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ABD00287610 VCM UNLOADING OPERATING MANUAL ABERDEEN CHEMICAL PLANT ABERDEEN, MISSISSIPPI JUNE 3, 1983 Revised By \ *3. C. Greene Process Engineer Approved B (D. L. D. Honeycutt Yard Supervisor Cult Approved By: P. 'E. Markey ^ Vinyl Operation Supt. ABD00287678 ATTACHMENT B , EMERGENCY ORGANIZATION CALL LIST 1-9 When advised by the Shift Supervisor, or his designee, the guard will start calling the names listed bleow in numerical sequence (rank order) from the appropriate list. Vinyl Compound Utilities 1. D. J. Miller 369-9234 2. P. E. Markey 369-6019 3. L. D. Honeycutt 343-5595 4. C. R. Miller 369-9100 5. A. H. Sather 369-9271 6. V. A. Belk 369-4416 7. J. friend 369-7377 (1) J. Frossard 369-6990 8. J. L. Horseman 369-6005 9. C. E. Davis 369-8780 10. C. R. Snowden 1-327-7382 11. F. W. Frantz 369-8508 12. P. J. Kober 369-7096 13. R. G. Gilreath 369-7745 14. J. G. Roberts 369-8059 15. J. V. Uptain 369-8109 16. M. H. Williams 1-963-2796 17. G. A. Morgan 369-6522 18. R. A. Miller 1-327-0951 19. R. A. Frohreich 1-328-3628 20. V. L. Thornhill 369-8952 21. S. C. Hillman 369-7892 1. R. G. Gilreath 1. J. L. Horstman 369-7745 369-6005 2. P. J. Kober 2. F. W. Frantz 369-7096 369-8508 3. L. D. Honeycutt 3. C. E. Davis 343-5595 369-8780 4. C. R. Miller 4. C. R. Snowden 369-9100 1-327-7382 5. A. H. Sather 5. C. R. Miller 369-9271 369-9100 6. V. A. Belk 6. A. H. Sather 369-4416 369-9271 7. J. Friend 7. V. A. Belk 369-7377 369-4416 8. J. Friend 369-7377 (2) L. Michels (3) J. Pope 369-6743 Unlisted (Call So. Central Bell Operator) 8. J. L. Horstman 9. L. D. Honeycutt 369-6005 369-5595 9. C. E. Davis 10. P. E. Markey 369-8780 369-6019 10. C. R. Snowden 11. D. J. Miller 1-327-7382 369-9234 11. F. W. Frantz 12. P. J. Kober 369-8508 369-7096 12. P. E. Markey 13. R. G. Gilreath 369-6019 369-7745 13. D. J. Miller 14. J. G. Roberts 369-9234 369-8059 14. J. G. Roberts 15. J. V. Uptain 369-8059 369-8109 15. J. V, Uptain 16. M. H. Williams 369-8709 1-963-2796 16. M. H. Williams 1-963-2796 22. J. C. Green 27. R. W. Rye 369-9288 369-4730 23. W. W. Robinson 28. D. D. Knight 369-8606 1-205-698-9545 24. W. F. Higginbotham 29. R. D. Jackson 1-327-0827 369-2405 25. J. A. Dixon 30. V. E. Messick 369-8372 1-327-0741 26. J. L. White 369-2991 31. D. S. Cox 369-8752 Section 1.231 Page 12 ABD00287679 A ABD00287680 ATTACHEMENT 0 PLANT EMERGENCY ALARM DATA SHEET DATE: ALARM: (Circle One) Fire Vapor TIME: Evacuation* Tornado** * Evacuation alarm must follow either the fire or vapor alarm. ** The tornado alarm and the evacuation alarm are the same alarm. The difference lies in the fact that the evacuation alarm by itself means a tornado is approaching. The evacuation alarm must be proceeded by either the fire or vapor alarm. LOCATION: ____________________ SPECIFIC NATURE OF PROBLEM Alarm Activated By: Section 1,232 Page 15 ABD00287681 SAMPLE RAILCAR PLACARD ABD00287682 ABD00287683 F. PHOTOGRAPHS 1-9 ABD00287684 1-9 FIG. 3 - UNLOADING ARRANGEMENT FOR VCM TANKCARS ABD00287685 A 1-9 TO BULLETS COMPRESSOR #4 LIQUID VAPOR LINE COMPRESSOR #5 LIQUID VAPOR LINE COMPRESSOR #3 LIQUIP/VAPOR LINE COMPRESSOR n LIQUID/VAPOR LINE ------------ #1 SIGHT GLASS LINE -------#2 SIGHT GLASS LINE #3 SIGHT GLASS LINE FIG. 4 - PIPING AND VALVES ON VIEST SIDE OF THE COMPRESSOR SHED ABD00287686 1 4 FIG. 5 - SIGHT GLASSES FOR CHECKING VCM LIQUID UNLOADING, LOCATED ON EAST SIDE OF COMPRESSOR SHED SEEN LOOKING NORTHWARD ABD00287687 FIG. 7 - T (201) EMISSION RECOVERY SYSTEM KNOCKOUT POTNORTHWEST CORNER OF COMPRESSOR SHED OF COMPRESSOR SHED ABD00287611 VCM UNLOADING OPERATING MANUAL 1~9 ABERDEEN PVC PLANT TABLE OF CONTENTS I. INTRODUCTION Page No. A. Operator Responsibilities ................................................................................... 1 B. General Process Description........................................................................................ 3 II. OPERATING PROCEDURES A. Railcar Hookup.................................................................................................................. 10 B. Unloading Railcars ..................................................................................................... 17 C. Recovering Vapor From Railcars .......................................................................... 22 D. Unhooking Railcars ..................................................................................................... 24 E. Troubleshooting and Miscellaneous Operating Procedures 1. Liquid in the CompressorSuction..................................................................29 2. High Pressure on the Sphere or Bullets (or Evacuation) ... 29 3. Evacuating a Compressor for Maintenance. . ..................................... 30 4. Lack of Liquid Flow in Sight Glass....................................................... 33 5. Tank Car Excess Flow ValveClosing............................................................. 34 6. Evacuating the VCM Vapor Line Knockout Pot and Recycle Pump for Maintenance...........................................................................................35 III. EQUIPMENT INDEX...................................................................................................................... 37 IV. SAFETY EQUIPMENT AND SYSTEMS..........................................................................................40 V. EQUIPMENT ENTRY PROCEDURES ....................................................................................... 44 VI. APPENDIX A. Valve Setup Checklist B. Checklist for Testing Auto Valves C. Empty Outbound VCM Tank Car Inspection Report D. Plant Emergency Plan E. Sample Railcar Placard F. Photographs G. P & I Diagram A ABD00287612 1-9 VCM UNLOADING OPERATION MANUAL ABERDEEN PVC PLANT INTRODUCTION A. Operator Responsibilities The purpose of the VCM Tank Farm is to safely unload and store Vinyl Chloride Monomer (VCM). VCM is brought into the plant in tankcars. It is the main raw material used in making the plant's major product, polyvinyl chloride (PVC). VCM is a colorless sweet-smelling gas at atmospheric pressure that is stored and transferred as a liquid at moderate pressure (30-70 psig). The yard department is responsible for the offloading of VCM tankcars and the related transfer equipment. The yard operator helps fulfill the tankfarm's purpose by making sure that the VCM is safely unloaded without endangering his fellow workers or equipment. The operator is able to attain his goals in safety, job performance and efficient operation through a training period, on-the-job experience, and passing written and field examinations. The operator fulfills his responsi bilities by: 1. Demonstrating understanding of how his equipment functions. 2. Being able to explain what role each piece of equipment plays in the process. 3. Keeping a close and regular check on equipment. 4. Being able to demonstrate troubleshooting and corrective measures. 5. Keeping his area of responsibility safe and clean. 6. Keeping complete and accurate records. 7. Reporting equipment problems promptly and writing maintenance work orders as needed. 8. Operating the equipment in an environmentally sound manner and promptly taking corrective measures should process leaks occur.9 9. Wearing the proper respiratory protection. ABD00287613 VCM Unloading Operating Manual Page 2 1-9 I. INTRODUCTION (Cont.) A. Operator Responsibilites (Cont,) This operating manual will cover the normal responsibilities and duties of the yard operator when unloading VCM railcars. Each phase of the unloading procedure will be covered. In addition to normal operating procedures it will also discuss operations under abnormal conditions. The operator must be prepared to meet these situations with temporary measures until the abnormal condition is corrected or ceases to exist. The goal for VCM overexposure to employees is "ZERO". This is accom plished by operating the equipment as designed, prompt attention given to leaks per continuous monitor sensors and follow up work orders for maintenance. As we meet our goals for overexposure, all governmental guidelines will also be kept. Safety takes second place to no plant activity. The safety of the plant personnel and equipment is to be carefully considered before any job is started. The Conoco safety slogan is "Our work is never so urgent or important that we cannot take time to do it safely". Safety on the job must be our first and most important consideration. When we do a good job of planning our work with safety in mind, we are less likely to suffer injury or cause an accident. This allows us to meet our plant goal of employees going home unhurt. ABD00287614 VCM Unloading Operating Manual Page 3 1-9 I- INTRODUCTION (Cont.) B. General Process Description VCM tankcars are brought into the plant from various VCM plants through out the United States. Most of the VCM that comes into this plant comes from Conoco1s VCM Plant in Lake Charles, Louisiana. VCM also occa sionally comes from PPG in Lake Charles, B. F. Goodrich in Calvert City, Kentucky, Uniroyal in Gelsmar, Louisiana, or from Shell Norce Georgia Pacific, Plaquemine. A VCM Tankcar typically holds 175,000 pounds of VCM (about 23,000 gallons of liquid). If for some reason an Inbound VCM car*s gross weight is less than 255,000 pounds, the car must be rewelghed and spotted on the west track until billing weights are verified. This insures we receive what has been billed to the Aberdeen Plant. The cars are shipped to Aberdeen and stored on the Monroe lead until they are brought into the plant. Only the Monroe lead or new VCM spur can be used to store VCM railcars. This is a safety precaution so that all the VCM cars are kept in one general area. The railroad crew is responsible for bringing the VCM cars into the plant and "spotting" them at the VCM transfer stations that are on the platform at the VCM tank farm. This is usually done once per day except on weekends or holidays. A maximum of ten tankcars can presently be brought into the tank farm. The tank farm has eight transfer (unloading) spots. The platform is located between two sets of railroad tracks such that there are four transfer spots on each side. These are referred to by name as Spot No. 1, Spot No. 2, Spot No. 3, and Spot No. 4, from south to north (east side); and Spot No. 6, Spot No. 7, Spot No. 8, and Spot No. 9, from south to north (west side). Spot No. 5 (east side of platform) and Spot No. 10 (west side of plat form) are the two north locations for "spotting" tankcars, but there are no unloading facilities at these two spots. Once the railcars have been "spotted", it is the yard department's responsibility to unload the VCM ABD00287615 VCM Unloading Operating Manual Page 4 1-9 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) into T-60I which is commonly called the "sphere". This is done using the five Corken compressors at the tank farm. They are commonly referred to as Compressor No. 1, Compressor No. 2, Compressor No.3, Compressor No. 4, and Compressor No. 5, from north to south, respectively. Compressors No. 3 and No. 5 combined have about the same capacity as either Compressor No. 1, No. 2, or No. 4. The tankcars are connected to the compressor piping and the sphere piping with flexible hoses. The compressors pull vapor from the top of the sphere and compress it into the tankcars, forcing liquid out of the cars through a stand pipe, into the bottom of the sphere. Each tankcar has three valved connections in the dome of the car (two liquid lines and one vapor line). The liquid lines are 2" lines and point toward each end of the tankcar. The vapor line is a 1*5" line and points toward the side of the car. Refer to the photograph in the Appendix. Only one liquid line is usually hooked up on a car because the car does not unload significantly faster with two lines and it takes longer to hook up the car. Both liquid lines have to be hooked up on some type of cars (ACFX and PPGX cars) because the excess flow valves are set to close at lower rates than our normal unloading rate of 65-95 gpn:. The operator can tell when all the liquid has been unloaded from a car by watching the sight glass in the liquid transfer line. When the tankcar has been emptied, the 4-way valves on the compressor are reversed such that the compressor evacuates vapor from the car and discharges it into the top of the sphere. When the specified amount of vapor is removed from the tankcar, the compressors are shut down and the transfer lines VCM Unloading Operating Manual Page 5 ABD00287616 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) are evacuated. This must be done because of EPA (Environmental Protec tion Agency) regulations concerning the release of VCM vapor to the atmosphere. Then the transfer line can be unhooked and the cars are sent back to the respective VCM plant for reloading. All outbound VCM cars are to be weighed. Cars containing a heel greater than 600 pounds should be set aside for additional unloading. The plant can lose considerable amounts of VCM on heavy outbound cars, which can drastically impact on our plant*s cost effectiveness. There is a big difference in winter and summer operation of the tank farm. The primary reason is probably because the vessels are uninsulated and the transfer lines are lengthy and are exposed to ambient tempera tures along their entire run. The vapor pressure drops in the vessels and the tankcars as the temperature drops, making it harder to unload in cold weather because there is less VCM pressure to move the liquid through the pipes. Thus, unloading conditions can also vary from day to night and when rapid changes in weather occur. During the summer, eight tankcars can be hooked up at one time and unloaded with four or five compressors. Also, the tankcars will usually start unloading as soon as the valves on the liquid lines are opened. During winter conditions (ambient temperature approximately 40F or less), it is harder to start the VCM liquid unloading and only four tankcars can be unloaded at a time, with four or five compressors. If the weather gets extremely cold, it may take four compressors to unload only two or even one car, but this has not happened since the ABD00287617 VCM Unloading Operating Manual Page 6 1-9 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) system has been revised and vapor from the sphere is used. The volume of VCM kept in the sphere is usually large enough that sufficient vapor is available for the compressors. When the bullets were used, there was not enough vapor available and the tankcars unloaded very, very slowly, if at all. Other equipment at the tank farm includes the bullets, T-201 (west) and T-202 (east). These are not used for unloading VCM, even though each one presently contains a small amount of liquid VCM. They are piped up to take inerts from the recovered vinyl receivers if the incinerator should be down for an extended period of time. The transfer pumps on the bullets (Conoco Nos. 72-211 & 72-218) and the sphere (Conoco Nos. 72-217 & 72-270) are the responsibility of the vinyl department. The sphere transfer pumps send liquid VCM through a 4" line to the old and new reactor modules where it is charged into reactors and made into PVC. The bullet transfer pumps are not used at the present time. The emission recovery system knockout pot is also located at the tank farm, northwest of the compressor shed. The emission recovery system is located in the vinyl department old reactor module and is designed to collect and contain miscellaneous VCM emissions. It runs continuously. The knockout pot is connected to it via a 2" line that runs to the tank farm. A 15" Hg. vacuum should be maintained on this line at all times. This line is used to evacuate the VCM vapors from the transfer lines prior to unhooking cars. The knockout pot is the responsibility of the VCM Unloading Operating Manual Page 7 ABD00287618 X-9 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) vinyl department, but the yard operator should be familiar with the purpose of it. The knockout pot collects VCM vents from the following: a. Double Mechanical Seals on the sphere and bullets transfer pumps- Used by vinyl to bleed VCM from the seals when maintenance is required on the pumps. b. Corken Compressor Packings- The pot recovers vapor that leaks through the compressor packing into the distance piece. The vapor goes through a rotameter on each compressor into the pot. The valve above the rotameter should always be open when the compressor is running. The knockout pot must always have a slightly positive pressure on it or oil can be sucked out of the bottom of the compressors through the packing around the piston rods. This is the reason for the back pressure control valve on the knockout pot. c. Corken Compressor Relief Valve Discharges- The relief valve dis charges are piped to the knockout pot through a locked open valve. d. Corken Compressor Liquid Traps- Liquid caught in the traps is drained to the knockout pot through the 1" Jamesbury valves on the traps. Opening the 1" valve should let the liquid flow into the knockout *pot and then it is recovered to the emission recovery system. e. VCM Sphere and Bullet Recovery- The vessels can be recovered through the knockout pot. A procedure will be given for this in the opera ting procedures section. f. Sphere Liquid Lines Relief Valve Discharges- The three liquid lines ABD00287619 VCM Unloading Operating Manual Page 8 1-9 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) under the sphere have relief valves that discharge into a 1" line that goes to the knockout pot. The 1" valve on the line south of the compressor shed is locked open. The line runs into the header at the west side of the knockout pot, where the main 2" valve is also locked open. g. Compressor No. 1 Liquid Line Relief Valve Discharge- This relief valve is piped up to the compressor relief valve header through a locked open valve. h. Vapor Line Knockout Pot Relief Valve Discharge- This knockout pot is equipped with a relief valve whose discharge is piped through a locked open valve into the compressor relief valve header. The compressor relief valve header is connected to the emission recovery system knockout pot. i. VCM Recycle Pump Relief Valve Discharge- The VCM recycle pump located below the liquid line knockout pot is equipped with a relief valve which is piped up to the compressor relief valve header. A second knockout pot, called the vapor line knockout pot, is located just north of the emission recovery system knockout pot. The purpose of the vapor line knockout pot is to collect liquid VCM that may have collected in the main vapor line and prevent this liquid from slugging the compressors. A VCM recycle pump is located below this knockout poand is used to pump the contents of the pot to the sphere. The pump is started and stopped by two level switches in the pot. VCM Unloading Operating Manual Page 9 ABD00287620 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) Complete and accurate records must be kept on VCM unloading. These are necessary for accounting purposes and for communication between shifts. A VCM Unloading Card must be filled out and turned in to the accounting group for each car unloaded. Records are also kept in the yard scale-house on which cars were unloaded, when they started, when they were put on vapor, and when they were unhooked. A valve setup checklist also must be filled out by the yard opera tor when hooking up cars and starting unloading. Copies are to be kept on file by the yard supervisor. A copy of the checklist is included in the Appendix. Also included is a copy of the empty outbound VCM tank car inspection report. The automatic valves under the sphere are tested every Wednesday morning. The checklist used to record the results of this testing is shown in the Appendix. Copies of this checklist are to be kept on file by the yard supervisor. This testing must be coordinated with the vinyl panel operators so that the valves are not closed during VCM transfer to the reactor units. This should be coordinated by using the radios. ABD00287621 VCM Unloading Operating Manual Page 10 1-9 II. OPERATING PROCEDURES A. Railcar Hookup After VCM cars are brought into the plant, the yard operator "hooks up" each car by connecting transfer hoses to it. Vapor can then be trans ported into the car and the liquid VCM can be sent into the sphere. In the summer, two cars can be hooked up at each transfer station for unloading. During winter operation or when a rapid change in the weather is anticipated during unloading, only one car can be unloaded from each transfer station. Fresh air masks must be worn under the compressor shed, while opening or closing the railcar dome, or while connecting and disconnecting the transfer hoses. Gloves must be worn while handling the nipples and the transfer hoses. VCM cars are not to be hooked up during an electrical storm. Equipment Required 1. Fresh Air Mask 2. 1 1/2" Teflon Tape 3. 0-rings for Weco fittings (if needed) 4. Gloves Procedure 1. Get a fresh air mask and a roll of 1 1/2" Teflon tape, from the yard scale house. Also get "0" rings that are needed to replace the ones at the tank farm. Inspect the "0" rings individually for cracks and nicks. Do Not Use Defective "0" Rings. VCM Unloading Operating Manual Page 11 ABD00287622 1-9 H. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) 2. Raise the blue metal flag located on the railroad track south of the roadway. This flag states "Stop! Tankcar Connected." This procedure is necessary to Isolate the eight unloading stations and notify railroad personnel that VCM unloading is taking place. 3. Engage the derailer located near the blue flag. This will prevent railcars from entering the tank farm area when unloading is taking place. 4. Visually check the valves under the sphere to make sure they are set up for unloading. The 4" valve on the vapor line and the 6" valve under the sphere on the liquid line to the sphere must be open (both valves are actuated valves). 5. Record the sphere level on the checklist (see checklist in Appen dix). Turn the handle on the gauge to move the tape, then take the reading. If the tape does not bounce, notify the yard supervisor. The maximum allowable sphere level is 38 feet. To unload 4 tankcars the level must be below 32 feet - 3 inches (27 feet - 0 inches for 8 tankcars). 6. Check the railcar chocks and handbrake and ground the railcar. Make sure that the chocks are in good condition and are against the railcar wheels. Manually check the handbrake to make sure it is tight. Inspect the grounding cables to ensure that they are intact and in good working condition. Bond each car to the ground rod by attach ing the grounding clamp to the north side of the vertical siderail of the ladder. This prevents static accumulation during unloading ABD00287623 VCM Unloading Operating Manual Page 12 1-9 II. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) 6. (Continued) and eliminates dangerous sparking which could ignite any VCM leaks. It also prevents loss of the ground clamp if it is left connected during switching. Should one of the grounding clamps or cables be damaged, use the backup cable located on the south liquid boom arms at each spot except Spots No. 4 and No. 9 which have no backup cables. 7. Drain the water from the breathing air filter if necessary. (The filter is located between the rail tracks). 8. Climb the stairs to the unloading platform. If the stairs are wet or icy, be especially careful. Always be sure to use the handrail. 9. Go to the station you want to unload from, loosen the locks on the walkramp, and use your foot to push the ramp onto the car dome. The ramp will not operate if it is not in the middle of the platform opening. Adjust the height and length of the ramp and lock the ramp into place. Watch for pinch points when positioning the ramp and do not put any unnecessary strain on your back. 10. Unlatch the vapor and liquid line(s) and swing each line over the railcar dome area. Be careful not to let the lines swing back and catch your arm or hands. (The vapor line is the lV' line). 11. Remove the nipples from the holders and peel off the old Teflon tape. Inspect the threads and retape them with new tape up to 2" from the end of the threads. If the threads are worn, write a work order to replace the old nipples with new ones. VCM Unloading Operating Manual Page 13 ABD00287624 I_9 TI. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) 12. Remove the pipewrench from the holder and fasten it on one nipple. Then carry the pipewrench and nipples to the dome area of the car. Be careful not to drop the nipple and damage the threads. 13. Put on the fresh air mask and tighten it. Test the face seal by blocking the hose with one hand while trying to breathe in. If it leaks, adjust the straps or facepiece. Make sure you have a good face seal. 14. Purge the air line of any water that may be in the line. Connect the fresh air mask to the fresh air hose that is on the transfer line booms. 15. Break the domelid seal with the pipewrench and slide the latching bar so that the lid can be raised. Open the domelid and push it all the way back so that it cannot close. Be careful to use proper lifting procedures when raising the lid. 16. Visually check inside the dome area for leaks. Leaks will be indicated by condensation or icing around the valves and fittings. Check the plugs and caps and attached chains - if any are missing, note on the checklist. 17. Test the valves to make sure they are closed by pushing the valve handles against the closed stop. 18. Select the correct size wrench to fit the railcar valve plugs and remove the plugs. Be alert to the fact that the wrench could slip and trap your hand or fingers against the dome. Also do not stand in the direction of the valve opening in case a valve is leaking and VCM spews out. ABD00287625 VCM Unloading Operating Manual Page 14 1-9 II. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) 19. Push the port hole covers aside and screw the nipples into the valve opening until they are hand tight. Then tighten the nipples with the pipewrench. Be careful not to let the wrench slip. The nipples must be very tight or they will leak. Double check them after installing. 20. Close the vacuum breaking valves on the end of the transfer line booms. Make sure they are fully closed so that VCM will not leak to the atmosphere. 21. Unhook the flexlines and or Weco fittings from the holders on the booms. Be careful to minimize bending and twisting the flexlines during hookup. Excessive bending of the flexlines causes early failure of the lines. Visually inspect the flexlines for small holes or extremely worn areas of the armored weave. If a flexline is punctured, badly twisted or damaged, or in your judgment has a likely potential for failure during operation, contact maintenance and have the hose replaced. 22. Inspect the "0" rings individually and install them in the slots. The "O'* ring must be evenly seated to prevent leaks. "0" rings with cuts or nicks should be discarded. 23. Press the Weco union attached to the flex hose against the nipple inserted in the railcar. Check the alignment of the "0" rings to make sure there is a good seal. "0" rings that are pinched or crooked will cause leaks. Completely tighten the Weco hammerlock to prevent leakage. VCM Unloading Operating Manual Page 15 ABD00287626 1-9 II. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) 24. Check to make sure that the valve on the transfer line closest to the railcar dome is closed (it should be closed from the previous unhooking). Slowly pull the handle of each railcar valve up to open it. Opening the valves too fast can cause an undesirable surge of pressure. Check for leaks around each coupling and vacuum breaking valve as the railcar valves are opened. 25. Slowly open the liquid valve(s) on the end of the booms. Then open the vapor valve at the end of the boom. Make sure that the valves are fully opened or flow will be restricted. 26. Recheck the valves on each transfer line to make sure they are open. The railcar dome valve and both tranfer line valves must be open. The vacuum breaking valve must be closed. Initial the checklist to show that the valves are open. 27. Inspect the flex hose for leaks. Contact maintenance to replace any leaking flex hoses. (Note: The line must be disconnected using proper procedures prior to replacing. The procedure is on page 24 - "Unhooking Railcars"). 28. Disconnect the fresh air mask and check the pressure gauges at the platform on the vapor and liquid lines and make sure that they are showing pressure. Lack of pressure may indicate a leak, a plug or a closed valve. 29. Hookup additional railcars using steps 9-27. ABD00287627 VCM Unloading Operating Manual Page 16 1-9 II. OPERATING PROCEDURES (Cont) B. Unloading Railcars After the VCM cars at the tank farm are hooked up, the cars are unload ed using the Corken compressors. The compressors take vapor from the top of the sphere and compress it into the tank cars, forcing the liquid in the cars to flow into the bottom of the sphere. It usually takes 4-6 hours to unload the liquid VCM from a tankcar. It is very important for the valves on the compressors to be set up correctly or the compressor will dead-head. Running the compressors in a dead-headed condition will raise the compressors* relief valves and force VCM into the emission recovery knockout pot T-201. A pressure switch on T-201 will shut down all compressors if the pressure in the pot reaches 70 psig. Equipment Required 1. Fresh Air Mask. Procedure 1. After hooking up the cars, carefully come down the stairs from the unloading platform, using the handrails. Check the valves that are between the railroad tracks going to each unloading station, which is to be used for unloading cars. All the valves should normally be open. Initial the checklist if the valves are open. If any of the valves are closed, do not startup any compressors going to that unloading station. 2. Go to the compressor shed and put on the fresh air mask, check for face seal, and connect it to the fresh air hose. VCM Unloading Operating Manual Page 17 ABD00287628 1-9 II. OPERATING PROCEDURES (Cont.) B. Unloading Railcars (Cont.) Procedure (Cont.) 3. Open the main liquid valve on the west side of the compressor shed on the sphere liquid line (it should have been closed prior to unhooking previous cars). Initial the checklist appropriately after opening the valve. 4. Visually inspect each liquid unloading line from where they come out of the ground on the east side of the compressor shed through the valves near the ground, through the sight glasses, across the compressor shed, and through the valves above the liquid header on the west side of the shed. All valves must be open from each spot being unloaded from. During summer operations, flow may be observed in the sight glass after opening the main liquid valve. This is due to the vapor pressure in the car forcing liquid to start unloading. Initial the checklist after making sure that the valves are open (Checklist Item: Valves Under Sight Glasses, etc.). 5. Open the main vapor valve at the west side of the compressor shed on the sphere vapor line (it should have been closed prior to unhook ing previous cars). Initial the checklist appropriately after opening the valve. 6. Open the vapor line knockout pot inlet and outlet valves to allow vapor to flow through the knockout pot. These valves are located near the main vapor valve. Close the vapor header block valve located between the knockout pot inlet and outlet valves. 7. Visually trace the vapor lines going from the sphere vapor line, through the manual valves to the 4-way valve on each compressor. The manual valve must be open for each compressor that will be run. ABD00287629 VCM Unloading Operating Manual Page 18 1-9 II. OPERATING PROCEDURES (Cont.) B. Unloading Railcars (Cont.) Procedure (Cont.) Initial the checklist after checking the vapor valve for each com pressor. 8. Check the level of the VCM in the vapor line knockout pot by observing the sight glass located on the east side of the pot. The level should be below the pot's high level switch before unloading is started. The level in the pot is automatically controlled by high and low level switches. Should the instruments malfunction and the level be above the high level switch, notify the yard supervisor and proceed to drain the pot manually. Do this by placing the VCM recycle pump switch in the "hand" position. This switch is located on a panel on the south side of the knockout pot. The recycle pump will pump the contents of the pot to the sphere. When the level in the pot has lowered to the low level switch, place the pump switch back in the "auto" position. 9. Turn the handle of each 4-way valve so that the handle is in the vertical position. This sets up the compressor to pull from the sphere and discharge into the tank cars. (NOTE: The handles can be installed in the opposite direction. If maintenance works on a 4-way valve, check the arrows on the valve and make sure the flow is from the sphere to the tankcars when the valve handle is vertical. This must be checked before signing off the work order.) 10. Check the suction pressure of each compressor. It should read the saiiie as the sphere pressure. If the pressure is 0 psig, the liquid trap may be full of liquid which closes the high level shutoff valve in the trap and will not allow any flow to the compressor. The trap can be drained ABD00287630 VCM Unloading Operating Manual Page 19 1-9 II. OPERATING PROCEDURES (Cont.) B. Unloading Railcars (Con.t) Procedure (Cont.) by opening the Jamesbury valve that goes to the emission recovery knockout pot by the compressor shed. When the liquid is drained off, the pressure will rise on the suction (as the shutoff valve opens). When this occurs, close the Jamesbury valve. 11. When the suction of each compressor is set up correctly, visually trace the vapor discharge lines for each compressor. When all of the compressors are to be run. Compressors No. 3 and No. 5 should dis charge to the No. 3 transfer station. Compressor No. 2 should dis charge to No. 2 transfer station. Compressor No. 4 should discharge to the No. 4 transfer station, and Compressor No. 1 should discharge to the No. 1 transfer station. When one or more compressors are not to be run, or if fewer than four railcars are to be unloaded, it is best to setup the compressors on common discharge by opening the four valves on the No. 5 compressor header. This allows all the compres- i sors to be set up on one common header. Check the valves on the line from the No. 5 compressor to made sure they are set up correctly and be sure to check the jumper lines that connect the lines going to the four spots. Finally, check the four vapor valves near the ground going to the four transfer stations. The valve to each transfer station that is to be unloaded from must be open. Initial the checklist after making sure the appropriate valves are open. 12. When all the lines have been traced for each compressor, push the start buttons for the compressors to be run. 13. Check the oil pressure on each compressor. It must read between 10-20 psig. ABD00287631 VCM Unloading Operating Manual Page 20 I_9 II. OPERATING PROCEDURES (Cont.) B. Unloading Railcars (Cont.) Procedure (Cont.) 14. Check the discharge pressure on each compressor. If it is under 100 psig, go to the sight glasses and watch for liquid flow. If the discharge pressure is above 110 psig, one of the valves between the compressor and the tank car is closed. Shut off the compressor and retrace the piping until the valve is opened. 15. Check for liquid flow to the sphere in all the sight glasses. Lack of flow may indicate a closed valve between the tank car and the sphere. 16. Check to see that the Jamesbury valves on the compressor suction liquid traps are closed. 17. Take off the fresh air mask, disconnect it, and roll up the hose. 18. Record the identification numbers of the railcars being unloaded and log into log book. A VCM Unloading Operating Manual Page 21 ABD00287632 1-9 II. OPERATING PROCEDURES (Cont.) C. Recovering Vapor from Railcars When the liquid VCM has been unloaded from the VCM tank cars, the Corken compressors are used to remove most of the remaining VCM vapor from the car. The compressor is set up to take vapor from the tank car and send it back to the sphere. The railcars are pulled down to about 6-8 psig. If they are recovered to less than 6 psig it causes problems at the VCM plants, because the car may be below atmospheric pressure and pull air into the car. If the cars are not recovered to less than 8 psig, we are charged for some of the VCM which is left in the car. It normally takes 1-2 hours to recover vapor from the railcars. Equipment Required 1. Fresh Air Mask. Procedure 1. Go to the tank farm and check the sight glasses to make sure the liquid has blown out of the railcars. NOTE: If one of the cars blows out before the others, hook up and put on the fresh air mask and open the four valves from the No. 5 compressor header (this sets up all the compressors on one common header). Then close the valve near the ground on the vapor transfer line at the east side of the compressor shed for the transfer station which has blown out. This will cause the cars that have not blown out to empty faster. After the cars have'blown out, be sure to reopen any valves on the vapor transfer lines that were closed. If there are 2 cars hooked up on any of the transfer stations, both cars will have to be checked to see if they have blown out. Use the follow ing procedure: (Assume that railcar A and railcar 8 are hooked up ABD00287633 VCM Unloading Operating Manual Page 22 ^ II. OPERATING PROCEDURES (Cont.) C. Recovering Vapor From Railcars (Cont.) Procedure (Cont.) on the same transfer station and that the sight glass for that transfer station shows vapor flow). A. Go to the dome of railcar A and close the liquid valve(s). This allows you to check the sight glass and see if the liquid has blown out of railcar B. B. Go to the sight glass and check for liquid blowing through the line. If liquid flow shows in the sight glass, railcar B has not blown out. Finish unloading it by closing the vapor valve on railcar A. C. When the sight glass shows that railcar B has blown out, go back to the platform and open the liquid and vapor valve(s) on railcar A. D. Next, close the liquid valve(s) on railcar B to make sure that railcar A has blown out. E. Check the sight glass as in step B (Above). If liquid flow shows in the sight glass, railcar A was not blown out and must be unloaded. Close the vapor valve on railcar B. F. When the sight glass shows that railcar A has blown out, re-open the liquid and vapor valve(s) on railcar B. G. After all the cars have blown out, reopen any valve that you closed to check or unload the railcars. 2. Put on the fresh air mask, check for face seal, and connect it to the fresh air hose. ABD00287634 VCM Unloading Operating Manual Page 23 * II. OPERATING PROCEDURES (Cont.) C. Recovering Vapor from Railcars (Cont.) Procedure (Cont.) 3. Open the four valves on the No. 5 compressor header so that all the compressors are on one comon header. 4. Reverse all the 4-way valves so that the handles are in the horizon tal position. 5. Close all liquid line valves located beneath the sight glasses at the ground level. 6. Check the compressor discharge pressures to make sure the compres sors are not dead headed (pressure should be 70-100 psig). 7. Take off the fresh air mask, disconnect it and roll up the hose. 8. Record in the logbook the time that the cars were put on vapor. D. Unhooking Railcars When the VCM railcars at the tank farm have been unloaded and evacuated to the specified pressure, the compressors will be automatically shut off by the low pressure switches. Before the cars can be unhooked, the amount of VCM vapor in the transfer hose must be reduced to 0.13 cubic feet of VCM vapor (at 20 C and 29,92 in. Hg) to comply with EPA regula tions. To meet this requirement, the lines must be evacuated to a 10" Hg vacuum. Then the lines can be unhooked and the cars can be sent out of the plant. Fresh air masks must be worn under the compressor shed and while con necting the transfer hoses. Gloves must be worn while handling the nipples and the transfer hoses. VCM cars are not to be unhooked during an electrical storm. Equipment Required 1. Fresh Air Mask 2. Gloves ABD00287635 VCM Unloading Operating Manual Page 24 *~y II. OPERATING PROCEDURES (Cont.) D. Unhooking Railcars (Cont.) Procedure 1. Go to the tank farm and climb the platform stairs. Be especially careful if the stairs are wet or icy and be sure to use the hand rail. 2. Check the pressure on each transfer station according to the gauges on the platform. Make sure that the car(s) at each transfer station have been pulled down to 6-8 psig. NOTE: If one of the transfer stations has reached the proper evacu ation pressure before the others, close the valves at the platform for that transfer station. Since the compressors are on one common header, this will allow the other transfer statlon(s) to evacuate faster. When all the transfer stations have been properly evacu ated, reopen the valves on the transfer lines which you closed. 3. Climb down from the platform (carefully). Go to the compressor shed and put on the fresh air mask, check for face seal, and then connect it to the fresh air hose. 4. Turn off the compressors. 5. Close the 4" main vapor valve from the sphere and the 6" main liquid valve to the sphere that are on the west side of the compressor shed. 6. Check the pressure gauge on the line to the emission recovery system. (Gauge is at the southwest corner of compressor shed.) It must read at least 10" Hg vacuum. Open the four manual valves that evacuate the transfer lines to the emission recovery system. NOTE: If there is not at least 10" Hg vacuum on the line, notify the vinyl control room. It is the vinyl department's responsibility to maintain at least 10" Hg vacuum on the line. ABD00287636 VCM Unloading Operating Manual Page P.5 1-9 II- OPERATING PROCEDURES (Cont.) D. Unhooking Railcars (Con.t) Procedure (Cont-) 7. Immediately after opening the four manual evacuation valves, care fully climb the stairs to the unloading platform, hook up and put on the fresh air mask, check for face seal, and connect it to the fresh air hose. Close the valves in the railcar dome on each car that was unloaded (you will have to unhook and reconnect the fresh air mask at each station). 8. Open the actuated valves that evacuate the transfer lines to the emission recovery system by opening the switch at each transfer station. (Write work orders for any valves that do not open or close correctly.) 9. When the pressure gauge at the transfer station reads 10" Hg vacuum or less, put on the fresh air mask and close the valve on the trans fer line that is closest to the railcar dome. The pressure gauges should be maintained in good working condition or be replaced. The stainless steel flex hose is now valved off at 10" Hg vacuum or less, which complies with EPA regulations. 10. Open the V vacuum breaking valve at the end of the transfer line boom. 11. Disconnect the Weco hammerlock coupling. 12. Inspect the "0" ring on the Weco coupling nipple. Discard it if it has any nicks or cracks on it. Close the vacuum breaking valve. 13. Connect the transfer line to the boom and swing it out of the way. 1A. Unscrew the nipples from the railcar valve opening with the pipe- wrench. Remove them from the dome and cover the portholes. ABD00287637 VCM Unloading Operating Manual Page 26 I~9 II. OPERATING PROCEDURES (Cont.) D. Unhooking Railcars (Cont.) Procedure (Cont.) Be careful not to let the pipewrench slip and trap your hand9 or fingers against the railcar. 15. Select the correct size wrench to fit the railcar valve plugs and screw them tightly into the valve opening. Once again, do not let the wrench slip while tightening the plugs. All the plugs must be in place tight and have chain attached. 16. Put the nipples, pipewrench and wrench on the transfer station walk ramp and close the railcar dome lid. Be careful not to let the lid trap your hands or fingers. Slide the latching bar shut to hold the lid closed. Seal lid and record the lid seal number on the checklist. 17. Unhook the fresh air mask and take the pipewrench, nipples, and wrench back to the main platform. Place them in the racks provided for them. Be careful not to drop the nipples or damage the threads. 18. Turn off the switch to close the actuated valves that evacuate the transfer lines to the emission recovery system. 19. Latch the transfer line booms to the platform. Be careful not to let them pinch your arms or hands. Do not bend or twist the flex lines excessively. This can cause early failure of the flexlines. 20. Loosen the locks on the walk ramp and pull it away from the tank car. Lock it after raising it into the vertical position. .21 Repeat steps 9-20 to unhook the other railcars. ABD00287638 VCM Unloading Operating Manual Page 27 1-9 II. OPERATING PROCEDURES (Cont.) D. Unhooking Railcars (Cont.) Procedure (Cont.) 22. After unhooking all the railcars, climb down the steps from the platform. Do Not leave the fresh air mask on the platform. Take it back to the yard scale house with you and place it in the proper receptacle for cleaning at the end of your shift. 23. Unhook the ground cable from the unloading station. 24. Turn the placards on the railcar over so that they read "Empty." These placards must be present on both sides and both ends of each car. The placards must be right side up and all must be in place before car leaves the plant. A sample of the railcar placards is attached in this manual. 25. Close the manual valves on the 1" lines from the VCM transfer lines to the emission recovery header (under northeast corner of compres sor shed). Also close the 2" emission recovery valve located over head at the southwest corner of the compressor shed. These must be manually blocked in to prevent air or VCM leaks into the emission recovery system and to prevent VCM leakage through the automatic valves during railcar unloading. 26. Lower the blue flag to show that tank cars are no longer connected. 27. Disengage the deraller located south of the roadway. 28. Go to the sphere and record the level. Record this level and other Information about unhooking the car in the logbooks in the yard scalehouse. ABD00287639 VCM Unloading Operating Manual Page 28 I_9 II. OPERATING PROCEDURES (Cont.) E. Troubleshooting and Miscellaneous Operating Procedures This section describes various problems that occasionally occur in con nection with the Corken compressors and unloading the VCM tank cars. The standard operating procedure for solving each problem is given after the problem description. Normal rules concerning the use of safety equipment apply in all of these situations. Fresh air masks must be worn under the compressor shed. 1. Liquid in the Compressor Suction The symptoms of this problem and the solution are given in the operating procedures on unloading railcars, step No. 8. 2. High Pressure on the Sphere or Bullets (or Evacuation) Occasionally, the pressure on the bullets or the sphere needs to b reduced. This can be done by opening the appropriate valves and letting the emission recovery system pull on the vessel(s). A. To pull vapor from the sphere: a. Close the five valves on the west side of the compressor shed that are on the sphere vapor line. b. Open the main 4" valve on the sphere vapor line. c. Open the valve on the bullets vapor line that connects to the sphere vapor line. d. Open the 2" valve on the line that connects the bullets vapor line to the emission recovery knockout pot at the northwest corner of the compressor shed. This is the same line that the compressor relief valves discharge into. The knockout pot is set up to relieve any pressure over 3 psig to the emission recovery system. VCM Unloading Operating Manual Page 29 ABD00287640 1-9 II. OPERATING PROCEDURES (Cont.) E. Troubleshooting and Miscellaneous Operating Procedures (Cont.) 2. High Pressure on the Sphere or Bullets (or Evacuation) (Cont.) B. To pull vapor from the bullets: a. Open the valves at the bullets on the line that goes to the sphere vapor line from the bullets. b. Follow step (d) in the procedure for pulling vapor from the sphere. C. To evacuate the sphere or bullets: Considerable planning and preparation must be done prior to attempting this procedure. However, the following concept should be utilized. a. Follow the above procedure for pulling vapor from the appro priate vessel. b. Close the manual 2" valve on the line from the Corken com pressor distance pieces to the emission recovery knockout pot. This will prevent the oil from being pulled out of the compressors when the knockout pot is pulled to below atmos pheric pressure. c. Open the bypass valve for the pressure control valve that is south of the knockout pot. This will allow the vessel being evacuated to be pulled below 3 psig using the exist ing piping. 3. Evacuating a Compressor for Maintenance Before taking a compressor down for maintenance, the lines to and from the compressor must be Isolated and the VCM vapors removed (down to below 0 psig). This can be done by using the emission recovery system. When using the emission recovery system. ABD00287641 VCM Unloading Operating Manual Page 30 1-9 II. OPERATING PROCEDURES (Cont.) E. Troubleshooting and Miscellaneous Operating Procedures (Cont.) 3. Evacuating a Compressor for Maintenance (Cont.) Compressor No. 5 must be evacuated by a different procedure than the other compressors. a. Using the emission recovery system: NOTE: Not for Compressor No. 5. (1) Close the 3" valve'coming off the sphere vapor line for the compressor to be evacuated. Tag the valve with a "Do Not Operate" tag. (2) Close and tag the 3" valves on the east side of the compres sor shed that are on the transfer lines coming from the compressor that is to be evacuated. The valves on the transfer line and the valve from Compressor No. 5 must be closed and tagged. (3) Close and tag the valve on the compressor liquid trap and the valve above the rotameter. (A) Open the 1" manual valve that will evacuate the blocked off lines to the emission recovery system. (5) Open the actuated valve that evacuates the line to the emission recovery system. On some of the valves this can be done by overriding the valve and blocking off the air. On the ones without overrides, block the air off on the valve to the liquid line (to keep it closed) and open the vapor valve by using the switch at the transfer stations (on the platform) VCM Unloading Operating Manual Page 31 ABD00287642 1-9 II. OPERATING PROCEDURES (Cont.) E. Troubleshooting and Miscellaneous Operating Procedres (Con.t) 3. Evacuating a Compressor for Maintenance (Cont.) (6) When the pressure reaches less than 0 psig on the compres sor, close the actuated and manual 1" valves on the line that goes to the emission recovery system. Be sure to open the air valve for the actuated valve on the liquid line if it was closed in step (5). (7) Close the air to the actuated valve on the vapor line and tag it. The compressor should now be ready for maintenance. (Make sure maintnenace blinds all the lines when working on a compressor). b. Using the emission recovery system for Compressor No. 5: NOTE: One of the other compressors must also be evacuated because the emission recovery system valves tie in only to the four transfer lines dwonstream of the Compressor No. 5 block valve. (1) Same as step (1) in (a) above. (2) Close one of the 3" valves on the vapor station transfer lines at the east side of the compressor shed. Open the valve on that line from the Compressor No. 5. Leave the Compressor No. 5 block valve open. Close the 3" valve that comes off of the sphere vapor line on the west side of the compressor shed that will isolate the compressor that discharges to the transfer line which was blocked off. (3) Same as step (3) in (a) above. ABD00287643 VCM Unloading Operating Manual Page 32 *- II. OPERATING PROCEDURES (Cont.) E. Troubleshooting and Miscellaneous Operating Procedures (Cont,) 3. Evacuating a Compressor for Maintenance (Cont.) (4) Same as step (4) in (a) above. (5) Same as step (5) in (a) above. (6) When the pressure reaches less than 0 psig on Compressor No. 5, block off the Compressor No. 5 block valve on the east side of the compressor shed and tag it. (7) Close the actuated valve that was opened in step (5) and reopen any air that was blocked off. (8) Open the blocked in 3" valves on the east and west side of the compressor shed that were closed in step (2). Compressor No. 5 should now be ready for maintenance. 4. Lack of Liquid Flow in Sight Glass Occasionally, there will be little or no liquid flow in one or more of the liquid sight glasses after starting up the compresi sor, even though all the valves are open. This may be caused by a lower pressure on one of the railcars, more pressure drop in one of the lines due to length of pipe, or other reasons. This problem only occurs occasionally and it usually happens in only one of the transfer lines. If there is not a closed or partially closed valve in the line, the problem usually corrects itself after 5-10 minutes. To speed up this process, use the following operating procedure. a. First, trace all the lines and check the valves going to and from the transfer station that is giving the problem. Make sure that all the valves are fully open and that the compressor discharge pressure is normal. ABD00287644 VCM Unloading Operating Manual Page 33 1-9 11 * operating procedures (cont.) E. Troubleshooting and Miscellaneous Operating Procedures (Cont.) 4. Lack of Liquid Flow in Sight Glass (Cont.) b. After making sure that all valves are open and pressures are normal, open the valves on the No. 5 compressor header to put all compressors on a common header (if these were not already open). c. Close the vapor transfer valve on the lines of one or more of the cars which are flowing normally. This will put more flow to the transfer station that is having trouble. d. After establishing normal flow in the sight glass that was giving problems (this usually takes only a minute or two), reopen the vapor transfer valves to the other transfer stations. Normal flow will usually be reestablished in the other transfer lines when the valves are reopened. e. Close any valves that you opened on the No. 5 compressor header. 5. Tank Car Excess Flow Valve Closing Occasionally, the excess flow valve on a tank car will close. This is caused when the flow in the line exceeds a set flow rate. This condition can be detected either when the liquid valves are opened and a pinging noise is heard at the dome of the car or when the compressors are started and there is no liquid flow in the sight glass and all valves are open. Usually there will be a pinging sound in the car dome when an excess flow valve shuts off. This situation can be overcome by hooking up the other liquid line at the transfer station. If it is already hooked up, use one or a ABD00287645 VCM Unloading Operating Manual Page 34 1-9 II. OPERATING PROCEDURE (Cont.) E. Troubleshooting and Miscellaneous Operating Procedures (Cont.) 5. Tank Car Excess Plow Valve Closing (Cont.) combination of the following procedures: a. Partially close the liquid valves on the dome of the car. This will slow down the flow and should reseat the valve. If this reseats valve, reopen all partically closed valves. b. Turn off the compressor and let the car unload itself for a period, then reopen all valves partially closed and restart the compressors. This can usually be done only in summer condi tions. NOTE: If the excess flow valves shut in a car that has both liquid lines hooked up, this indicates that the valve is probably faulty. The car number should be noted so that it can be shopped after unloading. On ACFX and PPGX cars, the excess flow rates are set at a lower flow rate than on most UTLX, RTMX, and NATX cars. For the ACFX and PPGX cars, the liquid lines should always be hooked up to each car. 6. Evacuating The VCM Vapor Line Knockout Pot and Recycle Pump For Maintenance Before taking the knockout pot and recyclye pump down for main tenance; the pot, pump, and related piping must be isolated and the VCM vapors removed (down to below 0 psig). This will be done by using the emission recovery system. a. Close the 4" inlet and outlet valves to the knockout pot. Tag these valves with "Do Not Operate" tags. b. Close and tag the recycle pumps's IV discharge and recir culation valves. & VCM Unloading Operating Manual Page 35 ABD00287646 T XI. OPERATING PROCEDURE (Cont.) E. Troubleshooting and Miscellaneous Operating Procedures (Cont.) 6. Evacuating the VCM Vapor Line Knockout Pot and Recycle Pump For Maintenance (Cont.) c. Open the 2" manual valve that will evacuate the knockout pot and pump to the emission recovery system. d. When the pressure in the knockout pot and on the pump reaches less than 0 psig, close the 2n valve to the emission recovery system. The knockout pot and pump should now be ready for maintenance. ABD00287647 VCM Unloading Operating Manual Page 36 1-9 III. EQUIPMENT INDEX A. T-601 (Sphere) - Conoco No, 93-001 Purpose : VCM storage tank which holds fresh VCM taken from railcars for use in the reactor units. Description : Spherical tank, mounted on 9 columns, 54* - 9" diameter, 57* overall height, with capacity of 640,594 gallons, carbon steel construction, built in 1975. Normal Operating Conditions : Ambient Temperature and 10-60 psig. Design Conditions: 125F and full vacuum to 100 psig. Relief Settings : Rupture discs (2) " 100 psi @72F. Safety valves (2) " 100 psi. B. Bullets: T-201 (West) and T-202 (East) - Conoco Nos. 89-201 & 89-202 Purpose : Spare VCM storage tanks to hold fresh VCM from railcars for the reactor units or to store inerts from RVCM receivers if incinerator goes down. Description : Horizontal-mounted, 80' straight wall length, 10' - 10V diameter, with approximate capacity of 61,450 gallons, carbon steel construction, built in 1962. Normal Operating Conditions : Presently kept at ambient temperature and approx imately 0-20 psig. Design Conditions: 250 psig maximum allowable working pressure. Relief Settings : Rupture discs (2 per vessel) = 136 psi @72F. Safety valves (2 per vessel) 150 psi. C. Big Corken Compressors (Compressors No. 1, No. 2, and No. 4) Purpose : Unloading and evacuation of VCM tankcars. Description : Corken model 690, 2-cylinder, 825 RPM vapor com pressor. Normal Operating Conditions : Rated for 60 ICFM at 825 RPM, 295 psig maximum dis charge pressure. Relief Settings : North - Cannot read tag, 250 psi when purchased. South - 225 psi. VCM Unloading Operating Manual Page 37 ABD00287648 HI. EQUIPMENT INDEX (Cont.) D. Little Corken Compressors (Compressors No. 3 and No, 5) Purpose : Unloading and evacuation of VCM tankcars. Description : Corken Model D490, 2-cylinder 825 RPM vapor compressor. Normal Operating Conditions : Rated for 35.5 ICFM at 825 RPM, 295 maximum discharge pressure. Relief Settings : North - No tag, 250 psi when purchased. South - 250 psi. E. Sphere Transfer Pumps (North and South) Purpose : To transfer VCM liquid from the sphere to the old or new unit fresh VCM receiver. Description : Centrifugal type, Duriron A5Q, 3xl%- 10, 3500 RPM. Normal Operating Conditions : Rated for 150 GPM at 252" of differential head. F Bullets Transfer Pumps (East and West) Purpose : To transfer VCM liquid. Presently not in use. Description : Centrifugal type, Duriron A50, 3 x 1% - 10, 3500 RPM. Normal Operating Conditions : Rated for 150 GPM at 252" of differential head. G Emission Recovery System Knockout Pot (T-201) - Conoco No. 45-305. Purpose To collect miscellaneous VCM emissions. Description : Vertical-mounted, four-foot straight wall height, eight-foot overall height, four-foot diameter with an approximate capacity of 470 gallons. Normal Operating Conditions : Ambient temperature and 3 psig. Design Conditions: 150 psi at 366F. Relief Settings : Rupture disc 150 psi @ 72F. Safety valve * 150 psi. ABD00287649 VCM Unloading Operating Manual Page 38 r-9 III. EQUIPMENT INDEX (Cont.) H. VCM Knockout Pot (T-202) - Conoco No. 45-061 Purpose : To remove liquid VCM from the vapor line and prevent liquid slugging of the compressors. Description : Vertically mounted on supports 6 feet above grade, 5-foot straight wall height, 2.5-foot diameter, with capacity of 150 gallons. Normal Operating Conditions : 70F and 40 psig. Design Conditions: 150 psig 0 200F. Relief Valve Setting : 150 psi. I. VCM Recycle Pump (P-250) Purpose : Removal of knockout pot contents to sphere. Description : CMP model #3 x 1^ x 5, canned centrifugal pump, 3 HP driver. Normal Operating Conditions : 10 GPM @ 58 feet of differential head. Relief Valve Setting : 170 psi. J. Compressor Low Pressure Switches Purpose : To shut off compressors at the end of vapor recovery from railcars. Description : Static-O-Ring diaphragm type. Set Point : 6 psig decreasing. K. Vapor Line Knockout Pot bevel Switches - High and Low Purpose Description : To start and stop VCMrecycle pump as liquid VCM collects in the knockout pot. Robertshaw switches. & VCM Unloading Operating Manual Page 39 ABD00287650 IV. SAFETY EQUIPMENT AND SYSTEMS A. Continuous Flow Fresh Air System In order to provide personnel protection, a continuous flow fresh air system has been installed. This system consists of personnel fresh air masks and a constant flow breathing air supply. The supply lines are piped to various locations around the VCM tank farm. The indiviual hookup stations consist of quick connect/disconnect-type fittings. The individual line to the area is designed to allow a minimum flow of 6 SCFM to each mask at approximately 10-15 psig. An air pressure regu lator, shutoff valve, and an air filter are provided at the piping header to the area. Fresh Air masks are required to be worn during the following tasks: 1. Opening railcar dome lids, hooking up or disconnecting VCM tankcars. 2. Any time you enter the tank farm compressor shed, whether the compressors are running or not. 3. Whenever performing leak detection operations where the VCM con centration is expected to exceed 10 ppm. 4. Entering any vessel that normally contains VCM. 5. Blanking or line breaking of any line or vessel which has contained VCM. Clean fresh air masks are stored in the yard scalehouse. After using the mask, it should be properly disposed of by placing it in the used fresh air mask receptacle Inside the yard scalehouse. Fresh air masks are not to be left on the transfer station platform at the tank farm. ABD00287651 VCM Unloading Operating Manual Page 40 IV. SAFETY EQUIPMENT AND SYSTEMS (Cont.) B. VCM Canister Masks VCM Canister Masks may be used under the following conditions: 1. Working in a contaminated area of less than 10 ppm VCM for up to 10 hours. NOTE: If the HNU monitor reads greater than 10 ppm VCM, a fresh air mask must be used. 2. Performing leak detection operations when Honeywell units are indicating between 1 and 10 ppm VCM. 3. Escape from an area of high concentration of VCM to obtain a Scott Air Pack. C. Scott Air Packs Scott Air Packs are self-contained breathing equipment and must be worn when entering concentrations of VCM which are above 1000 ppm or in unknown concentrations. Scott Air packs are located south of the sphere near the electrical breaker switches and north of the compressor shed. D. Firewater System The firewater system consists of a deluge system on the bullets and compressor shed, a 6" weir to the top of the sphere, and fire monitors. All firewater to the tank farm deluge systems and monitors is supplied by the six diesel operated fire pumps from the firepond and Number 5 waste water pond. Process water can be used in fire fighting by hook ing hoses to the fire hydrant south of the tankfarra in the MCC area. 1. Fire Monitors There are four fire monitors located around the diked area at the VCM tank farm. Three of these are kept pointed toward the bottom of the sphere with the manual valve to them open. Water can A VCM Unloading Operating Manual Page 41 ABD00287652 1-9 IV. SAFETY EQUIPMENT AND SYSTEMS (Cont.) D. Fire Systems (Cont.) 1. Fire Monitors (Cont.) be sent to these monitors by opening the tank farm monitor switch on the module charge panel in the vlnly control room. Opening this switch operates a pressure switch that automatically turns on the fire pumps. A manual backup switch is located south of the sphere at the tank farm. The monitors should be used to lower VCM concen trations in the area in the event of a VCM leak or to help put out fires. (A manual bottle back up system can also be used to open this fire monitor supply valve.) 2. 6" Weir To Top of Sphere Water can be sent to the top of the sphere by activating a switch on the old module charge panel in the vinyl control room. A manual backup switch is located south of the sphere at the tank farm. Thermal sensors under the sphere can also activate the system and send water through the weir. Water through the weir is rated at 3000 gpm. The primary purpose of the weir is to supply water for cooling the sphere in the event of a fire in the area. (A manual bottle backup system can also be used to open this weir supply valve.) 3. Deluge System The deluge system supplies water through sprinklers to cover the bullets and the compressor shed. This system can be set off with a switch on the old module charge panel in the vinyl control room. The valve must be manually reset at the concrete basin north of the bullets. A manually activated trip is located at the basin. ABD00287653 VCM Unloading Operating Manual Page 42 1-9 IV. SAFETY EQUIPMENT AND SYSTEMS (Cont.) D. Firewater System (Cont.) 3. Deluge System (Cont.) Thermal sensors under the compressor shed or on the bullets can also set off the deluge system. The deluge system is designed to lower VCM concentrations in the bullets and compressor shed area, to cool the bullets in the event of fire in the area, and help put out fires. Because of the dikes around the sphere and bullets, fire water should be used judiciously in the area. The dikes are designed to contain any VCM spill from the vessesl. The VCM will float on water, and if the dikes are overfilled liquid VCM will be allowed to escape from the area, enlarging the hazard. The dikes can be drained with post-indicator valves on the west side of the dikes. If a dike is drained, make sure that the drain is closed / after draining. The valves are to be checked daily. The person draining the dike should stay in the area and close the valve when draining is completed. The four actuated valves on the sphere inside the dike can be closed from the old module charge panel in the vinyl control room or from switches outside of the dike, south of the sphere. (These are the valves that are tested every Wednes day - See Appendix B for checklist). E. Fixed Point VCM Monitor A fixed point VCM monitor is used to detect VCM and record the VCM concentration at various locations at the VCM tank farm. The recorder and alarm annunciator are located in the vinyl control room. The vinyl panel operators will inform the yard operator of any high readings at the VCM tank farm. VCM Unloading Operating Manual Page 43 V. EQUIPMENT ENTRY PROCEDURE ABD00287654 1-9 EPA standards for VCM emissions and OSHA regulations on personnel exposure to VCM require that certain operating procedures be followed when there is the possibility of VCM emission to the atmosphere or personnel exposure to VCM. For this reason and to ensure safe working conditions at all times, the "Engineering and Work Practice Control Program for the Reduction of Employee Exposure to Vinyl Chloride" manual should be consulted whenever equipment in the VCM tank farm is opened for any reason. This manual contains a list of detailed procedures as well as safety precautions for equipment opening. ABD00287655 A 1-9 VI. APPENDIX ABD00287611 VCM UNLOADING OPERATING MANUAL 1~9 ABERDEEN PVC PLANT TABLE OF CONTENTS I. INTRODUCTION Page No. A. Operator Responsibilities ................................................................................... 1 B. General Process Description........................................................................................ 3 II. OPERATING PROCEDURES A. Railcar Hookup.................................................................................................................. 10 B. Unloading Railcars ..................................................................................................... 17 C. Recovering Vapor From Railcars .......................................................................... 22 D. Unhooking Railcars ..................................................................................................... 24 E. Troubleshooting and Miscellaneous Operating Procedures 1. Liquid in the CompressorSuction..................................................................29 2. High Pressure on the Sphere or Bullets (or Evacuation) ... 29 3. Evacuating a Compressor for Maintenance. . ..................................... 30 4. Lack of Liquid Flow in Sight Glass....................................................... 33 5. Tank Car Excess Flow ValveClosing............................................................. 34 6. Evacuating the VCM Vapor Line Knockout Pot and Recycle Pump for Maintenance...........................................................................................35 III. EQUIPMENT INDEX...................................................................................................................... 37 IV. SAFETY EQUIPMENT AND SYSTEMS..........................................................................................40 V. EQUIPMENT ENTRY PROCEDURES ....................................................................................... 44 VI. APPENDIX A. Valve Setup Checklist B. Checklist for Testing Auto Valves C. Empty Outbound VCM Tank Car Inspection Report D. Plant Emergency Plan E. Sample Railcar Placard F. Photographs G. P & I Diagram A ABD00287612 1-9 VCM UNLOADING OPERATION MANUAL ABERDEEN PVC PLANT INTRODUCTION A. Operator Responsibilities The purpose of the VCM Tank Farm is to safely unload and store Vinyl Chloride Monomer (VCM). VCM is brought into the plant in tankcars. It is the main raw material used in making the plant's major product, polyvinyl chloride (PVC). VCM is a colorless sweet-smelling gas at atmospheric pressure that is stored and transferred as a liquid at moderate pressure (30-70 psig). The yard department is responsible for the offloading of VCM tankcars and the related transfer equipment. The yard operator helps fulfill the tankfarm's purpose by making sure that the VCM is safely unloaded without endangering his fellow workers or equipment. The operator is able to attain his goals in safety, job performance and efficient operation through a training period, on-the-job experience, and passing written and field examinations. The operator fulfills his responsi bilities by: 1. Demonstrating understanding of how his equipment functions. 2. Being able to explain what role each piece of equipment plays in the process. 3. Keeping a close and regular check on equipment. 4. Being able to demonstrate troubleshooting and corrective measures. 5. Keeping his area of responsibility safe and clean. 6. Keeping complete and accurate records. 7. Reporting equipment problems promptly and writing maintenance work orders as needed. 8. Operating the equipment in an environmentally sound manner and promptly taking corrective measures should process leaks occur.9 9. Wearing the proper respiratory protection. ABD00287613 VCM Unloading Operating Manual Page 2 1-9 I. INTRODUCTION (Cont.) A. Operator Responsibilites (Cont,) This operating manual will cover the normal responsibilities and duties of the yard operator when unloading VCM railcars. Each phase of the unloading procedure will be covered. In addition to normal operating procedures it will also discuss operations under abnormal conditions. The operator must be prepared to meet these situations with temporary measures until the abnormal condition is corrected or ceases to exist. The goal for VCM overexposure to employees is "ZERO". This is accom plished by operating the equipment as designed, prompt attention given to leaks per continuous monitor sensors and follow up work orders for maintenance. As we meet our goals for overexposure, all governmental guidelines will also be kept. Safety takes second place to no plant activity. The safety of the plant personnel and equipment is to be carefully considered before any job is started. The Conoco safety slogan is "Our work is never so urgent or important that we cannot take time to do it safely". Safety on the job must be our first and most important consideration. When we do a good job of planning our work with safety in mind, we are less likely to suffer injury or cause an accident. This allows us to meet our plant goal of employees going home unhurt. ABD00287614 VCM Unloading Operating Manual Page 3 1-9 I- INTRODUCTION (Cont.) B. General Process Description VCM tankcars are brought into the plant from various VCM plants through out the United States. Most of the VCM that comes into this plant comes from Conoco1s VCM Plant in Lake Charles, Louisiana. VCM also occa sionally comes from PPG in Lake Charles, B. F. Goodrich in Calvert City, Kentucky, Uniroyal in Gelsmar, Louisiana, or from Shell Norce Georgia Pacific, Plaquemine. A VCM Tankcar typically holds 175,000 pounds of VCM (about 23,000 gallons of liquid). If for some reason an Inbound VCM car*s gross weight is less than 255,000 pounds, the car must be rewelghed and spotted on the west track until billing weights are verified. This insures we receive what has been billed to the Aberdeen Plant. The cars are shipped to Aberdeen and stored on the Monroe lead until they are brought into the plant. Only the Monroe lead or new VCM spur can be used to store VCM railcars. This is a safety precaution so that all the VCM cars are kept in one general area. The railroad crew is responsible for bringing the VCM cars into the plant and "spotting" them at the VCM transfer stations that are on the platform at the VCM tank farm. This is usually done once per day except on weekends or holidays. A maximum of ten tankcars can presently be brought into the tank farm. The tank farm has eight transfer (unloading) spots. The platform is located between two sets of railroad tracks such that there are four transfer spots on each side. These are referred to by name as Spot No. 1, Spot No. 2, Spot No. 3, and Spot No. 4, from south to north (east side); and Spot No. 6, Spot No. 7, Spot No. 8, and Spot No. 9, from south to north (west side). Spot No. 5 (east side of platform) and Spot No. 10 (west side of plat form) are the two north locations for "spotting" tankcars, but there are no unloading facilities at these two spots. Once the railcars have been "spotted", it is the yard department's responsibility to unload the VCM ABD00287615 VCM Unloading Operating Manual Page 4 1-9 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) into T-60I which is commonly called the "sphere". This is done using the five Corken compressors at the tank farm. They are commonly referred to as Compressor No. 1, Compressor No. 2, Compressor No.3, Compressor No. 4, and Compressor No. 5, from north to south, respectively. Compressors No. 3 and No. 5 combined have about the same capacity as either Compressor No. 1, No. 2, or No. 4. The tankcars are connected to the compressor piping and the sphere piping with flexible hoses. The compressors pull vapor from the top of the sphere and compress it into the tankcars, forcing liquid out of the cars through a stand pipe, into the bottom of the sphere. Each tankcar has three valved connections in the dome of the car (two liquid lines and one vapor line). The liquid lines are 2" lines and point toward each end of the tankcar. The vapor line is a 1*5" line and points toward the side of the car. Refer to the photograph in the Appendix. Only one liquid line is usually hooked up on a car because the car does not unload significantly faster with two lines and it takes longer to hook up the car. Both liquid lines have to be hooked up on some type of cars (ACFX and PPGX cars) because the excess flow valves are set to close at lower rates than our normal unloading rate of 65-95 gpn:. The operator can tell when all the liquid has been unloaded from a car by watching the sight glass in the liquid transfer line. When the tankcar has been emptied, the 4-way valves on the compressor are reversed such that the compressor evacuates vapor from the car and discharges it into the top of the sphere. When the specified amount of vapor is removed from the tankcar, the compressors are shut down and the transfer lines VCM Unloading Operating Manual Page 5 ABD00287616 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) are evacuated. This must be done because of EPA (Environmental Protec tion Agency) regulations concerning the release of VCM vapor to the atmosphere. Then the transfer line can be unhooked and the cars are sent back to the respective VCM plant for reloading. All outbound VCM cars are to be weighed. Cars containing a heel greater than 600 pounds should be set aside for additional unloading. The plant can lose considerable amounts of VCM on heavy outbound cars, which can drastically impact on our plant*s cost effectiveness. There is a big difference in winter and summer operation of the tank farm. The primary reason is probably because the vessels are uninsulated and the transfer lines are lengthy and are exposed to ambient tempera tures along their entire run. The vapor pressure drops in the vessels and the tankcars as the temperature drops, making it harder to unload in cold weather because there is less VCM pressure to move the liquid through the pipes. Thus, unloading conditions can also vary from day to night and when rapid changes in weather occur. During the summer, eight tankcars can be hooked up at one time and unloaded with four or five compressors. Also, the tankcars will usually start unloading as soon as the valves on the liquid lines are opened. During winter conditions (ambient temperature approximately 40F or less), it is harder to start the VCM liquid unloading and only four tankcars can be unloaded at a time, with four or five compressors. If the weather gets extremely cold, it may take four compressors to unload only two or even one car, but this has not happened since the ABD00287617 VCM Unloading Operating Manual Page 6 1-9 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) system has been revised and vapor from the sphere is used. The volume of VCM kept in the sphere is usually large enough that sufficient vapor is available for the compressors. When the bullets were used, there was not enough vapor available and the tankcars unloaded very, very slowly, if at all. Other equipment at the tank farm includes the bullets, T-201 (west) and T-202 (east). These are not used for unloading VCM, even though each one presently contains a small amount of liquid VCM. They are piped up to take inerts from the recovered vinyl receivers if the incinerator should be down for an extended period of time. The transfer pumps on the bullets (Conoco Nos. 72-211 & 72-218) and the sphere (Conoco Nos. 72-217 & 72-270) are the responsibility of the vinyl department. The sphere transfer pumps send liquid VCM through a 4" line to the old and new reactor modules where it is charged into reactors and made into PVC. The bullet transfer pumps are not used at the present time. The emission recovery system knockout pot is also located at the tank farm, northwest of the compressor shed. The emission recovery system is located in the vinyl department old reactor module and is designed to collect and contain miscellaneous VCM emissions. It runs continuously. The knockout pot is connected to it via a 2" line that runs to the tank farm. A 15" Hg. vacuum should be maintained on this line at all times. This line is used to evacuate the VCM vapors from the transfer lines prior to unhooking cars. The knockout pot is the responsibility of the VCM Unloading Operating Manual Page 7 ABD00287618 X-9 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) vinyl department, but the yard operator should be familiar with the purpose of it. The knockout pot collects VCM vents from the following: a. Double Mechanical Seals on the sphere and bullets transfer pumps- Used by vinyl to bleed VCM from the seals when maintenance is required on the pumps. b. Corken Compressor Packings- The pot recovers vapor that leaks through the compressor packing into the distance piece. The vapor goes through a rotameter on each compressor into the pot. The valve above the rotameter should always be open when the compressor is running. The knockout pot must always have a slightly positive pressure on it or oil can be sucked out of the bottom of the compressors through the packing around the piston rods. This is the reason for the back pressure control valve on the knockout pot. c. Corken Compressor Relief Valve Discharges- The relief valve dis charges are piped to the knockout pot through a locked open valve. d. Corken Compressor Liquid Traps- Liquid caught in the traps is drained to the knockout pot through the 1" Jamesbury valves on the traps. Opening the 1" valve should let the liquid flow into the knockout *pot and then it is recovered to the emission recovery system. e. VCM Sphere and Bullet Recovery- The vessels can be recovered through the knockout pot. A procedure will be given for this in the opera ting procedures section. f. Sphere Liquid Lines Relief Valve Discharges- The three liquid lines ABD00287619 VCM Unloading Operating Manual Page 8 1-9 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) under the sphere have relief valves that discharge into a 1" line that goes to the knockout pot. The 1" valve on the line south of the compressor shed is locked open. The line runs into the header at the west side of the knockout pot, where the main 2" valve is also locked open. g. Compressor No. 1 Liquid Line Relief Valve Discharge- This relief valve is piped up to the compressor relief valve header through a locked open valve. h. Vapor Line Knockout Pot Relief Valve Discharge- This knockout pot is equipped with a relief valve whose discharge is piped through a locked open valve into the compressor relief valve header. The compressor relief valve header is connected to the emission recovery system knockout pot. i. VCM Recycle Pump Relief Valve Discharge- The VCM recycle pump located below the liquid line knockout pot is equipped with a relief valve which is piped up to the compressor relief valve header. A second knockout pot, called the vapor line knockout pot, is located just north of the emission recovery system knockout pot. The purpose of the vapor line knockout pot is to collect liquid VCM that may have collected in the main vapor line and prevent this liquid from slugging the compressors. A VCM recycle pump is located below this knockout poand is used to pump the contents of the pot to the sphere. The pump is started and stopped by two level switches in the pot. VCM Unloading Operating Manual Page 9 ABD00287620 I. INTRODUCTION (Cont.) B. General Process Description (Cont.) Complete and accurate records must be kept on VCM unloading. These are necessary for accounting purposes and for communication between shifts. A VCM Unloading Card must be filled out and turned in to the accounting group for each car unloaded. Records are also kept in the yard scale-house on which cars were unloaded, when they started, when they were put on vapor, and when they were unhooked. A valve setup checklist also must be filled out by the yard opera tor when hooking up cars and starting unloading. Copies are to be kept on file by the yard supervisor. A copy of the checklist is included in the Appendix. Also included is a copy of the empty outbound VCM tank car inspection report. The automatic valves under the sphere are tested every Wednesday morning. The checklist used to record the results of this testing is shown in the Appendix. Copies of this checklist are to be kept on file by the yard supervisor. This testing must be coordinated with the vinyl panel operators so that the valves are not closed during VCM transfer to the reactor units. This should be coordinated by using the radios. ABD00287621 VCM Unloading Operating Manual Page 10 1-9 II. OPERATING PROCEDURES A. Railcar Hookup After VCM cars are brought into the plant, the yard operator "hooks up" each car by connecting transfer hoses to it. Vapor can then be trans ported into the car and the liquid VCM can be sent into the sphere. In the summer, two cars can be hooked up at each transfer station for unloading. During winter operation or when a rapid change in the weather is anticipated during unloading, only one car can be unloaded from each transfer station. Fresh air masks must be worn under the compressor shed, while opening or closing the railcar dome, or while connecting and disconnecting the transfer hoses. Gloves must be worn while handling the nipples and the transfer hoses. VCM cars are not to be hooked up during an electrical storm. Equipment Required 1. Fresh Air Mask 2. 1 1/2" Teflon Tape 3. 0-rings for Weco fittings (if needed) 4. Gloves Procedure 1. Get a fresh air mask and a roll of 1 1/2" Teflon tape, from the yard scale house. Also get "0" rings that are needed to replace the ones at the tank farm. Inspect the "0" rings individually for cracks and nicks. Do Not Use Defective "0" Rings. VCM Unloading Operating Manual Page 11 ABD00287622 1-9 H. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) 2. Raise the blue metal flag located on the railroad track south of the roadway. This flag states "Stop! Tankcar Connected." This procedure is necessary to Isolate the eight unloading stations and notify railroad personnel that VCM unloading is taking place. 3. Engage the derailer located near the blue flag. This will prevent railcars from entering the tank farm area when unloading is taking place. 4. Visually check the valves under the sphere to make sure they are set up for unloading. The 4" valve on the vapor line and the 6" valve under the sphere on the liquid line to the sphere must be open (both valves are actuated valves). 5. Record the sphere level on the checklist (see checklist in Appen dix). Turn the handle on the gauge to move the tape, then take the reading. If the tape does not bounce, notify the yard supervisor. The maximum allowable sphere level is 38 feet. To unload 4 tankcars the level must be below 32 feet - 3 inches (27 feet - 0 inches for 8 tankcars). 6. Check the railcar chocks and handbrake and ground the railcar. Make sure that the chocks are in good condition and are against the railcar wheels. Manually check the handbrake to make sure it is tight. Inspect the grounding cables to ensure that they are intact and in good working condition. Bond each car to the ground rod by attach ing the grounding clamp to the north side of the vertical siderail of the ladder. This prevents static accumulation during unloading ABD00287623 VCM Unloading Operating Manual Page 12 1-9 II. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) 6. (Continued) and eliminates dangerous sparking which could ignite any VCM leaks. It also prevents loss of the ground clamp if it is left connected during switching. Should one of the grounding clamps or cables be damaged, use the backup cable located on the south liquid boom arms at each spot except Spots No. 4 and No. 9 which have no backup cables. 7. Drain the water from the breathing air filter if necessary. (The filter is located between the rail tracks). 8. Climb the stairs to the unloading platform. If the stairs are wet or icy, be especially careful. Always be sure to use the handrail. 9. Go to the station you want to unload from, loosen the locks on the walkramp, and use your foot to push the ramp onto the car dome. The ramp will not operate if it is not in the middle of the platform opening. Adjust the height and length of the ramp and lock the ramp into place. Watch for pinch points when positioning the ramp and do not put any unnecessary strain on your back. 10. Unlatch the vapor and liquid line(s) and swing each line over the railcar dome area. Be careful not to let the lines swing back and catch your arm or hands. (The vapor line is the lV' line). 11. Remove the nipples from the holders and peel off the old Teflon tape. Inspect the threads and retape them with new tape up to 2" from the end of the threads. If the threads are worn, write a work order to replace the old nipples with new ones. VCM Unloading Operating Manual Page 13 ABD00287624 I_9 TI. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) 12. Remove the pipewrench from the holder and fasten it on one nipple. Then carry the pipewrench and nipples to the dome area of the car. Be careful not to drop the nipple and damage the threads. 13. Put on the fresh air mask and tighten it. Test the face seal by blocking the hose with one hand while trying to breathe in. If it leaks, adjust the straps or facepiece. Make sure you have a good face seal. 14. Purge the air line of any water that may be in the line. Connect the fresh air mask to the fresh air hose that is on the transfer line booms. 15. Break the domelid seal with the pipewrench and slide the latching bar so that the lid can be raised. Open the domelid and push it all the way back so that it cannot close. Be careful to use proper lifting procedures when raising the lid. 16. Visually check inside the dome area for leaks. Leaks will be indicated by condensation or icing around the valves and fittings. Check the plugs and caps and attached chains - if any are missing, note on the checklist. 17. Test the valves to make sure they are closed by pushing the valve handles against the closed stop. 18. Select the correct size wrench to fit the railcar valve plugs and remove the plugs. Be alert to the fact that the wrench could slip and trap your hand or fingers against the dome. Also do not stand in the direction of the valve opening in case a valve is leaking and VCM spews out. ABD00287625 VCM Unloading Operating Manual Page 14 1-9 II. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) 19. Push the port hole covers aside and screw the nipples into the valve opening until they are hand tight. Then tighten the nipples with the pipewrench. Be careful not to let the wrench slip. The nipples must be very tight or they will leak. Double check them after installing. 20. Close the vacuum breaking valves on the end of the transfer line booms. Make sure they are fully closed so that VCM will not leak to the atmosphere. 21. Unhook the flexlines and or Weco fittings from the holders on the booms. Be careful to minimize bending and twisting the flexlines during hookup. Excessive bending of the flexlines causes early failure of the lines. Visually inspect the flexlines for small holes or extremely worn areas of the armored weave. If a flexline is punctured, badly twisted or damaged, or in your judgment has a likely potential for failure during operation, contact maintenance and have the hose replaced. 22. Inspect the "0" rings individually and install them in the slots. The "O'* ring must be evenly seated to prevent leaks. "0" rings with cuts or nicks should be discarded. 23. Press the Weco union attached to the flex hose against the nipple inserted in the railcar. Check the alignment of the "0" rings to make sure there is a good seal. "0" rings that are pinched or crooked will cause leaks. Completely tighten the Weco hammerlock to prevent leakage. VCM Unloading Operating Manual Page 15 ABD00287626 1-9 II. OPERATING PROCEDURES (Cont.) A. Railcar Hookup (Cont.) Procedure (Cont.) 24. Check to make sure that the valve on the transfer line closest to the railcar dome is closed (it should be closed from the previous unhooking). Slowly pull the handle of each railcar valve up to open it. Opening the valves too fast can cause an undesirable surge of pressure. Check for leaks around each coupling and vacuum breaking valve as the railcar valves are opened. 25. Slowly open the liquid valve(s) on the end of the booms. Then open the vapor valve at the end of the boom. Make sure that the valves are fully opened or flow will be restricted. 26. Recheck the valves on each transfer line to make sure they are open. The railcar dome valve and both tranfer line valves must be open. The vacuum breaking valve must be closed. Initial the checklist to show that the valves are open. 27. Inspect the flex hose for leaks. Contact maintenance to replace any leaking flex hoses. (Note: The line must be disconnected using proper procedures prior to replacing. The procedure is on page 24 - "Unhooking Railcars"). 28. Disconnect the fresh air mask and check the pressure gauges at the platform on the vapor and liquid lines and make sure that they are showing pressure. Lack of pressure may indicate a leak, a plug or a closed valve. 29. Hookup additional railcars using steps 9-27. ABD00287627 VCM Unloading Operating Manual Page 16 1-9 II. OPERATING PROCEDURES (Cont) B. Unloading Railcars After the VCM cars at the tank farm are hooked up, the cars are unload ed using the Corken compressors. The compressors take vapor from the top of the sphere and compress it into the tank cars, forcing the liquid in the cars to flow into the bottom of the sphere. It usually takes 4-6 hours to unload the liquid VCM from a tankcar. It is very important for the valves on the compressors to be set up correctly or the compressor will dead-head. Running the compressors in a dead-headed condition will raise the compressors* relief valves and force VCM into the emission recovery knockout pot T-201. A pressure switch on T-201 will shut down all compressors if the pressure in the pot reaches 70 psig. Equipment Required 1. Fresh Air Mask. Procedure 1. After hooking up the cars, carefully come down the stairs from the unloading platform, using the handrails. Check the valves that are between the railroad tracks going to each unloading station, which is to be used for unloading cars. All the valves should normally be open. Initial the checklist if the valves are open. If any of the valves are closed, do not startup any compressors going to that unloading station. 2. Go to the compressor shed and put on the fresh air mask, check for face seal, and connect it to the fresh air hose. VCM Unloading Operating Manual Page 17 ABD00287628 1-9 II. OPERATING PROCEDURES (Cont.) B. Unloading Railcars (Cont.) Procedure (Cont.) 3. Open the main liquid valve on the west side of the compressor shed on the sphere liquid line (it should have been closed prior to unhooking previous cars). Initial the checklist appropriately after opening the valve. 4. Visually inspect each liquid unloading line from where they come out of the ground on the east side of the compressor shed through the valves near the ground, through the sight glasses, across the compressor shed, and through the valves above the liquid header on the west side of the shed. All valves must be open from each spot being unloaded from. During summer operations, flow may be observed in the sight glass after opening the main liquid valve. This is due to the vapor pressure in the car forcing liquid to start unloading. Initial the checklist after making sure that the valves are open (Checklist Item: Valves Under Sight Glasses, etc.). 5. Open the main vapor valve at the west side of the compressor shed on the sphere vapor line (it should have been closed prior to unhook ing previous cars). Initial the checklist appropriately after opening the valve. 6. Open the vapor line knockout pot inlet and outlet valves to allow vapor to flow through the knockout pot. These valves are located near the main vapor valve. Close the vapor header block valve located between the knockout pot inlet and outlet valves. 7. Visually trace the vapor lines going from the sphere vapor line, through the manual valves to the 4-way valve on each compressor. The manual valve must be open for each compressor that will be run. ABD00287629 VCM Unloading Operating Manual Page 18 1-9 II. OPERATING PROCEDURES (Cont.) B. Unloading Railcars (Cont.) Procedure (Cont.) Initial the checklist after checking the vapor valve for each com pressor. 8. Check the level of the VCM in the vapor line knockout pot by observing the sight glass located on the east side of the pot. The level should be below the pot's high level switch before unloading is started. The level in the pot is automatically controlled by high and low level switches. Should the instruments malfunction and the level be above the high level switch, notify the yard supervisor and proceed to drain the pot manually. Do this by placing the VCM recycle pump switch in the "hand" position. This switch is located on a panel on the south side of the knockout pot. The recycle pump will pump the contents of the pot to the sphere. When the level in the pot has lowered to the low level switch, place the pump switch back in the "auto" position. 9. Turn the handle of each 4-way valve so that the handle is in the vertical position. This sets up the compressor to pull from the sphere and discharge into the tank cars. (NOTE: The handles can be installed in the opposite direction. If maintenance works on a 4-way valve, check the arrows on the valve and make sure the flow is from the sphere to the tankcars when the valve handle is vertical. This must be checked before signing off the work order.) 10. Check the suction pressure of each compressor. It should read the saiiie as the sphere pressure. If the pressure is 0 psig, the liquid trap may be full of liquid which closes the high level shutoff valve in the trap and will not allow any flow to the compressor. The trap can be drained ABD00287630 VCM Unloading Operating Manual Page 19 1-9 II. OPERATING PROCEDURES (Cont.) B. Unloading Railcars (Con.t) Procedure (Cont.) by opening the Jamesbury valve that goes to the emission recovery knockout pot by the compressor shed. When the liquid is drained off, the pressure will rise on the suction (as the shutoff valve opens). When this occurs, close the Jamesbury valve. 11. When the suction of each compressor is set up correctly, visually trace the vapor discharge lines for each compressor. When all of the compressors are to be run. Compressors No. 3 and No. 5 should dis charge to the No. 3 transfer station. Compressor No. 2 should dis charge to No. 2 transfer station. Compressor No. 4 should discharge to the No. 4 transfer station, and Compressor No. 1 should discharge to the No. 1 transfer station. When one or more compressors are not to be run, or if fewer than four railcars are to be unloaded, it is best to setup the compressors on common discharge by opening the four valves on the No. 5 compressor header. This allows all the compres- i sors to be set up on one common header. Check the valves on the line from the No. 5 compressor to made sure they are set up correctly and be sure to check the jumper lines that connect the lines going to the four spots. Finally, check the four vapor valves near the ground going to the four transfer stations. The valve to each transfer station that is to be unloaded from must be open. Initial the checklist after making sure the appropriate valves are open. 12. When all the lines have been traced for each compressor, push the start buttons for the compressors to be run. 13. Check the oil pressure on each compressor. It must read between 10-20 psig. ABD00287631 VCM Unloading Operating Manual Page 20 I_9 II. OPERATING PROCEDURES (Cont.) B. Unloading Railcars (Cont.) Procedure (Cont.) 14. Check the discharge pressure on each compressor. If it is under 100 psig, go to the sight glasses and watch for liquid flow. If the discharge pressure is above 110 psig, one of the valves between the compressor and the tank car is closed. Shut off the compressor and retrace the piping until the valve is opened. 15. Check for liquid flow to the sphere in all the sight glasses. Lack of flow may indicate a closed valve between the tank car and the sphere. 16. Check to see that the Jamesbury valves on the compressor suction liquid traps are closed. 17. Take off the fresh air mask, disconnect it, and roll up the hose. 18. Record the identification numbers of the railcars being unloaded and log into log book. A VCM Unloading Operating Manual Page 21 ABD00287632 1-9 II. OPERATING PROCEDURES (Cont.) C. Recovering Vapor from Railcars When the liquid VCM has been unloaded from the VCM tank cars, the Corken compressors are used to remove most of the remaining VCM vapor from the car. The compressor is set up to take vapor from the tank car and send it back to the sphere. The railcars are pulled down to about 6-8 psig. If they are recovered to less than 6 psig it causes problems at the VCM plants, because the car may be below atmospheric pressure and pull air into the car. If the cars are not recovered to less than 8 psig, we are charged for some of the VCM which is left in the car. It normally takes 1-2 hours to recover vapor from the railcars. Equipment Required 1. Fresh Air Mask. Procedure 1. Go to the tank farm and check the sight glasses to make sure the liquid has blown out of the railcars. NOTE: If one of the cars blows out before the others, hook up and put on the fresh air mask and open the four valves from the No. 5 compressor header (this sets up all the compressors on one common header). Then close the valve near the ground on the vapor transfer line at the east side of the compressor shed for the transfer station which has blown out. This will cause the cars that have not blown out to empty faster. After the cars have'blown out, be sure to reopen any valves on the vapor transfer lines that were closed. If there are 2 cars hooked up on any of the transfer stations, both cars will have to be checked to see if they have blown out. Use the follow ing procedure: (Assume that railcar A and railcar 8 are hooked up