Document aJN7z5eDxEG7a170Xo9Jk4Q4N

PPG INDUSTRIES, INC. CHEMICAL DIVISION - U.S. LAKE CHARLES, LA ff TRAINING MANUAL FOR THE POSITION OF "DH OPERATOR IN PLANT B-II EDC/VDCM COMPLEX CONFIDENTIAL S '~~1 object Protective Order HUf 2.4th Judicial District Court; i - Uo# 91-1145 0lU5 SL OBJECTIVE UPON COMPLETION OF THE TRAINING AS SPECIFIED IN THIS MANUAL, THE TRAINEE WILL HAVE THE KNOWLEDGE, SKILLS AND ABILITIES NECESSARY TO PERFORM AS A PROFESSIONAL OPERATOR IN PLANT B-II. CONFIDENTIAL PROPERTY OF PPG INDUSTRIES, INC. This document includes proprietary and confidential information which is to be maintained in strict confidence. Reproduction, use or disclosure without express authorization is prohibited. SL 011206 CONFIDEHTIM.* Subject to Protective Order of 14th Judicial District Court No. 91-1145 PREFACE PPG - Lake Charles utilizes on-the-job training for operators. This training manual is provided for use in conjunction with the on-the-job program. The content of the manual was compiled with cooperation and assistance from operators and unit supervisors. It is intended to be used as a guide in learning the general skills associated with the job. The training technique used in the manual is a step-by-step building block approach. The building blocks are training modules which contain the tasks that must be learned to perform the job safely and effi ciently. Although the modules are arranged in logical sequence for learning, the order may be changed depending on operating conditions. Each module contains a learning exercise in the following form: OBJECTIVE - A statement outlining the intended results of the module. RATIONALE - An introductory section explaining why you need to learn each task and how the task applies to the job. LEARNING ACTIVITIES - Exercises that tell what to do in order to learn that part of the job. They include information that must be read and learned. TASK DETAILING - A reference list of the subtasks necessary to perform the tasks in the module SL 0112Q7 COWFiPSHTlAtl Abject to protective J*6* L4th Judicial District Court YOUR ON-THE-JOB TRAINER, LEAD OPERATOR AND SUPERVISOR WILL ASSIST YOU DURING YOUR TRAINING PERIOD. HOWEVER, YOU ARE THE PERSON MOST RESPON SIBLE FOR YOUR LEARNING. Read the Objective and Rationale. If you have any questions about the task or why it is done, ask your on-the-job trainer or supervisor. Once the task and the reasons you perform it are clear to you, go on to the learning activities. The first part of the Learning Activities will provide you with or refer you to information that must be learned in order to correctly and safely perform the task. Your on-the-job trainer will help you with the second part which is the practical application of the information to the job. Qualification Standards for this job are listed in the last section of the training manual. Your job performance will be measured using these standards as a guide. You must meet these standards to qualify for this job. The final evaluation of your performance will include several items, the most important of which will be your performance on the test given at the completion of your training. THIS MANUAL IS NOT INTENDED TO COVER EACH AND EVERY ASPECT OF THE JOB. IT CONTAINS THE BASICS OF THE JOB AND WILL BE MODIFIED AS NECESSARY. SL 011208 CONFIDENTIAL* Subject to Protective Order f 14th Judicial District Court No. 91-1145 Listed below is the suggested timetable for the completion of this manual. This schedule need not be strictly followed, but is furnished as a guide. MODULE #2 COMPLETION TIME IN WORKING DAYS 2 3 #6 #10 10 Modules 13 Working Days There is a reminder of the estimated completion time at the beginning of each module. NOTE: The generic pronoun "he" is used throughout this manual for the sake of convenience. There is no intent to discriminate by sex. SL omo9 CONFIDENTIAL: diciai District Court Mo* 91*1145 CONCERNS FOR YOUR FUTURE Three important concerns for your future are Safety, Environmental Control and Energy Conservation. How you handle them directly effects PPG's profitability. SAFETY is the personal responsibility of each employee. He has a re sponsibility to his family, to his fellow workers, and to his employer by whom he is paid to work safely. In the performance of his duties, he will be expected to observe safe practice rules as well as instructions relating to the efficient handling of his work. There must be 100% compliance with safety rules and regulations. ENVIRONMENTAL CONTROL is both an important national consideration and a serious concern of PPG Industries. In order to maintain an environment that is healthy and in compliance with government requirements, all PPG employees must assume a personal responsibility for preventing spills, which would contaminate the environment. ENERGY is not only an exhaustable natural resource, it is a major and ever-increasing expense to PPG. It increases in cost with consumption such that each unit of energy used increases the cost of all our energy. All employees are expected to recognize and take steps to eliminate waste and use efficiently that energy necessary to properly and efficiently complete his assigned task. 02 fo CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 These concerns can be managed successfully with the full cooperation of every employee. CONTENTS Page 1. Plant History ............................................................................................. 1 2. Introduction to Major Job Responsibilities ............................ 6 3. Training Modules including Task Detailing: 3.1 Module #1: 3.2 Module #2: 3.3 Module #3: 3.4 Module #4: 3.5 Module #5: 3.6 Module #6: 3.7 Module #7: 3.8 Module #8: 3.9 Module #9: 3.10 Module #10: Equipment Layout. ... ................... Sampling.......................................... . 13 Lab Analysis............................ Running Sample on a Gas Chromatograph .......................................... . 28 Changing Septums...................................... . 35 Switching Carrier Gas Cylinders. . . 40 Tar Buggies ............................................... Cooling Tower Duties............................ Transfer Product...................................... Recharging the HQMME Tank................... 49 4. Glossary of Terms . 54 5. Task List.................. 6. Qualification Standards................................................................. oi uil2l? CONFIDENTIAL; Subject to Protective Order f 14th Judicial District Court No. 91-1145 PLANT HISTORY The PPG Industries, Inc. Industrial Chemicals Division Plant in Lake Charles was constructed by the U.S. Government during World War II for the purpose of manufacturing magnesium. It was originally operated by Mathieson Alkali Works (Olin Chemical Corporation) for the Defense Plant Corporation. In 1945 Southern Alkali Corporation, a jointly owned subsidiary of Pittsburgh Plate Glass Company and American Cyanamid Company, acquired the Lake Charles Plant for the purpose of converting the plant for the manufacture of chlorine and caustic soda. The first of four electrolytic chlorine cell circuits was put into operation on October 7, 1947. In 1951 PPG bought the minority interest held by American Cyanamid and changed our name to Columbia-Southern Chemical Corporation. Columbia-Southern became the Chemical Division of Pittsburgh Plate Glass Company in 1961 and on April 1, 1968. the name was again changed, this time to PPG Industries, Inc., Chemical Division, U.S. The Lake Charles Plant started with chlorine/caustic and has grown into a major producer of industrial chemicals. Vinyl chloride monomer, ethyl chloride, chlorinated solvents and silica products are among these chem icals. Two major chlorine/caustic/power expansions have taken place since the seventh diaphragm cell circuit was completed in 1955. PPG became the Ci 011213 CONFIDENTIAL s 1 Subj ct to Protective Order f 14th Judicial District Court No. 91-1145 first company to market caustic in pellet form in 1968 with the start-up of the caustic prill unit (PELS). In 1969 a major expansion in chlorine and caustic production was made with the Mercury Cell Unit. This type unit was built to help utilize the surplus salt from the Diaphragm Cell area. The Mercury Cell area differs in that it produces a low salt, saleable strength caustic soda. There is no additional expense involved in processing the caustic soda. From time to time there have been modifications made in the original Diaphragm Cells to increase their capacity. The products of Plant A are Chlorine, which is used as feedstock for other units, a bleach, and swimming pool water treatment to name a few and Caustic Soda, used in the paper industry and as a granular substance to uplug sink drains in homes. The third product of Plant A is hydrogen. This is compressed and sold to Gulf Oxygen and to Jupiter Chemicals. Some of the is used to fire the boilers at Powerhouse "C" in Plant C. In 1968, the Silicas Products plant was started up. This was the first of its kind to be constructed in the South. The Silicas plant was the first unit built in Plant C, which in 1977-78 underwent an expansion with the construction of Chlorine, Caustic and Power units. This expansion was a 1500 ton per day C^ expansion. A prototype of the Plant C cell was operated in Plant A before the area of Plant C was built. As a result of the Cl^ expansion in Plant C, Liquefaction was expanded. Another expansion of Plant C was started up in 1980. To help SL- 011214 to Prtectiv Order of 14th Judicial District Cour No. 91-1145 handle the increased Cl, production. North Liquefaction was built in Plant A. With the purchase of the Alkali Plant from the government, PPG also purchased Power Plant A. The Riverside Power Plant was purchased from the government by Gulf States Utilities. Riverside Power Plant was expanded in 1950 to meet the growing demand for electrical energy on the Gulf Coast. The 1955 Chlorine/Caustic expansion brought about the expansion of Power Plant A. Another boiler and turbine was added. In 1965, PPG purchased Riverside from G.S.U. This was in preparation for the Mercury Cell Unit that came on stream in 1969. Riverside was expanded from 85 megawatts to 165 megawatts. The name was changed to Power Plant "B". Power Plant "C" was built in Plant C to help meet the energy demands there. This Power Plant incorporated the latest technology and design in modern power plants. It utilizes a gas turbine to generate electric ity and the waste heat is used in a Heat Recovery Steam Generator. This steam in turn is used to generate electricity. At the present, the energy capabilities are: Power Plant A is 96 mega watts and 1,575,0Q0#/hour of steam, Power Plant B which has 165 megawatts and 1,570,000#/hour of steam and Power Plant C with 156 megawatts and 1,350,000#/hour of steam. The expansion in Plant B is a complex, intertwined affair. The names of the process units and the chemicals used and produced are alien to the majority of new operators. Through related use, you will become familiar with the chemicals regardless of how strange the names may sound. The Lake Charles Plant entered the organics market in 1960 with the construction of an Ethyl Dichloride Unit (EDC). This EDO unit was to prove to be a feedstock for several units to be built later. After the success of the EDC unit a Methyl Chloroform (MC) and Hydrogen Chloride (HC1) units were built. The MC is an electrical cleaner. This is also sold by other companies as a liquid to unplug kitchen sink drains. The HC1 was sold to Continental Oil Company and also used as a feedstock in the MC unit. Next in the growth of the organics units was the construction of Perchloroethylene and Trichloroethylene unit (Per-Tri). The primary use is as a degreaser. Women use it to remove grease spot by spraying it on the clothes before washing them. Dry cleaners use Per because it is also a dry cleaning agent. Tri is used by the auto manufacturers and space industry as a degreaser. After Per-Tri came on stream a Vinyl chloride monomer (VCM) and Ethyl Chloride (EC) unit was built. VCM is used in the manufacture of plastic pipe and furniture covering. EC is used as a refrigerant and in the manufacture of tetraethyllead for gasoline. In the VCM process; HC1 is produced and sold as a feedstock and muriatic acid. SL 011276 4 CONFIDENTIAL* Subject to of 14th Judi To help utilize the HC1 produced by the VCM unit an Oxyhydrochlorination unit (OHC) was built. The OHC unit manufactures EDC which serves as a feedstock for the VCM unit and Tetrachloroethane units. Modifications were made to the old MC unit to convert it to an EDC unit. A new MC unit was built. It was named TE-II after the registered trade name of Tri-ethane. After the construction of the TE II unit, Plant B was divided into B-I and B-II. In B-I the units are Perchloroethylene-Trichloroethylene, Ethyl Chloride, Vinyl Chloride Monomer, Tetrachloroethane, Waste-Treatment, Hydorgen Chloride, and Oxyhydrochlorination. B-II is comprised of the Ethylene Dichloride, Methyl Chloroform, Oxyhydrochlorination and Vinyl II units. As can be seen, there has been a tremendous amount of growth at the PPG Lake Charles complex. Most of these units produce saleable products. In order to move these products from the complex to the customer, the Shipping Department was created. This department has been expanded over the years to keep pace with the complex expansions. The Shipping Department started with a Chlorine and Caustic barge loading facility. Now there are Chlorine, Caustic, and Organics barge loading facilities. In addition to the barges, ships are loaded at the dock facilities. Now the Shipping Department loads barges, ships, drums, railcars, and trucks. The history of the Shipping Department is like the rest of the complex, one of growth. SL 011217 CONFIDENTIAL? Subject to Prot ctive order Of 14th Judicial District Court 5 No. 91-1145 I INTRODUCTION TO MAJOR RESPONSIBILITIES The EDC/VDCM "D" Operator has responsibilities in four (4) operating units. These units are EDC #1, EDC #2, and VDCM. Don't let the large area of responsibility scare you, some of your duties are the same in all four units. We will discuss the operation of these units and give your responsibility areas. Thus far we have talked about some strange things called EDC and VDCM. What are these things? EDC is the abbreviation for ethylene dichloride and is used basically as a feedstock. VDCM is vinylidene chloride monomer and is used to make a type of plastic, the most common being Saran. The EDC if1 and EDC if 2 units are operated basically in the same manner therefore, these two units will be discussed together. Feeds for the EDC reactors are chlorine <01^) and ethylene ^2^). These feeds combine in the presence of liquid EDC, in the reactor, to form EDC. The liquid EDC is in the reactor to help provide a better medium in which the reaction can occur. The EDC leaves the reactor as a gas and goes into the reactor condenser. In the condenser, the EDC vapors are condensed to a liquid. Some of the EDC is returned to the reactor and the rest goes to the stripper. In the stripper, the HC1 is removed from the EDC crude. After being processed through the stripper, the EDC goes to the heavies still for a SL 011219 COMriDBHTlM. final cleanup. This clean EDC is then stored in storage tanks for sale or use as a feedstock. Your third major area of responsibility is the VDCM unit. This unit is divided into two basic parts. These parts are the TCE purification unit and the VDCM unit. The TCE purification unit processes the TCE feedstock through a heavies still to remove the heavy compounds and then through a stripper to remove the trichloroethylene. After the trichloroethylene is removed, the purified TCE is sent to a storage tank until needed as feed for the VDC reactor. The second unit is the VDCM section. This unit takes the TCE and mixes it with cell liquor (NaOH). The TCE-NaOH mixture is pumped into the VDC reactor. Steam is injected into the bottom of the reactor to drive the organics (mainly VDC) out the top. The organics, with some water, goes out the top and is condensed to a liquid. Some of this liquid is pumped back to the reactor as reflux with the remainder going to the VDC DH still for drying. The VDC DH still performs a dual function of drying the VDC and removing an impurity known as MCA. Dry VDC is pumped to the VDC still for removal of heavier impurities. A VDCM grade product goes overhead out the top of the VDC still and is stored. 7 The preceding is a brief and very basic description of the EDC #1, EDC #2, and VDCM units. As time progresses, you will become more familiar with the operation of the units. You are encouraged to learn more about these units as time permits. The job of EDC/VDCM Auxiliary Operator is an entry level job but it is a very important one. Your duties vary from analyzing samples to doing housekeeping in the units. Because of your varied duties you will cover a great deal of the units. This makes you the eyes and ears of the "A, B, and C" operators. You will see leaks that may occur or hear pumps that are noisy. When you see or hear an abnormal condition you should report it to the Lead Operator or the operator in charge of the unit. The quicker these abnormal conditions are corrected, the less chance there is of damaging equipment or someone getting hurt. SL Of/22, CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court HO. 91-1145 CO N> N> N> Oft 1 etr fstr u- (o0 as O ue au H* *3 o as * oH- '3 vo V- b H- 51 (J 1 *-e V- H` O M * ot ft > U* ft nw re* 3" oO ft ? is *1 S. A t ft B-i HCL C2H4 1 ETHYL CH LORIDE %c) t EC SALES i HCL HYDRO GEN CHLOR DE (HCL) t HCL SALES CL2 PC BOTTOMS PRODUCT 02 i__i PERCH LOROETHYLENE TRICHLOROETHYLENE (PER-TRQ * PER SALES TRi SALES B-2 i i i iCL2 C2H4 ICE CAUSTIC - ETWYLENE------ BICHLORIDE (EOC.VDCM) EDC SALES EDC FEEDSTOCK CHLOROPIVALOYL CHLORIDE T CPC PLANT "B" DISTRIBUTION FEEDSTOCK INCINERATOR 'J 22J Subject CtZFlDEttri*L* 01 i,th *-inrKfs frder o. l-n||rlct CO0rt EDC NO. 1 PLANT RODUCT COOLERS LUW~4 & INCINERATOR @> VENT STACK l4tl* judleiaJtectjv< 0r(J^ *> Court NO. 1 PLANT ' BOTTOHS EDC NO- 2 PLAN1 ---------------------------- (*>-Ccr <tu rr <5 Uutj/c oi j *utH**2 SZ3U0 IS I f CO Ps) fs> Ol from retention , TANK -a 150# STEAM t TO WTU STEAM ta c STRIPPER `tr %64 X <Lr*8 O* O***0*9 "MZ9 wHl Hto Ornf Bz -o 3 *-* 0 H4 it > wrr *Hi- < O rr O na oa cn n VDC SECTION SAMPLING One of your major functions at the EDC/VDCM Complex will be catching and analyzing samples. This is a very important job. The operators make adjustments based on the results of your lab analysis. As you catch and analyze samples, care should be taken not to contaminate the sample. A contaminated sample could give a wrong analysis. This wrong analysis could result in the wrong adjustment being made by an operator. When you analyze a sample and get an out-of-spec result, you should notify the Lead Operator or the operator in charge of the unit. An abnormal result can be an indication of trouble in the unit. The sooner corrective action can be taken, the less damage to the equipment. If the operator asks for a resample you should get one to determine whether there is an abnormal condition or not. You are responsible for catching and analyzing samples in the EDC/VDCM Complex. Along with the catching and analyzing samples comes the responsibility of reporting abnormal sample results. After you have performed the sample analyses you will be responsible for logging the results in the appropriate place. These lab sheets are used by the unit operator for reference to see if a trend is occurring or problems that may have occurred on the other shifts. This lab sheet will also be helpful to you to see if there have been any abnormal sample results. W'iSSSfti. order 4 9 ABNORMALITIES These operating units are like all other pieces of equipment, they have failures. When a unit shuts down or has to be started up you may have to assist. You may be required to open and close valves or check levels in vessels by reading a sight glass. A sight glass is a glass tube that allows the reading of the level in a vessel. The start-up and shutdown is a good opportunity to learn the workings of equipment and the operating unit. During the start-up and shutdown, keep in mind that it must be done as safely as possible. You are subordinate to the Lead Operator. He can give you a great deal of help and advice with problems that you might encounter on your job. The Lead Operator will sometimes assign jobs that are not a part of your regular job. These jobs are necessary for the safe and efficient operation of the operating units. He may also assign duties such as cleaning up the units. Keeping the units clean of trash and scattered hoses will make for a safer working area. You should keep in mind that your job is important to the safe and efficient operation of the EDC/VDCM complex. It is imperative that you perform your duties well. Your responsibilities are not to be taken lightly. If you are confronted with problems or situations you are,not familiar with, do not hesitate to consult the Lead Operator. How well you perform in your job will help determine the efficiency of the operating units. ,,,, SL 01 1228 A good performance will also make your job more CONFIDENTIAL} Subject to Protective Order 10 14th Judicial District Court No. 91-1145 enjoyable and easier. If you encounter any problems on your job, please consult the Lead Operator, operator in charge of the unit or one of the supervisors. Log abnormalities in the proper log book. A set of diagrams for Plant B-I, B-II, EDC I, EDC II, and VDCM are on the following pages. 1l229 CONFIDENTIAL: ibject to Protective Or"u 4th Judicial District Court 11 training modules The following pages are a series of modules designed to aid you in learning your job. These modules are arranged in a logical order to help you learn. There will be occasions when, because of varying operating conditions, you will want to change the sequence of the modules. In the event these conditions occur, it may be beneficial to go to the module that pertains to the situation. If this becomes the case, please do so. si 011230 CONFIDENTIALi Subject to Protective Order o 14th Judicial District Court No. 91-U45 12 MODULE #1 EQUIPMENT LAYOUT Time required to complete this module should be approximately two days. OBJECTIVE Upon completion of this module, you will be able to locate the major pieces of equipment in the EDC/VDCM Complex. RATIONALE Now that you have been assigned to the EDC/VDCM Complex, one of your responsibilities will be to become familiar with the area. Your primary duties will be in these areas. In order to function as an operations personnel in the EDC/VDCM Complex, you will need to be able to locate some of the pieces of equipment. A knowledge of the work area will be useful to make your job easier. It will be necessary that you learn the location of the equipment in order to perform. You will need to know the unit to catch samples, make rounds and operate the unit. In an emergency, a good knowledge of equipment location is vital. If you see or hear something unusual, such t as a leak or noisy pump, you can tell the Lead Operator the location. Much of the equipment will be alien to you when you first enter the EDC/VDCM Complex. After working here for a short time the equipment SL 011231 CONFIDENTIAL* Subject to protective Orosf pi 14th Judicial District Cfetftfs *f ft 1 V % A C will become familiar to you. Because of the size and shape of some of the equipment, you may be overwhelmed. Time will bring familiarity and you will be more at ease. LEARNING ACTIVITIES 1. Study the flow diagrams in the introduction of this manual. Note the major pieces of equipment such as furnace stills and tanks. 2. Make a list, from the flow diagrams, of the major equipment in EDC I, EDC II, and VDCM. 3. Follow the trainer on a sample round. 4. Ask the trainer to point out the major pieces of equipment such as the reactors, stills and strippers. 14 MODULE n SAMPLING Time required to complete this module, should be approximately one day. OBJECTIVE Upon completion of this module, you will be able to catch representative samples in the EDC/VDCM Complex. RATIONALE The bulk, of your work will be concerned with samples and sampling of the different process streams in the EDC/VDCM Complex. These samples are very important to the control of the different processes. From your sample analyses, data is gathered on which decisions are made in the control of the operating units. It is important that you use caution in catching your samples. A contaminated sample will give an incorrect indication of the process. This can lead to incorrect adjustments in the operating unit by the operators. These incorrect adjustments can lead to a great deal of expense in bad product or damaged equipment. The sampling process Is very simple. You catch some of your samples in bottles with screw caps. You will have to also catch pressurized samples. These samples have a special apparatus called a "coil" to catch the sample. The coil is used to catch samples containing VDC. Since VDC is a carcinogen (cancer causing), exposure should be kept to a 011233 CONFIDENTIAL* Subject to Protective Order 15 of 14th Judicial District Court No. 91-1145 minimum. Coils allow for an enclosed sampling system with low to zero exposure. These coils are not in use not but will be later. The EDC/VDCM Units have a vapor detector system in them. This consists of a mechanism that will detect combustible vapors. Care should be exercised while catching samples or blowing lines clear. The vapors from a sample could activate the vapor detectors. These vapor detectors are tied into the sprinkler system. To avoid unnecessary tripping of the sprinklers or shutdown systems, care should be taken while catching samples. It would be advisable to become aware of the vapor detector locations. Knowledge of the vapor detector locations and wind direction could avoid tripping the sprinklers. LEARNING ACTIVITIES 1. Follow the trainer as he catches samples. 2. Observe the procedure for catching samples. 3. Observe the location of the sample points. 4. Catch the samples with the trainer observing. Ask the trainer to demonstrate the procedure for catching a representative sample, 5. Read the Task Detailing in this module for Coil Samples. CONFIDENTIAL: Subject to Protective Order ; 14th Judicial Oitrlct Court Wo. 91-1145 16 VENT lU lttb rt b li- U - t U L / VUUH-4 SL 011235 CONFIDtwtlM** Subject to Protective Order of 14th Judicial District Court No. 91*1145 COIL SAMPLE BOARD TASK DETAILING Using a Sample Coll 1. Obtain a sample coil from the process lab and take it to the sample point you wish to sample. 2. Some of the sample boards have a switch that will allow you to sample two different pumps. Turn the switch (7) to the pump you wish to sample. 3. Turn the switch (4) to the vent position, 4. Unblock the vent line (5) if it is blocked, 5. Unblock the N2 line (6) if it is blocked. 6. Allow the sample point to N2 purge for a minimum of one minute. 7. Block the N2 line (6) and vent line (5). 8. Using the quick-connect fitting (2), disconnect the flexible line (3). 9. Switch the valve on the sample coil to the vent position. The vent position will be the side with the quick-connect fitting. CONFIDENTIAL: Subject to Protective Order 17 Of 14th Judicial District Court No. 91-1145 10. Using the quick-connect fitting on the sample coil, disconnect the flexible line on the sample coil. 11. Connect the sample coll to the flexible line (3) on the board. 12. Connect the flexible line on the coil to the quick-connect fitting (2) on the board. 13. Switch the valve on the sample coil to the sample position. The sample position is the side with the flexible line screwed into it. 14. Switch the valve (4) on the board to the sample position. 15. Allow the minutes. sample to circulate for a minimum of fifteen (15) 16. After the sample has circulated and you are ready to remove the sample coil, switch the valve (4) on the board to vent and the valve on the sample coil to vent. 17. Unblock the line (6) and the vent line (5) and allow to for a minimum of one minute. purge 18. Block the 1^ line (6) and the vent line (5). 19. Remove the sample coil by disconnecting the quick-connect fittings. SL 011237 CONFIDENTIAL* cout 20. Connect the flexible line (3) on the board to the quick-connect fitting (2). 21. Turn the valve (4) on the board to the sample position and leave in this position. This will allow flow to circulate through the sample point and thus reduce plugging of the sample point. 22. If you have difficulty catching a coil sample, consult the Lead Operator or the EDC/VDCM "B" Operator. J238 CONFIDENTIAL: Subject to Protective order .of 14th Judicial District Court 19 No. 91-1145 MODULE #3 LAB ANALYSIS Time required to complete this module should be approximately three days. OBJECTIVE Upon completion of this module, you will be able to safely and effi ciently perform lab analyses such as G.C., pH, and moisture content in the EDC/VDCM process lab. RATIONALE A large part of your job will be analyzing samples. This is also a critical part of your job. Error in analysis may result in wrong ad justments being made to the operating units. An error in analyses may also result in your having to catch extra samples to see if a problem exists. You should be as careful and accurate as possible in your lab analyses. While performing lab analyses, you should wear safety glasses or goggles. There is always the potential for eye injury from splashing chemicals. The number of cases of lab eye injury is small compared to the potential. There is also the hazard of cuts since most of the lab equipment is made of glass. Take care when handling the glassware. SL 011239 Order t Court Before performing lab analysis you should verify that your containers are clean by washing them with water or acetone. If a sample is to be checked for water, the apparatus should be cleaned with acetone. If a pH is to be checked, water will be sufficient as a washing agent. Con tamination of lab equipment or samples can give a wrong result. Care should be taken to avoid contamination of the sample and lab equipment. While working in the lab, you should also keep safety in mind. To assist you in performing lab duties, a lab procedure manual is pro vided. This procedure manual, combined with the on-the-job trainer will help you learn the sample procedures. Repeated running of samples will improve your techniques and abilities in the lab. LEARNING ACTIVITIES 1. Observe the trainer performing lab analyses and note the procedures. 2. Become familiar with the Lab Procedure Manual. Make a notebook from the Lab Procedure Manual of the samples you must run. 3. Perform one each of the lab analyses wth the trainer observing. 4. Read the procedure for operation of Mitsubishi moisture meter Model CA-05. O^iAO of 14fh 7 i? f**otective Order Of 14th Judicial District Cour No. 91-1145 21 5. Ask the operator to show you the procedure for operation of the Mitsubishi moisture meter Model CA-05. Si 011241 t COMttDENTIM,* Subject to Protective Ord r of 14th Judicial District Court No. 91-1145 22 rig. 3 Cell Colt 1-drylng tube 2-drylng tude 3-cathode solution cell -titration cell assembly 5-sample Injection port S-draln port 7-stlrrlng bar 8- speed control1 for stirrer 9- electrode 10-bllnd plug St ot(Ser OPERATION OF MITSUBISHI MOISTURE METER MODEL CA-05 Starting Condition: 1. Turn power switch on left side of instrument to the on position. 2. Move Speed Adjust control to 6 on stirrer. 3. If titration speed (on left side of the display) indicates a negative number, inject 1/4 mL of the check solution or 1 mL of the sample and depress the titration button. The titration will begin indicating wait. After it has corrected the negative number, an electronic buzzer will sound and the display will display "END". After this, depress the CL button and you are now ready to go to step 4. 4. At this point, depress the Sample button and then the ENT button until a V appears on the display. Then on the keyboard enter the size sample you intend to use (1 mL) and depress ENT again. This will cause SG to come up on the display which stands for specific gravity. Enter the desired specific gravity on the keyboard and press ENT again. At this point depress the CL button and display will indicate RDY. Titration of Sample: 23 1. Rinse the syringe supplied with sample 4-5 times before drawing up the proper amount of sample to be injected into the titration flask. 2. Before injecting the sample into the titration flask, make sure the RDY is displayed on the display. If so, depress the Start button and "Add Sample" will come up on the display. At this point inject the sample into the titration flask. It will automatically start to count out the ug of H^O. When the buzzer sounds, it will display ug of H^O and also print out ppm H^O. Changing Solutions: 1. Changing C Solution: a. Move speed control (It8) to zero and allow stirring bar (#7) to come to a complete stop. b. Removing drying tube (//1) from cathode solution cell (#3). Using a Dropper Pipette draw out all of the solution in the cathode solution cell (#3). c. Using a funnel inserted into the hold for the drying tube (#1) on the cathode solution cell (//3), pour the contents of one ampule of Aquamlcron C. d. Replace drying tube (#1) back into cathode solution cell. (Make sure drying tube has fresh Drierlte in it.) e. Move speed control knob on stirrer back to 6 on scale. SL 011244 ve Order rict Court Depress titration button. The titration will begin indicating wait. After it has dried out the new solution, the buzzer will sound and the display will display end. After this, depress the CL button and you are now ready to go to step 1 of "Titration of Sample". ;ing A Solution: a. Move speed control (#8) to zero and allow stirring bar (#7) to come to complete stop. b. Open drain port (if6) and allow all of the solution to drain out. c. Close drain port (if6). d. Remove blind plug (#10) from top of titration cell assembly (#4). Using a funnel, add all of the contents from a Generator Solution A (Anode) bottle to the titration cell assembly (if4) and replace the blind plug (#10). e. Be sure to keep fresh Drierite in drying tube if2. f. Move speed control knob on stirrer back to 6 on scale. g- Depress the titration button. The titration will begin indicating Wait. After it has dried out the new solution, the buzzer will sound and the display will display END. After this depress the CL button and you are now ready to go to step 1 of "Titration of Sample". Troubleshooting: 1. Open detector indicated. SL 011245 25 confidential. V Ord r rict Court a. Unplug and plug back pin jacks (11, 12). b. Turn power off and back on at Power Switch. c. Depress formula key (F), then depress on the keyboard and then enter. (This will clear out any error in the calculation formula.) d. Depress formula key (F) again, then depress 5^ on the keyboard and then enter. instrument.) (The correct formula is now in the e. Depress print key, then depress 3 on the keyboard enter. and then f. You are now ready to go to step 4^ on starting conditions. No end point or stops titrating. a. Change solution A and C_ as described in "Changing Solutions". Sample TBL NPL BLM DME EC VCM VDCM EDC Furnace Feed MC -314 -324 -343 -348 -366 -368 PER -232 -208 -229 -230 01)246 SPECIFIC GRAVITY FOR H20 TITRATIONS Specific Gravity 0.781 0.806 0.831 0.861 0.924 0.969 1.212 1.262 1.262 1.326 1.310 1.326 1.308 1.310 1.320 1.625 1.625 1.625 1.625 CONFIDENTIAL*. 26 Subject to Protective Order of 14th Judicial District Court No. 91-1145 TRI -113 -127 -138 -143 -145 McCl, l Mix ' -147 DOL/SBL/Dox NRE/MC 366/208 366/230 1.468 1.468 1.462 1.465 1.465 1.460 1.321 0.930 1.124 1.385 1.460 $L 011247 CONFIDENTIALf Subject to Protective Order 14th Judicial District Court 27 MODULE #4 RUNNING SAMPLE ON A GAS CHROMATOGRAPH Time required to complete this module should be approximately one day. OBJECTIVE Upon completion of this module, you will be able to perform Gas Chro matograph analyses by following the procedure on the front of the G.C. RATIONALE As the "D" Operator you will be required to analyze some samples with a Gas Chromatograph (G.C.). This is a machine that analyzes a gas or liquid as to components and records the analysis. The G.C. appears to be a complex machine but the principle is fairly simple. A sample is injected through a rubber barrier called the sep tum. The septum is located on the injection port. Vaporization of the sample occurs in the injection port. After the sample is vaporized, it is moved by a carrier gas into the separating column. The principle behind a separating column is similar to allowing materials to separate by settling. Inside the separating column, which is a coil of tubing, the gases are separated as to molecular weights. The lighter or smaller molecules, the faster they will go through the separating column. Heavier or larger molecules go through the separating column at a slower speed. This would be similar to water going through a filter faster CONFIDENTIAL: SL 011248 than oil. When the sample leaves the separating column it passes over a detector. This detector analyzes the sample that passes it. Information of the anlaysis is picked up by the integrator which calculates and records the sample. The G.C. is useful in determining the composition of product and control streams. Using these results, the "B" and "C" Operators can determine the needed changes in their process unit. These G.C. analyses are also used to determine if a reactor or still has the proper feed ratio or temperature. As with most machinery there are some do's and don'ts. The first to remember is DO NOT attempt to take short cuts. These could damage the G.C, or give the wrong analysis. Clean syringes help insure an accurate analysis. The syringe should be cleaned with acetone. Do not clean the syringe with a sample. There should not be a barb on the needle. This will damage the septum. Another item on the list will be the use of the proper amount of sample. This will be written on the front of the G.C, In the event a sample is injected into the wrong column, allow the sample to go through. If another sample is injected too soon you could get a composite of the two samples. The final basic rules are very common sense but sometimes overlooked. Simply put, they are to read the instructions and if you have problems to check the Troubleshooting Guide that is provided in this module. LEARNING ACTIVITIES 1. Get your trainer to demonstrate the procedure for injecting a sample into the G.C. SL OII249 Prtective Order 29 ivth Judicial District Cour No. 91-1145 2. Study the Troubleshooting Guide. 3. Read the Task Detailing for Running Sample On Gas Chromato graph. 4. Run a G.C. sample while your trainer observes. 5. Make a list of the things that will help guarantee a good represen tative sample. TASK DETAILING RUNNING SAMPLE ON A GAS CHROMATOGRAPH 1. Read the card on front of the G.C. to determine the machine settings and proper sample. 2. Check box on side of G.C. for "ready" and "run" lights. Set numbers on box for respective sample. 3. From the card determine the proper column. This will be either "A" or "B" column. You do not have to select the column on the new G.C., only the old one. 4. Double check card and lights to verify machine is ready for your sample. 5. Remove syringe from the holder, 6. Open sample bottle and insert needle into the sample. 7. Pull the syringe plunger back and forth two or three times to clear the air from the syringe. 8. Use the prescribed amount of sample in the syringe. Si 'l25t CONFIDENTIAL t Subject; to Protectiv Order I4th Judicial District Court No* 91-1145 31 Push the needle through the septum. Hold your finger on the end of the plunger to prevent pressure in the G.C. from blowing the plunger out. Press the plunger into the syringe. After the sample is injected into the G.C., remove the syringe from the septum. Push the "START" button on the front of the G.C. Write the name of the sample on the G.C. readout paper. If problems develop, refer to the Troubleshooting Guide. ' r. inder. roup. i and `g y :ptum sam- ELY d. t essd m ad 3ld t be *'as r was JP ily Confidential* Subject to Protective Order Of 14th Judicial District Court 32 So, 91-1145 C. UNEXPECTED PEAK 1. Wrong file selected 2. Dirty syringe 3. Dirty sample bottle 4. Wrong sample III. NO SMALL PEAKS 1. 2. Very small sample injection Baseline below zero 1. Select proper file for sample. 2. Clean syringe well and rinse with sample. 3. Clean sample bottle or use new one. 4. Draw correct sample I. a)Change septum b)Use new syringe 2. Set baseline before injection. Si. 01^253 C0"rl?ocUve ora r Subject to P District Court oi 34 a"""-n MODULE #5 CHANGING SEPTUMS Time required to complete this module should be approximately one day. OBJECTIVE Upon completion of this module, you will be able to change septums in the G.C. without damaging the G.C, RATIONALE One of the instruments used in your sample analysis is a Gas Chroma tograph (G.C.). This machine separates a sample into its components and analyzes the amount of each component. After performing this analysis, the G.C. then records the amounts on a piece of paper. The G.C. depends on a gas flow to serve as a carrier for the sample. This carrier gas goes past the injection port. To prevent the carrier gas from escaping to the atmosphere while a sample is being injected, a septum is provided. A septum is a rubber disc that covers the injection port and is held in place by the septum holder. The sample is injected through the septum with a syringe. As samples are injected, the holes in the septum made by the syringe needle become bigger and more i numerous, allowing the carrier gas to escape. Changing the septum at the beginning of each shift will prevent escaping carrier gas. This escaping gas will cause a reduction in the carrier gas flow rate. The flow rate of the carrier gas is critical to the separation of sample SL 01 12 5 4 CONFIDENTIAL* 35 Subject t Protective Ord r of 14th Judicial District Court OI.IUC components. If the flow rate is altered, it could cause the G.C. to misidentify. Another reason the septum should be changed is that you can lose your sample through a bad septum. Excessive damage to a septum takes place when the needle point has a burr on it or is bent. Do not throw away the bad syringe. Place them in a box to be repaired. Changing the septum is important in that it will aid in the proper operation of the G.C, and correct sample analysis. Changing the septums at the first of your shift eliminates the possibility of incorrect sample analyses. It takes about 5-10 minutes for the G.C. to be ready after a septum is changed. This is a short time to wait when you consider the improved quality of your sample analysis. When changing a G.C. septum, you should be careful that you do not get burned. The septum holder and ceramic cover are HOT. These should be removed carefully to prevent burns. Included in this module is the procedure for changing the G.C. septum. Proper care of the G.C. will lead to more reliability and longer operating life of the instrument. Also, following the proper procedures for changing the septum will help insure a more accurate sample * analyses. The G.C.'s cost a great deal of money and the "B" and "C" Operators depend on your correct analyses, so give the proper required care to these machines. SL 011255 tP>f *144+thH J1u7d7ic:iarel cDeisivtreicOt rCdoei Wo. 91-1145 36 LEARNING ACTIVITIES Observe your trainer changing septums. Read the Task Detailing for changing septums. 3. You change the septum on the G.C. explaining the steps to your trainer before doing them. 011256 CONFIDENTIAL? Subject to Protective Order Of 14th Judicial District Court No. 91-1145 37 TASK DETAILING CHANGING SEPTUMS IN G.C. 1. Verify the machine is not in use by checking the lights on the front of the machine. When there is only a green light, this means the machine is ready for a sample. A red light means the machine is in use. You should have a green light before changing septurns. 2. On the front of the machine near the bottom is an "OFF" switch. 3. CAUTION: The septum holder and ceramic cover are hot. 4. Use a paper towel or glove to remove ceramic cover from septum holder. 5. Unscrew septum holder. 6. Old septum is located inside the septum holder. 7. Take some type of rod and remove the old septum. 8. Place new septum into the septum holder. 9. Screw septum holder back onto the G.C. SL 011257 CONFIDENTIALi Subject to Protective Ordefr of iHh Judicial District tiOUfl I?. aWii* 38 Place the ceramic covers back in place. Check pressure gauge on front of the new machine. Pressure should be up when machine is ready. It should take 5-10 minutes before machine is ready. >I258 CONFIDENTIALi Subject to Protective Order of 14th Judicial District Court No. 91-U45 MODULE #6 SWITCHING CARRIER GAS CYLINDERS Time required to complete this module should be approximately one day. OBJECTIVE Upon completion of this module, you will be able to switch carrier gas cylinders. RATIONALE The Gas Chromatograph (G.C.) depends on a gas to carry the sample through it. This gas is called the carrier gas. The carrier gas comes in cylinders with up to 2500 pounds of pressure in them. When this pressure gets low (around 500 pounds), the cylinders should be switched. To avoid low carrier gas pressure, the pressure should be checked at the beginning of each shift. The G.C. has a part in it called the detector. If gas flow past the detector were Interrupted, It could burn it out, A setup has been provided to allow switching of the carrier gas cylinders without inter rupting the gas flow. Protection of the detector is one reason for t switching gas cylinders at around 500 psi. The other reason is to avoid contamination of the gas cylinder. CONFIDENTIAL* Subject to Protective Order of 14th Judicial District Court St- 01)259 40 When handling gas cylinders, care should be taken. Do not beat on them or allow one to fall over. If the valve on the end of the cylinder is broken off, the cylinder becomes an uncontrollable missile. There have been cases of cylinders going through brick walls when the valve was broken off. When a cylinder is being moved, the cap should be on. This will protect the valve in the event the cylinder falls. Proper switching of the cylinders will help prolong the life of the G.C. Safe handling of the cylinders should be kept in mind. LEARNING ACTIVITIES 1. Read the Task Detailing in this module for Switching Carrier Gas Cylinders. 2. Go to the carrier gas cylinders and become familiar with the valv ing. 3. Ask the trainer to explain the procedure for switching carrier gas cylinders. 4. Switch carrier gas cylinders while the trainer observes. 5. Observe the position of the valve handles when they are in the proper position. SL 011260 41 TASK DETAILING Switching Carrier Gas Cylinders 1. Check pressure gauge on cylinder. If 500 to 400 psi, you will need to switch cylinders. 2. Close valve on top of the empty cylinder. 3. Using a wrench, loosen connection on hose to empty cylinder. This connection is screwed into the valve on top of the cylinder. 4. After the connection is loosened, shake the hose to allow pressure to bleed out the hose before disconnecting it. 5. Open the valve on top of the full cylinder connected to the carreir gas header. 6. Place cap on the empty cylinder. 7. Place the empty cylinder in the "empty cylinder rack". 8. Get a full cylinder from the "full" rack. 9. Place the cylinder in the area vacated by the empty cylinder. 10. Note in the logbook that you changed a cylinder. SL 011261 MODULE if! TAR BUGGIES Time required to complete this module should be approximately one day. OBJECTIVE Upon completion of this module, you will be able to safely pull the EDC tar buggy to their prescribed area and safely empty the tar buggy into the classifiers. RATIONALE The EDC units have waste products that are disposed of in a portable tank called a tar buggy. This means of disposal is used because of the nature of the waste material. On evening and graveyards shifts, you may be required to pull these tar buggies to the Waste Treatment Unit for disposal of the waste material. This material is considered hazardous and must be handled safely. LEARNING ACTIVITIES Ask the trainer to go to the field and explain the method for hooking up to the tar buggy and its destination. SL 011262 CONriDEHTlRLi . a__ 43 MODULE /'8 COOLING TOWER DUTIES Time required to complete this module should be approximately one day. OBJECTIVE Upon completion of this module, you will be able to monitor the cooling tower, adjust chemical feed and clean the screens. RATIONALE The cooling tower is an important piece of equipment to a process unit. Cooling towers provide cooling water for heat exchangers in the process unit. Your job is to assure a constant supply of treated water from the cooling tower. You must operate the cooling tower such that the water is properly treated to avoid damage to the heat exchangers. LEARNING ACTIVITIES 1. Read the following on cooling towers. COOLING TOWER The EDC/VDCM cooling tower cools water by evaporation. As water evaporates, the water left behind is cooled because liquids absorb heat when they evaporate. The tower aids in evaporation by providing a place CONFIDENTIAL: S1- 011263 dicial District Court No. 91-1145 for air Co contact the water. This is called a closed circulation system. The cooling water is pumped from the tower, through the cooling equipment in the field, then back to the tower. As the heated water returns, it covers the top of the tower and flows down through a network of slats. Because the water is dispersed as it falls, the surface area available for contact with air is increased. Exhaust fans on top of the tower pull air through the curtain of falling water on each side and out the top. This type of cooling tower is called a cross-flow type because the air flows horizontally across the water. The exhaust fans pull in a great volume of air which increases efficiency. The water that falls into the tower basin is cooled and is ready to be pumped back to the field. As pure water evaporates, it leaves impurities behind. This evaporation causes impurities to concentrate in the cooling water. Impurities can cause deposits which hamper the heat transfer qualities of operating equipment or plug it. Impurities can also errode the cooling equipment. Blowdown of the cooling tower helps remove these impurities. Make up water is added to the tower to replace the loss from evaporation and blowdown. Makeup and blowdown must be balanced to prevent the tower from emptying or running over. As blowdown and makeup water are adjusted, the treatment chemical amount in the cooling tower is lessened. You must adjust these chemicals to maintain proper treatment levels. SL 01 12 64 Some of these chemicals are hazardous CONFIDENTIAL: Subject to Protective Order *5 of 14th Judicial District Court No. 91-1145 and must be handled as such. You should wear rubber gloves, face shield and rain suit top when it becomes necessary to batch feed the cooling tower. Proper operation of the EDC/VDCM cooling tower is essential to bett r operations in the EDC/VDCM complex. 2. Observe as the trainer collects and analyzes samples of the cooling tower. 3. Ask the trainer to explain the importance of the samples and the adjustments that need to be made. 4. Observe while the trainer makes adjustments to the cooling tower. 5. Ask the trainer to explain the procedure for cleaning the screens. SL 011265 46 der MODULE #9 TRANSFER PRODUCT Time required to complete this module should be approximately one day. OBJECTIVE Upon completion of this module, you will be able to safely and properly transfer VDC product to storage. RATIONALE Product transfers are made for two major reasons. One reason is to make room for more production and the other is to make material available for shipment. In making transfers, care should be taken to assure that the correct valves are operated. Opening the wrong valve can result in the wrong product being transferred or good product being contaminated. Another possible error could be in transferring into a tank that is full. Transferring into a full tank could result in spillage and tank damage. The end result of the spillage would be wasted product and/or pollution. SL 0U266 Subject o i" Jud`ci8,i-U5 court 47 LEARNING ACTIVITIES Ask the trainer to show you how to line up transfers to the VDCM Storage Tanks. Show the trainer how to line up transfers to the VDCM Storage. S{_ 01 loan COHFIDEMTIM# * Subject to Protective order of 14th judicial District Court No. 91-1145 48 MODULE #10 RECHARGING THE HQMME TANK Time required to complete this module should be approximately one day. OBJECTIVE Upon completion of this module, you will be able to safely recharge the HQMME Tank. RATIONALE HQMME is an additive used in the VDCM process. This additive acts as an oxygen scavenger and to prevent reaction of VDC with itself to form solid polymer. The polymer would cause plugging in the vessels and piping. It is important that an adequate amount of HQMME is in the VDC streams. Your responsibility will be keeping the HQMME Tank charged. LEARNING ACTIVITIES Ask the trainer to show you the HQMME Tank. Read the procedure, in this module, for charging the HQMME Tank. SL 011268 .sS8arsu o itth 3^ n-u 49 3. Ask the trainer to demonstrate the procedure for charging the HQMME Tank. 4. You explain to the trainer the procedure for charging the HQMME Tank. 5. Demonstrate your ability to charge the HQMME Tank while the trainer observes. This can be a mock demonstraton. SL 011269 CONFIDENTIAL! Subject to Protective Order of 14th Judicial District Court No. 91-1145 50 TASK DETAILING Recharging the HQMME Tank 1. Check the level (7) In the HQMME Tank. If the level is 20% or less, the tank should be recharged. 2. Shut off the HQMME flow from the tank by closing the valve (1) at ground level. 3. Block the steam tracing (8). This will help cool the tank and thus help reduce the pressure in the tank. 4. Open the vent valve (6) on top of the tank. 5. While the tank is venting, get two drums of HQMME. Lay the drums on their side and beat with a piece of pipe to break the HQMME into chunks. 6. Place the drums in the hoist. 7. Go to the first level on the tank and check the pressure (1). The pressure should read "0n, If the pressure is not "0", check the N, valves (2) to verify they are blocked. If the N^ is blocked and you still cannot bleed the pressure off, notify the Lead Operator. 8. After the pressure is "0", open the large valve (9) on top of the HQMME Tank. SL 011270 CONFIDENTIAL! Subject to Protective Order Of 14th Judicial District Court 51 No. 91-1145 9. Go to the second level (top) of the tank, operate the hoist to take the drums to the top of the tank. 10. Place the drums on the platform. 11. Take the lid off of the funnel (10). 12. Check the grinder (12) to verify it is clear. You check the grinder (12) by looking into the funnel (10). If the grinder is clear, start the grinder by pressing the start button (5), If not clear, notify the Lead Operator. 13. Open the drums of HQMME and slowly pour into the funnel (10). If HQMME chunks become lodged in grinder, stop grinder, before breaking chunks with a rod or similar object. 14. After the drums are emptied, stop the grinder by pressing the stop button (5). 15. Place the lid back on the funnel (10). 16. Using the hoist, lower the empty HQMME drums to the ground. 17. Fill the tank with VDC by opening the valves (3 & 4) on top of the tank. 18. After the tank is full (7), close the valve (9) on top of the tank. SL 011271 CONFIDENTIALt 52 Subject to Protective Order of 14th Judicial District Court No. 91-1145 19. Close the bleed valve (6). 20. Pressurize the tank to 35# (11) by opening the valves (2). 21. After the tank is pressurized to 35#, close the valves (2). 22. Take the empty drums to the trash dumpster. 23. Unblock the HQMME flow valve (1) at the ground level. 24. Inquire of the EDC/VDCM "B" Operator as to whether the steam tracing (8) should be unblocked. 25. Make a final check of the tank pressure (11) to verify it is about 35#. 26. Note in the logbook that you recharged the HQMME Tank. SL 011272 to n,vwvwv- . dicial District Court No. 91-1145 53 GLOSSARY ABSORBER Equipment in which a gas is absorbed by contact with a liquid. Tetra: Absorbs in EDC feed to the reactor, the HC1 in the lights still vent. VC: Vinyl chloride is absorbed in EDC and fed to the strip HC1: per. The overhead stream of the absorber is clean HC1. HCl gas is absorbed in a weak muriatic acid solution to form a strong muriatic solution. TE-II: Removes the DCE-MC from the HC1 off of the MC reactor by contacting it with TCE/Tetra (Product still bottoms). PER-TRI: Absorbs in well water, the HC1 in the reactor vent after it passes through the primary and secondary condensers. AMBIENT TEMPERATURE The temperature of the atmosphere. ANALYZER An instrument that determines the composition of the material being fed to it. ANTI-BACK UP VALVE A valve set up such that it will not permit a backwards flow. AQUEOUS A solution of water with HC1 gas absorbed in it. BACK-PRESSURE CONTROL VALVE SL 0)/273 A valve that will open when the Subject to Pc 54 of 14th Judicia pressure in the line reaches a preset value. In the Tetra unit this valve relieves to the scrubber when the HCl pressure gets too high. BALL VALVE A valve in which the flow is regulated by a ball that is turned by the handle on the valve. BAYONET TUBE A dual-tube apparatus with heating fluid (steam) flowing into the inner tube and out of the annular space between the inner and outer tubes. Example: Chlorine vaporizer. BICARB A solution used in the OHC units to neutralize HCl in the recycle stream. It is formed by caustic (NaOH) combining carbon dioxide (CO2). The formula for bicarb is NaHCO^. BIG THREE A company that is one of the suppliers of N2 and 0^ to PPG. BLOWDOWN A purge taken off of the bottom of a vessel such as a kettle; the removing of catalyst from the centrifix or cyclone. Purge steam from cooling towers. PER-TRI: Purge off of bottom of organic vaporizers and also re moving of catalyst from the centrifixes. OHC: Removing catalyst from the centrifixes or cyclones. ci 011774 CONFIDENTIALt ,. Subject to Protective Order 0f 14th District Court 1 Mb BOTTOMS The heavy chlorinated organics waste in a unit. In the Bottoms Unit, bottoms can refer to the kettle feed or the waste off the bottom of the kettle. BRINE A liquid used in a refrigeration system, usually a solu tion of water and calcium chloride, which is cooled by contact with the evaporator surface and then goes to the vessel to be refrigerated. Also, brine is salt water. BUBBLE CAP A metal cup covering a hole in a plate within a distilla tion tower; designed to permit vapors to rise from below the plate, pass through the cap, and make contact with liquid on the plate. BURNING OHC; Reacting 0^ with ethylene (C^) to form CC>2 and water without the C2H^ being utilized to form EDC. PER-TRI: A desirable reaction in the Per-Tri reactors, when con trolled, that is necessary for the formation of perchloroethylene and trichloroethylene. BUTTERFLY VALVE A valve that utilizes a turnable disk element to regulate flow. CATALYST A substance that promotes or retards a reaction. Si. fl275 Qrder Subject to frt strict Court 14th Judicial notice 56 CAUSTIC Sodium hydroxide; a basic (nonacid) substance composed of sodium hydroxide. It can exist as a liquid when dissolved in water or as a white, brittle substance when dry. It can cause chemical burns. Some of its uses are acid neutralization, bleach and chloral destruction CELL LIQUOR A weak solution of caustic and water. CENTRIFIX A piece of equipment used to remove the catalyst carry over from the Per-Tri and OHC reactors. CHECK VALVE A device for automatically limiting flow in a piping system to a single direction. CHEST PRESSURE The pressure of the steam on a vessel needed to heat it to the desired temperature. Example; reboilers and heaters. CHROMATOGRAPH An instrument used to determine the composition of a gas or liquid by separating the elements in the gas or liquid. CHLORINATION Reacting with chlorine; an excess of unreacted chlorine. COMPRESSOR A machine used for increasing the pressure of a gas. $L 0 1 12 76 CONFIDENTIAL? Subject to Protective Order ^ of 14th Judicial District Court M,- <1 ] ! ' CONCENTRATION The amount of a substance in a solute in proportion to the total amount. CONDENSATE The liquid product of a condenser; the water from cooled steam. CONDENSER A heat-transfer device that changes a gas to a liquid by cooling the gas. CONVERSION To change from one isometric form to another. VC; Percent EDC that is converted to vinyl in the crackers. OHC: Percent of ethylene converted to EDC. COUPLING An apparatus used to connect the motor and pump. It is designed to allow some flexing between the motor and pump shaft. CRACKING To break up chemical compounds into different com pounds by heat. CTW Abbreviation for cooling tower water. CYCLONE A piece of equipment that removes particles from a vapor or liquid by centrifugal action. Used in OHC to remove the catalyst from the reactor vapors. DEFLUIDIZE SL To loose or cause the loss of fluidization. 011277 CONFIDENTIALt 58 Subject to Protective Order DEGASSER A vessel in which dissolved gases are removed from a liquid. DEMISTER A packing like material in a vessel whose purpose is to remove entrained liquid from a gas. Also called a mist eliminator. DESUPERHEATER A device that is used to cool steam by water injection into the steam. DEVIATE When a control instrument indication is not aligned with the set value. DH Abbreviation for dehydration. DIAPHRAGM VALVE A valve in which the open-close element is a flexible diaphragm. DISTANCE PIECE An area in a positive displacement, reciprocating compressor where the drive rod is located. DISTILLATION The process of producing a gas or vapor from a liquid by heat. DISTRIBUTOR An apparatus usually in a packed column, such as a scrubber, that causes the liquid coming into the top to be distributed over the area of the packing. o, L 01 1278 COHPIOEMTIMt* 59 Subject to Protectiv Order of 14th Judicial District Court No. 91-1145 DOUBLE BLOCK AND BLEED An arrangement of valves consisting of two block valves with a bleed valve located between them. D.P. CELL Differential pressure cell; A transmitter that reads a pressure difference to determine a level or flow. DUMPING A term used usually to indicate an uncontrollable emptying of a distillation column; a term meaning the emptying of a dopp kettle. ECONOMIZER A forced-flow, once through heat exchanger that usually uses a process flow on the tube and shell side. It is used to heat up one stream while cooling another. ENDOTHERMIC A reaction which absorbs heat. END POINT That stage in the titration at which an effect, such as a color change occurs, indicating that a desired point in the titration has been reached. ENTRAIN To have a fluid, in the form of a fog or mist, carried by a vapor. ENTRAINMENT SEPARATOR SL 011279 A vessel whose function is to remove a mist from a vapor. 60 CONttW3NTlMt Sublet to rr^tV^^ctrcourt ot Ith EXOTHERMIC A reaction that produces heat. EXPANSION BOTTLE An apparatus used in a pipe line to allow for expansion of the fluid or gas, also used to take some of the surge out of a flow when it is not a smooth flow. FCV Abbreviation for flow control valve. FINES The spent catalyst, from a Per-Tri or OHC reactor, that is blown out of the centrifix or cyclone. FLASH The rapid conversion of a liquid into a vapor. FLASHER A vessel used for the rapid conversion of a liquid into a vapor. FLOAT CHAMBER A vessel containing a float that indicates a liquid level. FLOODED Distillation term meaning too high of a level in a reboiler or tray; to have too high of a level. FLUIDIZED BED REACTOR A reactor in which the catalyst, such as Per-Tri or OHC, is suspended by the incoming gases. The catalyst has a boiling appearance. fcONFIDENTIAt.* guMect 'to Prdt^ctiv Ordof 61 dfc 14th Judicial District Court No. 91-1145 FREE RADICAL INITIATOR The catalyst in the Tetra and TE-II unit that prevents unreacted Cl2 from being excessive. FREEZE PRECAUTION" A water purge taken on water lines and showers to prevent freezing. FURAN The trade name for a plastic-like material. There are pipe and vessels constructed of this at PPG. FURNACE An apparatus in which heat is liberated and transferred directly or indirectly to a liquid for the purpose of effecting a physical change. These are used at VC to crack EDC and at Per-Tri and OHC to heat Dowtherm. GATE VALVE A valve with a disc-shaped closing element that fits tightly over an opening through which a fluid passes. GC-GAS CHROMATOGRAPH An instrument used to determine the composition of a gas or liquid by separating the elements in the gas or liquid. GLOBE VALVE A device for regulating flow in a pipeline, consisting of a movable disc-type element and a stationary ring seat in a generally spherical body. SL 01128) itONFIDENTlAtt Subject to protective1Order ot Uth Judicial District Court No. 91-1H5 62 H.A.D. - HEAT ACTIVATED DEVICES A device used to trip the sprinkler system when there is a sudden increase in temperature. HAVEG The trade name for a type of material that has the appearance of being epoxy and clay mixed. It is used to make piping and vessels. HEADER A pipe or conduit which distributes fluid or gas from a series of smaller pipes or conduits. HEAD TANK A tank that is elevated above a piping system. The function of the tank is to allow fluid to flow into the system to assure that the piping system Is full at all times. Examples of these are in the brine system and Dowtherm system. HEAVIES In the organic area, these are defined as material that is chlorinated too much for use in a unit. The particu lar unit may not have the facilities to clean up this material. BOTTOMS PLANT: This term can be the feed to the Bottoms unit or can be the waste of the Bottoms unit. INTERFACE ei 011282 Ul XL The boundary between any two phases: generally a term used to define the separation between two liquids such as organics and water. 63 COWPIOEWtlAt.* Subject to Protective Order of 14th Judicial District Court No. 91-1145 JACKETED Having an outer cover or casing through which steam or a coolant flows around a vessel. KARBATE The brand name for an impervious graphite material used in heat exchangers. This is an acid resistant material. KYNAR The brand name for a plastic like material from which valves and piping are made. This is an acid resistant material. LCV: LEVEL CONTROL VALVE A device (valve) which is able to maintain, raise, or lower the level in a vessel or pro cessing system as desired. LIGHTS The lesser chlorinated organics in a unit. These are usually EDC or lighter, depending on the operating unit. LIQUID AIR The name of one of the two companies that supply PPG with O2 and Nj. LIQUID BED REACTOR The process vessel in which the reaction of th reactants takes place in liquid. MAKE-UP WATER Water feed needed to replace that which is lost by evaporation or leakage in a closed-circuit, recycle operation. Primarily used with cooling towers and st am 1281 ^ generators. CONFIDENTIAL* Subject to Protective Order 64 of 14th Judicial District Court No. 91-1145 MANIFOLD A piping arrangement through which a flow or flows can be diverted to several outlets. MANUAL 1. Any processing operation performed by hand. 2. Controls arranged for their operation by hand. MECHANICAL SEAL Mechanical assembly that forms a leakproof seal between flat, rotating surfaces to prevent highpressure leakage. MFH: MIXED FEED HEADER A pipe that allows a mixture of the organic feeds before they enter the reactor. MIXED FEED NOZZLES The small openings through which the mixed organic feeds are fed to a reactor. MLS: MANUAL LOADING STATION A valve that is operated by a signal sent to it by a human operator and not an automatic controller. NEUTRALIZE To make a solution neutral (neither acidic or basic, pH of 7) by adding a base to an acidic solution, or an acid to a basic solution. Usually at PPG we use a neutralizer to remove acid from a stream by adding a basic solution. OPTIMIZE Adjusting a unit or piece of equipment to run as effi ciently as possible at a desired rate. SL 011284 Subject 65 Order ORGANICS Of chemical compounds, based on carbon chains or carbon rings and also containing hydrogen with or without oxygen, nitrogen, or other elements. ORIFICE PLATE A disk, with a measured hole, placed into a pipeline to measure flow. ORIFICE RUN A piece of pipe containing an orifice to measure a flow. 0^ RISER A piece of pipe on a reactor head through which the 0^ is fed into a reactor. The end rises above the head to insure the reaction does not take place at the reactor head. PACKED COLUMN A column, usually a distillation column, designed to increase contact between liquid and phases. PACKING A material (can be steel rings, gravel, ceramic saddles or rings, or Kynar rings or saddles) used to increase surface contact between a liquid and gas. PAD SYSTEM An arrangement of piping and valves that allows a layer of inert gas, into a process vessel, to serve as a cush ion or for protection. SL 011285 66 Ota* PCV: PRESSURE CONTROL VALVE A device (valve) which is able to maintain, raise, or lower the pressure in a vessel or processing system as desired. PH A scale from 0 to 14 measuring the acidity or alkalinity of a solution. PHASE SEPARATOR A vessel used to separate liquids of different density by having a reduced flow rate that allow the heavier liquid to settle. PLUG COCK VALVE A valve fitted with a plug that has a hole through which fluid flows and that is rotatable through 90 for operation in the open or closed position. Also known as a plug cock. PLUGGING 1. The formation of a barrier (plug) of solid material in a process flow system, such as a pipe or reactor. 2. A term used in P/T and OHC to refer to the restriction of feed through the reactor heads. PNEUMATIC Pertaining to or operated by air or other gas. POSITIVE DISPLACEMENT A term used in reference to pumps and compressors. In the pump or compressor a piston dis places the material in the cylinder. SL 011286 vvnrxi;r<nrxnbl Subject to Protective Order t 14th Judicial District Court 67 No. 91-1145 PSIG: POUNDS PER SQUARE INCH GUAGE The guage pressure. measured by the number of pounds-force exerted on an area of 1 square Inch. The guage has been calibrated to take atmospheric pressure into consideration. PSIA: POUNDS PER SQUARE INCH ABSOLUTE The absolute, thermo dynamic pressure, measured by the number of pounds-force exerted on an area of I square inch. This means that an adjustment for atmospheric pressure has not been made. QUICK CONNECT A hose fitting that has two handles to latch it to another fitting. RAM VALVE A special valve that has a sliding plug to clear valve when it is opened. RATIO The relationship in quantity, amount or size between two or more things. REACTION The action of molecules that act upon one another to produce a new set of molecules (products). REACTOR A device or process vessel in which chemical reaction (catalyzed or noncatalyzed) take place during a chemical conversion type of process. SL 011287 COHPibEWTI At t Subject to Protective order Of 14th Judicial District Court No. 91-1145 68 REACTOR HOT SPOT The level at which the major reactions occur in the reactor. REBOILER A heating unit for a distillation column designed to supply heat to the lower portion of the column. RECIRCULATION Taking stream from a vessel and returning it., The purpose of this stream is usually for cooling, drying or mixing of the vessel contents. RECYCLE REFLUX REWORX That portion of a product stream that has passed thru a processing unit and is recirculated (recycled) back through the process. The purpose of recycle is usually to recover some usable material in the stream. In a chemical process, that part of the product stream that may be returned to the process to assist in giving increased conversion or recovery, as in distillation. Taking part of the product stream and returning it to the process vessel for the purpose of cooling and or purification of a product. To send an out-of-spec stream back through the process in order to get it in spec. ROTAMETER A rate-of-flow volume meter in which the fluid or gas flows upward through a tapered tube, lifting a shaped weight to a SL 011122-888 69 f ^CONFIDENT!M,* cia 1 atrict^ourt No. 91-1145 1 1 1 1 1 1 1 1 1 1 1 1 1 1 position where upward fluid or gas force just balances its weight. R/D: RUPTURE DISK A disk designed to burst at a predetermined pressure differential; sometimes used as a safety valve. Protects a process vessel or line from over-pressurization. SADDLES A term for U-shaped material used for packing in process equipment. They are commonly made of ceramic, PVC, or Kynar. SATURATED STEAM: DESUPERHEATED STEAM Steam that has had condensate added so that the steam temperature equals the temperature of boiling at the pressure existing on it. SCFH: STANDARD CUBIC FOOT PER HOUR steam. A flow measurement of gases or SCRUBBER A device for the removal, or washing out, of entrained liquid droplets, or for the removal of an undesired gas component from process gas streams. SEAL LOOP A loop in a line that will relieve pressure. These are used at home as sink traps. They also stop the escape of vapors. SL 011289 coxfweW'IM'' 70 SEAL POT A container on a line or tank to act as a relief point. These are low pressure applications. Usually they are filled with a liquid. The liquid blows out to avoid over-pressurization. SEPARATOR A process vessel used for separating liquids of different specific gravity; phase separator separates water and organics. SET POINT The value selected to be maintained by an automatic controller. SIDE-ARM COOLER A heat exchanger (cooler) that is located on the side of a process vessel for cooling the liquid in the vessel. TETRA: Reactor side-arm cooler; used to cool the reactor liquor. SIGHTGLASS A glass tube or a glass-faced section on a process line or vessel; used for visual reading of liquid levels or of manometer pressures. SNUFFING STEAM The steam used to avoid or to put out fires on the vent stacks. Also, the steam that could be turned on into the VC and Dowtherm furnaces if a tube rupture occurs causing a fire. f-n protect 0r<Isr rVkiii 71 SOP: STANDARD OPERATIONS PROCEDURES A reference that is used to list the specifications for an operating unit that the operators use in producing a product. SPARGER: PERFORATED-PIPE DISTRIBUTOR A device that distributes liquid or gas in a vessel. It usually consists of a length of pipe or tubing with holes at spaced intervals along the length; used in the liquid-bed reactors and scrubbers. SPEC Abbreviation of specification. SPIRAL EXCHANGER: SPIRAL-TUBE HEAT EXCHANGER A countercurrent heat exchange device made of a group of concentric spirally wound coils. SRV: SAFETY RELIEF VALVE A spring-loaded, pressure-actuated valve that allows a gas or liquid to escape from a vessel at a pressure slightly above the safe working pressure of the vessel. STABILIZER An ingredient added to a product so that it can be han dled or stored with less change in composition. STEAM TRAP A device which drains and removes condensate auto matically from steam lines or reboilers. STILL: DISTILLATION COLUMN A vessel used in the process of pro ducing a gas or vapor from a liquid by heating the liquid in the column and collecting and condensing the vapors into liquids. COHF1DEHTIM-* SL 01129, ofS^rh^uSac,,t STRAP A procedure in which storage tanks are measured thru their top with steel measuring tapes to calculate the volumetric capacity of the tank for increments of height. STRIPPER An evaporative device for the removal of vapors from liquids; can be in a bubble-tray distillation tower, a vacuum vessel, or an evaporator; if it is a part of a distillation column below the feed tray, it is called the stripping section. SUPER VALVE The inlet valve on a Quench Tower. Called this because of the difficulty to operate the valves. TARS A viscous material composed of complex, high molecular weight compounds derived from the distillation of organics. BOTTOMS PLANT: The heavy material that is burned in the incin erators. TCV: TEMPERATURE CONTROL VALVE An automatic valve used to maintain the temperature of a process vessel within desired limits. THERMOCOUPLE A device consisting basically of two dissimilar con- ductors joined together at their ends; the thermoelectric voltage developed between the two junctions is porportional to the temperature difference between the junctions, so the device can be used to measure the temperature of one of the junctions when the SL 011292 confidential* 73 Order Subject to prff,fR`Vrt ct Cstirfe ot *4tht IJIt-V, Jill* I til '''RT-U 91 - ^ * other is held at a fixed, known temperature, or to convert radiant energy into electric energy. THERMOSYPHON REBOILER A liquid reheater (as for distillation tower bottoms) in which natural circulation of the boiling liquid is obtained by maintaining a sufficient liquid head. The circulation is from the bottom to the top of the reboiler. THERMOWELL A receptacle for holding thermocouples or thermometers. Another function of the thermowell is to enable the read ing of a liquid or gas temperature while it is contained in a pipe or vessel. It also protects the thermocouple or thermometer from the process. TI: TEMPERATURE INDICATOR Thermometer. TRAY A metal sheet in a distillation column that provides intimate contact between the falling liquid and rising vapor. TUBES A long cylindrical body with a hollow center used espe cially to convey fluid. TUBESHEET A mounting plate for elements of a larger item of equipment; for example tubes for heat exchangers or coolers. SL 011293 CONFIDENTIAL* ibjeet to protective <>** L4th Judicial District Court 74 lV`> * VAPORIZER A process vessel in which a liquid is indirectly heated with steam until it vaporizes. Clj VAPORIZER: Liquid Cl^ is heated until it vaporizes. PER-TRI ORGANIC VAPORIZER: Organics are heated until they are vaporized. VAPOR SPACE The area within a vessel that does not contain liquid. VELOCITY The speed at which the gas flows through a Per-Tri or OHC reactor. VENT An opening provided for the discharge of pressure or the release of pressure from tanks, vessels, reactors, processing equipment, etc. The gases that are discharged from the processing equipment are called the vent. WATER HAMMER A pressure rise in a pipeline caused by a sudden change in the rate of flow or stoppage of flow in the line. At times, a very loud noise is caused by this pressure rise when opening into a steam line too fast. WEIR A device over which a fluid flows that serves to regulate fluid level or measure flow. W.W. Abbreviation for well water. SL 011294 75 ZERO ADJUSTMENT Setting the pointer position of an instrument or meter to read zero when the measured quantity is zero. SL JI29S CONFIDENTIAL* . Subject to Protective Ora f of 14tir Judicial District Court Ho. 91-1145 76 EDC/VDCM "D" OPERATOR MAJOR TASK LIST LAB RELATED DUTIES 1. Catch samples In the EDC I, EDC II, and VDCM units as part of routine duties. 2. Analyze the samples from the units. 3. Notify the operators of abnormal sample results. 4. Record sample analyses on lab sheet in their proper place. 5. Prepare sample bottles for first (graveyard) shift on third (evening) shift. 6. Catch samples for main lab per schedule. 7. Change septums on G.C. every shift. 8. Fill out lab supply list. 9. Change G.C. carrier gas cylinders when the pressure approaches 500#. MISCELLANEOUS DUTIES 10. Recharge the HQMME Tank when the level approaches 202. 11. Line up tanks (South terminal #1 and #2, EDC Dock and EDC million gallon tank) for the EDC Operator product transfers. -COItflPWIftfrj.,, -gl SL 011296 11 EDC/VDCM "D" OPERATOR MAJOR TASK LIST 12. Transfer from the VDC Day Tank to VDCM storage. 13. Report abnormal conditions to the Lead Operator. 14. Report spills to the Lead Operator. 15. Record operations difficulties in the logbook. 16. Read the logbook. 17. Assist during start-up and shutdown. 18. Perform general housekeeping in the EDC I, EDC II, EDC III and VDCM units. 19. Perform housekeeping in the lab and truck. 20. Take electrical readings and outlying tank readings on first (graveyard) shift. SL 01 1297 CONFIDENT! hht f Subject |Vm,:. co'ift of *V? P:ctoctive Order 78 o 14th Judicial District Court Mo 91-1X45 QUALIFICATION STANDARDS 1. Wears proper safety and personal protection equipment and follows safety rules at all times. Contributes to overall safety program by reporting or correcting unsafe conditions. 2. Accurately runs and records necessary laboratory analysis. 3. Obtains current knowledge of unit by reading logs and talking with others in the unit. 4. Keeps others informed of the condition of the operations of the area by making necessary entries in logs and talking with the Lead Operator and other operators. 5. Protects the environment. 6. Reports all spills immediately to the Lead Operator. 7. Follows written and oral instructions of Lead Operator and Supervisors. 8. Maintain area in a safe, efficient and orderly condition' by performing housekeeping duties. 9. Safely recharges the HQMME Tank when the level reaches 2QX. SL 011298 COWPIDMWi',*' Subject to Protective 14th Judicial District Cou^. 79 No. 91-1145 10. Properly lines up EDC million gallon tank for the EDC Operator. 11. Properly transfers from the VDCM Day tank to VDCM Storage. 12. Assists during start-up and shutdown. 13. Safely catches and properly analyzes samples on the recovery still. 14. Safely catches and properly analyzes samples on the EDC Neutralizers. 15. Properly analyzes samples for moisture. SL 01l29g 80