Document e7VpqvB8L13q7Oj4w7Rez7BRg
PROPOSAL PVC REACTOR RELIEF TEST RUN
September 29, 1980
Work by:
Mark S. Whitney Chemical Engineer Chemicals Division Process Engineering Department
DTH 000069720
TABLE OF CONTENTS PVC REACTOR RELIEF TEST RUN
Page No.
PROPOSAL..................................................
1
HISTORY ..................................................................................................................................
1
PROPOSED TEST RUN DESCRIPTION ...............................................................................
1
RESULTS OF SIMULATION .... ...............................................................................
4
SCHEMATIC ..............................................................................................................................
6
INSTRUMENT LIST AND SPECIFICATIONS ......................................................................
8
DTH 000069721
PVC REACTOR RELIEF TEST RUN
Page 1
Proposal
R&D are requested to test the adequacy of Conoco's simulation of PVC reactor relief systems.
History
The existing Conoco PVC reactor relief system consists of two "Q" orifice relief valves (11.05 square inch relief area each) and an eight-inch double rupture disc (50.2 square inch area) vented to the atmosphere. It is planned to replace the double rupture disc systems with relief valves since the rupture discs can (and have) fail prematurely, resulting in unnecessary atmospheric emissions.
The expansion reactors at both Oklahoma City and Aberdeen are being built with only relief valve protection. Budget designs (totaling $910,000) to modify the existing reactors have been prepared.
To design these systems, PED have recently simulated the reactor relief system. This simulation is complex, involving nonisothermal polymerization kinetics, multiphase, flashing critical flow while working with existing API equations for relief device capacity.
Finally, Conoco's reactor relief area for existing reactors is less than 50 percent of the recommended relief area for an FIA 1970 report and is thought to be less than several other manufacturers.
Proposed Test Run Description
The test run should accomplish the following:
1. Allow comparison of our nonisothermal kinetics model to actual data during runaway conditions.
2. Allow comparison of our critical flow relief valve capacity model to actual data, including both relief valves and equivalent orifices.
3. Allow comparison of our homogeneous, two-phase flow model to actual data giving pressure drop across rupture discs and entrance and exit effects.
The fifty-gallon reactor will be required for this test to provide sufficient reaction mass for scaleup. This test run will require venting VCM to the atmosphere (approximately 130 pounds per run). To minimize the possibility of personnel exposure, the test should be done on the weekend and during favorable weather conditions. It is our understanding that, because of the size of the test, no EPA report is required.
DTH 000069722
Page 2
Proposed Test Run Description (Continued)
A proposed schedule of runs is given in Table I.
Data collected should include the following:
Pressure
- Reactor - Inlet of Relief Valve or Orifice - Exit of Relief Valve or Orifice - Near End of Relief Header
Temperature - Reactor - Exit of Relief Valve or Orifice
Since the total relief is expected to last less than two minutes, high speed pressure and temperature measurements are needed. CED have indicated that they have a high speed multitrack tape recorder and some high speed pressure transmitters available.
It is also recommended that the atmospheric relief be recorded on film. This may allow for a qualitative analysis of relief system dynamics.
It should also be considered to sample air downwind of the release to analyze for flammability.
Note that the design calls for the use of the existing rupture disc or a manual vent for a backup method of overpressure control.
MSW-lkm 9/29/80
DTH 000069723
TABLE I LIST OF RUNS PVC REACTOR RELIEF TEST RUN
Page 3
A. 1 1/2"-F-2M Relief Valve
The run is to check the accuracy of the simulation and to calibrate the high speed instruments.
B. l"-E-2" Relief Valve
The run simulates the proposed reactor relief system.
C. "E" Size Orifice
The orifice is to be placed after the rupture disc. The run is to determine the difference in flows between relief valves and orifices of the same size.
D. 1 1/2", Schedule 40 Pipe
The 3.5-foot long pipe is to be connected to a header leading out of the building. This run is to simulate a double disc system.
The above runs should be done using conditions for 5385 resin. Cooling and agitation should be stopped at about 30 percent conversion. An additional run should be done using 5465 resin conditions, as this should produce higher pressures. Also, higher and perhaps lower conversions should be tried to confirm the simulation's results. Additional runs should be done using the "E" orifice relief valve system.
A total of at least six runs is, therefore, requested.
MSW-lkm 9/29/80
DTH 000069724
SIMULATION RESULTS PVC REACTOR RELIEF TEST RUN
Page 4
Relief System "F" Relief Valve "E" Relief Valve "E" Orifice 1 1/2", Schedule 40 Pipe
MAXIMUM REACTOR PRESSURE,
PSIG Conversion(i)
10% 30% 50%
70%
203 203 202 201
210 208 207 203
207 216 225 207
203 - - -
(1) Values given are the polymerization conversion when the cooling water fails.
MSW:ke 9/29/80
DTH 000069725
SIMULATION BASIS PVC REACTOR RELIEF TEST RUN
VCM Charge, Pounds WaterrMonomer Ratio Catalyst Catalyst Charge, Pounds
Run Temperature, F
148 1.4:1 L-223
0.5(1)
134
Page 5
Relief System "F" Relief Valve "E" Relief Valve "E" Orifice 1 1/2", Schedule 40 Pipe
RV Area, Sq In
0.307
0.196
0.196
-
RELIEF SYSTEM DESCRIPTION(2)
RD Set Point PSig
200
200
200
200
RV Set Point PSig 190 190
-
(1) Polymerization time to 80 percent is 365 minutes. (2) All systems use 1 1/2-inch inlet and two-inch outlet pipes.
MSW:ke 9/29/80
DTH 000069726
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DTH 000069727
NOTES FOR SCHEMATIC DIAGRAM
Page 7
1. Not all details of existing equipment are shown. 2. SV-1 is on the existing 1 1/2-inch flange. 3. RD-1 replaces the existing two-inch RD at 200 psig. 4. PT-2 is to be as close to SV-1 as possible. 5. All PT's are quartz pressure transducers using a 1/2-inch screwed
connection. 6. PT-1 and TT-1 may be replaced with existing instruments if their
response speed is adequate. 7. PT-3 is to be as close to SV-1 as possible. 8. TT-3 is to be as close to PT-3 as possible. 9. PT-4 is to be close to the end of the pipe. 10. RD-1 may be replaced with a remote-operated valve. 11. All TT's are fine wire thermocouples. 12. SV-1 is E or F orifice, depending on the run. 13. All signals from PT's and TT's go to multitrack tape recorder Z-l. 14. SV-1 outlet piping is new.
MSW-lkm 9/29/80
DTH 000069728
Sheet 2 of 2
INSTRUMENT LIST PVC REACTOR RELIEF TEST RUN
Page 8
Item No.
Pressure Instruments PT-1 PT-2 PT-3 PT-4
Temperature Transmitters TT-1 TT-2
Rupture Discs RD-1 RD-2
Safety Valve SV-1
Other Instruments Z-l
Z-2
Z-3 (Optional)
Service
Reactor Pressure Relief Valve Inlet Pressure Relief Valve Outlet Pressure End of Vent Pipe Pressure
Reactor Temperature Relief Valve Outlet Temperature
Reactor Emergency Relief Reactor Relief for Test
Reactor Relief for Test
High Speed Multitrack Recorder for Instruments
High Speed Movie Camera for Velocity and Quality Measurements
Accelorometer for Measurement of Shock Wave Velocity
MSW-lkm 9/29/80
DTH 000069729
Page 9
(conoco)
Continental Oil Company Engineering Center Ponca City, Oklahoma
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NOTES:
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MANUFACTURER SHALL VERIFY SELECTION OF ORIFICE SIZE AND MATERIALS jl vAuVE6 SHALL MEET DIMENSION REQUIREMENTS OF AP RP-S26
VAi-VES SHALL MEET test REQUIREMENTS OF API RP-S27
9/29/80 j
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yrH 000069734 ,
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INSTRUMENT SOCIETY OF AMERICA
SHEET
1_____ OF___ Z___ REV_
444
Page 14
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ENGINEERING CENTER
PONCA CITY, OKLAHOMA SPECIFICATION SHEET
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9/29/80
SHEET.
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