Tank for TTCB. 1 - 11,500 gallon Aluminum Day Tank for 1242 (Existing). 1 - 11,500 gallon Aluminum Day Tank for 1254 (Existing). 1 - 12,000 gallon Aluminum Blend Tank for A13B. 1 - 18,000 gallon Aluminum Storage Tank for KA-PPO. 1 - Existing and relocated 2,000 gallon Aluminum Blend Tank for Toluene and Xylene Blends. All storage tanks to have plate coil heaters and to be insulated on lower half. Existing day tanks will be left "as is". The 2,000 gallon blend tank will be left "as is" except it will be relocated. The 12,000 gallon Aluminum Blend Tank for A13B will have plate coils, heaters, insulation and an agitator. The 18,000 gallon Aluminum Blend Tank will have plate coil heaters and insulation. 0355831 TOWOLDMONOQ44736 Appendix D CEA 1430 Page 2 Pumps . All 316 SS except TCB and TTCB which are cast iron. 1242 - common loading pump for 2 storage tanks to loading spots; existing transfer pump from day tank to storage. See Code 93 paragraph 5 concerning pumps. 1254 - Common loading pump for 2 storage tanks to loading spots; existing transfer pump from day tank to storage. See Code 93 paragraph 5 concerning pumps. 1248/1221 - Existing transfer pump from receiver to storage - common pump. See Code 93 paragraph 5 concerning pumps. 1262 - Existing transfer pump from receiver to storage. See Code 93 paragraph 5 concerning pumps. 1248/1221/1232/1262 - Common loading pump from storage to loading spot. 1260 - Existing transfer pump from receiver to storage - loading pump from storage to loading spot. See Code 93 paragraph 5 concern ing pumps. TCB and TTCB have one common pump for unloading from tank cars and one common pump for transfer to blend tanks. Blend tank for A13B and storage tank for KA-PPO will have common trans fer pump from tanks to loading spot or drumming. Blend tank for Toluene and Xylene blends will have a transfer pump from tank to drumming. Filters All 316 SS or 304 SS. Separate filters (Alsop) are provided for 1242, 1254, 1260 and 1248/ 1262/1221/1232. A new filter (Sparkler) is provided for A13B/KA-PPO from mix and finished blend storage tanks. An existing Sparkler filter will be relocated for the Toluene and Xylene blends. ipiaa Separate transfer lines are provided for; 1242 - From day tank to storage to loading docks. 1254 - From day tank to storage to loading docks. 1260 - From receiver to storage to loading docks. 03668^ TOWOLDMONOQ44737 Appendix D CEA 1430 Page 3 12G2 - From receiver to storage.to loading docks. 1221/1248 - Common line from receiver to storage to loading docks. All above lines are 3" aluminum, traced and insulated. piping is provided for circulating the contents of each finished goods tank. Piping from tank cars for TCB and TTCB to storage and from storage to mix tanks will be steel. Utilities 1. Spur track from main track to 5th Street with 2 covered loading docks for tank cars. One of these will be used for unloading TCB and TTCB. 2. One covered loading dock on 5th Street for loading tank trucks. 3. 6" steam main from Building 27 to tank farm. 4. 2" N, transfer line from existing N_ storage tank to tank farm (all tanks except TCB and TTCB are Nj blanketed.) 5. Electrical: Existing HB40 transformer will be dismantled and scrapped; HB40 load will be picked up on Aroclor motor control center. New load in the tank farm-warehouse area will be supplied from pole line transformer supplied from the existing HB40 overhead feeder. Roads An approximate 80' X 15' wide loading area at side of 5th Street will be provided as a loading area for tank trucks. Structures and Foundations Two tank car spots and one tank truck loading spot are weather protected by roofing. All storage tanks will be on ring walls with compacted sand fill except the 2000 gallon blend tank which will be on a concrete pad. Area be tween tanks will be covered with chat. 0355833 TOWOLDMONOQ44738 1 Appendix D CEA 1430 Page 4 01 - Equipment 1 As per Equipment List and Summary. 02 - Instruments As per Instrument List and Summary. 1 03 - Setting and Testing Equipment Tank farm is immediately adjacent to 5th Street and east of Aroclor office. Truck deliveries can be made directly to site. 1 04 - Setting and Testing Instruments Nothing unusual. 05 - Piling 1 None allowed for. 06 - Excavation 1 - For railroad spur track Tank foundations - 12 9-1/4 yd3 each 1 Tank pad for 2000 gallon mix tank .Pump foundations - 8 @ 1 yd3 each n Filter foundations - 6 2/3 yd3 each 2 Tank car loading docks 2 yd3 each i 1 Tank truck loading dock Pipe support foundations = 7,000 yd3 = 111 yd3 = 15 yd3 = 8 yd3 = 4 yd3 = 4 yd3 = 2 yd3 = 15 yd3 All excavated earth will be spoiled in immediate area. 07 - Foundations Tanks 12 ring walls @ 3 yd3 each Forms 155 ft2 each 1 Crushed rock and sand fill Pad for mix tank Form 1 Pipe Support Foundations 1 6 @ 2-1/2 yd3 each Forms @ 100 ft2 each l = 36 yd.3 cone. = 1860 ft2 = 95 yd3 - 15 ydJ cone. = 80 ft2 = 15 yd3 = 600 ft2 0355834 TOWOLDMONOQ44739 3 Loadinq Docks Forms 3 8 Pump Foundations @ 1 yd each Forms @ 60 ft2 6 Filter Foundations @ 2/3 yd2 each Forms @ 20 ft2 each Appendix D CEA 1430 Page 5 = 6 yd3 cone = 120 ft2 5= 8 yd3 cone = 480 ft2 S= 4 yd3 cone = 120 ft2 Approximately 6 borings for soil bearing determination will be made. 08 - Supports, Platforms and Structures 1 Pipe bridge over 5th Street = Pole supports to loading dock structure = Miscellaneous steel at ground level pipe supports 2-20' high ladders with safety cages. . = 3-1/2 ton steel 3 ton steel 2 ton steel Platforms over tanks in farm Platform Stair Treads Grating Double pipe hand rail Toe plate 3 loading docks (with covers over) Galbestos roofing 5 ton steel 50 1050 ft2 750 ft 700 ft 6 ton steel 600 ft2 10 - Sprinklers and Fire Protection None 0355835 TOWOLDMONOQ44740 Appendix D CEA 1430 Page 6 11 - Piping - Process and Service 750* - For 1242 - From Bldg. 27 to storage tanks to loading docks A-ll const. - 3" Sch. 40 - I.P.S. - Aluminum 750' - For 1254 - From Bldg. 27 to storage tanks to loading docks A-ll const. - 3" Sch. 40 - I.P.S. - Aluminum 750' - For 1260 - From Bldg. 27 to storage tanks to loading docks A-ll const. - 3" Sch. 40 - I.P.S. - Aluminum 600' - For 1262 - From Bldg. 27 to storage tanks to loading docks A-ll const. - 3" Sch. 40 - I.P.S. - Aluminum 700' - 1221/1248/1232 - From Bldg. 27 to storage tanks to loading docks All above 3" aluminum pipe to be single traced with 1/2" copper tubing. Trap condensate each 200` of tracing. . 300' - 125# steam from Bldg. 27 - F-41 const. - 6" Sch. 40 steel pipe 300' - 125# steam - F-41 const. - 2" Sch. 40 steel pipe 500' - N, Nitrogen unit east of Chlorine - 2" vinyl covered Sch. 40 steel For TCB and TTCB from loading dock to storage - F-ll const. 350' Sch. 40 3" steel pipe For TCB and TTCB from storage to mix tanks - F-ll Sch. Toluene to mix tank - A-ll const. - 20' - 3" Sch. 40 Xylene to mix tank - A-ll const. - 20' - 3" Sch. 40 KA-PPO to loading dock A-ll const. - 320' - 3" Sch. 40 A13B to loading dock A-ll const. - 320' - 3" Sch. 40 12 - Ductwork None 0355836 TOWOLDMONOQ44741 Appendix D CEA 1430 Page 7 13 - Electrical ' Yard lighting for tank farm area - 13 tanks - approx. 60' X 100' area. Lighting for two tank car loading docks and one tank truck loading dock area. 6 - Street light type Mercury Arc fixtures for loading dock and tank farm perimeter plus 8-175 watt Mercury Arc lighting fixtures over tank farm area. 8 - 15 HP motors on pumps 2 - 7*j HP motors on agitators Pushbuttons at each pump and at remote location. Install 300 KVA pole type transformer for warehouse and tank farm load. 14 - Site Preparation Grade area east of Aroclor office to an elevation of 746'i. Area equals approx. 120' north from 5th Street X 60' east of Aroclor office. Terrace down from 746' elevation to 742' immediately to east of leveled area. 3 Earth moved approximates 300 yd and will be spoiled in immediate area. . 15 - Sewers and Drains None required. 16 - Underground Mains . None required. 17 - Yards and Roads 1. Establish tank truck loading spot on 5th Street adjacent to tank farm. Area approx. 1200 ft^ (80' X 15'). Grade off approx. 50 yd3 earth. Crushed rock ballast for loading spot (8" thick) = 35 yd3 1200 ft3 2" thick asphalt paving. 2. Tank Farm Area (120' X 60') . Crushed Rock = 70 yd3 ' 0355837 TOWOLDMON0044742 Appendix D CEA 1430 Page 8 3. Repair construction damage to,5th Street. Assume resurfacing of 3000 ft^ (30' X 100') 2" asphalt paving. 18 - Railroads Install approximately 1700' rail spur from main line at north side of plant. Spur to extend along west side of Parkwin to 7th Street. Then offset to west approximately 130' and extend to 5th Street. This includes switch, bumper, ties, track, ballast and 4 crossings. Excavation for this spur is included in code 06. 19 - Insulation Tank insulation to be 1-1/2" thick calcium silicate - Std Kll.2 Std 100 with weather barrier. Tanks as follows: 4-13' diameter 600i ft2 each = 2400 ft2 5 - 12' diameter @ 400i ft2 each = 2000 ft2 2-11' diameter @ 300i ft2 each = 600 ft2 Pipe insulation to be the same spec Std as tanks For 1242 1-1/2" - 100 - 750' - 4" pipe For 1254 For 1260 For 1262 For 1221/1248 For Steam For Steam 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" 1-1/2" - 100 - 750' - 4" pipe - 100 - 750' - 4" pipe - 100 - 600' _ 4.. pipe - 100 - 700' _ 4" pipe - 100 - 300' - 6" pipe - 100 - 300' - 2" pipe Pump and filter insulation to be same Kll.2 Std 100 insulating system with weather barrier. 6 - Pumps to be traced and insulated. 5 - Filters to be traced and insulated @ 25 ft2 = 125 ft2 20 - Painting All structural steel to be hot dipped galvanized. Touch-up damaged areas with inorganic zinc coatings in field, (carbo Zinc #11) TOWOLDMONOQ44743 Appendix D CEA 1430 Page 9 90 - Dismantling Remove and scrap 3 X 15,000 gallon and 1 X 11,000 gallon horizontal storage tanks and 1 X 10,000 gallon vertical mix tank: Item No. Equipment No. _____________ Description 201 22-0077 10' X 26' long horizontal tank 202 22-0089 8' X 30' long horizontal tank 203 22-0076-01 10' X 26' long horizontal tank 204 - 10' X 26' long horizontal tank 205 22-0108 14' X 10' high tank 208 - Taber vertical subm. pump 209 - Taber vertical subm. pump 214 - Taber vertical subm. pump 215 - Taber vertical subm. pump Remove and scrap existing HB-40 transformer. 93 - Relocations and Modifications Expense 1. Existing feeder cable from existing HB-40 transformer to Aroclor motor control center. 2. 360' of 8' high cyclone fencing. 3. Existing Sparkler filter (18"), from building 27 to new tank farm. 4. Existing 2000 gallon jacketed SS mix tank with agitator, from building 27 to new tank farm. 5. Money for replacing three existing transfer pumps is to be included in this scope. The existing pumps referred to are those noted in the "General" section of this scope under "Pumps" for transferring 1248/1221,1262 and 1260 from exist ing day tanks and/or receivers to new storage facilities. 0355839 TOWOLDMONOQ44744 CEA 1430 Date: August 28, 1967 By: H. D. Gabelitian SCOPE OF WORK Aroclor Expansion at Anniston Drumming and Flaking Appendix "E" 0366840 TOWOLDMONOQ44745 Appendix E CEA 1430 Page 1 General This scope covers the installation of drumming and flaking facilities in a new prefab structure north of 5th Street and at eastern boundary of block 4 (east of tank farm, see Appendix D). Space and detail de sign will allow for attaching a warehouse to the north of this struc ture. The warehouse is a separate project covered by CEA 1452. These facilities are intended to 1. Provide for drumming and flaking in an area, removed, but adja cent to the manufacturing area, so as to allow for greater effi ciency in use of manpower, both in the manufacturing area and in packaging and warehousing. 2. Rail and truck loading and unloading facilities at point of packag ing to minimize handling will be provided (see Appendix D). 3. Provide storage space for bags and a limited number of drums both empty and full. 01 - Equipment See Drumming and Flaking equipment lists. 02 - Instruments See Instrument list. 03 - Set and Test Equipment 04 - Set and Test Instruments 05 - Piling None 06 - Excavation Buildinq foundation Intermediate buildinq foundations Pipe Supports 15 @ 2-1/3 yd3 each City Water - 50' @6 ft3/ft = 300 ft3 C.T.W. - 30' @ 12 ft3/l = 360 ft3 Fire Water - 120' 6 ft3/l = 720 ft3 = 80 yd' = 40 yd' = 35 yd' = 11 yd = 14 yd' = 45 yd' 035SB1*1 TOWOLDMON0044746 Appendix E CEA 1430 Page 2 Backfill (CW, CTW, FW) - 70 yd3 Spoil in immediate area - 177 yd3 (use for building fill) Building fill - 1600 yd3 (needed fill available from ) (R.R. excavation for tank farm) Excatation and backfill for 500' of 4" pressure sewer - 225 yd each Excavation for sewage ejector - 14' deep - 52 yd3 Excavation and backfill for 4" connecting sewers - 93 yd each 07 - Foundations Building Foundations and Floor Forms - 300 yd3 concrete - 5000 ft2 Pipe Supports Forms - 35 yd 2 concrete - 750 ft2 6 Borings for soil bearing analysis. Drumming: Air Compressor Pad for sewage ejector Concrete fill around ejector - 2 yd3 concrete - 1.5 yd3 - 2000 psi concrete 7 yd' Supports, Platforms and Structures Flaking: - Structural Steel - Grating - Stair Treads - Double Pipe Handrail - Toe Plate - Miscellaneous Steel Drumming Miscellaneous Steel - 30 ton - 1800 ft2 - 80 - 150 ft. - 90 ft. - 2 ton - 2 ton All structural steel to be hot dipped galvanized; building steel to be painted (see Code 20). 09 - Building A 120' clear span structure 60' long with 23' eave height will be provided. A canopy will be extended over the railroad tracks. The side next to tracks will be open for loading and unloading rail cars. One half of south side will be open to serve as a truck loading and unloading dock. East, north and part of south side will be covered with corrugated transite and corrugated vinyl. ' Walls Corrugated transite Corrugated vinyl - 5000 ft 2 o - 1200 ft 03 55 8*2 TOWOLDMONOQ44747 Appendix E CEA 1430 Page 3 Roof and Roofing Corrugated "Galbestos" and Vinyl panels with 8' overhang over rail road tracks and 6' canopy over truck loading area. 2 Corrugated Galbestos = 7500 ft ' Corrugated Vinyl = 1000 ft2 Gutters and Downspouts ' 240' - 6" Aluminum guttering 120' - 6" Aluminum downspouts 10 - Sprinklers and Fire Protection Structure - Provide an automatic dry pipe sprinkler fire protec tion system designed for extra hazard spacing and pipe sizing for approximately 7200 ft2 (1 head each 100 ft2) = 72 heads. 11 - Piping Drumming 2" parallel traced and insulated aluminum for 1242, 1254, 1248/1221/1232/1262, 1260, blend A13B, blend KA-PPO all originating at battery limits (connected to lines running to loading docks) - 6 lines @ 120' each = 720'. 2" parallel traced and insulated aluminum for Xylene and Toluene blends - 1 line = 300' 3" steel insulated line for HB-40 = 600' 4" steel insulated line for steam = 200' 2" steel miscellaneous piping (for Jet, air comp, etc.) = 200' assumed Flaking 3" X 2" jacketed steel line for 1168 & 5460 2" steel traced and insulated for Bi^> 3" steel insulated line for Therminol 4" steel for CTW, S&R - 2 lines @ 150' each 2" steel insulated steam for Bi^ surge tank 2" steel insulated steam for Miscellaneous piping = 450' = 500' = 900* = 300' = 200' = 200' 12 - Ductwork Flaking 12" - 304 SS 18 gauge = 100 ft. 0355842.01 TOWOLDMONOQ44748 Appendix E CEA 1430 Page 4 13 - Electrical power from pole line transformer into motor control center in building (approx. 50' distance). Power from motor control center to following motors: Drumming: 1 - 25 HP Air Compressor Motor Flaking: 1 - 15 HP 1268 Mill 10 HP Aroclor Flaker Motor 5 HP Bi(j> Flaker Motor 3 HP Bag Flattener Motor 5 HP Fluidizing Air Blower Motors 5 HP Suction Blower Motors 3 HP Transfer Pump Motors 3 HP Conveyor Motors V4 HP Shaker Motor 1*5 HP Ejector Compressor Motors Lighting for ground level - area 120' X 60' (7200 ft ) 18 - 175 watt mercury arc lights Lighting for 14' level - area 30.' X 60' (1800 ft^) 5-175 watt mercury arc lights 14 - Site Preparation Grade truck loading and unloading area at southeast corner of drumming and flaking structure. 40' X 50' area - Move approx. 80 yd earth. 15 - Sewers and Drains 300' - 12" V.C. storm sewer (Along east side of structure to Snow Creek) 200' - 8" V.C. storm sewer for gutters 3 - Floor Drains 200' - 4" V.C. connecting sewers to floor drains. Provide 30 GPM sewage ejector with tank, controls, etc. 500 lineal feet 4" CX pressure sewage line from ejector to pipe shop service line. 140 lineal feet of 4" Cl sewer to connect existing sewers to ejector. 1 manhole at ejector, 10' deep with cover. 1 m*nV>r\l shoD. s' *----- --- TOWOLDMON0044749 Appendix s CEA 1430. Page 5 16 - underground Mains ' 50' 2" C.I. City Water Main 60' 12" C.I. Fire Main 60' 6" C.I. Fire Main 60' 4" Steel C.T.W. - Supply'and Return 17 - Yards and Roads 2000 ft 2 X 8" thick concrete truck pad = 50 yd3 concrete. 2 700 ft asphalt - street repair at sewage ejector. 18 - Railroads None 19 - Insulation Pipe insulation to be 15s" thick calcium silicate Kll.2 Std 100 with weather barrier. Quantities as follows: Drumming: 4" - 200' 3" - 1620' 2" - 200' Flaking: 3" - 1400' 2" - 400' 20 - Painting Building steel to have 3 coat vinyl system. 90 - Dismantling Disconnect and remove 4 septic tanks. Item No. Equipment No. _____________ Description 631 22-0700 Flaker hold tank with agitator, drive and motor. 690 14-0031 Model VMG 5-56, with 5HP motor. Biphenyl Flaker Flaker, size 24" X 48" 0355844 646 17-0027 2DH Micro Pulverizer with 1/3HP motor TOWOLDMONOQ44750 Appendix E CEA 1430 Page 6 Relocation 1. Relocate 520' of existing 24" acid sewer. Excavate and in stall new V.C. sewer between two existing manholes. 2. Relocate parking lot, extend to north of existing parking lot, 70' X 120', 8400 ft.2 of asphalt paving with parking stalls. 0355845 TOWOLDMONOQ44751 CEA 1800 Date: August 28, 1967 By: R. S. Yates SCOPE OF WORK Aroclor Expansion at W. G. Krummrich New 40 M lbs./yr. Plant Appendix "F" 0355846 TOWOLDMONOQ44752 Appendix F CEA 1800 Page 1 General The facilities included in this project are 1. installation of a new continuous chlorination system. 2. installation of two distillation units with a capacity of 25 M lbs./yr. in each system. 3. Porocel/bauxite treatment for four different Aroclors. 4. Replacement of present off-gas recovery system with a new system. Major Equipment Includes A biphenyl mix (2000 gallon) and feed tank (2000 gallon) to supply continuous chlorinator line. 4 - 1200 gallon (4' Dia. X 201) chlorinator units with attached coolers, pumps and entrainment system. 1 - 2500 gallon continuous blow tank. 1 - 15,000 gallon intermediate storage tank. 2 - Flash distillation systems consisting of still pot, entrainment separator, condenser, receiver, and external therminol heater. Off-gas system consisting of gas cooler-condenser, surge tank (3000 gallon). Therminol cooling system for still condensers. 4 - Fixed bed absorbers (3' Dia. X 15') with associated tankage, filters and pumps. External therminol heating system for supplying therminol to the still pot heaters. 035584? TOWOLDMONOQ44753 Appendix F CEA 1800 Page 2 m - Equipment See Equipment List and Summary. 02 - Instrument Items See Instrument List and Summary. 03 - Setting and Testing Equipment Area is accessible for truck and train unloading. High lift can be used advantageously. 04 - Setting and Testing Instruments A control room is available for the instruments and panel. 05 - Piling For Structural Steel 14 Concrete piles X 3 cu.yds. Size 24" dia, X 25' long 42 cu.yds. For Blow Tank, Item 422 4 Concrete piles X 3 cu.yds. For Inter Storage Tank, Item 424 12 cu.yds. 7 Concrete piles X 3 cu.yds. 21 cu.yds. For Aroclor Surge Tank, Item 586 4 Concrete piles X 3 cu.yds. 00 Excavation 12 cu.yds. For Floor of Operating Area 2300 ft2 X 1' deep 85 cu.yds. For Motor Control Center and Foreman1 Office 5 cu.yds. 6* deep X 5' wide X 40' 07 - Foundations For Structural Steel 14- 20" square pads 3' deep 4.2 cu.yds. 0355848 TOWOLDMONOQ44754 Appendix F CEA 1800 Page 3 For Blow Tank 1.75 cu.yds. 1 - 1' X 3' high X 7' long support 1 - l*s' X 2' deep X 8' long support For Inter Storage Tank, Item 424 6.4 cu.yds. 18" thick X 12' dia. For Floors 85 cu.yds. Miscellaneous Supports, etc. 5 cu.yds. Pipe Supports 6X2 cu.yds. 12 cu.yds. For Motor Control Center & Foreman's Office Support 5' X 1.5' X 80' = 600 ft2 6 cu.yds. Floor 800 ft2 08 - Supports Structure Supports 65 tons Grating 4500 sq.ft. Handrail 500 ft. Toe Plate 500 ft. Stairway (15 ft. elev.) 4 For Motor Control Center & Foreman's Office 5 tons For Item 545 09 - Building Items 5 tons 5 unit heaters with associated piping for operating structure. For Motor Control Center and Foreman's office 2 personnel doors (3' X 6'8") Windows for office, 3 units 4' X 10' 10 - Sprinklers None 0355849 TOWOLDMON0044755 Appendix F CEA 1800 Page 4 - piping Notes * With 2 - 1/2" O.D. copper tracers and insulated ' - 1-1/2" thick insulation. ** With 1 - 1/2" O.D. copper tracer and insulated - 1-1/2" thick insulation. Item 403 - Biphenyl Mix . * Charge - 50 ft. of 2" IPS C.S. pipe with 2 No. CD3 valves. * Overflow - 50 ft. of 3" IPS C.S. pipe. * vent - 15 ft. of 3" IPS C.S. pipe with spark arrestor jacketed. Steam - 30 ft. of 1" IPS C.S. pipe to coil with 2 valves. - 30 ft. of 1" IPS C.S. pipe from coil with 2 valves. Item 404 - Biphenyl Feed * Charge - 20 ft. of 2" IPS C.S. pipe with 1 No. CD3 valve. * Overflow - 25 ft. of 2" IPS C.S. pipe. * To Item 405 - 20 ft. of 3" IPS C.S. pipe with 2 No. CD3 valves. Items 406, 410, 414 and 418 - Continuous Chlorinators Chlorine Charge Line 200 ft. of 4" IPS C.S. pipe with 6 DE6 valves. * Circ. lines 280 ft. of 3" IPS C.S. pipe with 28 CD3 valves. * Transfer to Item 422 75 ft. of 3" IPS C.S. pipe with 4 CD3 valves. Vent Lines 50 ft. of 3" IPS C.S. pipe with 2 CD3 valves. Trace chlorinators to allow for winter operation - 400 ft. of 1/2" copper tracing per chlorinator. Item 405 - Biphenyl Feed Pump * Chlorinator Charge - 80 ft. of 2" IPS C.S. pipe with 4 No. CD3 valves. * Chlorinator Return - 70 ft. of 2" IPS C.S. pipe with 1 No. CD3 valve. 0355850 TOWOLDMONOQ44756 Appendix F CEA 1800 Page 5 Tf.em 422 - Blow Tank ' * Charge 30 ft. of 44 " IPS C.S. pipe with 1 No. CD3 valve. Vent 35 ft. of 66 " IPS Saran lined steel pipe. Blow Line 30 ft. of 22 " IPS C.S. pipe with 4 valves. To Item 423 10 ft. of 33 " IPS C. S. pipe with 1 No. CD3 valve. Item 424 - Intermediate Storage ** From Item 423 75 ft. of 2" IPS C.S ** Overflow 25 ft. of 3" IPS C.S Vent ** To Item 425 10 ft. of 3" IPS C.S 10 ft. of 3" IPS C.S Item 425 - Transfer Pump ** To Item 502 & 511 - 50 ft. of 2" IPS C.S. pipe with 2 No. CD3 valves. ** To Existing Chlorinators - 75 ft. of 2" IPS C.S. pipe with 3 No. CD3 valves. Off-Gas System Present HC1 header at southwest section of 12 ft. level to be modified and new line run from this header to new off-gas con denser, Item 427. ** Piping Required 30 :ft. of IPS <:.s. pipe. t* From Chlor. 6-9 100 ft. of 6" IPS C.S. pipe with 2 CD3 valves Circ. Water System 75 ft. of 3" IPS C.S. pipe. Drain From Item 427 15 ft. of 4" IPS C.S. pipe. To HC1 Recovery 40 ft. of 6" IPS C.S. pipe. HC1 Transfer 1300 ft. of 8" IPS C.S. pipe from Dept. 246 to Dept. 218. Steam to Item 429 * * To Item 431 ** From Item 431 60 ft. of 2" IPS C.S. pipe. 20 ft. of 3" IPS C.S. pipe. 90 ft. of 2" IPS C.S. pipe. 0355851 TOWOLDMON0044757 Appendix P CEA 1800 Page 6 Aroclor Circulating System To Items 504 & 526 125 ft. of 4" IPS C.S. pipe. From Items 504 & 526 125 ft. of 4" IPS C.S. pipe . With 4 valves. Item 502 - Still Pot Item 511 - Still Pot . Montar Drawoff 2-15 ft. of 2" IPS C.S. pipe = 30 ft. With 4 valves To Items 505 & 512 2-15 ft. of 14" IPS C.S. pipe = 30 ft. ' From Items 505 & 512 2-25 ft. of 10" IPS C.S. pipe = 50 ft.Above lines insulated with 2" thick insulation. Item 506 - Still Condenser Item 513 - Still Condenser To Item 508 & 515 2-15 ft. of 3" IPS S^S. pipe = 30 ft. Item 508 & 515 - Still Receivers To Items 523 & 524 2-30 ft. of 4" IPS C.S. pipe = 60 ft. with 2 valves ** To Items 510 & 517 2 - 15 ft. of 3" IPS S.S. pipe = 30 ft. with 1 valve Item 523 & 524 - Catch Tanks Drain Lines To Ejectors ) Items 509 & 516 ) 2-35 ft. of 2" IPS C.S. pipe = 70 ft. with 2 valves 2-15 ft. of 4" IPS C.S. pipe = 30 ft. with 2 valves. Item 509 & 516 - Ejectors Steam Lines 60 ft. of 1-1/2" IPS C.S. pipe Drain Line 30 ft. of 3" IPS C.S. pipe 0355B52 TOWOLDMON0044758 Appendix F CEA 1800 Page 7 Item 518, 519 & 520 - Aroclor Cooling System From Item 519 to Item 520 30 ft. of 2" IPS C.S. pipe with 2 valves. From Item 520 to Items 506 & 513 60 ft. of 2" IPS C.S. pipe with 2 valves. From Items 506 & 513 to Item 518 30 ft. of 2" IPS C.S. pipe From Item 518 to Item 519 ' 30 ft. of 2" IPS C.S. pipe Item 503 & 525 - circulating Pumps ** 2-15 ft. of 4" IPS C.S. pipe = 30 ft. with 4 valves ** 2-10 ft. of 4" IPS C.S. pipe = 20 ft. with 2 valves * 1 - 150 ft. of 2" IPS C.S. pipe for transfer to Still No item 530 & 537 - Surge Tanks From Items 510 & 517 To Items 531 & 538 Water/Steam Overflow From #2 Still Receiver 2-25 ft. of 2" IPS A1 pipe with 2 valves 2-20 ft. of 2" IPS A1 pipe with 2 valves 100 ft. of 2" IPS C.S. pipe 2-15 ft. of 3" IPS A1 pipe 200 ft. of 2" IPS A1 pipe with 2 valves Items 532, 539 & 540 - Absorbers * To Absorbers 100 ft. of 2" IPS A1 pipe with 5 valves ' * From Absorbers 100 ft. of 2" IPS A1 pipe with 5 valves Items 541 & 533 - Filters **75 ft. of 2" IPS A1 pipe with 4 valves Items 534 & 535 - Surge Tanks * Vent Lines * To Item 544 * To Item 536 * From Item 544 * From Item 536 Steam Lin? 2-25 ft. of 3" IPS A1 pipe 20 ft. of 3" IPS A1 pipe 20 ft. of 3" IPS A1 pipe 100 ft. of 3" IPS A1 pipe 125 ft. of 3" IPS A1 pipe 100 ft. of 1-1/2" IPS C.S pipe Items 426 & 433 - Scrubbers Water Inlet Drain Line 100 ft. of 2" C.S. pipe with 3 valves 30 ft. of 8" Saran lined steel pipe 30 ft. of 12" Saran lined steel pipe 0^853 TOWOLDMONOQ44759 Appendix F CEA 1800 Page 8 m< scellaneous Feed line from batch blow tank to Items 502 & 511 ** 125 ft. of 2" C.S. pipe with 4 valves To Item 434 - 20 ft. of 3" C.S. pipe with 1 valve ) ? - Ductwork None required. 13 - Electrical Motors to be installed and wired 5 - 2 HP 1 - 3 HP 7 - 5 HP 1 - 7*5 HP 7 - 10 HP 6 - 15 HP 2 - 20 HP 1 - 50 HP . Allow for remote pushbuttons and alarms for 15 motors. Lighting required: Operating area: Foreman's office: 16 - 20 ft. X 20 ft. bays 2 225 ft Motor Control Center: 225 ft^ Install 600 ampere breaker in Sub. No. 17. Install fans in Sub. No. 17 transformer. Transfer feeder 8-1 from Sub. #8 to #17. Install overhead feeder cable from Sub. #17 to Bldg. CF, capacity 600 amperes, length 400 ft. Install 400 ft. of feeder cable from breaker 8-1 to Dept. 246, capacity 600 amperes. . -** ~ Site Preparation None allowed for. 0355854 TOWOLDMONOQ44760 Appendix F CEA 1800 Page 9 IS - Sewers Floor drains Sewer pipe Excavation Sewer tie-in Drinking fountains 6 surface drains. 130 ft. of 4" permanite sewer pipe with two tie-ins to existing 8" sewer which runs directly south of Dept. 246. 2 ft. X 4 ft. X 130 ft. = 40 cu.yds. Two for scrubbers. Two required. 16 - Underground Mains None allowed for. 17 - Yards Allow for gravel surfacing approximately 2000 ft of access areas. 18 - Railroads None allowed for. 19 - Insulation Piping Equipment Vessels - Refer to Code 11. - As below - Material Std #100, Weather-proof Std #65. Item Area Thickness 403 404 422 424 429 430 500 501 502 505 508 511 512 515 519 235 ft2 235 ft2 540 ft2 855 ft2 428 ft2 100 ft2 20 ft2 20 ft2 330 ft2 130 ft2 205 ft2 330 ft2 130 ft2 205 ft2 100 ft2 iy iy 1*5" 1*5" 1*5" 1*5" 1*5" 1*5" 2" 2" 1*5" 2" 2" 1*5" . 1*5" 0355855 TOWOLDMONOQ44761 Appendix F CEA 1800 Page 10 Item 537 539 540 541 542 543 530 532 533 534 535 585 586 409 413 417 421 504 526 545 20 Pumps Area 205 ft2 160 ft2 160 ft2 50 ft2 330 ft2 330 ft2 205 ft2 160 ft2 50 ft2 330 ft2 330 ft2 120 ft2 200 ft2 60 60 ft2 60 ft2 60 ft2 100 ft2 100 ft2 160 -- H>f t to <1t*o Thickness 1*5" 1*5" 1*5" 1*5" 1*5" 1*5" 1*5" 1*5" 1*5" 1*5" 1*5" 3" 2*5" 1*5" 1*5" 1*5" 1*5" 1*5" 1*5" 1*5" 1*5" Painting Coating Std #502, Epoxy system Supports for Items 408, 518, 523 and 524. 412, 416, 420, 426, 433, 427, 509, 516, Items 406, 410, 414, and 418 Uninsulated piping - air, water. Walls. Masonry, Roofs Concrete block structure attached Allow for 4 walls 15` X 20' high. to existing control room, total area - 1200 ft . Concrete roof deck, with tar paper coating - area 250 ft2 . 035586b TOWOLDMONOQ44762 Appendix F CEA 1800 Page 11 -in - Dismantling Item No. 172 173 Equipment No. 21-5150 38-5588 Description Mist eliminator, 30" X 13' Brinks unit Heat exchanger, 16" o.D. X 8' long Present 6" HC1 line to Dept. 218 will be dismantled. 93 - Relocations and Modifications Expense Move and relocate one power line pole and electric wires now in conflict with the new structure. Move and relocate the following pipe lines which are south of the existing plant and which will interfere with the new struc ture. Air line - 40 ft. of 4" C.S. pipe Chlorine line - 40 ft. of 4" C.S. pipe Instrument air line - 40 ft. of IV' C.S. Pipe Water line - 40 ft. of 3" city water line 035585* TOWOLDMONOQ44763 CEA 1800 Date: August 28, 1967 By: R. S. Yates SCOPE OF WORK Aroclor Expansion at W. G. Krummrich Storage Tank Farm Appendix "G" 0355858 TOWOLDMONOQ44764 Appendix G CEA 1800 j j Date: August 28, 1967 i . By: R. s. Yates ; Page 1 1 -'<> facilities included in this project are intended to: J. insure adequate supply of biphenyl. Assure storage capacity for minimum inventories of various Aroclors * so that bulk shipments can be made on demand. 3. Minimize the potential for cross contamination. i. provide additional unloading facilities for biphenyl. 0. Remove existing underground storage tanks. "nor Equipment Includes 1 - 100,000 gallon Steel Tank for Biphenyl. 2 - 22,000 gallon Aluminum Tanks for Aroclor 1242. 1 - 22,000 gallon Aluminum Tank for Aroclor 1254. 1 - 22,000 gallon Aluminum Tank fpr Aroclor 1260. 1 - 22,000 gallon Aluminum Tank for Aroclor 1248. All storage tanks to have plate coil heaters and to be insulated over the lower half. Tank for 1260 to be completely insulated. Punas All 316 SS. 1242 - Common pump for two storage tanks. 1254 - Pump for two storage tanks. 1260 - Pump for one storage tank. 1249 - Pump for one storage tank. Pi Iters All 316 SS. Separate filters for 1242, 1254, 1260. .'.-Jrate transfer lines from existing transfer pump (Item 144) to each 1 to truck dock as follows: 03518*9 TOWOLDMONOQ44765 Appendix G CEA 1800 Page 2 . -,2 - From day tank to storage - to manifold station ..34 - From day tank to storage - to manifold station ^<30 - From day tank to storage - to manifold station 1148 - From day tank to storage --to manifold station separate circulating lines on each tank. Linos to be 2" & 3" IPS aluminum with single 1/2" copper tracer and insulated. railroad 1. Extend spur track #10A, 125 feet and tie into existing track 10. 01 Equipment ' See Equipment List and Summary 01 instrument Items See Instrument List and Summary 03 Setting and Testing Equipment Area is accessible for truck and train unloading. High lift can be used advantageously. 01 Setting and Testing Instruments . Normal conditions. Ojj Excavations For 100,000 gallon tank - 251 x 30' high For good soil (30'0 x 15 feet deep) Ring Wall (25'0) Sandfill Pump Foundations 400 cu yds 10 cu yds 19 cu yds 3 x 2 cu yds Pipe Supports 6 cu yds 9 \: 3 cu yds 27 cu yds 0355860 TOWOLDMONOQ44766 Appendix G CEA 1800 Page 3 For 5 storage tanks For good soil 880 cu yds 35' x 35' x 15' = 18,400 ft? 20' x 18' x 15' = 5,400 ft3 23,800 Total Excavation Spoil Backfill 1,369 cu yds 1,300 cu yds 07__ Foundations Pumps 4x2' x 3' x 2' 2 CU yds Pipe Supports 9 x 2-1/2 cu yds 25 cu yds Loading Dock 5 cu yds Miscellaneous 5 cu yds Base for 5 tanks 5 x .78 x 142 x 10/12 = 635 ft? 5 x 3.14 x 14 x 4' x 10/12 = 735 ft? 1370 ft 55 cu yds Soil tests will be required. 08 Supports, Platforms and Structures Loading Dock - (2 required for biphenyl cars) 2 ton Tank Platforms 4 ton Ladder to top of biphenyl storage tank - 30 ft Grating 700 sq ft- Handrail 350 lin ft Toe Plate 350 lin ft y-' Building Items None 2.1 Sprinklers and Fire Protection None required. t 03558*>1 TOWOLDMONOQ44767 Appendix 0 . CBA 1900 Page 4 j'iuing j-.em 401 - Piuhenyl Storage Tank )5 ft c 4" IPS CS pipe for pump suction with one valve. '0 ft of 2" IPS CS pipe for circ. line with r.o valve. 100 ft of 2" IPS CS pipe from unloading spot to tank with two valves. ' ?.0ft of 2" IPS CS pipe from pump dischar.-.; to Item 1C'2, exist--.:, ifpkenyl storage tank, with two valves. 200 ft of 3" IPS CS pipe from Building CR to storage tank with two valves for stetm supply. 2C0 ft of 1" IPS CS pipe for miscellaneous steam services at storage tank. Proc :ss Piping -lx 1/2" OD copper tubing tracers with 2-1/2 insulation, 2" thick. Steam Piping - 2" thick insulation. Stc:: a a a ranks (Item 558-562) 5 Circ. Lines - 250 ft of 2" IPS A12 pipe with 5 AL valves. 5 Vent Lores - 53 ft of-3" IPS A12 pipe with 5 AL valves. 200 ft of 1-1/2" IPS CS pipe for steam to plate coils with .16 valvea. Piping - i x 1/2" OD copper tubing tracer with 2-r/2" & 3-1/2" druneter insulation 2" thick. Steam piping - 2" insu lation. Nitrogen Picinq 250 ft of 1-1/2" IPS CS pipe with 10 valves from existing nitrogen station., Instrument Air Pipi.ng 200 ft of 1-1/2" IPS galvanized pipe with 16 valves. Transfer Piping to Storage Yanks Tie into existing lines at Tanks 9, 10, 11, (Items 117, 118, 119). Piping required: 200 ft of 2" IPS aluminum pipe with 8 valves. (Note for 1254, 1242, 1262; 03558b2 TOWOLDMONOQ44768 Appendix G . CEA 1800 Page 5 Kew 1248 line from existing transfer pump (Item 144) piping required: 150 ft of 2" IPS aluminum pipe with 2 valves. piping; 1 x 1/2" OD copper tubing tracer with 2-1/2" diameter insulation 2" thick. Transfer Piping to Loading Station (Tank Car) Pnr 1242: 225 ft of 3" IPS aluminum pipe with 3 valves and aluminum loading arm for tank cars. For 1254; 225 ft of 3" IPS aluminum pipe with 3 valves and aluminum loading arm for tank cars. For 1260: 250 ft of 3" IPS aluminum pipe with 3 valves. For 1248; 250 ft of 3" IPS aluminum pipe with 3 valves. Pipings 1 x 1/2" OD copper tubing tracer with 3--1/2" diameter insulation ;2" thick. Transfer Pipinql to Loading !Station (Truck Dock) For 1242: 100 ft of 3" IPS aluminum pipe with 1 valve. For 1254: 100 ft of 3" IPS aluminum pipe with 1 valve. For 1260: 100 ft of 3" IPS aluminum pipe with 1 valve. For 1248: 100 ft of 3" IPS aluminum pipe with 1 valve. iin2* 1 x 1/2" OD copper tubing tracer with 3--1/2" diameter insulation 2" thick. Transfer Piping to Drumming Station For_ 1242: 100 ft of 2" IPS aluminum pipe with 2 valves. For 1254;: 100 ft of 2" IPS aluminum pipe with 2 valves. For 1260: 100 ft of 2" IPS aluminum pipe with 2 valves. For .1248: 100 ft of 2" IPS aluminum pipe with 2 valves c_;_ng i 1 X 1/2" OD copper tubing tracer with 2-1/2" di. insulation 2" thick. rlrCt Work F'.he 0355863 TOWOLDMONOQ44769 Appendix G CEA 1800 Page 6 j rl ectrical. install 4 x 15 HP motors for pumps. SO interlocks or alarms required. install 8 street light type, 400 watt mercury arc fixtures for load ing dock, tank farm perimeter and area lighting. install 8-175 watt mercury arc fixtures over tank farm area. 11__ site preparation None 15 Sewers and Drains None 16__ Underground Mains None _!_?__ Yards, Roads, Fencing Chat will be placed around storage tank area, depth 12". ror Item 401 2,500 ft2 For 5 Storage Tanks 2 1,600 ft 18 Railroads Spur track #10A will be extended 125 ft and a switch installed at the end to bring the spur back into main track #10. Existing bumper will be removed. .13__ Insulation Piping; Insulation is covered in the category #11 - piping. Tanks; Item 401 Item 558 Thick, 1-1/2", insul. Spec. No. 100 (Calc, Silicate) with weather barrier. Side Wall - 7fDH = 3.14 x 25' x 30' 2,360 ft2 Top - 7f D2 = 3.14 x (25)2 490 ft2 44 2,850 ft2 Thick, 1-1/2", Insul. Spec. No. 100 (Calc. Silicate) with weather barrier. Side Wall - ff DH = 3.14 x 13' x 12' = 490 ft2 3 Remaining area to be spray covered with cork filled asphalt mastic. Spec. No. 700 1 TOWOLDMONOQ44770 . Side Wall _ - Top TTP = .78 x (13) 4 Appendix G CEA 1800 Page 7 490 ft? 132 ft 622 ft2 Item 559 Item 560 Item 562 - Same as - Same as - Same as Item 558 Item 558 Item 558 Item 561 - Thick, 1-1/2", Insul. Spec. No. 100 (Calcium Silicate) with weather barrier. Side Wall - 771>H = 3.14 X 13 X 24 = 980 ft2 Top area to be spray covered with cork filled asphalt mastic, Spec. #700. Top 132 ft2 20 Painting Spec 502 for all steel items. 90 Dismantling Remove pump 4247 and motor 9905 now on Tank #10,(Item 118). Dismantle 3 X 14,000 gallon underground storage tanks and associated equipment: Item No. Equipment No. 148 21-0768 149 19-0585, 66-0853 150 21-0769 151 19-0584, 66-1501 152 21-1310 153 19-0929, 66-0856 Description 10' Dia. X 26' long U.G. Hor. Tank Pump and Motor 10' Dia. X 26' long U.G. Hor. Tank Pump and Motor 10' Dia. X 26' long U.G. Hor. Tank Pump and Motor Relocation Replace two existing pipe supports going out to present tank car loading dock. 0355865 TOWOLDMONOQ44771 J Monsanto * `ocaiioni w. B. Howard - St. Louis ' August 28, 1967 ' : PROJECT LOSS PREVENT ION REPORT 67-65 CEA-1800 . J /rJro S. Yates (Project Manager) J- COPIES TO THOSE PRESENT J. R. Fullgraf H. D. Gabelman R. J. Green W. B. Howard J. MacPherson - Anniston M. J. Pistek - WGK H. F. Ray - WGK R. P. Stevens R. S. Yates . R. E. Doerr R. E. Howard J. L. Mathews H. B. Patrick - WGK S&PP Project File S&PP Location File ' DATE AND PLACE OF MEETING August 15, 1967, Creve Coeur, Missouri. CEA-1800 Increase Liquid Aroclors1 Capacity, WGK Plant, Sauget, Illinois. This project is for installing a new aroclor manufacturing plant and a tank farm. The capacity will be 40M ppy. The capital is approximately $1.4M; completion target is approximately January, 1969. ' The project includes installation of a 100M gallon biphenyl storage tank and extension of trackage for access to this tank. Two biphenyl unloading docks will be provided. The drainage from the 100M gallon biphenyl tank will be away from the process. PROCESS Biphenyl Storage Tank This storage tank will be air blan keted; it was stated that contact of the biphenyl with air will not result in deleterious effects on the biphenyl. The flash point of biphenyl is 235F. It was therefore , agreed that low pressure steam (5 psig max.) would be used for heating the large storage tank, the 25,000 gallon tank, and tank cars, in order to avoid heating above the flash point. 0) 03^86b TOWOLDMONOQ44772 2 2. Addition of Ferric Chloride to Biphenyl Mix Tanks The ferric chloride is added batchwise to the mix tanks by opening the tanks and dropping in the solid. It was agreed that, in order to prevent formation of any flammable mix tures above the biphenyl in these tanks (Nos. 403 and 404), the temperature of material in the mix tanks will be held below the flash point. 3. Chlorination System The chlorination proceeds at a tempera ture of about 150C; approximately 550 BTU's are evolved per pound of chlorine added. Heat removal is accomplished by circulating batch material through an external air cooler and back into the chlorinator. Safety provisions include the following: (a) A high temperature sensing element in the chlorinator mass detects high temperature, shuts off chlorine, and alarms. (b) Circulating pump shutdown (motor circuit detection) shuts off chlorine feed. (c) A temperature detector in the circulating line is used for temperature control in the system. When this ele ment detects low temperature it alarms and also shuts off the air cooler fan. (d) A temperature detector in the chlorinator mass (separate from No. _a_;_ above) alarms at a high temperature which is lower than the temperature at which the element in a. alarms and shuts off chlorine. FIRE PROTECTION A new open type structure will be erected adjacent to Building CR. No automatic sprinkler protection is required for this structure. It should be noted, however, that a spill of biphenyl at a tem perature above its flash point (235F) has resulted in fires. The existing hydrant protection is considered adequate to extin guish such a fire. LOSS EXPOSURE The therminol furnace consists primarily of a cylindrical combustion chamber containing finned tubes. Although an explosion in the combustion chamber is possible, the combustion chamber could in all probability contain the explosion pressure. There appears to be no major hazard from this source. The stack might of course be blown off. fa) 0355867 TOWOLDMON0044773 A more likely source of loss exposure would appear to be the burning of a tube in the therminol furnace. A tube could be replaced within about two days if one is in stock. On a soldout basis the business interruption loss would be approximately $20M. The repair cost was approximated at $3M. LOSS PREVENTION GUIDE Attached to R. S. Yates' copy of this report is a copy of Form G-1425, Loss Prevention Review Guide, which can be used as a safety checklist for this project. LOSS PREVENTION REVIEW BY PLANT The S&PP Branch of CED docs not plan a complete review of design prints for safety provisions. S&PP requests plant personnel, including plant safety personnel, to follow the development of design prints and to check the pro gress of construction with particular emphasis on personnel safety and loss prevention. . SAFETY MANAGER R. J. Green will be Safety Manager for this project. Please contact him for reviews during the design phase of this project. La)- |~4 W. B. Howard j's o3.j58b8 TOWOLDMONOQ44774 W. B. Howard - General Offices August 29, 1967 CC: PROJECT LOSS PREVENTION REPORT 67-64 iCt CEA-1430 ro Mr. R. S. Yates (Project Manager) sr COPIES TO THOSE PRESENT J. R. Fullgraf H. D. Gabelman R. J. Green W. B. Howard J. MacPherson - Anniston M. J. Pistek - WGK H. F. Ray - WGK R. P. Stevens R. S. Yates* 1 2 R. E. Doerr R. E. Howard J. L. Mathews P. K. Ward - Anniston S&PP Project File S&PP Location File DATE AND PLACE OF MEETING Missouri. August 15, 1967, Creve Coeur, CEA-1430 Increase Liquid Aroclors Capacity, Anniston Plant, Anniston, Alabama. . This project is for a new tank farm, mixing area, flaking area^ and drumming area. Capital will be approximately $1.6M; completion target is January, 1969. Although no additional capacity is claimed under this project, the operation will be changed from three shift, seven day, to one shift, seven day. A flaker will be added for solid aroclors and another flaker for biphenyl. Exhaust systems will be provided to remove fumes from the flakers. 1. mix Tank Solutions of aroclors are prepared in toluene and xylene in a mix tank. The toluene and xylene used for this purpose are pumped from drums directly into the 2,000 gallon mix tank. This tank is jacketed for steam and for water. The tank will be nitrogen padded. 2. Biphenyl Surge Tank The flash point of biphenyl is 235F. The biphenyl surge tank in the flaking area will be heated, but only to approximately 80C. The biphenyl will thus be below the flash point. /Jpprrtb iy (v) 03 55 8<>9 TOWOLDMON0044775 i 3 3 ;j 3 J 3 ,3 .3 ,3 ,1 .3 3 3 3 3 ] .1 J Mr. R'. S. Yates -2- August 29, 1967 3. scale-up of Flaker Size The new flakers will be of significantly larger size than the present flakers. The aroclors are expected to perform on the new flakers as well as, or better than, they do on the present flakers. The biphenyl gives some problems in flaking with the present flakers, and some of these problems may continue with the new flakers. Although there is a scale-up factor with the new flakers, no significant scale-up problems are anticipated. ' FIRE PROTECTION A 120' x 601 x 1 story metal siding on steel frame prefabricated type building will be erected north of Bldg. 27 for flaking and drumming of aroclors. It is recommended that this building be provided with an ordinary hazard wet pipe system of automatic sprinklers. The system should be supplied from a feed connected to the fire main in Fifth Street with a post indicator type shut-off valve located at least 25 ft. from the proposed building. LOSS EXPOSURE The maximum probable loss is anticipated to occur from the scarring of an aroclor flaker roll. Re surfacing of the roll would require about one month. On this basis the BI loss would be approximately $100M. Equip ment repair costs for the resurfacing would be approximately $4,000. LOSS PREVENTION GUIDE Attached to R. S. Yates' copy of this report is a copy of Form G-1425, Loss Prevention Review Guide, which can be used as a safety check list for this project. LOSS PREVENTION REVIEW BY PLANT The S&PP Branch of CED does not plan a complete review of design prints for safety provisions. S&PP requests plant personnel, including plant safety personnel, to follow the development of design prints and to check the progress of construction with particular emphasis on personnel safety and loss prevention. SAFETY MANAGER R. J. Green will be Safety Manager for this project. Please contact him for reviews during the design phase of this project. , R. J. Green ^B- H W. B. Howard ps T (*) 0355870 TOWOLDMONOQ44776