Document e12eZbQNBryKdj7wj5y9B05nE

! J MONSANTO CHEMICAL COMPANY PLASTICS DIVISION TENTATIVE OPERATING PROCEDURE FOR OPALON COMPOUND BANBURY-MILL ROLL LINE Refs Tentative Process Job No. 1095* "Opalon Dry Blending and Compounding", April 28, 19531 E H. Hankey, H. P. Shannon, E. B. McIntyre Approved by: ______________________ G. T. Barks - Manufacturing Superintendent F - Research Group Leader T. E. al !r Project Engineer Distribution: 1. Research File 2. Research Group Leader - F. J. Locke 3o Research Process Development File 5. Division Engineering 5. Plant Laboratories - L. M,, Debing 6. Manufacturing Superintendent - G,, T. Barks 7. Operating Superintendent - P. A. Klingsporn (3) >8. Standards Department Date Issued - August, 1953 Prepared by: B. E. Steinkuhler RSV0023949 OPALON COMPOUND TENTATIVE OPERATING PROCEDURE FOR #5 AND #6 BLENDERS August 14, 1953 B. E. Steinkuhler RSV0023950 TABLE OF CONTENTS 510 -00. - Blending Procedure - Opalon Compound 511.00 Objective 512 .00 Summary 513.00 Equipment 514 .00 Formulations 515.00 Specifications 516.00 Operating Details 516.10 Control Panel 516.20 Resin Handling System 516.30 Plasticizer Handling System 516.40 Miscellaneous Ingredients Handling System 516.50 Blender Operation 516.60 Blending Cycles 516.70 Operating Difficulties 516.80 Avoidance of Contamination 517.00 Cleaning 518.00 Safety 519.00 Records RSV0023951 ^10.00 - Blending Procedure - Opalon Compound 511.00 - Objective This procedure describes the operation of blenders #5 and #6 in preparing a homogeneous mixture of polyvinyl chloride resin, plasti cizers, stabilizers, lubricants, fillers and other miscellaneous ingredients. The mixture is termed "premix" and is discharged from the blenders to the Banbury mixer for compounding. Extensive experience in preparing premix for compounding operations in Building 85A has been utilized. Another guide has been the Research Tentative Process entitled "Opalon Dry Blending and Compound" issued on April 28, 1953. RSV0023952 2 512.00 - Summary The Ingredients are mixed in Robinson ribbon blenders. The blenders are jacketed and piped for either steam or vater as required. The stepvise procedure is as follows for typical Opalon formulations s 1. Resin is discharged from a storage hopper into a weigh lorry. The ribbon blender is started, and the weighed resin is charged to the blender. If necessary, steam is applied to the blender jacket to raise the resin to a specified temperature before adding the plasticizer. 2. Plasticizers are charged to the scale tank and preheated. 3. When the plasticizers and resin have reached the proper temperatures, the plasticizer mixture is sprayed into the blender through nozzl s. 4. The resin-plasticizer mixture is heated to a specified filler addition temperature. Stabilizers, fillers and miscellaneous ingredients are then charged. 5. The final mixture is heated to the prescribed end temperature and is then ready to be discharged to the Banbury mixer as required. RSV0023953 513.00 - Equipment See Plastics Division Engineering Report 85D for a complete description of equipment. The major items are described as follows: Equipment No. Name and Manufacturer Description Item 140-1-23-4 Roof Resin Storage Hoppers Four hoppers of 33,000 lbs. capacity, Lastiglas lined. In addition, one hopper of 30,000 lbs. capacity, Amercoat lined was moved from Bldg. 85A. The hoppers are fed by a Dracco conveying system from Bldg. 88. Item 155 Resin Weigh Lorry Capacity of 3,000 lbs. of resin. Mounted on over head rails and capable of being placed directly underneath any of the storage hoppers. It is also capable of being placed directly over any of the blenders so as to discharge resin into the charge chute by a handoperated slide valve. 01-400- 1 01-400-2 Ribbon Blender #6, Robinson (from 85A) Ribbon Blender #5, Robinson (Item 200-3, C-51-J) Stainless steel, insulated, jacketed (steam or water#, 4,000 lb. capacity, agi tator speed of 22 RPM. Equipped with plasticizer spray pipe containing eleven nozzles (Spraco T-30) Removable aluminum covers, charge chute with magn tic grate. Vent port to dust collector system. Blender equipped with thermowell. Discharge air slide valv of Monsanto design. Jacket working pressure of 75 psi with 50 psi relief valves. See description for 01-400-1 Nozzles are Spraco T-22. Aluminum cfcvers are hinged. RSV0023954 01-410 01-412 01-414 01-416-1-2-3-4 01-418-1-2-3-4 -4 - Plasticizer Scale Tank- Working capacity of 2,500 lbs. Stainless steel. / Equipped with Hove scale, cabinet dial and overhead suspension. Scale Tank Heat Exchanger I Steam on shell side, plasticizer in tubes. Steam flov controlled by Taylor TRC instrument to give prescribed plastici zer temperature. Plasticizer Charge and Recirculating Pump, Viking Gear-type, relief valve mounted on pimp housing. Plasticizer Drum Racks Drum Unloading Pumps, Viking Gear-type. Relief valve mounted on housing. RSV0023955 514.00 - Formulations Rav Material Opalon 300 DOP TCP Paraplex G-50 Paraplex G-60 DOA Hercoflex 150 Santlcizer 160 Panaflex BN-1 RB-40 Clorafin 42S Flexricin P-8 #33 Clay Whitetex Atomite Tribase Tribase E B*S cWflLo Sta. #52 Antimony Oxide Barium Stearate Stearic Acid Fractol A 0PAL0N COMPOUND FORMULATIONS - PARTS/100 PARTS RESIN 1006 1016 1018 1028 1038 1112 1206 1216 1308 100 50 - - - - - 11 - - 8 - - - 3 - 2 100 45 - 5 - 8 - 2 100 42 - - - - - - - - 18 - 7 14 ~ 8 - - ~ - 1/4 - 100 42 - - - - - 22 - - 1 20 - 15 8 - - - - 1/4 100 54 - 3 -- -- -- -- 20 - 15 5 - 1/4 100 25 - 5 17 -- _ -- -- -- - 2 - 1/4 100 15 45 -- -- - -- -- -- 15 - 5 - 2 100 - 4o 15 _ _ _ _ 10 - 8 _ -- 1 100 - 5 - 40 12 14 - _ 25 6 - 1/4 1406 100 -- 45 5 __ 5 -- _ 10 3 1/4 1606 100 _ -- 22 30 _ _ 10 8 _ 3 . Color may be added as required to the basic formulations listed above. RSV0023956 515-00 ~ Specifications Rav Material Opalon 300 DOP TCP Paraplex G-50 Paraplex G-60 DOA Hercoflex 150 Santiclzer 160 Panaflex BR-1 HE-40 Clorafin 42S Flexricin P-8 #33 Clay VlMtetex Aromite Tribase Tribase E E.S -W.L. Stab- #52 Antimony Oxide Barium Stearate Stearic Acid Practol A -6 - Source Roof Storage Hoppers Tenk Farm Drums Drums Tank Farm Tank Farm Tank Farm Drums Drums Drums Drums Drums Bags Bags Bags Drums (Fiber) Bags Bags Drums Bags Bags Bags Drums Sp cificatlon FMS-88-1A RMS-155D RMS-58B RMS-230 RMS-272 RMS-226 RMS-293 RMS-171A. To be issued. RMS-223A RMS-229 To be issued. RMS-231 RMS-239 RMS-219 RMS-310A To be issued. To be issued. To be issued. RMS-312 To be issued. RMS-281A RMS -225 RSV0023957 -7 - 516.00 - Operating Details The description of the blending process is divided into five sections: resin handling, plasticizer handling, miscellaneous ingredients handling, blender operation and blending cycles. The resin is dravn from any one of the five storage hoppers mounted on the roof of Building 85B. The resin is delivered to these hoppers from Building 88 by means of a Dracco conveying system. Pour storage tanks are available for plasticizers. The tanks are numb red 1, 2, 3, and 4 and contain dioctyl phthalate, dioctyl adipate, Paraple* G-60 and Hereoflex 150, respectively. Dioctyl phthalate is dravn from tank by activating tank charge pump #1 and operating a quick-closing valve at the scale tank. To direct flov of plasticizer from #2, #3 or #4 tanks to the scale tank, three three-way valves and three tank charge pump controls are located on the control panel. Other plasticizers are supplied from the drum pumping station located on the blender floor. This station consists of four pumps vith appropriate piping and controls. 516.10 - Control Panel (See Figure l) Figure 1 shovs the controls on the panel vhich apply directly to the Opalon compound line. 1. Plasticizer Scale Tank #3 T.R.C. - Taylor Fulscope instrument vhich controls and records plasticizer temperature. 2. Blender Temperature - Foxboro Multi-Record six-point instrument vhich records the temperature of the material in each of the blenders. 3. Plasticizer Scale Tank to Blenders - selector svitch vhich controls the solenoid valves for charging plasticizer to either #5 or #6 blenders. 4. Blenders #5 and #6 - "start-stop" svitches for ribbon drives. 5. Plasticizer Charge and Recirculating Pump - "start-stop" svitch for pump vhich recirculates plasticizers through heat exchanger and charges plasticizers to blenders. 6. Drum Unloading Pumps - "start-stop" svitches for the four drum unloading pumps located on the blender floor. 7. Tank Charging Pumps - "start-stop" svitches for the four pumps located at the four plasticizer storage tanks. 8., Three-Way Valves From Plasticizer Storage Tanks - These three valves vill direct flov of plasticizer from #2, #3 and #4 storage tanks, respectively, to either #3 scale tank (Opalon compound line) or #4 scale tank (Farrel calender line). RSV0023958 -8 - 516.20 - Resin Handling System A. To Charge the Resin Weigh Lorry 1. Close the manually operated slide valve at the bottom of the weigh lorry. 2. Check the weigh lorry scale as indicating zero. 3 Move the weigh lorry under the desired resin hopper so that the hopper outlet is centered over one of the two lorry inlets. 4. Open the resin hopper slide valve by operating the appropriate air valve (located on posts north of blenders). 5. After 1400-1500 pounds of resin have been withdrawn, close the hopper slide valve. 6. Reposition the lorry to center the hopper outlet over the inlet on the other side of the lorry. 7. Complete the charging to the specified weight. B. To Charge Resin from the Lorry to the Blender 1. Check that proper blender operating precautions have been taken. 2. Lift the cover on the blender charge chute. 3. Position the weigh lorry so that its outlet valve is directly over the charge chute. 4. Make certain that blender ribbon drive is running. 5. Dump lorry contents into blender by opening outlet valve. Be certain that the lorry scale reads zero. Some tapping of the lorry sides with a rubber-faced mallet may he necessary to run out all the resin. 6. Close the weigh lorry slide valve. 7. Replace blender charge chute. 516.30 - Plasticizer Handling System (See Figure 2) 516.31 - Charging of Plasticizer to Scale Tank #3 A. Preliminaries RSV0023959 -9 - 1. Check to insure that scale tank is empty and scale reads zero. 2. Close scale tank outlet valves 9 and 18. 3 . Close all other valves in plasticizer recirculating and charging system (10 to 17) B. Drawing Dioctyl Phthalate from Storage Tank #1 1. Open valve 1. 2. Start #1 tank charge pump. 3. Close valve 1 (quick-closing type) so as to deliver the specified charge weight to the scale tank. 4. Immediately stop #1 tank charge pump. C. Drawing Plasticizers from either Storage Tank #2, #3* or #4. 1. Open the appropriate three-way valve (2, 3, or 4) so that the arrow on the valve handle points to"#3 Scale Tank" (to the left). 2. Start the appropriate tank charge pump (#2, #3 or #4). 3. Close the three-way valve (arrow on valve wheel pointing upwards to "Off") so as to deliver the specified charge weight to the scale tank. 4. Immediately stop the tank charge pump. D. Pumping Plasticizers from the Drum Unloading Station Pour unloading pumps are provided to prevent cross-contamina tion due to line hold-up. 1. Make the drunset-up at the appropriate drum rack. Be sure to remove the side bung after the drum is on the rack. 2. Close the Cuno filter by-pass valve* and open the Cuno filter outlet and inlet valves. 3. Open the pump inlet valve and the drum outlet valve. 4. Open the appropriate quick-closing valve at the scale tank inlet. Valves 5* 6* 7* and 8 apply to pumps #1, #2* #3 and #4, respectively. RSV0023960 10 5o Start the appropriate drum unloading pump. 6. Close the scale tank inlet valve so as to discharge the specified charge vieght. 7. Immediately stop the drum unloading pump. 516.32 - Heating the Plasticizers A. Preliminaries 1. Check total weight of plasticizers in scale tank. 2. Check to be sure that valves 12 to 17 are closed. 3. Adjust the steam pressure to the plasticizer heat exchanger to the following value depending upon formu lation ; Formulation Heat Exchanger Steam a. 1006, 1016, 1018, 1028, 1038, 1112, 1308 and 1606 20 psig b. 1406 40 psig c . 1206 and 1216 No steam required. Plasticizers charged at less than 40C. 4. Close the by-pass and open the inlet and outlet valves for steam control valve. 5. Close the steam trap by-pass valve and open the inlet and outlet valves to the trap. B. Heating 1. Open pump discharge valves 10 and 11. 2. Open scale tank outlet valve 9, 3. Start the plasticizer charge and recirculating pump. 4. Set the T.R.C. instrument to the desired plasticizer temperature. See the section on "Blending Cycles". 516.33 - Charging Flasticlzers to Blender The plasticizers must be sprayed into the blender when the resin has reached the temperature prescribed in the section on "Blending Cycles". RSV0023961 11 A,, Preliminaries 1. Check to insure that the selector switch for the solenoid valves is turned to the "off*' position. 2. Open the appropriate manual valve located in the plasti cizer charging line (15 for #5 blender or 16 for #6 blender). Check that the valve for the line to the other blender is closed. This is to insure that the plastici zer will not be charged to the wrong blender if the solenoid valve is incorrectly manipulated or malfunctions. 3. Check the plasticizer temperature. B. Charging 1. Open the by-pass valve (12) for the charge and circulating pump . 2. Open the inlet and outlet valves (13 and 14) for the Cuno filter. 3. Close valve 11 and check to insure that valve 10 is open. 4. Start the charge and circulating pump if it is not already running. 5. Set the selector switch for the appropriate solenoid valve. Turn the selector switch to "ON"= This opens the solenoid valve in the plasticizer charging line at the blender. 6. Adjust the pump discharge pressure by partially closing the pump by-pass valve (12) so as to charge the plasticizer to the blender in a 20-minute period. Flow of plasticizer to the blender can be checked through the visual sight box. Note: The correct pump discharge pressure to give a 20-minute plasticizer addition period will be determined when the equipment is initially operated. 7. When the scale tank is almost empty (20-30 pounds), open valve 17 to drain the heat exchanger. 8. When the scale tank reads zero, stop the pump. Allow about two minutes for complete drainage before closing any valves. 9. Turn the selector switch for the solenoid valve to "Off". Close the valve (15 or 16) in the plasticizer charge line (located immediately before solenoid valve). RSV0023962 12 1C. Close the inlet and outlet valves (13 and 14) to the Cuno filter. 11. Close scale tank discharge valve 9. 516.40 - Miscellaneous Ingredients Handling System The Color Laboratory is responsible for preparation and weighing of miscellaneous ingredients. This category includes stabilizers, fillers, lubricants and flame-proofing agents. The materials are weighed, identified and placed in appropriate containers. These ingredients are stored in an area on the blender floor and charged to the blenders when required. To charge miscellaneous ingredients s 1. Collect all miscellaneous ingredients for the blend. 2. Check materials to be added for identity and weight. 3. When the prescribed addition temperature or condition has been reached (see section on "Blending Cycles"), open the blender charge cover. 4. Pour any liquid ingredients into the blender. 5. If solids are to be charged, place the portable charging hood over the charge chute. 6. Connect the exhaust vent line to the hood and check for suction at the vent. 7. Put on dust respirator and charge the solids. 8. Disconnect the vent from the charging hood, remove the hood, and replace the charging chute cover. 516.50 - Blender Operation (See Figure 3) A. Charging Preparations 1. Make certain that the blender is empty. 2. Make certain the blender discharge valve is closed. 3. Start the blender ribbon drive. B. Applying Steam to the Jacket 1. Drain any water from the jacket byi a. Close water inlet valve (J) if open. RSV0023963 - 13 h. Open sewer valve (G). Check to he sure that the upper jacket drain valve (K) is open. c. Check to insure that the blender jacket valves are open (B and C). Under normal operation conditions these valves will remain open at all times. d. When the jacket has drained, close the upper jacket drain valve (H). 2. Adjust steam pressure to 30 psig except when preparing to blend either Opalon 1216 or 1206. The latter two formulations require 10 psig jacket steam. 3. Open the inlet (D) and outlet (F) valves for the condensate traps. 4. Open the steam inlet valve (A). 3. Open the steam trap by-pass valve (E) until the trap warms up. Then close the by-pass. Note; The following valves are located one floor level below the blender floor but have long handles extending up to the blender floor to provide more convenient controls Inlet valve to steam trap (D) Steam trap by-pass valve (E) Sewer drain valve (G) C . Applying Cooling Water to the Jacket 1. If steam is on the blender jacket, vent it as follows: a. Close steam inlet (A). b. Carefully open the upper jacket drain valve (). c. After the steam pressure has been dissipated, open the upper drain valve (H) fully. d. Close steam trap inlet valve (D). 2. Open the water inlet valve (J). Check flow of water at upper drain pan. D. Discharging a Blender 1. The blender operator should notify the Banbury operator when a blend is ready. RSV0023964 14 2. The Banbury operator vill draw premix Into the Banbury weigh hopper as required by operating the blender discharge valve and the natural frequency vibrating conveyor. 3. When the blender is empty, the Banbury operator will stop the ribbon drive (start-stop switch at Banbury panel). 4. The red indicating light will go out on the blender control panel signaling the blender operator that the blender is ready to charge again. 516.60 - Blending Cycles The blending cycle is controlled on a temperature basis. Due to the varying types of plasticizers, blending cycles depend upon formu lations . The following cycles apply only for preparation of premix to be compounded. A. Opalon 1006, 1016, 1018, IO38, 1308, and 1606. 1. Preheat the blender jacket with 30 psig steam. 2. Start the blender ribbon drive. 3. Charge the Opalon ^00 resin, dry lubricants (barium stearate) and dry colorants (if specified). 4. Heat the resin to 60C. 5. Charge the plasticizer mix which has been preheated to 60C using 20 psig steam on the heat exchanger. Adjust the oharge pump pressure so that plasticizer addition time is 20 minutes. If the formulation requires Fractol A, add this ingredient through the charge chute during the plasticizer addition interval. 6. Heat the res in-plasticizer mix to 90C. 7. Add the fillers. stabilizers and remaining miscellaneous dry ingredients through the blender charge chute. 8. Continue heating the final mixture to 100C. The mix should be dry, homogeneous and sandy in texture and is now ready for compounding. 9. Turn off the steam inlet valve to the blender jacket and carefully open the upper jacket drain valve. B. Opalon 1112 1. Preheat the blender jacket with 30 psig steam. RSV0023965 - 5 2. Start the blender ribbon drive, 3. Charge the Opalon 300 resin and stearic acid. 4. Heat the resin to 60C. 5. Charge the plasticizer mix which has been preheated to 60C using 20 psig steam on the heat exchanger.. Adjust the charge pump pressure so that plasticizer addition time is about 20 minutes. During the plasticizer addition interval, add the Stabilizer #52 and colorant concentrates (if specified). 6. Heat the mix to 110C. The mix should be dry and homogeneous and is now ready for compounding. 7. Turn off the steam inlet valve to the blender jacket and carefully open the upper jacket drain valve. 8. Do not shut off the blender agitation as Opalon 1112 premix will cake at temperatures near 100C if not agitated. C. Opalon 1216 and 1206 1. Apply cold water to the blender jacket and cool to 40C or lower. 2. Start the blender ribbon drive. 3. Charge the Opalon 300 resin. 4. Charge the plasticizer mix which is at 40C or lower. Adjust the charge pump pressure so that plasticizer addition time is about 20 minutes. Add the Fractol A through the charge chute during the plasticizer addition interval. 5. Apply 10 psig steam to the blender jacket. 6. Heat the resin-plasticizer mix to 90C. 7. Add the filler and stabilizer. 8. Continue heating the mix to 100C. The mix should be dry, homogeneous and sandy in texture and is now ready for compounding. 9. Turn off the steam inlet valve and carefully open the upper jacket drain valve. D. Opalon 1406 1. Preheat the blender jacket with 30 psig steam. RSV0023966 - 16 2. Start the blender ribbon drive. 3. Charge the Opalon 300 resin, barium stearate and dry colorants (if specified). 4. Heat the resin to 90C. 5* Charge the plasticizer mix vhich has been preheated to 110C using 40 psig steam on the heat exchanger. Adjust the charge pump pressure so that plasticizer addition time is about 20 minutes. 6. Heat the resin-plasticizer mix to 110C. 7. -Add the filler, stabilizer and flame-proofing agent. 8. Continue mixing to 115C. Shut off the steam inlet valve and hold the mixture at 115C for 20 minutes. 9. The mix should be dry, homogeneous and sandy in texture and is now ready for compounding. E. Opalon 1028 1. Preheat the blender jacket with 30 psig steam. 2. Start the blender ribbon drive. 3. Charge the Opalon 300 resin, fillers (Clay and Atomite), stearic acid and dry colorants (if specified). 4. Heat the resin, fillers and lubricant to 60C. 5. Charge the plasticizer mix which has been preheated to 60C using 20 psig steam on the heat exchanger. Adjust the charge pump pressure so that plasticizer addition time is 20 minutes. Add the Plexricin P-8 through the charge chute during the plasticizer addition. 6. Heat the mix to 90C. 7- Add the stabilizer (Tribase). 8. Continue heating the mixture to 100C. The mix should be dry, homogeneous and sandy in texture and is now ready for compounding. 9. Turn off the steam inlet valve to the blender jacket and carefully open the upper jacket drain valve. RSV0023967 - 17 - F. Approximate Time Cycle The following estimated time cycle must be considered approximate. This time cycle will vary somewhat due to characteristics peculiar to different formulations. One major exception to this time cycle will be Opalon 1406. Due to the nature of the plasticizers , Opalon 1406 may require a time cycle of approxi mately three hours. 1. Weighing resin and charging to blender * 2. Heating resin to 60C. 10 min,, 40 min. * 3. Charging plasticizers to scale tank and preheating 40 min. to 60C . 4. Spraying plasticizer to blender. 20 min. 5. Heating resin-plasticizer mix to 90C. 30 min. 6. Adding stabilizers, fillers and other ingredients. 7 o Heating mix to 100C . 10 min. 20 min. Total cycle, about 2 hours 10 minutes. * Steps 2 and 3 are performed simultaneously. G. Cooling Premix The premlx must be cooled to 45c by applying water to the blender jacket whenever: 1. The premix has to be drummed out. 2. The premix has to be held in the blender for any period exceeding four hours after completion of blending cycle. When the premix has cooled to 45C, turn off cooling vat?r to blender jacket, and stop tbe blender agitator. Cooling tKe premix lower than 40-45C may result in moisture condensing on the inside of the blender walls. Any moisture in the finished premix is detrimental to the compounded stock due to porosity. 516, 70 - Operating Difficulties A, Wet Blends The premix should be dry and free-flowing after tbe blending cycle Is completed. If the premix appears wet, the following action should he taken; RSV0023968 - 18 1. Check the blender temperature chart. If the blend vas not Seated to the specified temperature, re"heating to the proper temperature may improve the texture of the blend. 2 ,, If the blender temperature chart Indicates that the proper hjending cycle vas followed, then some raw material may have been mis charged. The blender mixing record should be checked. If raw material mischarglng did occur, supervision should specify disposition of the premix. The plasticizer weigh scale should be checked. B. Mischarglng of Plasticizer Weigh Tank If the plasticizer weigh tank is mischarged, supervision should be notified immediately. 1. If an incorrect ingredient is mixed with the other materials, it will probably be necessary to drain the contents of the weigh tank into drums. Identify the composition of the mixture in the drums. 2. If an ingredient has been overcharged, adju3t the proportions of the other ingredients if scale tank capacity permits. The excess mix can he used in subsequent blends of the same formulation. 3. If an ingredient is overcharged to the extent that scale tank capacity does not permit adjustment, drain the contents into properly identified drums. Note t Before draining any plasticizer from the scale tank, recirculate through the heat exchanger (steam off) for at least 10 minutes to insure a homogeneous mixture. 516.80 - Avoidance of Contamination The work area and equipment must he kept clean. Contamination of any nature can't he tolerated in the production of Opalon electrical or profile compounds. 1. Keep the blender chute covers closed when not In use. 2. Keep the blender covers on at all times except when cleaning the blenders. This is necessary from both a contamination and safety standpoint. 3. Sweep the blender floor area at the end of each shift. All powder spillages should be cleaned up. 4. Plasticizer spillages are dangerous. Use rags to soak the spillage up immediately. RSV0023969 - 19 5. Cut >'ags containing dry ingredients for proper charging. Pulling out the thread at the top of the bags will leave loose bits of paper and thread which may contaminate the blend. There is no provision for a scalping screen between the blenders and Banbury miner. 6. Do not allow any foreign material to fall into a blender. A magnetic grate is provided at each charging chute. 7. Keep raw material containers covered until ready to use. Any lead stabilizer containers must not be reused for products or raw materials other than lead stabilizers. RSV0023970 - 20 - R17.00 - Cleaning A, Major Cleanout 1. Follow the lockout procedure outlined In the "Safety section. 2, Remove the sock connecting the hlepder discharge auc|t to the natural frequency premix conveyor, Place a piece of cardboard or film over the conveyor inlet to prevent material from failing into the conveyor. Remove or open the blender covers. and scrape the undersides. Blender #5 has three hinged-type covers and one fixe i-type cover, Blender #6 has two removable type qovers and one fix ed-type cover, All hinged or removable covers must be opened or removed___b__efore entering the blender^ The fixed cover contains the (exhaust vent port and can be allowed to remain in place during cleaning Scrape the underside of the fixed Cover, the exhaust vent, the ends and sides of the blender jacket and the shaft a na ribbon. Place the scrapings in drums. Ticket as code 9^^ "no value" stock and classify as "blender devout". The scraped surfaces should then be washed with eith er dioctyl phthalate or soap and water. If sqap and water is u sed, wipe the vashu e-urfaces with DOF afterwards to prevent amy possible detrimentcl effect to the premix electrical proparti ss from soap residue. > 7. Notify the Shift Foreman who must inspect the blender before the covers are replaced. .8 If the blender is sufficiently cleaned, remove all tbols and cloths, replace the covers, and clqse the discharge (valve 9. Reconnect the blender discharge dudt to the premix conveyor B. Surface (Minor) Cleanout 1. Follow the lockout procedure outlined in the "Safetyf' section o Remove the sock connecting the bladder discharge due t to the natural frequency premix conveyor. ! Place a piece of ----* Li * . v J. * 'wL or film over the conveyor inlet to |prevent material from falling into the conveyor. 3 Remove the blender covers, and serdpe any loose mate rial from. the undersides. j k Scrape the underside of the fixed cfover. Scrape any loose material from, the sides and ends of the blender and the shaft and ribbon. RSV0023971 21 5. Flace the loose material in drums. Ticket as code 9014 "no value" stock and classify as ''"blender cleanout" , 6. Notify the Shift Foreman vho must inspect the blender before the covers are replaced. 7. Remove any tools, replace the covers and close the discharge valve. 8. Reconnect the blender discharge duct to the prernix conveyor, Co Miscellaneous 1. The blender exhaust vent ducts are cleaned once per veek under preventive maintenance procedure. 2. Clean the Cuno filters in the plasticizer lines once per shift by turning the handle on top one complete revolution. Draining and cleaning the Cuno filters by maintenance personnel vill be established as a periodic preventive maintenance procedure. 3. The beat exchanger may require periodic cleaning due to fouling of the tubes vith decomposed plasticizer. Indications of this condition vill be excessive heating cycles and high pressure drop through the exchanger tubes. 4. The scale tank should be flushed vith dioctyl phthalate and drained periodically to remove sediment (usually decomposed plasticizer). RSV0023972 22 518.00 - Safety A. Safety Equipment 1. Fire e?tlnguishers 2. R` 1000 AI> type respirators for use in areas containing premia dust. 3 E -31 type respirators for use in area containing harmful fumes. 4. Goggles, gloves, coveralls, etc. B. Safe Practices 1. Since lead compounds used in blending operations are known to be toxic, the following must be rigidly adhered tos a. "Wear a R-1C00 AD type respirator, coveralls and gloves when ever charging dry ingredients or whenever cleaning the blender. The greatest hazard from lead compounds occurs during blender charging due to concentration. bo Respirators should be washed thoroughly after each usage and stored in boxes supplied by the manufacturer. Cartridges should be changed when the breathing becomes restricted. c. Eating or storing food in the operating area is forbidden. d. Hands and face must be washed throughly before eating or smoking. 2. The procedure to enter a blender for cleaning or maintenance is as follows with lockouts conforming to Plant Bulletin E-210. a. Obtain the necessary locks from the assistant foreman. b. Lockout the disconnect switch of the blender ribbon motor. c. Chain and lock the blender agitator. d. Close the manually operated valve in the plasticizer charge line located just above blender against south wall of the building. {Valve 15 or 16 in Figure 2). e. Lock out the air control valve for the blender discharge slide valve (Banbury panel). ivote In the absence of suitable lockout brackets for the air valve, have the area mechanics shut off the air supply to the air valve and break the line at some suitable union. This will insure that the slide valve can't be operated. RSV0023973 - 23 f. Remove or open all removable or binged covers to insure adequate ventilation. g. Tvo persons must be on the job at all times whenever entering a blender for cleaning or maintenance. 3. Drums that have contained lead compounds can't be used elsewhere in the building for any other material. 4. The only permissible cleaning agents are either dioctyl phthalate or soap and water. 5. Observe proper lifting procedures when handling drums or bags of raw materials. 6. Good housekeeping is essential to safety. Cleanup all powder or liquid spills immediately. RSV0023974 - 24 519.00 - Records A. Opalon Blender Schedule (see attached sample form 596 AHB 35S2( This form Is Issued by Planning containing the following Information and Is sent to the Color Laboratory Foreman 1. Formulation 2. Color name and number 3- Amount to he produced 4. Blend numbers 5, Disposition of premix The Color Laboratory Foreman indicates the type of resin to be used and issues the "Blender Mixing Records", B. Blender Mixing Record - Opalon Premix (see attached sample form) This record is prepared by the Color Laboratory Foreman, All ingredients and their weights are indicated on the form, A "Blender Mixing Record" is assigned to each blend number. Indica tion is made if any of the ingredients are to he added at the Banbury, The completed form is sent to the Color Laboratory where the stabilizerss fillers, lubricants^ colorants and small amounts of miscellaneous ingredients are weighed and tagged. The weigher or weighers must initial the form. The form is returned to the Color Laboratory Foreman who forwards it to the Shift Assistant Foreman together with the "Blender Schedule", The Shift Foreman sends both the "Blender Schedule" and the "Blender Mixing Record" to the blender operator. The blender operator removes the tags from the preweighed materials at time of usage and checks the weights. These tags are attached to the "Blender Mixing Record." The blender operator records the following informations 1. Blender Schedule a. Blend number, b. Date and time blend is ready. c. Time blender emptied. d. Operator's number. 2, Blender Mixing Record a. Resin hopper from which resin is drawn. RSV0023975 - 25 - b. Time when each operation is started and .finished. Co Time vhen each ingredient was charged, d. Source of plasticizers. C. Shift Blending Log (see attached sample form)- This log is kept by the blender operator as a record of the shift's operations and a guide to the incoming crew. A carbon copy is made. The original is turned into the Shift Foreman at the end of each shift, and the carbon copy is kept at the blender area. The following information is recorded; 1. Date, shift, operator's name. 2. Blender number. 3,, Formulation and color. 4. Number of blends completed and disposition. 5. Amount and type of rework added at blender. 6. Total weight blended. 7. Status of blenders at end of shift. I) The following data is tabulated and kept at the blender areas 1. Resin data sheet a. Blend number. b. Date of blend. c. Amount of resin used. d. Hopper from which resin was taken. 2. Blender data sheet a. Blend number. b. Formulation and color. c. Date and shift. E. Plasticizer Heating Chart This chart is recorded by a Taylor Fulscope TRC instrument and gives a record of the plasticizer heating cycle for each blend. The blender operator must change the chart at the end of the 11-7 shift and deliver it to the Shift- Foreman. RSV0023976 - 26 F. Blend Temperature Chart This chart Is recorded bj a Foxboro Multi-Record si*-point Instrument, The chart serves as a history of the heating cycle for each blend. The blender operator must change the chart at the end of 'the 11-7 shift and deliver it to the Shift Foreman. RSV0023977 fORH 596 AHfi 35BZ OPALOH/: _ 56 F^^LENDERS NO. J AND J ND. 3 EH BLENDER SCHEDULE No. rn ft/i NO. 4 THIS SCHEDULE FOLLOWS / SUPERCEDES SCHEDULE NO____________ FORMULATION- 1028 .COLOR NO. OOOO .COLOR NAME- UTOAL -___________ rDELTLHB,Ss sTcDheBdEole. 100^000 E :nd nos. scheduled - FR0M_52Q______T0_5^5- .INCLUSIVE ALSO NOS.. ESTIMATED TIME SCHED. WILL-START - DATE__ _______ -__________ .TIME____--._____ - - STOP - DATE. l rUAL TIME SCHEO. DID - START - DATE- -TIME- - STOP - DATE- THIS PREMIX TO BE 1. BANBURIED []'] 2. PACKED OUT CH ____ 3. EXTRUDED CH SPECIAL INSTRUCTIONS: PURPLE _TIME_ JIT ME_ END FO. DATE AND TIME READY TIME EMPTIED OPER. NO. REMARKS BLEND NO. 1 *0 8A8/53 2*20] >11 6*00P K 0^3 #5 Blende P 521 8A8/53 ^*001 *n 9:00 PW043 #6 Blende P | 12 8A8/53 8:30] N12jOOP * 01S #5 Blende P DATE AND TIME READY TIME EMPTIED - OPER. NO. REMARK5 RS\700239 78 V. y.'-X, FSju-V"-'or; OOLDii H/.MJV OPALON 1028 HATURAL XXJOXX PURPLE r Opaloni.^1, &uj, r?'ij "I 1 xxmx te=:--*-^vciW` ,vvv:4^wt ijjop T r'^rtT'rrs^^npis-* ,j -tr 1 Panaflcr BN-1 Pt/iiEj.U Cr '03' -, 1?0 ?B-* rrt <'' ji - v<- 'c wi #T*'in et" . ' > Tank Farm s-*rrr.r- <i * j #33 Clay^........... j Atomlte^ j Tplbase_ ......... I Stearic Acid Color Lab Weigher's Initial 8/18/53 520 >' ..5 7-3 . 12:15 it~. Ci --1v,-:i 0^ 0 1 . 1:10 1:50 .12 ;20 , . J:2p . 12:20 2:00 .12:21 u-aT.-, - i . r i .c '*ry 12:00 ll-'.V' . l2:3p" .0 . fi 2:20 '12?5P 444* m r 1 Col r Lab Foreman RSV0023979 Blender Op rator 11-7 7/19/53 John Smith 1028 Hatural 524 #5 3957 Banbury 1028 Natural. #526 - Resin heating to 60C and plasticizers heating to 60C. 1028 Natural 523 3957 Banbury #6 1028 Natural 525 3957 Banbury 2/3 Pull RSV0023981 i FIGURE 1 \ BLENDER CONTROL PANEL | OPALON COMPOUND LINE j 8/14/53 B.E.S. O Plast. Scale Tank #3 T.R.C. Blender Temp. s> Plas .Scale Tank #3 To Blenders [ cf c 1v i/5 #6 Blenders !0 Lo Plast.Charge & Reclrc. Pump Scale Tank if3 0 c !o :o _c_ c L2. #1 #2 #3 #4 Drum Unloading Pumps 10 :0 |c c [0 ,0 1C 12. #1 #2 #3 #4 Tank Charge Pumps OFF to scale ra 'ik *3 TO SCALE TANK "4 FROM TANK*Z OFF 70 SCALE , i 1 TO SCALE TANK l J TANK 4 FROM TANK"3 OF F TO SCAL TANK "3 to scale TANK *4 FROM TANK *4 THREE-WAY VALVES FROM PLASTICIZER STORAGE TANKS i i 1 STEA.fl Pi ft: r. r.Ht.. ... L . .t. - CCNOtNi.'TE^ FIGURE 2 PLASTICIZER HANDLING SYSTEM OPALON COMPOUND LINE 8/14/53 B.E,S. H EAT EXCHANGER FROM ST^HAC, ' cop ~ TANK **/ ~\ AN -A wioh LE*rL "'r'"Ff To f.*si T. fftC. n VENjT lU PLASTICIZE r SCALE TANK. *3 .2 'LL , 3. rz '3 :*4 F P r M P TOfiAfi TANKS n'l'l P- %*- $1 \ i / TO "S 6 LENDER ?9 I PLA5T. CKAPQt AMD RE.CIRC. POMP CRAJM LINE RSV0023982 o u AX- l-a-DCh\J~fCl-i.VTNOK -l-LO--D-0-- DRUM DRUM ! t--LG fr i'' utr v *h<-cxh 3 z UNLOAD! NG or s-t-I -{XL *3 PUMPS C, L --L-G- 9k A xK~U M -U *4 A - Steam Inlet B &C - Jacket Inlets D -Steam Trap Inlet E -Steam Trap Bypass P -Steam Trap Outlet G - Lover Drain to Sever H - Upper Drain to Sever J - Water Inlet K - Pressure Relief FIGURE 3. BLENDER STEAM AND WATER PIPING OPALON COMPOUND LINE 8/14/53 B.E.S. jg Z 2 _/jv r~Q K B -L-'.r * D; j BLEiMCER "5 K! J rTU-i y < 0LE NDfc'H *6 fb tu* e BlN;F 2..,L ... ^_____ ( r? 9 -LO- ^--u 1 -X-7?--DO----- . I H yyr DFAiN steam Y SLENDER RSV0023983 ---------- DtC--(X--Cfr- V rD E F i W^rLX ~-LDXp~ ? 9 -J--M-->- -> CONDENSATE