Document dQY6XBDd8ek8JaGkDx2gye51B

HCL PURIFICATION PROCESS FAMILIARIZATION VALVE OPERATION f/A eeis>od PURPOSE: TO FAMILIARIZE YOU WITH THE LOCATION, TYPE, OPERATION AND PURPOSE OF ALL VALVES USED IN THE HCL PURIFICATION AREA. CONTROL VALVE OERATION WILL BE COVERED IN "CONTROL AND SENSING SCHEMES" SECTION. RESOURCES: PLANT FLOW SHEETS, EXPERIENCED PERSONNEL, PICS DISPLAY IPT RESOURCE INFORMATION SHEETS. REQUIRED LEVEL OF PERFORMANCE: 100% CORRECT OBJECTIVES: 'T. PHYSICALLY LOCATE, OPERATE (AS APPLICABLE), AND STATE THE FUNCTION OF ALL MANUAL BLOCK VALVES IN YOUR AREA. YOU WILL BE TESTED AS A MINIMUM ON THE FOLLOWING: A. FRC(2052) FEED TO E-51 C/V MANUAL VALVES / BYPASS B. TRC(2056) OIL TO E-52 C/V MANUAL VALVES / BYPASS C. TRC(2067) V-70 TEMP C/V MANUAL VALVES / BYPASS D. MANUAL VALVES TO THE BTMS R-50 E. MANUAL VALVES TO THE TOP R-50 F. MANUAL VALVE TO THE INLET OF R-60 G. MANUAL VALVE TO THE OUTLET OF R-60 H. MANUAL BYPASS VALVE AROUND R-60 I. MANUAL VALVE TO THE INLET OF E-72 SHELL SIDE J. MANUAL VALVE ON THE OUTLET OF E-72 TUBE SIDE K. FRC(2208) R-12 TO E-74 C/V MANUAL VALVES / BYPASS L. FRC(2212) R-12 TO E-73 C/V MANUAL VALVES / BYPASS M. MANUAL VALVE ON R-12 OUT OF E-73 N. PRC(2200) C-70 OVHD PRES C/V MANUAL VALVES / BYPASS O. PRC(2179) USER PRESS C/V MANUAL VALVES / BYPASS P. LRC(2206) C70 BTMS LEVEL C/V MANUAL VALVES / BYPASS Q. D-71 LEVEL C/V MANUAL VALVES / BYPASS R. D-71 VENT C/V MANUAL VALVES / BYPASS S. MANUAL VALVES TO THROX FROM PURIFICATION T. MANUAL VALVE TO SOLVENTS AT CANAL U. MANUAL VALVE FROM V2 TO CMP AT CANAL 2. GIVEN ANY VALVE, STATE IF OPENED OR CLOSED. ZZD5 60rt>tl Level' DO 013971 CONFIDENTIAL HCL PURIFICATION PROCESS FAMILIARIZATION TANKS AND VESSELS PURPOSE: TO FAMILIARIZE YOU WITH THE PURPOSE, DESIGN, AND OPERATION OF MAJOR TANKS AND VESSELS IN THE HCL PURIFICATION AREA. UPON COMPLETION, YOU WILL BE ABLE TO POINT OUT (ON A BLANK DRAWING) ALL TANKS AND VESSELS AND EXPLAIN THERE FUNCTION. RESOURCES: P&ID'S, EXPERIENCED PERSONNEL, PRESSURE VESSEL DATA SHEETS, IPT RESOURCE INFORMATION REQUIRED LEVEL OF PERFORMANCE: 100* CORRECT OBJECTIVES: 1. LOCATE THE FOLLOWING TANKS AND VESSELS . EXPLAIN THEIR PURPOSE AND OPERATION, INCLUDING THE SERVICE FLOWS AND PRODUCT AND OUTLET. A. E-5 1 D. R-60 G. E-72 B. E-52 E. E-61 H. C-70 C. R-50 F. V-70 I. D-71 2. DRAW A SIMPLIFIED DIAGRAM OF THE EQUIPMENT LISTED ABOVE. DO CH39P? CONFTDFNTTAL HCL PURIFICATION PROCESS FAMILIARIZATION MECHANICAL EQUIPMENT t------------------------------------------------------PURPOSE: TO FAMILIARIZE YOU WITH THE FUNCTION, LOCATION, AND MAINTENANCE OF THE MECHANICAL EQUIPMENT IN THE HCL PURIFICATION AREA, UPON COMPLETION, YOU WILL BE ABLE TO PHYSICALLY LOCATE AND STATE THE FUNCTION AND MAINT ENANCE REQUIREMENTS OF ALL MECHANICAL EQUIPMENT, RESOURCES: EXPERIENCED PERSONNEL, EQUIPMENT MANUALS, DATA SHEETS. IPT RESOURCE INFORMATION REQUIRED LEVEL OF PERFORMANCE: 100X CORRECT OBJECTIVES: 1. PHYSCIALLY LOCATE THE FOLLOWING PSV'S AND STATE THEIR SETPOINTS A. PSV50 A/B R-50 D. PSV71 A/B C-70 B. PSV R-60 E. PSV73 A/B E-73 C. PSV70 A/B V-70 F. PSV72 A/B D-71 2. EXPLAIN ANY SPECIAL SAFETY HAZARDS ASSOCIATED WITH THE EQUIPMENT IN ITEM #1. 00 010900 CONFIDENTIAL (- HCL PURIFICATION PROCESS FAMILIARIZATION CONTROL AND SENSING SCHEMES PURPOSE: TO GIVE YOU A GOOD UNDERSTANDING OF THE CONTROL AND SENSING SCHEMES IN THE HCL PURIFICATION AREA, INCLUDING LOCATION AND PURPOSE OF KEY INSTRUMENTATION. RESOURCES: P&ID'S, EXPERIENCED PERSONNEL, IPT RESOURCE INFORMATION REQUIRED LEVEL OF PERFORMANCE: 100% CORRECT OBJECTIVES: 1. EXPLAIN TH PURPOSE AND FUNCTION OF THE FOLLOWING CONTROLLERS: A. FRC(2052) FEED TO E-51 C. TRC(2067) V-70 TEMP E.' FRC( 2208 ) R-12 TO E-74 G. PRC(2200) C-70 OVHD PRES I. LRC(2206 ) C70 BTMS LEVEL B. TRC(2056) OIL TO E-52 D. TRC(2083) E-61 TEMP F. FRC(2212) R-12 TO E-73 H. PRC(2179) USER PRESS 2. PHYSCIALLY LOCATE THE FOLLOWING INSTRUMENTATION AND EXPLAIN THEIR FUNCTION. 6. & 'fl \ FT(2052) TT(2056 ) DPT(2069 ) DPT(2076 ) PIC(2200) FT(2212) LT(2210 ) FT(2208) FT(2214 ) LT(2206 ) FT(2182 ) PT(217 9 ) FT(2180 ) PT(2188) FT(2181 ) TT(2083) E-51 FEED FLOW TRANS E-52 TEMP TRANS R50/60 DIFF PRES TRANS V-70 DIFF PRES TRANS C-70 OVHD PRESS TRANS E-73 R-12 FLOW TRANS E-73 LEVEL TRANS E-74 R-12 FLOW TRANS C-70 BTMS FLOW TRANS C-70 BTMS LEVEL TRANS C-70 RECYCLE TO E-51 USER PLANTS PRESSURE TRANS C-70 OVHD TO SOLVENTS FLOW TRANS C-70 OVHD TO SOLVENTS PRESSURE TRANS. C-70 OVHD TO CMP FLOW TRANS. E-61 TEMP TRANS 2. DRAW A DETAILED DIAGRAM OF THE HCL PURIFICATION SYSTEM AND WITH ALL CONTROLLERS AND INSTRUMENATION AND EXPLAIN THE FUNCTION OF THE CONTROLLERS AND/OR SENSING SCHEMES OF THE ITEM LISTED ABOVE DO 013904 GONF TDFNTTAt. C HCL PURIFICATION PROCESS FAMILIARIZATION AREA HAZARDS & PROTECTIVE MEASURES PURPOSE: TO FAMILIARIZE YOU WITH THE HAZARDS AND PROTECTIVE MEASURES TO REDUCE THOSE HAZARDS IN YOUR AREA. RESOURCES: S&LP, EXPERIENCED PERSONNEL, SAFETY PROCEDURES AND IPT RESOURCE INFORMATION REQUIRED LEVEL OF PERFORMANCE: 100* CORRECT OBJECTIVES: 1. STATE THE CORRECTIVE ACTION FOR THE FOLLOWING HAZARDS AND IDENTIFY THE EQUIPMENT AND/OR LOCATIONS WHERE THESE HAZARDS EXIST. A. CHEMICAL HAZARDS B. ROTATING EQUIPMENT C. ELECTRICAL HAZARDS 2. STATE ENVIRONMENTAL PROBLEMS AND ACTIONS TO BE TAKEN IN EVENT OF THE FOLLOWING SPILLS: A. HCL B. HOT OIL 3. STATE THE PROTECTIVE EQUIPMENT REQUIREMENTS FOR MAINTENANCE ON THE FOLLOWING: A. ALL OF PURIFICATION D0 0l39JL, conftdfntta1 HCL PURIFICATION PROCESS FAMILIARIZATION ( OPERATING DISCIPLINE v PURPOSE: TO GIVE YOU A GOOD UNDERSTANDING OF OPERATING PARAMETERS OF THE MAJOR EQUIPMENT IN. YOUR AREA. THE PROBLEMS ASSOCIATED WITH THE PROCESS BEING OUT OF OPERATING PARAMETERS AND NECESSARY CORRECTIVE ACTION TO GET THE PROCESS BACK INTO OPERATING PARAMETERS. RESOURCES: EXPERIENCED PERSONNEL, OPERATING MANUALS, REQUIRED LEVEL Q>fJfRFORMANCE: 100X CORRECT ECT^VES: A STATE THE NORMAL OPERATING CONDITIONS OF THE FOLLOWING: A. E-51 FEED FLOW B. E-52 TEMP C. R-50 TEMP D. R-60 TEMP E. VI IN C-70 OVHD F. ETHYLENE IN C-70 OVHD G. RECYCLE PRESSURE H. C-70 OVHD TEMP I . C-70 OVHD PRES 2. STATE THE RESULTS OF HIGH OR LOW PARAMETERS AND THE RESULTS IF IT REMAINS HIGH OR LOW. 00 0139?6 rONFTDFNTTAI. HCL PURIFICATION r1 SPECIAL SKILLS ^'1 PURPOSE: TO ALLOW YOU TO DEMONSTRATE YOUR ABILITY TO PERFORM TASKS IN A LOGICAL AND SAFE SEQUENCE, USING ESTABLISHED JOB PROCEDURES. RESOURCES: PROCEDURES, EXPERIENCED PERSONNEL REQUIRED LEVEL OF PERFORMANCE: 100X CORRECT ^CrT SWAPPING R-50 FLOWS (REVERSE FLOWING) 1ST THE STEPS (IN SEQUENCE) NECESSARY TO MAKE THE FOLLOWING QUIPMENT READY FOR MAINTENANCE: A. E-51 THRU C-70 DO 013907 CONFIDENT! Al HCL PURIFICATION ROUTINE CHECKLISTS if -------------------------v V. PURPOSE: TO FAMILIARIZE AND ALLOW YOU TO DEMONSTRATE COMPLETING ROUTINE CHECKLISTS IN YOUR AREA. RESOURCES: EXPERIENCED PERSONNEL, ROUND SHEETS, OPERATING MANUALS REQUIRED LEVEL OF PERFORMANCE: 100X CORRECT OBJECTIVES: 1. DEMONSTRATE MAKING A ROUND USING THE EXISTING HCL PURIFICATION ROUND SHEET EXPLAINING EACH ITEM AND ITS IMPORTANCE. DO 0139P& C, onftdfnttai HCL PURIFICATION CAPACITY AND EFFICIENCY PURPOSE: TO FAMILIARIZE YOU WITH AREA CAPACITIES AND EFFICIENCIES RELATING TO HCL PURIFICATION. RESOURCES: AREA ENGINEER, OPERATING MANUALS, MATERIAL BALANCE SHEETS REQUIRED LEVEL OF PERFORMANCE: 10096 CORRECT OBJECTIVES: 1. STATE THE MAXIMUM CAPACITY OF THE FOLLOWING EQUIPMENT: A. C-70 2. STATE HOW EACH OF THE FOLLOWING AFFECTS EFFICIENCY: A. C-70 OVERHEAD TEMP TO HIGH B. C-70 OVERHEAD PRES TO LOW C. C-70 BTMS TEMP TO LOW D. E-52 TEMP TO LOW HCL PURIFICATION EMERGENCY PROCEDURES PURPOSE: TO FAMILIARIZE YOU WITH EMERGENCY CONDITIONS AND PROCEDURES IN THIS AREA. RESOURCES: EMERGENCY STARTUP & SHUTDOWN PROCEDURES, PLANT PERSONNEL, REQUIRED LEVEL OF PERFORMANCE: 100* CORRECT 1. GIVEN AN EMERGENCY SITUATION AND SHUTDOWN PROCEDURE IN THIS AREA, SIMULATE (IN SEQUENCE) SHUTTING THE AREA DOWN. EXPLAIN WHAT IS OCCURRING IN EACH STEP. INCLUDE PRECAUTIONARY MEASURES SUCH AS WASHING OUT AND PURGING EQUIPMENT. YOU WILL BE TESTED ON THE FOLLOWING: A. LEAK ON C70 BTMS LINE UPSTREAM OF EBV B. R-50 TEMP INCREASING RAPIDLY C. LOSS OF REFRIGERATION 2. YOUR AREA HAS JUST EXPERIENCED A POWER FAILURE. EXPLAIN YOUR ACTIONS. (POWER IS STILL OFF). YOUR ANSWER SHOULD BE STEP-BY-STEP. DO 013930 r ONFTDFNTTAl HCL PURIFICATION PROBLEM ANALYSIS PURPOSE: TO ALLOW YOU TO DEMONSTRATE YOUR ABILITY TO HANDLE ABNORMAL SITUATIONS (UPSETS) WHEN THEY OCCUR IN YOUR AREA. RESOURCES: PROCEDURES, EXPERIENCED PERSONNEL, OPERATING MANUALS REQUIRED LEVEL OF PERFORMANCE: 100X CORRECT OBJECTIVES: 1. LIST THE SEQUENCE OF STEPS YOU WOULD TAKE IF THE FOLLOWING CONDITIONS WERE TO OCCUR AND WHY. A. HIGH VI IN C-70 OVERHEADS B. HIGH ETHYLENE IN C-70 OVERHEADS C. E-51 CONTROL VALVE WIDE .OPEN . D. LOW TEMP IN C-70 BTMS E. TRAY 6 TEMP IS HIGH CHLORINATED METHANES GENERAL RESOURCE INFORMATION Department: CMP Job Title: HCL PURIFICATION General Resource Information Scope: To povide the operator with the necessary information needed for the current IPT program HCL enters the plant thru E-5l^jLeje_control valve FRC-2052. The max feed rate is approx. (S3,"OOO0hr. From E-51 the HCL flow to E-52, where it is heatea up with hot oil to a temp of 110-115 deg C. From E-52 the HCL flows into R-50 where the ACETYLENE and HCL are reacted to form VINYL. From R-50 the HCL flows to R-60 where the ETHYLENE in the HCL is reacted to' ETHYLENE CHLORIDE (ETCL). From R-60 the HCL f lows enter the tube side of E-51, where it heats up the incoming HCL feed. From E-51 the HC1 flows to E-61, where it is cool d prior to entering V-70. The HCL then enters V-70, where any MERCURY or MERCURIC CHLORIDE from R-50 is absorbed. From V-70 the HCL flows to K-55 where its pressure is increased to approx. 240 psig. From K-55 the flow goes to D-55, where the oil from K-55 will be knocked out. From D-55 the flow goes to V-55, which are filters to catch any oil that wasn't knocked out in D-55. From V-55 the flow goes to E-72, where it is cross exchanged with cold HCL from C-70 overheads. This cools down the feed to approx 7-11 deg C. From E-72 the flow goes into C-70. The overhead of C-70 goes through pressure control valve PRC-2200 and through the tube side of E-72 and onto the HCL user plants. The bottoms of C-70 goes through LRC-2206 level control valve to D-751. From D-751 the product goes to R-750 where it is burned. PRC-2179 is the pressure control valve that controls the pressure on the HCL user plants line. IT accomplishes this by taking any excess HCL and recycling it back to the ini t of E-51. GR 6/19/90 HCLPRGEN.RES DO 01393? OONFTDFNTTAl. CHLORINATED METHANES '( GENERAL RESOURCE INFORMATION Department: CMP Job Title: E-51 General Resource Information Scope: To provide the employee with the necessary information needed for the current IPT program. E-51 is a shell/tube exchanger, which cross exchange cold HCL from the Vinyl 2 plant, with hot HC1 from the outlet of R-60. This is done to assist the heating up of the cold HCL prior to it entering R-50 and also cooling down the HOT HCL out of R-60 prior to entering V-70. DESIGN PRESSURE ' DRV WEIGHT HYDRO TEST TO TOTAL LENGTH NORMAL THICKNESS TUBES ORIGINAL COST GR 6/18/90 220# DESIGN TEMPERATURE 260F 6520 WET WEIGHT 8850 330# MAX FLOW HR. 33710 LBS 1 5 ' 9 7/8'' TUBE LENGTH 11'11 3/4" 3/8' ' MINIMUM THICKNESS 1/4' 342. 3/4''0.D., .085 WALL, 12'IN LENGTH $ 10285.00 E-51GEN.RES DO 013933 rONFTDFNTTAI. department: CMP CHLORINATED METHANES GERNERAL RESOURCE INFORMATION Job Title: E-52 General Resource Information Scope: To provide the operator with the necessary information needed for the current IPT program E-52 purpose is to heat up the HCL feed from E-51 to its control setpoint of approx 110-115 deg C prior to entering R-50. This helps start the reaction in R-50 and keeps it going. It accompl ishes this by using TRC-2056 temperature control valve which flows HOT OIL thru the shell side of E-52. In the event the ethylene in C-70 overheads starts to increase E-52 temp can be raised slighlty. This will raise R-60 temp which will help convert more of the ethylene to ethyl chloride. The HOT OIL comes from and returns to the R-250 hot oil system (D470). (see hot oil ipt module). SHELL TUBE MAWP 252 232 TEST PRESS 380 380 DESIGN TEMP. 500 F 260 F WEIGHT 2,130 EFF. SURF 160 SQ FT GR 6/19/90 E52GEN.RES 00 013934 rNFIDFNTr(lt CHLORINATED METHANES GENERAL RESOURCE INFORMATION partment: CMP Job Title: R-50 General Resource Information Scope: To provide the operator with the necessary information needed for the current IPT program R-50 is a reactor which uses iHlX-mecur^ciehloTicle oh'afctlvatXB (Carbon catalyst, to react ACETYLENE with HCL to form VINYL and small amounts of ALPA DI. The associated equipment with R-50 is E-51,E-52,R-60 and V-70. E51 cross exchanges R-50 feed with R-60 effluient. This heats up R-50 feed. The feed then enters E-52 where it is heated up with hot oil, then on to R-50. R-50 can be feed in through the top or the bottom of the reactor. This is due to the migration of the mecuric chloride.The flows are swapped at the first of each month. After leaving R-50 the HCL goes to R-60 then on to E-51 E61,then to V70. The minimum temperature that R-50 can run is 95 degrees C. The mecuric chloride combines with the acetylene and hcl, which breaks down to form VINYL and MERCURIC CHLORIDE. If the temp is below 95 degrees the ACETYLENE and MERCURIC CHLORIDE will not fully break down. The maximum temperature is 140 degrees c. at 150 degrees the mercuric chloride will start to vaDorize.driving the mercuric chloride out of R-50. A high concentration of VINYL in the incoming HCL can cause R-50 temp to increase rapidly. If R-50 should ever reach 140 degrees,R-50 should be shut down and a N2 purge started on it. Through experience we found that we can get a 100X conversion at 100 degrees C. R-50 is 30 feet tall and 6 feet in diameter with a 24 foot packed section. It has 5 thermowells and 3 manways. MAWP MAX TEMP. GR 6/18/90 230# 260 F. DESIGN PRESS. TEST PRESS. 220# 382 PSI. R50GEN.RES 00 013935 rONFTDFNTTAI J( CHLORINATED METHANES GENERAL RESOURCE INFORMATION Department: CMP Job Title: R-60 general information Scope: Resource information provide to employees for use with IPT program R-60 is a fixed bed catalytic reactor as is R-50. In fact, it has th same dimensions as R-50. It has a 24' packed section. R-60 is packed with ai30X byweightiincg0MoVi?Jfc*(ZnCl<**erv carbon-catalyst# The purpose of R-60 is to enable us to further purify the anhydrous HCL. The Zinc chloride cayalyst will react ethylene with HCL to form ethyl chloride (EtCl). This EtCl will be distilled out in C-70. An added benefit of the catalyst system is that it converts the VI out of R-50 to alpha-di. This unloads C-70 significantly because there will be only 25pom to remove in C-70 instead of 1800Dpm VI. R-60 was designed to be operated at the same temperature and pressure as R-50. The only difference is that the ZnCl is not as mobile as the gC12 in R-50. This means that R-60 will not have to be reverse flowed every month as is R-50. Research shows that ZnC12 catalyst will deactivate slowly over a 1-1.5 v ars. This deactivation is due to the carbon formation and temperature of operation.(NOTE: THE ZnCl IN R-60 HAS BEEN THERE FOR APPROX 5 YEARS WITHOUT RECHARGE!. This means that the conversion of ethylene has to be watched closely as well as R-60 temperature. Thru research we have found that we can run R-60 at approx 100 deg C and get a total conversion. However; as the cayalyst starts deactivating the control temperature will have to be increased. We have to also rememeber that to high o-f a temperature will shorten the life of the catalyst. MAWP = 232 PSIG MAX TEMP - 550 DEG F HYDRO TEST PRESS = 423 PSIG EMPTY WEIGHT = 32.000 LBS FULL WEIGHT = 87.000 LBS DIMENSIONS = 6' DIA X 30' LTH 24' PACKED SECTION CUBIC FEET = 628.6 COST = $36,252.00 GR 6/18/90 no oshtnFO.GEN 013936 OONFIDFNTTA! CHLORINATED METHANES GENERAL RESOURCE INFORMATION D partment: CMP Job Title: E-61 General Resource Information Scope: To provide the operator with the necessary information need d for the current IPT program E-61 is a fin fan cooler which cools down the HCL prior to ntering V-70. E-61 has a 7.5 horsepower, 213T frame, 1800 rpm. 1.15 s.f. 460 volt 3 phase, 60 cycle tefc motor at 632 rpm. E-61 is a product of marley cooling tower inc. TRC(2083) controls the pitch of the fan blades. It gets it signal from TT(2083). As the temperature increases the pitch of the fan blades increases to supply more air flow. MAX FLOW 33,710 LBS. NOR/MAX TEMP. 149/257 IN 105/150 OUT MAX PRESS. 240 # DESIGN PRESS. 220# DESIGN TEMP 260 F. ROWS 5 PASSES 2 TUBE LENGTH 8'X 8" ORIGNAL COST $ 25,088.00 GR 6/18/90 E61 GEN.RES ^0 013937 C0NFr0FNTlA!. CHLORINATED METHANES GENERAL RESOURCE INFORMATION Department: CMP Job Title: V-70 General Resource Information Scope: To provide the operator with the necessary information needed for the current IPT program Its purpose is to absorb any mercuric chloride that may be entrained with the HCL from R-50. The HCL temperature should run approx 40 deg C. The minimum operating temperature is 30 deg. If the temperature drops below 30 deg C V-70 will loose its efficiency in absorbing MERCURY and MERCURIC CHLORIDE. The maximum temperature is 75 deg C. At 85 degs the SULFUR will start vaporizing off of the carbon. DIAMETER 6' HEIGHT 13' PACKED SECTION 7' INLET PRES 250 PSIG OUTLET PRESS 244 PSIG INLET/OUTLET TEMP 65 DEGC GR 6/18/90 V7QGEN.RES DO 013900 CONFIDENTIAL ( CHLORINATED METHANES GENERAL RESOURCE INFORMATION Department: CMP Job Title: E-72 General Resource Information Scope: To provide operators with the necessary information needed for the current IPT program E72 is a vertical (U) tube exchanger which cross exchanges COLD HCL from C-70 overheads on the tube side with HOT HCL from K-55 discharge on the shell side. This process cools down the HCL f d prior to entering C-70 and also heats up the overhead product from C-70 before it is sent to the HCL user plants SHELL TUBES MAX FLOW 33,710 LBS. HR. 33,420 LBS.HR MAWP 245# 242# DESIGN PRESS 302# DESIGN TEMP. -20/300 F. TEST PRESS. 453# CORRIS. ALLOW 1/16" # OF PASSES 2 EMPTY WEIGHT 11,400 LBS. FULL WEIGHT 16,500 LBS. BUNDLE WEIGHT 7,800 LBS. OVERALL LENGTH 28'7" BAFFELS 10 - 2' 3 3/16" SPACING. TUBES 189 - X.75 OD. X .085 WALL X 48' -U TUBE / 23' 6 9/16" ONE WAY ORIGNAL COST 12,805.00 GR 6/18/90 E72GEN.RES DO 013909 f ONF I DFNTTAt CHLORINATED METHANES GENERAL RESOURCE INFORMATION ipartment: CMP Job Title: C-70 General Resource Information ScoDe: To provide the operator with the necessary information needed for the current IPT program. C-70 is a distillation column which along with its associated equipment (E-73,E74 and D71) purifies hcl from V2. C-70 contains a total of 30 trays. Tray 1-4 are bubble cap trays made of carbon steel and stainless steel. Tray 5-30 are ballast trays made of carbon steel. C-70 is 36" in diameter and is 38' 10 1/2" high (this is C-70 not including E-73). HCL enters C-70 at tray 4 in the column and is boiled up by the use of hot freon on E-74. The vapors going up through the column pass through E-73 which is an intergal overhead condenser which h lps condense the heavies in the overhead of the column.The heavies then act as a reflux on the column, only allowing purified HCL to leave C-70. The overhead of the column run approx. -15 deg. C. with less than 1 ppm vinly chloride/ethylene in the overhead product. The product leaving C-70 is cross exchanged with the hot HCL in E-72 and is then used at SOLVENTS,POLY C and here at METHANES. E-73 is a shell/tube exchanger which has freon on the shell side and process on the tubes. The freon is level controlled to E-73. The freon vapors out E-73 return to the 1st stage of K-1001. C-70 pressure is controlled by PRC(22C01 cn C-70 overhead flow. The control pressure setpoint is approx. 220#. As the pressure raises the control valve will open uo and let more flow exit C-70. The overhead flow from C-70 goes to the tube side of E-72. The operating range on this controller is approx. 220# thru 240#. If pressure is to low C-70 would have inadequate reflux to operate correctly. If the pressure is to high we would be to close to K-55 discharge shutdown pressure. The bottom of the columns (C-70) which contains the heavies VI and ALPH DI are level controlled LRC(2206) to D-71 which is a Knock out pot and then sent to R-750 (THROX) where they are burned. If the bottoms temp is to low there will be an excess amount of HCL in the bottoms flow to D-71 which we will be wasting. Normal operating conditions. Tray 6 = -14 Feed temp = 7 Tray 14 = -14.5 Pressure = 223# Tray 30 E-73 fl -14.7 Overhead = -15 7.5 Btms lvl = 60-70* MAWP - 356# DESIGN PRESS. = 300# DESIGN TEMP. = -20/300 F TEST PRESS, s 534# MAX TEMP = 300 F. MIN. TEMP = NA. DRY WEIGHT = 14,250 LBS. WET WEIGHT = 47,800 LBS. GR 6/18/90 C70GEN.RES OO 013940 CONF T OFNT T Al .r CHLORINATED METHANES GENERAL RESOURCE INFORMATION Department: CMP Job Title: E-73 General Resource Information Scope: To provide the operator with the necessary information needed for the current IPT program E-73 is a vertical intergal overhead exchanger, with a fixed tube sheet. Freon is level by LIC-2210 or flow controlled by FIC-2212 to the shell side of E-73 where it is cross exchanged with HCL in the tubes from C-70.The heavies that are in the HCL are condensed and flow back down the column and the pure HCL with less than 1 ppm vinyl chloride/etcl, leaves the column and are used at METHANES, SOLVENTS and POLY C. The signal from both controllers go to a low signal select controller LSS-2211. This control scheme allows the level and freon flow to be set with neither setpoint being exceeded. DESIGN FLOW SHELL 7,945 LBS. TOTAL FLOW TUBES 37,,097 LBS NOR/MAX TEMP.SHELL -18/100 NOR/MAX TUBES -5/100 DESIGN TEMP. -20/250 F. DESIGN PRESS.SHELL 150# DESIGN PRESS. TUBES 300# TUBES 600 - 8' X 1"O.D. 70-30 CU-NI. DRY WEIGHT 9,294 LBS. WET WEIGHT 14,849 LBS. GR 6/18/90 E73GEN.RES DO 013941 CONFTDFNTTAl K Department: CMP CHLORINATED METHANES GENERAL RESOURCE INFORMATION Job Title: E-74 General Resource Information Scope: To provide the operator with the necessary information needed for the current IPT program. E-74 is a "U" tube exchanger, with the tubes inside of C-70. E-74's purpose is to vaporizes any HCL which may have been condensed and is in the bottoms of the column. It accomplishes this by flow controlling FRC(2208) HOT liquid freon from K-1001 through the tubes of E-74, thus vaporizing the HCL and cooling the freon. The cooler freon is then returned to the liquid freon header downstream of E-1050. SHELL TUBE TOTAL FLOW 1,851 LB/HR DESIGN PRESS. 300# DESIGN TEMP. -20/300 F. NUMBER OF PASSES ID 17 3/8" TUEES 48 - 3/4" X 6'X 14 GUAGE GR 6/18/90 21,740 LB/HR. 200# 250 F. 6 E74GEN.RES no 010940 confidential ,1\ CHLORINATED METHANES GENERAL RESOURCE INFORMATION Department: CMP Job Title: HCL PURIFICATION/K55 safety devices Scope: To provide the operator with the necessary information needed for the current IPT program PSV NUMBER PSV 50 A/B PSV 60 A/B PSV 55 A/B PSV 56 A/B PSV 71 A/B PSV 73 A/B PSV 74 A/B GR 6/20/90 SET PRESSURE 220 PSIG 220 PSIG 330 PSIG 330 PSIG 300 PSIG 150 PSIG 300 PSIG PSV LOCATION R-50 R-60 D-55 D-56 C-70 E-73 D-71 HCLPRPSV.RES Oo OOA/p r^rrA/ CHLORINATED METHANES SAFE JOB PROCEDURE apartment: CMP Job Title: K-55 Start Up procedure Scope: Safe start up of K-55 and Purification Major Hazard(s): Environmental Release, Rotating Equipment Safety Equipment Required: Minumum Block Standards 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. 1. Make sure all jobs are complete and all red tags cleared. 2. Make sure that K-55 switchgear 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. 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. 7. If the process side of K-55 is pressured ud with nitrogen, depressure and pressure back 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 role the compressor in the process. 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. 10. Open the bypass around the check valve on the D-56 vapor out line to equalize the suction pressure with D-56. 11. Turn on P-57 hydrolic 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 modicoms agree. (NOTE OCCASIONALY HAVE TROUBLE WITH THE LOAD VALVE, THIS MAY TAKE SOME TIME TO PRIME THE PUMP AND GET THE LOAD VALVE TO 0% OUTPUT) DO 013944 rONFTDFNTTAI K-55 START UP PROCEDURE PAGE 2 13. Get the suction pressure up to approx 80-100 psig prior to starting K-55. 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 to high it may be necessary to depressure to the throx. 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) Usersi pres, C/V K-55 suction pressure load valve DPR(2146) K-55 brg diff pres C/V TRC(2281 ) E-60,E-65 out temp C/V LRC(2273) D-56 level C/V DPR(2276) D-56 diff press C/V PRC(2200) C-70 ovhd press C/V manual manual manual auto manual auto manual auto auto auto closed closed open 80-100 unload 75 psig closed 45% 80 psig 200 psig 16. Check the PICS display to verify that the system ready light is on. 17. Start the compressor. A. The main oil pump will start automatical 1y B. Eight seconds later, the modi com 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 computor will energize MK-55 starter. The modicom 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 K-55 starts, Put the load valve on cascade and start to slowly drop the suction pressure setpoint, until you get to 100 psig.(NOTE: OCCASIONALY WE HAVE TROUBLE WITH THE LOAD VALVE NOT FUNCTIONING PROPERLY, CONTROLLER HAY HAVE TO BE LEFT IN MANUAL AND ADJUSTED BY THE BOARD OPERATOR) 19. As soon as the suction pressure drops to 100 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. DO 010945 C0NFTDFNTTAL K-55 START UP PROCEDURE PAGE 3 20. 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. 21. Start a small freon flow to E-73, monitoring E-73 and C-70 overhead temp. 22. Start to slowly increase C-70 overhead pressure until you reach 220 psig. 23. 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. Hake sure we don't shake up the R-250 system in the process. 24. Continue to raise the load oh purification,monitoring C-70 overhead temperatures and purity 25. Place PRC(2179) user's pressure control valve in automatic and start gradually raising the setpoint to 200 psig 26. when C-70 overhead product is good send it to solvents and we can take some to. GR 6/20/90 K55SU.PRO DO 013946 OONFTDFNTTAL I I Mz>. O-* MZHT1 0mUJ) 3> Iu 1' !1 11!i 33Lj \Q2QOJ 7JL tJL D-* wia.. ^" $ I1 TV--in .*k . ;i J.. j... i..,, .i .. ... %i . Ey . _sr.i _ti rv .;..i......l.u... 4 l>rjj in * ij i/i" - imamf.. *__ l!.. I.-.. ; I !I --i-'I'-iT-r I ! 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