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SOLV/EPC & CMP PLANT NOTIFICATION OF PROCESS CHANGE CHECKLIST Type: LEVEL 1 (minor) LEVEL 2 (moderate) LEVEL 3 (major) Originator: Jim Haney Date of Origination: 05/12/97 Plant: Methanes Actual Date of Change: <02X97 Area: HCI Purification Equipment: K-55 Permanent B Yea Temporary Yes From: To: Description and Location of Change (Scope): Modify the K-55 seal that the atmospheric side of the seal can be purged with Technical Basis for Change: Installation of the N2 purge will help eliminate failure due to external corrosion. Impact on: Safety ElLoss Prevention nEnvironment Health Quality Production Other Type of Change: Alarm Shutdown Point instrument Process Computer Control Addition/Removal of Equip. ^Piping Modification HEquip./Material Modification Chemical Job Procedure No. Process Set Point Change Piping Spec. other: | Pre-modification Checklist: Applicable IS Applicable Applicable ^Applicable Applicable jApplicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable Applicable . -^Applicable v ^Applicable Applicable Applicable Applicable Applicable Applicable Applicable ^Applicable Applicable Applicable Applicable ^Applicable Applicable Applicable Applicable Applicable Written job scope and sketch of proposed change: POD# 1924. Project economics; attached. Consult piping and equipment specifications; Spec. # Comply with Engineering Practices. Consult Technology Center or comply with Tech. Ctr. guidelines. Equipment access/congestion considered. Consult Environmental function Environmental project checklist complete. Chemicals listed in the (TSCA) inventory before use. Perform Reactive Chemicals testing or review. Consult Safety function for compliance with S&LP and Block requirements Consult Process Safety for impact on PHA(F&EI, CEI, & Fire protection). State Fire Marshall notified. Consult Industrial Hygiene function Consult maintenance/Reliability Eng. Consult Instrument function. Consult Electrical function. Consult Analyzer function. Consutt/lnform Computer/Programming Support. Consult Area Engineer. Consult Operations. Consult Area Technologist Consult Inventory Management Consult Process Engineering. Evaluate and modify relief system. Work Order written. (List them) Consult Construction/Small Projects Consult Site Logistics Consult Quality (Customer Notification ?) Other (Name them) Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes . yL lUy 1 Date ^7 /y_ll7 Page 1 of 4 RR 4/96 DOW CONFIDENTIAL INFORMA TION Document I DO A 026519 CONFIDENTIAL Date: Date: s'//*/9 7 \ Date: [ Post-modification Checklist: (BEFORE START-UP) Applicable Applicable Applicable Applicable IS Applicable E3 Applicable ISApplicable ISApplicable Applicable Applicable Applicable Applicable Applicable Applicable ^Applicable Applicable Applicable Applicable El Applicable Perform prestartup audit: major equipment addition/mod. Lvl 3;attach. PSM files updated(such as piping circuits). Project list updated. Documented in Operating Discipline Library _________ Completed Job Procedures reviewed by: Operations SafetyEnvir. _________ Emergency Procedures _________ Training Aids (IPT, etc.) _________ Controlled copies of Critical Oper. Procedures updated _________ Safety/Environmental (cleaning, vessel entry, red tag) _________ Update plant Roundsheets, forms Plant equipment files updated. P&ID's. process flow sheets, and plot plans updated. Personnel trained on the change. Method: Critical instrument checklist updated. Updated HAZCOM Manual & equip. List. Pressure vessels, PVRVs, & PRD registered. Instrument loops checked and documented. Field switches, equipment, & MCC starters checked & labeled. Log sheets/controlled forms updated. GPI flow diagram & history/EDAS updated. GEMTS, PPM, & MSMS updated. Mod V program change checklist completed. Equipment RTO Checklist completed. Follow-up action plan completed prior to Final Approval(attached). Follow-up Yes Yes Yes Yes Yes Yes Yes Yes Yes Signature Date APPROVAL: Final Approver: Date: $ I dsjy-}' Lxj p Y Htvj Ale (y y Page 2 of 4 RR4/96 DOW CONFIDENTIAL INFORMATION Document 1 DO A 026520 CONFIDENTIAL Methanes MOC Training Sienoff Sheet MOC TITLE:. DATE:. Mark the box next to the appropriate individual that the communication/training is intended to reach. r\ SOS * Master# /^^gnattjre ' Date Taylor, D. 434501 Z1 Breaux, R. 43379>= w Haney, J. 091506 l/ peieler, B. 281334 KelleyTltr-- Storm, C. 239424 23949^. y "17 Bickham, CJ. J Cook, F. 432411 {jli 431977 Hunt, L.C. O&860O y Cavalier, N. 241889 ' %.o(UU / Rolke, R.W. ^ '097946 Grant, W.C. 432637 Stallcup WhjJet'ty.S. Young, Barry. 240558 434499 433620 y Gravouilla, D.C. ~7 Jackson, R. J. Metrejean, D.J. y Harrison, W. 434255 \y U'?? 433457 9-W - 241773 LN[ljlALUAAr~ (//Si 096480 j.SHzy ?A- Day Personnel Master# Signature Date Michel, A. Cook, J. J Dugas, D. 432203 433658 432407 l Brown, M.S. 433928 Rizzo, G. 432580 Johnson, J. 432541 Donatio, B. 434031 Carrier, B.P. 085908 Witt, J. 241996 Vavasseur, T. L Landry, C.P. 434160 434292 Site Logistics Clebert, J. Mathis, J. Simonson, F. Armond, N.L. Doucet, K Master# 432385 432997 432477 098664 432056 Signature Date Page 4 of 4 RR 4/96 DOW CONFIDENTIAL INFORMATION Document 1 DO A 026521 CONFTDFNTXAL n s \ H s a 1A tn s o o 2O n vH M Q O ZV H^ m yr 0> ~ V V to 7.U3 114^0 jk.' BUSK (S-U34 0J-Q5-1M7 IS E * .375-11 L*C SMCCO rt 5ttN roR JACK BOLTS. iwr KU wsm .Ilft.l.MO gnu 1 4 * t W >" ZEE1KH ,. I OTEE" -ssm ir m $ Brw;ILMEN GMW 1 war sl|^' H iiiuSu IH RW jpO 0 IM I 0.1* ByMW*g ite*-- B - M>2 ALLEN HO CAR SOWS CO. SPACES S.l [170] BC. n 'wwta.. tvotum. la at 1mr saws-WRrTS xsmwumi - 4nuntati to j B^E3gggmtimOmB W|,l*<^ --'W --WHO. wroww omn wmwiwi i __ |Tw . 4 ^n l. iwocsls ^^rr^"srss,,^Bfa 'MsgJgss M fKHAfnamw.nt<Muri TO: J7/V? umSImMiWiiI wwStwnh. N'rouvdiattwMMM JEaB .Wtft kOL VV**J <*** Dunaiwtefflc' WlttlMI 10 <BHW> -- 2B-Z&I47* I' , ..) .( .. ^.- a*.!.. .**.?. # l- r-*.'.*.-. - ^a. a/MHO! 150493 SINGLE INSIDE CARTRIDGE Typ[ FTO DURA SEAL SIZE FORMDRAWING 2D-281476 MATERIAL uiirn OPTIONS: Q s SHAFTSIZE: DURA SEAL BILL OP MATERIAL DISTRIBUTION EQUIPMENT: 3,250 ID BQUPDWGS: MYCOM HCL 250 SUD-L COMPRESSOR MYCOM MS300B30-DD MATLNOTE5: 2D-2B0286-R1 -li. *0*23871433 MKAX9840690 MNA17B38635 SLERVE J3L. E1MA2B15D5S 10 EXXA281505S EKIAA17970S JLLj H0AX8840421 JLL HVSR2750333 0.75 BRS SCC RSHft STL SOK HD CAP SCW 10.24 X Q. 375 STL HELICAL SPG LOCK HSHR HD 10 4 4 4 1 20 SS SLV ASSY 20 SS SLV 20 SS SLV COL 410 SS SET SCW 0.500 X 0.50 VIT O-RG 1 1 1 4 `1 l ) **" zo . M T> o ' Z \) -t J' T> V J vO ....... . 3/05/97 4ADRM I/M NO: 158493 SINGLE INSIDE CARTRIDGE pyre PTO DURA SEAL SIZE FORM DRAWING 20-281476 MATERIAL XL4X FVV OPTIONS: G S SHAFT SIZE; 30 19 DURA SEAL BILL OF MATERIAL DISTRIBUTION EQUTMENT: 3.250 IB EQUIP DWGS; KYCQM BCL 250 SUD-L COMPRESSOR MFCON MS 300030-00 MAT*L NOTES: 2P-280286-R1 Jt TXLT325QSB3 20 SS/SILICON CARBIDE 3 ROT D JS__ ASl. s 4, D E ci Si XL3T3250NB3 XKXK3250333 _ UC3C325D333 KKAX8B404O3 NX3N3250333 HRAXe540212 HKAX8B40217 KXAX8B40301 HEAX2297233 _ hit SILICON CARBIDE 3 SEAL RG 20 SS COMP UNIT 20 SS COL 20 SS SET SCW 0.250 X 0.25 20 SS COMP RG 20 SS PN 0.125 X 0.37 20 SS PS 0.125 X 0.72 20 SS SPG NO 1-A 316 SS SOX 9D CAP SCW 0.250/S p HVRR3250333 2 A4303250WV3 MKAX084O2O9 6 -HTOR3750333 s HJPG7750AS3 PEC PIT O-RG SILICON CARBIDE 1 INST 20 SS PN 0.12S X 0.25 VIT O-RG DHC 500 GSKT ___________ OPTIONAL PARTS AND/OR ASSEMBLIES 1 1 1 1 3 1 3 4 16 1 1 1 1 1 1 GLAND 1 CXB2815033A D HKAX8B40280 JL&. CKB2B15041A B T53AN070A03 Y53A3250AEJ JJL WA29568817 MEAX8B40663 . 3/05/9V BADJUJ Oq \ ^ mo Z fO cn 3> \> r 20 SS GLD RG 1 TAP/SPEC 20 SS PN 0.062 X 0.19 20 SS GLD RG NO 5 CBN BOSH NO 5 CBN BUSH 316 SS WAVE SPG 316 SS SOX BD CAP SCW 10-24 X 1 1 1 1 1 1 *** CONTINUED NEXT PAGE *** <\ <r mm vC H<\ z c in c <r m m cz oo c PIC Training & Development Procedures Chlorinated Methanes CMP PROCEDURE K-55 START UP PROCEDURE PROCEDURE # 460044 PURPOSE Safe start up of K-55 and Purification SCOPE To list the necessary steps required to safely and properly start up K-55 and the HCL purification system RELATED PROCEDURES DEFINITIONS K-55 oil circulation None SAFETY CONCERNS & Environmental Release, Rotating Equipment EQUIPMENT Minimum Block Standards ENVIRONMENTAL CONCERNS SPECIAL CONCERNS None Any line opening must be dried before placed back in service. This is a -40 dewpoint or better. REACTIVE CHEMICAL CONCERNS Event: Operating deviation: Consequences Extensive corrosion due to water in system Vessel put in service without checking dewpoint. Wet oil added to K-55 system. Water entering the system will cause severe corrosion and damage equipment. Spills are possible, and damage to the entire division HC1 system (Solvents, CMP, Vinyl II) is possible. Revision # 6 Dow Confidential Revision Date-5/26/96 This procedure is valid for 24 hours from the date viewed, June 30,1997,12:06 AM DO A 0?>577 CONFIDENTIAL Training & Development Procedures Chlorinated Methanes CMP PROCEDURE K-SS START UP PROCEDURE PROCEDURE # 460044 Line of Defense 1. HC1 system piping and valves always dried (purging or baking). 2. Oil sampled in compressor system to monitor for impurities. Event Damage to compressor due to carbon formation. Operating deviation: Adding the incorrect oil to D-60. Consequences Formation of carbon in the compressor and associated equipment. Production Loss PROCEDURE RECOMMENDATIONS Event: Use only the oil specified in the procedure to add oil to D-60 If a procedure is currently active at relief, state in the relief notes the status off the job and the steps that have been completed up to this point. Highlight the procedure steps as they are completed so operations personnel are aware of its status. This is especially important during shift reliefwhen jobs are incomplete. Avoid carryover of a job when possible. I.E. Starting a Job at 5:00 AM/PM, just prior to relief. Revised GR/RB 5/92 DO & CONF ^ Training & Development Procedures Chlorinated Methanes CMP PROCEDURE K-55 START UP PROCEDURE PROCEDURE # 460044 Outside Check Sheet K-55 System Step Action 1 Pressure test with snoop - no leaks @ 150 psig 2 K-55 alignment complete 3 Red Tag Master(s) cleared 4 K-55 test power on 5 D-56 pressure at least 30 PSIG below D-55 pressure 6 Circulate oil if down for more than 8 hrs 7 D-56 level 45% or more 8 D-55 level 5% or more 9 Manually opened oil valves to each bearing and roll K55 by hand to lubricate the bearing and seal 10 Oil pumps both down and in auto 11 Coupling guard installed 12 Test power off. 13 K-55 starter racked in, 14 Field switch in off position 15 Hydraulic'pump on. 16 Load valve stroked to full load and unload position (Unload confirmed on display 17 All red tags pulled and masters) cleared 18 Complete system checked (No hoses or tubing connected to process and all bleeds plugged and blinded. 19 All instrumentation checked and properly valved up (K55, C70, E-73, purification feed, etc.) Revised GR/RB 5/92 OO A 0?f>5?9 confidential Training & Development Procedures Chlorinated Methanes CMP PROCEDURE K-55 START UP PROCEDURE PROCEDURE # 460044 Outside Check Sheet Valving to Check Step 1 Action Limit 27 Steps Must be complete ______ Consequence_______ Action to be Taken Failure to do any one of Abort the start up these steps could result in a until all 27 steps are catastrophic failure of the complete. Contact compressor or its associated the Area Engineer if equipment. Loss of con any one ofthese tainment, chemical exposure Steps are not serious injury and death are completed. possible ifthese 27 steps are not followed. Vinyl II to HCL manifold open. 2 HCL feed control station: Block valves open. Bypass closed, and control valve in manual position closed. 3 E-51 temperature control station closed 4 E-52 Shell oil control station: Block valves open, bypass closed, and control valve in manual, position closed 5 R-50 valved for either up or down flow... 6 R-60, V70, and E61 block valves open 7 K-55 suction and discharge valves open 8 D-56 differential pressure control station: Block valves open, bypass closed, and control valve on auto with 80 psid setpoint. \ 9 D-56 level control station: Block valves open, bypass closed, and control valve on auto with 40-50% setpoint. 10 K-55 oil system lined up from D-56 through oil pumps, oil cooler, one filter, oil diff. pressure control station with block valves open, bypass closed, control valve on auto with 75 psig setpoint, and K55 case drain open to D-55 11 Oil cooler fans lined up, racked in and ready 12 K-55 discharge lined up thru E-72 to C-70 Revised GR/RB 5/92 DO A 026530 CONFIDENTIAL Training & Development Procedures Chlorinated Methanes CMP PROCEDURE K-55 START UP PROCEDURE PROCEDURE # 460044 13 C-70 overhead pressure control station lined up with block valves open, bypass closed, and control valve on auto with a setpoint at 200 psig 14 K-55 recycle control station (2" station directly below E-61) manually blocked in. 15 E-61 fan running. 16 Users pressure control station lined up with block valves open, bypass closed, and control valve on manual 100% open 17 Block valve downstream of user's pressure control station to feed line open. 18 C-70 btms lined up through btms control valve to D-751 with C-70 btms EBV closed 19 Freon control station to E-74 lined up with control valve closed 20 Freon control station to E-73 lined up with control valve closed 21 HCL from purification open into incoming HCL manifold 22 Solvents notified and HCL valve to solvents (Across canal) closed 23 K-55 suction pressure 60-80 psig 24 K-55 case drain closed 25 Oil valves to K-55 open 26 K-55 bypass oil valves closed 27 These checks have been completed and K-55 is ready to start up. Operators Signature. Revised GR/RB 5/92 CDOONFAIDENTIAL Training & Development Procedures Chlorinated Methanes CMP PROCEDURE K-55 START UP PROCEDURE PROCEDURE # 460044 PROCEDURE NOTE: There is a K-55 start up check sheet which can be used to assist you in lining up and starting up K-55. Step Action 1 Make sure all jobs are complete and all red tags cleared. 2 Make sure that K-55 switch gear is racked in. 3 Make sure that D-56 heaters are on. 4 If the oil is circulating shut down the P-55's and place both P-55's field switches in automatic. There is a Modicon timer that will not allow the compressor to be started until the pumps have been down for 5 minutes. 5 Once the oil has been stopped circulating, open the casing drain for approx. 10 minutes to assure ourselves that all the oil has been drained from the compressor. AFTER DRAINING CLOSE THE CASING DRAIN. 6 Line up all the oil lines to the compressor. Make sure bypasses are closed. Limit Conseauence Action to be Taken 3 manual valves No lubrication on start up Make sure the 3 lined up under will cause a catastrophic manual valves to the the compressor wreck ofthe machine. Loss compressor are open lined up = open of containment, serious and the 3 bypasses 3 bypass valves injury and chemical exposure are closed. = closed is possible. 7 If the process side of K-55 is pressured up with nitrogen, depressure and pressure t>ack up with process by slowly opening the suction and discharge block valves. Monitor the compressor while opening the valves to insure that we don't roll the compressor in the process. Limit Conseauence Action to be Taken Absolutely no Metal to metal contact with Watch the shaft while rolling while out lubrication can cause a pressuring up the putting process on complete wreck ofthe machine. Isolate the compressor machine. Loss of contain- immediately if it rolls ment, serious injury and over. Contact the chemical exposure possible Area Engineer Revised GR/RB 5/92 DO A 02653? OONFTDFNTTAL Training & Development Procedures Chlorinated Methanes CMP PROCEDURE K-55 START UP PROCEDURE PROCEDURE # 460044 8 Line up all control valves and block valves associated with purification. Make sure that FRC(2052) E-51 feed control valve is in manual and closed. 9 Make sure that PRC(2179) users pressure control valve is in manual and open up to 106% valve output. Limit Conseauence Action to be Taken Wide Open = Overpressure of C-70. Blown Double check Group 106% output PSV and release of AHC1. One (1) Slot 8 and on the TDC Serious injury and chemical make sure the valve C-70 PSV's set exposure possible. output is at 106% at 300 psi and it is in manual K-55 trip set at 265 psi 10 Open the bypass around the check valve on the D-56 vapor out line to equalize the suction pressure with D-56 and then close it back. The drain lines on the V-55's may have to blocked to prevent D-56 from pressuring back up to discharge pressure. 11 Tum on P-57 hydraulic oil pump for the load valve. 12 Bring the load valve position to 0% output. Make sure the permissives on the PICS screen indicates that the valve is actually unloaded and that both modicons agree fNOTE: OCCASIONALLY HAVE TROUBLE WITH THE LOAD VALVE, THIS MAY TAKE SOME TIME TO PRIME THE PUMP AND GET THE LOAD VALVE TO 0% OUTPUT). Tum off P-5 7. 13 Get the suction pressure up to approx. 80-100 PSIG prior to starting K55. You can do this by opening up E-51 feed control valve.(Make sure you close it back prior to start up). 14 If the suction pressure is too high, it may be necessary to de-pressure to the Throx. Revised GR/RB 5/92 DO A 026533 CONFIDENTIAL Training & Development Procedures Chlorinated Methanes CMP PROCEDURE K-55 START UP PROCEDURE PROCEDURE # 460044 15 Have the following control valves positioned as follows prior to start up. FRC(2052) E-51 feed C/V TRC(2056) E-52 temp C/V PRC(2179) Users press C/V LOAD VALVE DPR(2146) K-55 brg diff press C/V ME 55 A/B LRC(2273) D-56 level C/V DPR(2276) D-56 diff press C/V PRC(2200) C-70 ov'hd press C/V manual closed manual closed manual open manualunload auto 75 psig auto (40 deg) auto 45% auto 80 psig auto 200 psig 16 Check the PICS screen 155 display to verify that the system ready light is on. 17 Start the compressor. A. The main oil pump will start automatically B. Eight seconds later, the Modicon will look to see if the oil switches have cleared C. If the oil switches have cleared and the load valve switch shows that K-55 is unloaded, the computer will energize MK-55 starter. The Modicon will wait four seconds for the motor to start. If it doesn't start within the four seconds, the startup will be aborted and the entire sequence will have to be repeated. 18 As soon as the suction pressure drops to 60 psig, start opening FRC(2052) E-51 feed control valve. Bring the flow up to a 4-5 M# hr and place it in automatic. If the suction pressure should be low when bringing K-55 up, it may be necessary to open the feed control valve as soon as K^-55 in energized. 19 Start slowly opening up TRC(2281) temperature control valve, monitoring the oil temperature. When the oil temperature turns you can place the control valve in automatic and slowly adjust the oil temp setpoint until you reach 40-45 deg. 20 Start a freon flow to E-73, monitoring E-73 and C-70 overhead temp. 21 Start to slowly increase C-70 overhead pressure until you reach 220 psig. Revised GR/RB 5/92 n0 A 026534 MFtOENTlAt CO Training & Development Procedures Chlorinated Methanes CMP PROCEDURE K-55 START UP PROCEDURE PROCEDURE # 460044 22 Slowly start opening TRC(2056) E-52 temp control valve to about 10% valve output. Place the setpoint to approx. 110 deg and put in automatic. Make sure we don't shake up the R-250 system in the process. Ifthere are inerts (N2) in the system, take a bleed to the Throx via the 2" line downstream of the users' PCV. The more you vent the quicker you can get C-70 in spec. 23 Continue to raise the load on purification, monitoring C-70 overhead temperatures and purity 24 Place PRC(2179) user's pressure control valve in automatic and start gradually raising the setpoint to 200 psig 25 When C-70 overhead product is good, send it to Solvents, Poly C, and we can take some too. 26 Once liquid level is established in C-70 btm, ensure the btms out AOV is open and put C-70 LCV in auto. 27 Put E-74 freon in auto and control the freon out temp at 11.5 Deg C \ Revised GR/RB 5/92 DO A 026535 CONFIDENTIAL. Training & Development Procedures Chlorinated Methanes CMP PROCEDURE K-55 START UP PROCEDURE PROCEDURE # 460044 After Start Up Check Sheet Step Action 1 Oil pressure controlling at 75 psid 2 D-56 level controlling at setpoint and the V-55 drain valves are cracked open to D-56. Opening these valves too much can cause the D/P control valve on D-56 to wind up. 3 D-56 diff pressure controlling at 80 psig 4 K-55 oil temperature on auto and controlling at 40 deg C 5 Purification feed flow on auto and controlling to hold 60-100 psig on K-55 suction 6 C-70 overhead pressure controlling at 220 psig 7 E-73 freon on computer at approximately .50 ratio or as necessary to control vinyl in product 8 E-74 freon controlling R-22 out temp 9 User's pressure control on auto and controlling at 190 to 215 psig. 10 Shell oil on E-52 and temp, controlling at 110-119 deg C 11 Notify solvents when purity is good and recycle is high enough for them to start taking 12 Entire system checked for leaks at operating pressure after start up. 13 When purity is good, valve HCL to Poly C Revised GR/RB 5/92 DO A 026536 CONFIDENTIAL