Document aDzyLYDVwGEpVy74NE0y7wjY

ABD00249754 OPERATING MANUAL AMS EMERGENCY KILL SYSTEM ABERDEEN PVC PLANT UPDATED FEBRUARY 13, 1986 ABD00249755 A TABLE OR CONTENTS OPERATING MANUAL AMS EMERGENCY KILL SYSTEM ABERDEEN PVC PLANT Page No. I. INTRODUCTION .............................................................................. 1 A. PURPOSE............................................................................. 1 B. OPERATOR RESPONSIBILITIES ......................................... 1 C. PROCESS INFORMATION .................................................. 1 II. GENERAL PROCESS DESCRIPTION .......................................... 2 III. SAFETY............................................................................................ 5 IV. OPERATING PROCEDURES ............................................................ 7 A. WHEN TO USE . ............................................................7 B. HOW TO USE .................................................................... 8 C. NORMAL OPERATION................................................................. 11 D. TESTING PROCEDURE ....................................................... 13 V. APPENDIX............................................................................................. 16 VI. P & I DIAGRAMS................................................................................18 t ABD00249756 I. INTRODUCTION A. Purpose The purpose of the AMS Emergency Kill System is to in increase the reliability and effectiveness of equipment and procedures used to safely and quickly stop the poly merization reaction in the reactors. Stopping the reaction prevents excessive pressure buildup which can cause emergency releases through the reactor relief valves. This system allows any or all reactors to be shut down in an orderly and safe manner. This manual describes the system and the operator's responsibilities for operating and maintaining the system. B. Operator Responsibilities The operator is responsible for producing quality pro ducts in a safe and efficient manner. He fulfills his responsibilities by knowing the following: 1. Understanding how his equipment functions. 2. Understanding what role each piece of equipment plays in the process. 3. Keeping a close and regular check on equipment. 4. Knowing how to spot malfunctions and correct them. 5. Keeping his area of responsibility safe and clean. 6. Keeping complete and accurate records. C. Process Information The polymerization reaction of VCM to form PVC gives off heat and accelerates as temperature increases. It is therefore necessary to remove the heat of reaction with cooling water in the reactor Jacket and condenser. -1- ABD00249757 I. INTRODUCTION - Continued C. Process Information - continued Reactor agitation is also required to maintain uniform reactor mixing and efficient heat removal. If reactor cooling and/or agitation is lost, the polymerlzatlon reaction oust be stopped. Failure to do so will result in a runaway reaction with increasing temp erature and pressure. The reactor pressure would in crease until the rupture disc/safety valve assemblies would vent the reactor contents to the atmosphere. The AMS Emergency Rill System provides the capability of injecting up to 25 gallons of AMS into each of the large reactors and up to 60 gallons into the expansion reactors. This.can be done either remotely from the control room or manually at the reactor top manway plat form. AMS can be injected into a reactor as soon as agitation is lost to take advantage of mixing caused by residual swirling motion. Maintaining cooling water flow after loss of agitation will also help mixing by refluxing in addition to removing heat of reaction. II. GENERAL PROCESS DESCRIPTION Refer to the attached P & I diagrams for the complete system layout for each reactor area. Emergency kill injection pots are provided at grade level for each reactor. All injection pots are to be maintained at 250 to 275 pslg pressure using high pressure nitrogen cylinders. A separate nitrogen -2- A ABD00249758 II. GENERAL PROCESS DESCRIPTION - Continued cylinder end spere are provided for each Injection pot. A local AMS level gauge and a pressure gauge are provided on each pot in addition to a board-mounted low pressure alarm and a lay level alarm. The A operator is to check the appropriate injection pot level and pressure before starting each reactor charge sequence. Killing agent can be Injected Into the reactor either remotely by the lead operator or locally by the A~ operator. Normally, the emergency kill system Is activated from the board to minimize time and maxi mize mixing. One switch for each reactor operates auto* matlc double block valves at the reactor top manway level. Placing the switch in automatic mode opens the valves and allows a low level switch in the Injection pot to close the valves. Placing the switch In the momentary-contact manual mode also opens the valves but the valves close when the switch Is released. Each Injection pot low level switch also activates a local light at the manual Injection point at the reactor top manway level. The automatic closure of the remote In jection valves and the local low level Indicator light are provided to prevent nitrogen from being injected into the reactor, blanketing the condenser and reducing cooling efficiency. -3- & ABD00249759 II. GENERAL PROCESS DESCRIPTION - Continued An emergency Injection header la provided at the reactor top head level la each reactor module. The header allows any injection pot to be used to kill any reactor in the module or to inject additional killing agent if needed. The procedure requires two hosest one to connect the injection pot to the header, and one to connect the header to the reactor. Rilling agent can then Injected locally by the A operator or remotely by the lead operator. It should be noted that when the emergency injection header is used, the Injection pot low level switch will neither automatically close the remote injection valves nor light the appropriate local indicator light. Caution should be taken to prevent charging nitrogen into the reactor when using the header. The remote injection automatic valves are operated by nitrogen supplied by a high pressure nitrogen cylinder and spare. A board-mounted low pressure alarm is provided for each area to alert the board operator when the cylinder in use has dropped below 600 pslg. A cylinder with less than 600 psig pressure does not contain enough nitrogen to operate the control valves and is to immediately changed out with a full cylinder. A -4- rt ABD00249760 III. SAFETY The operation of the emergency kill system does not pre sent any extremely hazardous situations. In fact, its main purpose is to reduce the potential for having hazardous situations in the reactor area. However, some potential hazards are present and precautions should be taken to prevent serious incidents. A. The killing agent AMS has been in use for some time in the plant and the operators are already familiar with the corresponding safety hazards and proper handling procedures. The attached vendor literature describes chemical properties and safe handling procedures. It should be emphasized that AMS is highly reactive in the presence of the peroxide initiators used in the plant. AMS AND INITIATOR SHOULD NEVER BE MIXED UNDER AMY CIR CUMSTANCES. B. The AMS injection pots are to be maintained at 250 to 275 psig by high pressure nitrogen cylinders. Due caution should be exercised in the handling of nitrogen cylinders. Operators should avoid damaging the outlet valves on these cylinders. The AMS in jection pots will contain AMS at 250 to 275 psig pressure, so proper safety precautions should be taken while working with or near these vessels. An injection pot must be depressurized before the block valve on the AMS fill line is opened. A ABD00249761 III. SAFETY - Continued The nitrogen supply to the pot must be turned off at the pot prior to venting the pot. The pots are only to be vented through the bleed valve on che pressure gauge/pressure switch piping on the top of the pots. C. The rupture disk and relief assembly on each injec tion pot is set to relieve at 400 pslg, the vessel design pressure. Since the nitrogen bottle regulator may occasionally leak through, a potential exists for overpressuring an injection pot and causing the rupture disk to burst. Even if the killing agent didn't spray out when the relief devices opened, it is probable the relief valve would not completely reseat and the nitrogen bottle would slowly depressure through the pot and relief valve to atmosphere. The outside operator is to routinely check injection pot pressures to*Insure it is neither too low nor too high. D. The AMS killing agent is a volatile hydrocarbon, and thus fire and explosions are theoretically possible. Precautions are to be taken to prevent spills and excessive accumulation of flammable vapors. E. Since the injection pots are connected to the reactors, a potential exists for backing VCM into the pots. This poses no serious immediate problem since the AMS would kill any reaction that was occurring. However, it could present an exposure problem later when the Injection pot is opened. -6- & r ABD00249762 III. SAFETY - Continued The injection pots are to be maintained at 250 to 275 psig pressure except when refilling. F. Finally, operators are to keep in mind that this system will be used when the plant is in an upset condition, i.e., power failure, loss of cooling water, reactor runaway, etc. It is critical that this system operate properly in such an emergency. System maintenance and operator familiarity with this system are equally Important factors for ensuring the dependability of this system. IV. OPERATING PROCEDURES A. When To Ose The emergency kill system is to be used under the following circumstances: 1. If there is a power failure. 2. Extended loss of cooling water to a reactor in polymerization mode. 3. Extended loss of agitation to a reactor in polymerization mode. When agitation is lost, it is Important to kill the reaction as soon as possible. The reactor contents will con tinue to swirl for about four minutes after agitator shutdown, and AMS injection during this period is much more effective. -7- A f ABD00249763 XV. OPERATING PROCEDURES - Continued 4. A- runaway reaction with Increasing temperature and pressure which Is not responding to small tUf mi Ay* L -m 77^1 \ AMS injections (short stop) from the Initiator , ( charge pot. 5. Any other circumstance considered by the ajTH&tv*' /bo'P: ~T/ULL^d) operator to represent a significant chance of over pressuring the reactor or affecting safe operation of the plant. 6. If for any reason the reactot temperature or pressure reaches the following: a. 530545265 155 pslg 160F b. All- other resin types 145 pslg 142*F B. How To Use 1. The Lead Operator Is to depress the manual AMS emergency kill button and keep it depressed for two seconds after to open light comes on: This opens both remote operated valves and AMS Is Injected into the reactor. Both valves close when the button is released stopping the addition of AMS into the reactor. 2. The Shift Supervisor or Chief Lead will then check the local level gauge on the AMS in jection port to confirm AMS was added to the reactor and he will also determine the number of inches of AMS added from the ruler on the injection pot. A -8- p ABD00249764 IV. OPERATING PROCEDURES - Continued B. How To Use - continued 3. In case of a power failure, the Lead Operator is to kill reactors in the following order and all must be killed within two minutes. a. 5265 or 5305 batches b. Reactors which are near pressure drop c. Reactor just reaching end of heat up d. Remaining reactors 4. After AMS injection, the Lead Operator will closely monitor the reactor temperature and pressure and will add additional AMS per step 1 if the initial injection does not kill the reaction. 5. If the remote operated injection system falls to work, the A Operator is to manually Inject AMS into the reactor by opening the two manual valves on the manual AMS injection line at the reactor head level. 6. If all the AMS in the injection pot is added to the reactor and more AMS is required to stop the reaction, the emergency injection header is to be used. This header allows AMS which is contained in any of the other reactor injection pots to be added to the reactor which is being killed. To use this header, the A Operator connects one hose from a full and pressurized injection pot to the header and a second hose from the header to the reactor being killed. -9- A ABD00249765 IV. OPERATING PROCEDURES - Continued Additional AMS injection can then proceed either locally or remotely from the control room. Caution^is to be taken when using the header system since the injection pot low level switch shut off feature will not work in this situation and nitrogen may enter the reactor. 7. If excess nitrogen does enter the reactor, the condenser is to be vented to the recovery system. 8. As soon as possible after AMS injection, the A Operator is, to refill the AMS injection pot by the following procedure: a. Close the block valve on the nitrogen supply line at the pot. b. Depressure the pot through the pressure gauge vent valve. c. Refill the pot with AMS from the 55 gallon drum using the air-operated drum pump. d. Close and plug the pressure gauge vent valve. e. Pressure the injection pot to 250 to 275 pslg with the nitrogen supply system. f. Radio communication between personnel in the field and the Lead Operator is to be maintained at all times. The A Operator is to Inform the Lead Operator how the system is operating and what is being done -10- F & ABD00249766 IV. OPERATING PROCEDURES - Continued in the field. The Lend Operator is to keep the A Operator Informed of reactor pressure and of any apparent need for additional AMS injection. C. Normal Operation 1. A reactor is not to be charged unless its AMS injection system is in proper operating condition. It is the responsibility of the A Operator to check this in the field and notify the lead operator who will record the informa tion on the batch sheet prior to each reactor charge. The following items are to be checked immediately before each charge: a. The AMS level in the injection pot is to be at or above a seven-inch outage. The actual outage is to be recorded by the lead operator. b. The pressure in the injection pot is to be 250 to 275 pslg. This is to be checked on the injection pot pressure gauge. c. The pressure of the nitrogen cylinders being used for AMS injection is to be at least 1200 psig. Cylinders with lower pressures must be changed out and replaced with full cylinders. EMPTY BOTTLES ARE NOT TO BE LEFT IN THE BOTTLE RACKS. & -11- ABD00249767 IV. OPERATING PROCEDURES - Continued C. Normal Operation - continued d. The pressure of the nitrogen cylinder being used to actuate the automatic AMS injection valves must be at least 600 pslg. A cylinder with a lover pressure must be changed out and replaced full cylinder. The pressure on the outlet of the regulator for this cylinder is to be 100 pslg. e. The block valve in the AMS kill line (outlet valve at bottom of pot) is to be fully open. f. The block valve in the AMS Instrument nitrogen line at the reactor manway level Is to be fully open. g. Both block valves on the manual AMS injection line at the reactor manway level are to be fully closed. If any of the above conditions are not met, they are to be corrected before the reactor is charged. 2. To Insure proper operation of the system, the following items should be checked by the A Operator at the beginning of each shift: a. The pressure gauges between the double block valves on both the automatic and the manual injection lines should routinely be bled to 0 pslg. -12- A ABD00249768 IV. OPERATING PROCEDURES - Continued ^ C. Normal Operation - continued If pressure subsequently builds up on these gauges* It-indicates that one or both of the double block valves are leaking. Note: These gauges will have pressure on them after AMS injection. b. All spare nitrogen cylinders in the racks are to be full. The above items are vital to the proper operation of the emergency kill system. If any of these conditions are not met* they are to be immediately corrected. D. Testing Procedures 1. The AMS Emergency Rill System for each reactor vlll be tested per the frequency Indicated below. Each system will be checked to assure proper valve position* proper operation of the remote operated valves* and that the AMS inlet lines to the reactor are not plugged. The Shift Supervisor* the Chief Operator* the A Operator and the Lead Operator will conduct the testing. The testing procedure for each reactor is as follows: To Be Conducted Weekly a. The A Operator is to perform a complete visual check of the system both at grade level and the reactor manway level. All on-off valves are to be in their proper position and any problems detected with the system are to be noted and corrected. -13- [ A ABD00249769 IV. OPERATING PROCEDURES - Continued {* -T1 M '' ' D. ` Testing Procedures - continued * 5 - * To Be Conducted Weekly - continued^ .:OJ' . *--- ---------- b.' The'ShlTt'Supervisor Is to check for any 4 -3 .t 1 * t T S *. ,iy . pluggage In the manual Injection eyatem^. -0 nozzle (also the remote Injection system nozzle for D-300, D-700 and*745} using a rod through the rod-out port. Any blockage K,. .. found. la:ttf b_-removed/:* This check Is to be made during dump' or rlnse^of tKe reactor. The shift supervisor Is to note In his log book which reactors are checked for pluggage of the Injection-nozzles-;- c. The following procedure will be used to w.ix ''U..V.1check the .remote operj&ed system and to assure the Injection nozzle Is not plugged. The checkout will consist of Injection of a small amount of AMS into the reactor by cycling the remote operated AMS valves. The check Is to be made after dump Is complete and before the rinse to the sewer. The Lead Operator* who is in communication with the field operator* will cycle the remote operated valves using the manual addition button and will also check the lights on the panel for open and close indication. The field Operator will check the operation of the remote valves in the field. The A -14- A ABD00249770 IV. OPERATING PROCEDURES - Continued D. Testing Procedures - continued . - * * To Be Conducted Weekly - continued Operator will check the AMS Injection pot to ' assure AMS 'addition to the reactor by measuring the level In the AMS Injection pot before and after the AMS addition. The reactor is to be rinsed after the AMS Is Injected-and the A^perator Is .to refill, i * the AMS' Injection pot before the next batch Is charged In that reactor. The Shift Supervisor Is to note*- lnjhlsr-iog; took the reactors which are checked. 2. The normal pre-ch'Arge* checks are to be conducted on the AMS kill system before the reactor Is charged. 3. Whenever the ambient temperature drops below 20F, the AMS kill system for each reactor Is to be checked once per shift. The check is to assure the Injection nozzle Is open and Chat there Is no pluggage due to freezing in the kill system. The check out will consist of injection of a small amount of AMS into the reactor by cycling the remote operated valves and Is to be made after dump is complete and before the rinse to the sever. -15- r ABD00249771 IV. OPERATING PROCEDURES - Continued D. Testing Procedures - continued The Lead Operator, who is in communication with the field operators, will cycle the remote operated valves using the manual addition button and will also check the lights on the panel for open and close instruction. The field Operator will check the operation of the remote valves in the field. The A Operator will check the AMS injection pot to assure AMS addition to the reactor by measuring the level in the AMS injection pot before and after AMS addition. The reactor is to be rinsed after the AMS is injected and the A Operator is to refill the AMS injection pot before the next batch Is charged in that reactor. The A Operator is to record the checking of the AMS kill systems on his Vinter Protection Check List. A -16- ABD00249772 V. APPENDIX ABD00249773 STORAGE AND HANDLING OF ALPHA-METHLY STYRENE A Alpha-Methyl styrene Is usually stored and handled In steel equipment* It Is also compatible with stainless steel* aluminum* and galvanized Iron. Copper and copper alloys are not recommended for this service. This product has a fairly low freezing point (about -10F) and low viscosity. Underground storage tanks and lines should be considered* as their use will prevent freezing in winter and keep the product cool In summer. Storage temperature should not exceed 100F. Storage under a nitrogen blanket Is preferred; exclusion of air (oxygen) will reduce the chances of polymerization* peroxide formation* and fire. Piping can be of the materials listed above. A centrifugal pump is suggested for transfer service. "Teflon" is suitable for gaskets and packing. An Inhibitor* para-tertlary butyl catechol (10*20 ppm). Is used In alpha*methyl styrene to Inhibit polymerization. If storage time is prolonged* the Inhibitor concentration should be checked occasionally and more Inhibitor added* if needed. Alpha*Methyl styrene is a toxic chemical; contact with liquid or vapors should be avoided. -17- f ARnnn?4Q774 U.S. DEPARTMENT OF LA80R Occupational Safety and Health Administration MATERIAL SAFETY DATA SHEET Form m. 4MIMT RsquM undar USOL Saftty and Hsaith Rtgulationt for Ship Rpairing. Shipbuilding, and Shipbraaking (29 CFR 1915. 1916. 1917) SECTION I MANUFACTURER'S NAMt USS Cheated* Division, 0. S. Steel Corporation EMERGENCY TELEPHONE no. (614) 532-3420 AOORESS (Hhmhee, Street, Cilv, Stole, ami /.If Code) 600 Grant Street. Pittsburgh. Pa. CHCMlCAL NAME ANO SVWOnVM* 13230 HWYU-... tic HvdfOgifhm _ __ 1 TRADE NAMC ANO SYNONYMS ________ 9 10 SECTION II HAZARDOUS INGREDIENTS faintOacjervativie. e solvimts PIGMENT* C.T.LV.I "^4^, % TLV jUBdd. ALLOYS ANO METALLIC COATINGS EASE METAL ALLOY* VEHICLE SOLVENTS AOOITIVES OTHERS METALLIC COATINGS V FILLER METAL PLUS COATING OR CORE FLUX s sQTMCRS \ HAZARDOUS MIXTURES OS OTHER LIQUIDS. SOLIDS. oSS'eRgSE TLV % (UrM TLV % (UrM \ "^ OILING POINT <P.) VAPOR PRESSURE (mm M*.) VAPOR OCNSITV lAlRM) SOLUBILITY IN WATER APPEARANCE ANO OOOR SECTION III PHYSICAL DATA 329.2 Low 4.1 Nee. SPECIFIC GRAVITY (M,0.11 PERCENT. VOLATILE V VOLUME (%> EVAPORATION RATE 1 Water_____ n Less Than Colorless liquid v 0.907 Low 1 SECTION IV . FIRE AND EXPLOSION HAZARD DATA PLASM POINT |M*1ho4 uttdt 0 Tag Closed Cup - 114 P. FLAMMASLE LIMITS LM Ilf ax EXTINGUISHING MEDIA Water, foam, dry chealcal and carbon dioxide "special fire"fighting PROCEDURES __Water spray can be used to control unconflned fires, but a straight hose streea __ should not bemused.___Pireasn should have selfcontalned breathing apparatus. UNUSUAL FIRE AND~EXFLOSION HAZAROS Hone ___________________________________________ PAGE (1) (Continmd on imw sids) Fora 08HA20 Maw. tut ft ABD00249775 SECTION V HEALTH HAZARD OATA orLVa,/H3 u Per crptL'TSoeovERExPoIuRe ______Hudig^! dullness. llihthMdtdaiii. briithlmnin EMERGENCY ANO ^iMT MO ^ROCIOUMS Mov to freeh Ur,__ Keep quiet and *n. If not breathing, apply artificial respiration._________________________________ _______________________________________________ SECTION VI REACTIVITY DATA STARIUTV UNSTARLS CONDITIONS TO AVOIO X STAPLE IctSf 'incompatasiliTy {M4tfmis to triad) A*<d material* end ffii redteal *itiMtar* HAZARDOUS DECOMPOSITION PRODUCTS radical Initiators_____ HAZARDOUS POLYMERIZATION MAY OCCUR WILL NOT OCCUR CONDITIONS TO AVOID X Him gj&la.M3tfa. radical initiators SECTION VII SPILL OR LEAK PROCEDURES STEPS TO M TAKEN IN CASS MATERIAL IS RCLSASCO OR SPILLSD Largo --ounce - flush vita wittg but prsvnt paaaaga to drain# and Mvin Small amounts - with sand and burn WASTE OlSPOSAL MSTHOO Laras amounts - atomize Into an approved cotabus don chamber SECTION VIII - SPECIAL PROTECTION INFORMATION RESPIRATORY PROTECTION (Socafv Ivpt) Self-contained breathing apparatus for severe exposure VENTILATION LOCAL EXHAUST Preferred SPECIAL mechanical Honeni) OTHER None f protect.ve cloves Suitable rubber or of nonaoluble plastic materials. EYE PROTECTION f OTH^n PROTECTIVE EQUIPMENT. ... _ 1 Not a serious uunetrlal hazard - normal care. Safety gogglea SECTION IX . SPECIAL PRECAUTIONS PRECAUTIONS'"^ 0E TAKEN IN HANOLINO ANO STORING Keep awav from hast, sparks and open flans. ___________ ____ OTHER PRECAUTIONS Hona _______ PAGE 121 GPO )0 Form OSHA-20 ABD00249776 A^ ABD00249777