Document eveE8q4emzw9NeB8q4y3rqKkM

rSAHTO CHEMICAL COMPANY IC CHEMICALS DIVTSIOH AHHISTOH. ALABAMA REVISIOH OF PHOSPHATE DIVISION KNGINEERIHG DEPARTMEHT REPORT SO. 117 OH 12 OBIT BIPHEHYL PLABT AT AHHISTOH. ALABAMA Dated: December 23, 1948 by G. W. Jordan Amniaton Technical Services Department Report Ho. 729-68-9 by R. L. Hedvorth Distribution: "^A. M. E Hamburg - Haim Office R. H. Morris - Roberts Bldg. H. L. Hinckler - Roberts Bldg. R. S. Vobus - Roberts Bldg. F. J. Holsapfel - Roberts Bldg. L. L. Felllnger - Roberts Bldg. J. V. Graves - UGR (2) J. F. Stickley-Robts. Bldg. / D. B. Hosmer C. K. Edelblut J. H. Gould Jack Clegorn R. L. Hedworth Extra (3) DSW 462477 WATER PCB-SD0000050504 c INDEX J*ga. SUMMARY DESCRIPTIOH OF PROCESS........................................................1 - 5 EQUIPMENT DESCRIPTIONS.......................................................... Series 100: Gemerel Process........................ 6 - 40 Series 200: Blphemyl Ualts........................41 - 65 Series 300: Blphemyl Stills......................66 - 81 Series 400: Imstnaseetetioa......................82 - 89 Series 500: Utilities................................ 90 - 98. ( FLOW SHEETS DRAWING NUMBERS......................................................................99 -107 EQUIPMENT NUMBER LIST (DEPT.20)........................... 108 -117 MAINTENANCE SURVEY............................................................ Series 100: Gemerel Plmmt........................118 -124 Series 200: Blphemyl Umlts......................125 -128 Series 300: Blphemyl Stills................... 129 -131 Series 400: Imstrmaemtetlom................... 132 -134 Series 500: Utilities................................. 135 -139 ( DSW 462478 WATER PCB-SD0000050505 ( SUMMARY Fatar Biphenyl-Santovax requirements have necessitated aa lacrease la Blpheayl productioa while maintaining approximately the same Saatowax productioa. This productioa balaace caa be achieved oaly by iacreaslag the benzene feed rate. Numerous alteraatives caa be coaceived oa how this might be accomplished, but before aay evaluatioa caa be made, it was aecessary to deteraiae what must be doae to the exist lag plaat to obtain coatlaued productioa. Consequently, a Maiateaaace Survey was seeded to determiae the exteat of the aecessary repairs. la additioa, the Phosphate Divisioa Fiaal Desiga Data Report for the existiag Blpheayl plaat, prepared la 1948, was out-dated aad seeded revisiag. To minimize the work load, these jobs were combiaed. ( This report describes la detail the equipmeat used for the productioa of Blpheayl at Aanistoa. The equipment description is based oa equipment inspectioa, firsthand knowledge, aad oa information supplied in Phosphate Divisioa Engineering Depart ment Report No. 117, titled "Final Desiga Data da 12 Unit Diphenyl Plant at Anniston, Alabama," dated December 23, 1948, by 6. V. Jordan. The Maintenance Survey presented in this report'is based oa visual inspection of each item and includes only those repairs needed to put the plaat in good operating condition. Revisions to`the process, equipment improvements,piping alterations, etc., are beyond the scope of this report. These'alterations and/or additions will be presented in subsequent reports aad will be evaluated aad Justified oa their owa merits. The words "Blpheayl" aad "Diphenyl" are synonymous aad are interchangeable la this report. RLH/fb ( 9/27/57 WATER PCB-SD0000050506 DESCRIPTION OF PROCESS I. IHTRODPCTIOH Diphenyl is produced by a pyrolysis reaction between two molecules of benzol In which one molecule of diphenyl and one molecule of.hydrogen are formed. The pyrolysis is brought about in this particular case by stepwise vaporizing and super-heating benzol by bubbling the vapor through a series of pots filled with molten lead. The temperature to which the final lead pot or "converter" is heated determines the percentage of the benzol converted, which increases with higher temperatures. Several other pyrolysis reactions also occur producing mainly terphenyl and also some more highly polymerized compounds. In addition, some free carbon is foxmed which deposits in the units causing considerable maintenance difficulties because of plug-ups. The percentage of terphenyl in the crude Biphenyl is rough ly the seme as the conversion percentage of the benzol. SYNOPSIS OF PROCESS Liquid benzol is shipped in tank car lots to the plant site and unloaded through the top dome by a siphon type pumping arrangement delivering the benzol to storage tanks. The benzol delivery pipe is steam traced and the storage tanks have steam coils to prevent the benzol from freezing in the winter. Each of the five storage tanks has a sump pump for delivering benzol to the feed tank. These feed tanks are automatically refilled by a continuous "let-down" control. Only one of the storage tanks is allowed to feed the feed tank at a time. This choice of storage tank is manually determined by an operator. The single feed tank services all of the diphenyl units by means of a centrifugal pump fed from a bottom outlet la the tank. The benzol feeds a header where the Individual feeds are metered through orifices to the different units. Isopropyl alcohol is added to the benzene feed in concentrations of 0 to 0.5T by weight, usually 0.15Z is added. This isopropyl alcohol is pumped to the suction of the benzene feed pump where it is mixed and pumped to the waits. This material catalyzes the conversion, that is, n 40-60C. lower operating tempera ture can be maintained when this suiterlal is added to the feed benzene. There are twelve diphenyl units of equal capacity, each consisting of a pipe coil vaporizer located in the flue gas exhaust stack, two preheater pots and a converter pot filled with molten lead and suspended in a firebrick setting for burning natural gas, and a fractionating column with a condenser and split flow box. In two of the units. Nos. 4 and 5, one of the preheater pots is replaced with a heat exchanger. The units are numbered 2 through 13, there having been a No. 1 unit at one time. The present number of units were erected in five installments, Hos. 2 and 3 having been erected at diffensntfinds. Nos. 4 and S together. Nos. 6, 7, 8, 9, and 10 together, and Nos. 11, 12, and 13 together so that these groups are all SW 462480 WATER PCB-SD0000050507 2. lightly different in some detail*. However, there are only actually two funda mentally different types of units, Hos. 4 and 5 differing from the rest in that one of the preheater pots is replaced by a heat exchanger. Although the heat exchanger effected a gas savings a* predicted, it proved Impractical due to carbon formation fouling the tubes and the idea was abandoned on the subsequent units. After the benzol feed has been metered through an orifice, it passes through the vaporizer pipe coll in the flue gas exhaust stack where the liquid benzol is vaporized and at the same time recovers soae of the heat from the exhaust flue gases. The benzol vapor is then bubbled through molten lead la the two preheater pots in series and the temperature stepped up to the pyrolysis reaction tempera ture. The hot vapors are converted to 10-301 diphenyl as they leave the converter pot, which is similar to the preheater pots except that the molten lead is very carefully controlled at the desired reaction temperature, usually between 750 and 810C. The temperature is adjusted to give the percent conversion needed to maintain the balance between Biphenyl and Santowax needed to meet sales demands. After leaving the converter, the benzol and conversion products pass first through a lead trap (which is essentially a vide place la the line) for removing entrained lead and then enter the bottom plate of a fractionating column. A considerable amount of carbon adheres to the pipes between the converter and the lead trap,and the lead trap and the fractionating column, necessitating the re moval and cleaning of the pipes every one to six months. The super-heat in the vapors from the converter is utilized in a fractionating column to effect a partial separation of the benzol from the conversion products. The conversion products are later completely separated in a batch distillation. The colusrn top is maintained at(l00C. by refluxing the condensed benzol vapors back to the top plate. The conversion product and same benzol is condensed in the column and allowed to overflow from a carbon trap on the bottom of the column to a crude diphenyl catch tank for storage prior to batch distillation. The overhead vapors from the column are cooled by a partial condenser and the liquid benzol drained to a rotawelr for spitting the flow into reflux and benzol overhead which is "run back" to the benzol feed tank by gravity. The rotawelr is used to adjust the ratio between reflux and overhead. There are five differently sized and designed groups of condensers, a mew design having been made for each install ment of units as mentioned earlier, and a different design used to replace some had condensers. In addition, these condensers have been shifted from one unit to another to facilitate cleaning and repairing condensers. The conversion product hydrogen, saturated with benzol vapor, is bled off from the condenser and rotavelr, collected in a comon header, and passed through six coolers, connected in parallel, where some of the benzol is condensed and allowed to run by gravity back to the auxiliary feed tank. From the coolers the saturated hydrogen gas is passed to a collecting tank in which more of the benzol condenses out and is drained to the benzol pump tank in the compressor room. The hydrogen from the collecting tank is compressed in two stages to 250-300#/ia. An intercooler and aftercooler condenses the benzol vapor after each stage. This benzol is collected in pressure receivers after each stage and periodically . osW 462481 WATER PCB-SD0000050508 3. V blown by the hydrogen pressure over lto the pump tank for retarm to the benzol feed teak. The hydrogea is vented to the atmosphere or else used la the aaaufacture of HB-40, HB-20, etc. la the secoad type of ualt (Hos. 4 aad 5) the flow of Material is essentially the sane as that described above except the vaporized benzol feed eaerglag froa the vaporizer coll passes through a heat exchanger la lieu of oae of the preheaters. The conversion products aad benzol from the converter pot are also passed through the heat exchanger, countercurrent to the benzol feed, thus transferring sensible heat from the converted gases to preheat the feed. The conversion products and vapors froa the converter pot then pass on to a column as is the case vlth the other units. Sons of the units have been altered since their installation. Ualt Ho. 4 is being equipped vlth a 4 foot extension on the converter. This exten sion to the converter will act as a sojourn section. This addition reaction space will provide additional reaction time and permit a temperature redaction of 30-60C. in Che converter while maintaining the same percent conversion. This reduced temperature will minimize carbon formation and reduce the heat exchanger fouling and unit clean-outs. The lead traps vlll be eliminated. Unit Ho. 11 has a large coll in the lover section of the column which acts as a vaporizer. The flow Is through the large coll, the standard vaporizer coil in the stack, the three pots, and to the column. The hot gases from the converter ( pot heat the benzene in the large coil and vaporize the benzene. The recovery of heat from the converted gas stream has permitted an increased benzene feed rate of about 100 gallons per hour. The increase is due to better utilization of the heat input aad the reduced heat load on the column and condenser. Room for this large coil vas made available by removing the two lover bubble cap plates from the column. Units Hos. 12 and 13 are equipped vlth this large coll but the coil is being by passed because the units surged and caused excessive pressures throughout the unit, thus blowing the gaskets around the top of the preheater and converter pots. Ho. 11 unit also surges occasionally but since Ho. 11 unit is equipped with a sojourn pot (the same as vlll be Installed on Ho. 4 unit), the added space provides a cushion to absorb the sudden expansion caused by rapid vaporization of benzene in the large coil. Ho. 11 unit is being equipped vlth an automatic reflux control which vlll control the reflux rate to maintain a constant vapor temperature on the third plate from the top of the column. Each unit is equipped with two orifice plates betveen the converter and column. These orifice plates are sized to give a pressure drop of about 40 pslg and thereby permit an Increased pot operating pressure. Increased soujourn time, and a reduced operating temperature and minimize lead carryover from both entrainment and lead vaporization. The diameter of these orifices are 1.031 and 1.014 laches, the larger orifice being upstream from the smaller one. ( DSW 462482 WATER_PCB-SD0000050509 The sump product fro* *11 the column* la collected by gravity im two crude diphenyl catch tanka. Th* piping to the tanks la steaa jacketed to prevent the diphenyl fro* freezing and has a liquid trap to prevent vapors fro* entering the catch tank fro* the column. The tanks are vented into the hydrogen header to equalize the pressura. The two hatch stills' each consist of a horizontal, cylindrical tank surmounted by a fractionating column, a submerged Runsay pump, and a gas fired coil heater. The punp circulates the still charge fro* the tank, through the coll heater and back to the tank. The rate of distillation of the crude diphenyl is con trolled by the coobustioa rate of natural gas in the gas fired heater, which is controlled by an adjustable autonatic temperature recorder and controller so as to give a temperature rise of 20-25C. between inlet and exit temperatures of the still charge through the heater coil. If an attempt is ssade to increase the temperature rise above 25C., the coil becomes plugged with carbon. The vapors fro* the still are separated in a fractionating column. The first cut from the column at 80C. is benzol which is returned by gravity to a catch tank for subsequent return to the benzol feed tank for recycling through the diphenyl units. The benzol cut is not run directly back to the feed tank because of the possibility of not cutting the column at the proper time and allowing some con tamination to run back with the benzol. The next fraction, distilling between 80 and a distillate crystallizing point of 68.6C. is called "heads" and consists of light oils with boiling points nearing that of diphenyl. The diphenyl fraction is collected until the temperature in the still pot reaches 340-350C. The tail cut is collected until the distillate vappr temperature in the top of the column reaches 300C. The various distillation cuts are made with these reflux ratios: Benzol Cut Heads Cut Biphenyl Cut Tails Cut 201 501 201 151 The high boiler, remaining in the still as residue, is pumped to the high boiler catch tank fro* which it is run into 55 gallon drums for storage or pumped to the Santowax still or Santowax storage tank. In order to prevent freezing of diphenyl in the condenser at the top of the fractionating column, the consenser cooling water must be at a temperature near the melting point of diphenyl (158F.). The flow of pond water is adjusted to prevent freezing of the product. It is generally necessary only to cut back the flev of pond water at the end of a distillation. The diphenyl production is measured in a catch tank, and pumped to storage tanks or task cars by a 2" Rumsay vertical sump pump. The heads and tails are collected and charged back to the next still batch. DS'N^83 WATER PCB-SD0000050510 5. GEHKRAL DISCPSSIOB The carbon formed in the diphenyl omits partly deposits la the pipe after the converter omits, through the lead trap, la the pipe after the lead trap, aad la the fractloaatlag colon. These pipes become plugged with carbon aad must be dismantled and cleaned every oae to six months. The lead trap aad frac tionating colon are cleaned out at more infrequent intervals. This so called "carbon" deposit analyzes as follows: Lead.......................................... Insoluble in HNO*............ (carbon included).... Insoluble, ignited............ Iron oxide, insoluble... Carbon, combustion............ 56.51 42.71 18.51 0.71 28.91 As moch of this piping and equipment Is above the melting point of lead. It is evident that the adhering carbon prevents coalescence of the molten lead drop lets . The amount of reflux returned to the fractionating colon is controlled by the operator to niataia a temperature of sibout 100C. at the colun top. The cooling water to the condenser is operated a: full capacity and as the heat duty of each unit is approximately the same, it is apparent that the amount of reflux required will vary according to the effectiveness of each condenser at a particular time. When the temperature of the effluent water exceeds 70C., the condensers are cleaned. The diphenyl units produce crude diphenyl by a continuous process with a 24hour day operation. The number of units operated depends upon the diphenyl market or the maintenance required on the equipment. The crude diphenyl is collected and batch distilled at intervals depending upon the rate of collection. The batch distilling requires 10-12 hours. DSW 462484 WATER PCB-SD0000050511 EQUIPMENT DESCRIPTION SERIES 100 - GENERAL PROCESS EQUIPMENT Item Ho. 101; Benzol Unloading Pump (1-Requlred) 6. August 1957 Function: Operation: Materials Handled: Controls: Services: To unload benzol from railway tank cara to the benzol storage tanka. Intermittent. About 5 hours Is required for unloading one car. Prior to unloading, the car Bust be chocked to prevent movement, and grounded to the pump to prevent formation of a static electrical charge. The pump Inlet pipe is Inserted through the tank car dome, the valve nearest the pump suction Is opened, and the pump Is started. A small stream of water is adjusted to pour over the pump bearings for cooling. After the tank car Is unloaded, the pump is shut off, benzene is allowed to drain back into the pump suction line, and the valve nearest the pump suction is closed. This benzene is left in the line to prime the pump when the next car is unloaded. Air pressure is cut into the line which blows the benzol remaining in the line on to the storage tank. Vith the diphenyl plant operating at peak capacity and all 12 units producing, it is estimated that the pump will be required to unload an average of one car per day. Benzol at about 30 GPM at the existing head which is estimated to be about 80' TDH. Manually controlled by a motor starting switch located at the pump. Approximately 10 KWH per day average. A negligible amount of priming and cooling water. A negligible amount of compressed air. ( osW 462485 WATER PCB-SD0000050512 Item 101 Continued: Sira aad Type: Inlet Pipe: Strainers: Manufacturer: Material* of Construction: Motor: Drive: Locatioa: ( 7. Westco tarblae pump with removable liters aad lapel1era. The lalet pipe fora* aa arch with swivel joints so that it may be passed down through the tank car dome. A platform is provided for the operator to suaipulate the pipe. Am Acme pomp stralaer is iastalled la both the pomp ialet aad outlet. Veatco Pump Coapaay, Bettendorf, Iowa Liners aad impellera are ai-reslst aad shaft is stainless steel. 3 HP, 1740 RPM, 3 phase, 60 cycle, 220/440 v. TEFC Allls-Chalmers motor vlth #225 frame. Direct drive with flexible coupling. Located along side of railroad spur about 200 ft. vest of the diphenyl building. ( DSW 462486 WATER PCB-SD0000050513 Item 102: Benzol Storage Tanks (5-Requlrad) 8. August 1957 Fumctiom: Operstlom: Kstarlsls Hsmdled: Controls: Services: Size sad Type: Opealags: Msaufscturer: Capacity: Materials of Coastructloa: Steam Cell: To provide beazol ran material buffer storage betveea receipt aad use. Beazol Is periodically fed lato the storage taaka aad latermltteatly vithdraws as seeded to the beazol feed taak. The storage tanks provide about 5 days operatlag storage at maximum plaat capacity. Materials la: Beazol at approximately 30 GPM while ualoadiag. Materials out: Beazol at approximately 500 GPM while operating plant at maximum capacity. See Item 104 Steam is furnished to steam colls as needed on cold days depending on judgment of operator. The three newer tanks are 18' long x 10' I.D. horizontal tanks with dished heads. The two original taaks are slightly smaller(as shown below)la capacity. Top: 2'0n dia. manhole 6n dla. std. pipe suction 3n dia. std. pipe standpipe aad feed 3" dia. thief hatch 1%" dla. condensate aad steam pipe 2" dla. vent aad flame arrestor Adamson Company Three 10,800 gal. taaks aad two 9,800 gal. tanks. 5/16" steel plate taak with 3/8" steel plate dished heads. Flat hairpin type steam coll of 1" pipe installed la bottom of taak. DSW 462487 WATER PCB-SD0000050514 It** 102 Continued: Location: References: Located about 200' south of th diphenyl building. The five tasks are 31' apart and each located la a moat with a cycline fence surrounding the group. Drawings Monsanto Details of Storage Tanks Layout of Storage Tanks Location of Present Storage Tanka Foundation and Fence Details Detail of Hew Benzol Storage Tanka 9C-7961 9C-7960 9C-6668 9C-66S5 9C-7961 oS\N 462488 WATER PCB-SD0000050515 It-- 103: Benzol Transfer Pumps (5-Rcqulred) 10. August 1957 Function: Operation: Materials Handled: Controls: Services: Sire end Type: Manufacturer: Capacity: Materials of Coastructloa: Motor: Reducer: Straiaer: Locatioa: To traasfer beazol from the beazol storage taaks to the beazol feed taak. Each beazol storage taak has a separate beazol traasfer pump aad b--zol Is let dove from oae taak at a time. The pump operates intermittently for about 6 hours per day vhea the pleat is operatiag at maximum capacity. Beazol - Approximately 500 GPH (average) The operator manually sets a five poiat motor startiag svitch to select the storage taak froa vhich he desires the automatic let-dova syst-- to feed. (See It-- 104) Approximately 9 KWH per day (max.) Steam is supplies to copper coils sarrouadlag the pumps or is blova directly lato the pump from a hose coaaectloa to preveat the beazol froa freexlag la the pump oa cold days. Positive displaceseat pumps, model SU 100, aoasparklag coastructloa vlth 2V flaaged connec tions . Pump integral vlth reducer shown below. The pumps are self-primimg by mesas of a stand pipe aad priming taak integral with the pump. Blackaer Pump Company Viking Pump Coapaay 75 to 100 GPM of beazol vs. 25' TDH vlth a suction lift of about 11'. Bronze fitted. 2 HP, 1800 RPM, 3 phase, 60 cycle, 220/440 v., TEFC explosion proof motor. Gear reduction unit furnished with pump to give 525 RPM when using 1800 RPM motor. A pump straiaer is installed oa the pump outlet. Mounted on beazol storage tanks. DSW 462489 WATER PCB-SD0000050516 I tea 104: Isopropyl Alcohol Storage Tank (1-Rcqulred) August 1957 Function: Operation: Materials Handled: Controls: Sis* & Type: MeterIsis of Construction: Location: Maintenance Required: To provide buffer storage for isopropyl alcohol. Isopropyl alcohol is periodically fed into the storage tank and intermittently withdrawn as needed to the isopropyl alcohol feed tank. The storage tank provides about 3 months opera ting storage at maximum plant capacity. Material in: Isopropyl alcohol at approximately 30 GPM while unloading. (This material is unloaded at the benzol unloading dock. The benzol un loading pump is used for this purpose.) Material out: Isopropyl alcohol at approximately 4 gallons per hour while operating plant at iaaxinnim capacity. (Average) Hone provided. Tank 10'6" dia. x 15'6" long equipped with standard manhead and nozzle for flame arrestor vent, top inlet and top discharge. 5/16" steel plate with 3/8" steel plate dished heads. Located about 200 feet South of the biphenyl building and due east of the benzol storage tanks. Hone. DSW 462490 WATER PCB-SD0000050517 12. August 1957 Item IPS: Isopropyl Alcohol Trims far Puaip Function: To transfer isopropyl alcohol to tha isopropyl alcohol feed taak. Operatioat Isopropyl alcohol is pumped fro* the isopropyl alcohol storage taak to the isopropyl alcohol feed taak about oace each shift. Materials Haadled: Coatrols: Isopropyl alcohol The Operator maaually starts and stops this pump as required. The switch is located aear the isopropyl alcohol feed taak. Size & Type: Positive displacement, self-priming by aeans of a stand pipe and priming taak integral with the ptsap. Kaaufacturer: Blackaer Pump Company Capacity: Approximately 10 GPM at a 25 TDH with a maximum suction of 11 feet. Materials of Construction: Bronze fitted Location: Mounted on Isopropyl alcohol storage taak. DSW 462491 'WATER PCB-SD0000050518 13. August 1957 106: Benzol Feed Task (2-Required) Function: Operation: Materials Handled: 1: To provide a source of benzol for feeding to the diphenyl units. 2: To provide s catch tank for the benzol re turned from the diphenyl process. Let-dovn from benzol storage tanks is intermittent. Run-back from diphenyl units is continuous. Return from benzol recovery system is batchvise. Return from hydrogen coolers is continuous. This benzol returns to the auxiliary benzol feed tank and is periodically pumped back to the primary benzol feed tank. When returning recovered benzol to the primary benzol feed tank from the benzol recovery system (hydrogen compressors), the distilled benzol catch tank or the auxiliary benzol feed tank, the operator must first cut off the automatic let-dovn from the benzol storage tank and let the level of the benzol in the feed tank drop enough to provide for the additional benzol returned. In addition, the distilled benzol must be checked for clear color before returning it to the feed tank. The operator must manually once or twice per shift drain off the water in the feed tank which comes from the water priming during un loading and from condensed moisture from the atmosphere. Benzol: Out: 240 GPH per unit 2900 GPH (max.) 12 unit operating * In: 500 GPH from storage tanks 2000 GPH (avg.) returned from process Part of the benzol returned from the process is returned batchvise so that the above figures are only average. DSW 462492 WATER PCB-SD0000050519 ( Item 106 Continued: Controls: Services: 14. Vater: Some vater coadeasea from the atmosphere la the storage teak. Generali; the amount of vater is significant vhea the let-dovm control Is svltched to a aev tank aad diminishes to a negligible amount after the storage taak has been used awhile. The recycled benzol also contains traces of vater and finally divided carbon. The vater is slightly corrosive as It asatalns 0.031 sulfates, 0.031 chlorides, and some undetermined reducing compounds vhlch vll 1 react with oxygen. It Is necessary to return the recycled benzol to the feed tank rather than the storage tanks as it has been determined that the recycled benzol contains some undetermined catalyst vhlch upsets the operation of the diphenyl units. There fore, an effort is made to blend the recycled benzol in with the fresh feed In a more or less constant ratio to maintain smooth operation of the units. An automatic level (let-dovn) control is provided for maintaining the supply of benzol la the feed taak. When the level of benzol in the feed tank recedes to 15" below the top, the automatic con trol starts one of the transfer pumps. The transfer pump Is automatically shut off when the benzol level Is 9" below the top of the feed tank. Another similar level control to that controlling the transfer pump is provided for sounding a high and a low level alarm should the level exceed 3" beyond the control level. A manually operated five-point selector svltch is provided at the feed tank for selecting the benzol storage tank to furnish the benzol feed. Steam is provided to the steam coil during cold veather depending upon the judgment of the opera tor who merely feels the side of the tank to determine If it feels varm. A negligible amount of electricity Is necessary to operate the control system. DSW 462433 WATER PCB-SD0000050520 ( Itea 106 Continued: Sira & Type: Openings: ( Manufacturer: Capacity: Materials of Coastructioa: Steam Coils: Location: References: ( 15. 7'6" I.D. x 15*6" long, dished head horizontal tanks installed in a concrete walled enclosure about 4* high to catch the benzol in the event of a tank rupture. The feed tanks are located on a concrete slab surrounded by a cyclone fence. Top: 2'0" I.D. manhole centrally located for installation of the steam coils. (2) 8" flanged pipe nozzles for the automatic let-down controls. 2%" foam nozzle 2" vent to hydrogen coolers (Item 110) 4" benzol runback nozzle 4n benzol inlet nozzle (from storage) 2M rodding nozzle 2" thermal well Bottom: 2" outlet nozzle extending 6" above bottom of feed tank. 1" drain nozzle in dished well (for draining water). Chattanooga Boiler and Tank Works 5.000 Gallons. 3/8" steel plate Flat hairpin coils made from 1" XH seamless steel pipe forming three loops 5' long and with 1*0" pitch. The coils are supported on the bottom of the tank with one coil in each end. Located about 30' west of diphenyl building Drawings Monsanto Layout of Feed Tank Feed Tank Details Bill of Materials 9C-8205 9C-8206 9BM-54 DSW 462494 WATER_PCB-SD0000050521 t Itea 107: Benzol Feed Pump (2-Requlred) 16. August 1957 Function: To deliver the benzol feed fro the benzol feed tank to the benzol vaporizer coll of each diphenyl unit. Operation: One pomp la operated continuously while the other pumps are held at spares. Materials Handled: Benzol - Maxinun rate required is 55 GPM with all 12 units operating at full capacity. Controls: The pump is annually controlled by notor starting switch. The rate to each diphenyl unit is automatically controlled and recorded by an orifice and flow recorder and controller. The approximate head required at the orifice is around 170 pslg. r Services: Approximately 175 KWH per day electricity required. Size & Type: Two-stage Westco pump with removable liners. Manufacturer: Micro-Westco, Incorporated Materials of Construction: Impellers of Hi-Resist and shafts of stainless steel. Motor: 15 HP, 3740 RPM, TEFC, explosion proof Howell Electric Company notor. Drive: Direct drive with flexible coupling. Location: Located on concrete pad next to feed tank. ( DSW 462495 WATER PCB-SD0000050522 ( Itant 108: Isopropyl Alcohol Feed Tank 17. August 1957 Fumctloa: Operetlom: Materials Handled: Controls: Capacity: Location: To provide a source of Isopropyl alcohol for feeding to the benzene feed. Let-down from the Isopropyl alcohol Inter mittently. Isopropyl alcohol Out: 4 gal./hour Float to Indicate liquid level. 100 gallons Southwest corner of benzene feed tank area. r ( DSW 462496 WATER PCB-SD0000050523 ( Item 109: Isopropyl Alcohol Feed Pomp 18. August 1957 Fumctiom: Operatlom: Materials Hamdled: Cositrols: Locatiom: To tramsfer isopropyl alcohol to the suctioa of the bemxol feed pumps. Comtimuous Isopropyl alcohol The ptmtp is autaually coatrolled by a motor startimg switch. Hear isopropyl alcohol feed task. ( c SIV 462497 WATER PCB-SD0000050524 19. August 1957 I tea 110: Hydrogea Coolers (6-Requlred) Fuactioa: Operatioa: Materials Haadled: Size & Type: Maaufacturer: Locatioa: C teat: 1. To cool the gas aad vapors fro the beazol coadeaser la order to decrease the vapor load oa the hydrogea compressors. 2. To coadease some of the beazol vapor from the hydrogea gas. Coatlauous. The coadeased beazol is coatiauously dralaed by gravity to the beazol auxiliary feed taak. Hydrogea gas aad beazol vapors from the dipheayl Daits. Beazol vaipors veated from the crude dipheayl sump taaka. Beazol vapors veated from the primary beazol feed taak. Tvla 6-fia sectloa coolers BSS-248 6-12 "B" type modified with aa exteras1 water jacket. The coolers are coamected ia parallel aad lastalled horizoatally. Grlscom-Russel Compaay lastalled oa the hydrogea compressor room roof. The coolers were modified ia the field by the additlom of aa external water cooled jacket. WATER PCB-SD0000050525 20. , August 1957 Item 111: Benzol Catch Tamk (1-Requlred) Fumctiom: 1. To trap coadeased bemzol froa the hydrogem gas to lmsure its mot reachimg the hydrogem cootpresaors. 2. To provide a surge tamk for hydrogem gas prior to compresslom. Operatlom: Comtlmuoas. The comdemsed bemzol trapped im the tamk is comtimuously draimed to the pump tamk for returm to the bemzol feed tamk. Materials Hamdled: Hydrogea gas saturated vith bemzol vapor. Coadeased bemzol. Size & Type: 4'-0" O.D. x. 4'-0" lomg vertical tamk with dished heads. Top (4) 1" threaded outlets ( (1) 4" fImaged mlpples Side (2) 4" flamged mlpples (1) 1%" threaded outlet Bottom (1) 1" threaded outlet Kamufacturer: Chattamooga Boiler Works Capacity: 56 ft.3 50 palg pressure Materials of Comstructloa: 3/16" steel plate fabricated la accordaace with ASMS code for umfired pressure vessels. Locatlom: Suspemded from the cellimg lm the compressor room. Refereaces: Drawimgs Momsamto Hydrogem Compressor Tamks 9C-7367 DSW 462499 WATER PCB-SD0000050526 (' I tea 112: Hydrogen Compressors (3-Requlred) 21. August 1957 Function: To provide a mesas of recoveriag beazol from the by-product hydrogea gas. Operatioa: Coatiauous. The beazol is recovered by compressiag aad cooling the hydrogea gas ia two stages to 300 psig. The compressors automatically load at 3 psig aad unload at % psig inlet pressures. Materials Handled: Maximum volume operating at maximum rating. (Conditions 2500 gal/hr. feed @ 21% conv.) 10,900 CFH hydrogea @ 30C. aad 760 mm 13,000 CFH hydrogen plus beazol vapors @ 30C. and 760 mm 7.2# benzol/# hydrogen @ 15 psig, 30C. 0.8# benzol/# hydrogen @ 300 psig, 52C. 6.4# benzol recovered/# hydrogea compressed ( 0.0179# hydrogea produced/# diphenyl Controls: Pressure controller controls intake. Pressure controller controls pressure of first aad second stages. Pressures are all indicated. Services: Estimated electrical consumption is 700 KWH per day. Size & Type: Kotor: (2) Class 11 AT serial 6965, size 9 aad 4% x 9 Pennsylvania compressors. Max. rpm 275; working pressure 350#-Rated Capacity 110 CFM ea. (1) Two-stage Uorthiagtoa Compressor. Rated Capacity 75 CFM (2) 40 HP, 1175 rpm, type K6 motor with frame, #504 (1) 30 HP, 1175 rpm, type K motor with frame, #444 Drive: (2) 8 V-belt sheaves (1) 3 V-belt sheaves ( References: Bill of Material 9BM-47 DSW 462500 WATER PCB-SD6oOO~050527 C It-- 113: Iater-Coolar (3-Regalred) 22. August 1957 Fumctloa: Operatiou: Heat Duty: Services: Site & Type: Kaaufacturer: Capacity: To coademae beatol froa the hydrogea gas after the first stage coapressloa. Coatimuoua. The hydrogea froa the first stage coapresaioa of each of the three coapressors may be delivered to either of the two coolers. 80,000 BTO/hr. approximate (Roper's report). Coollag water. Wt. 160#, overall leagth 62-5/8" Aadale Eagiaeerlag Coapaay, Philadelphia, Pa. For 100# pressure f ( DSW 462501 WATER_PCB-SD0000050528 23. August 1957 Itos 114: Lov Pressure Receiver (3-Required) Function: Operatioa: Materials Saadied: Coatrols: Size & Type: Opealag: Kaaufacturer: Capacity: Material of Coastructloa: Hots: To proride a trap aad collect tag tank for the beazol coadeased from the hydrogen gas after the first stage compression. The receivers are provided vith piplag coanectioas so that either of the three compressors caa be coaaected to either of the tvo receivers. The beazol is periodically blow* from the re ceivers to the pomp taak. Hydrogea gas saturated vith beazol vapor aad coadeased beazol. Pressure - 65 paig A manually operated valve is provided ia the pipe out of the bottoa of the receiver, tfhea this valve is opeaed the hydrogea pressure forces the beazol up iato the pump taak. 3'-0" I.D. x 6'-0" high vertical taak vith dished heads. Top: 2%" standard pipe extending through ceater of top dova to the middle of the taak. Tvo 3/4" threaded outlets. Side: 6" haadhole 2" flaaged nipple 3/4" threaded outlet Bottoa - 3/4" threaded outlet Chattaaooga Boiler Works 100 pslg pressure 45 ft.3 5/16" steel plate Fabricated ia accordaace vith ASMS Code for uafired pressure vessels. 4,2.52 OS'N WATER.PCB-SD0000050529 Item 114 Coatiaued: Locatioa: . Refereacea: 24. Located la coapresaor rooa. Drawiaga Monaamto Hydrogea Coapreasor Taaka 907367-3 A6253 WATER_PCB-SD0000050530 25. August 1957 It 115: After-Cooler (3-Rcguired) Fuactioa: Operatioa: Pressure: Hest Duty: Services: Sire & Type: Haaafacturer: Capacity: To coadease beazol from the hydrogea gas after the secoad stage coapreasioa. Coatimuous 300 psig operatiag pressure 42,000 BTO/hr. approx. (Roper's report) Cooliag vater Vt. 160# - overall leagth 62-5/8" Aadale Eagiaeeriag Costpaay, Philadelphia, Pa. For 350# pressure ( c DSW 462504 WATER_PCB-SD0000050531 X7 u . August 1957 Itea 116: High Pressure Receiver (3-Requlred) Fumctiom: To provide s trsp sad collecting tsak for beazol coadeased froa the hydrogen gas after the second stage coapressioa. Operation: The receivers are provided with piping connec tions so that either of the three compressors can be connected to either of the two receivers. The benzol is periodically blown froa the re ceivers to the puap tank. Materials Handled: Hydrogen gas saturated with benzol vapor and condensed benzol @ 300 psig 52C. Controls: A annually operated valve is provided in the bottom outlet pipe connection to the puap tank. Size & Type: 2'-0" I.D. x 6'-0" long vertical tank with dished heads. All flanges are Crane #856E. Openings: Top: 2%" standard pipe extending through center down to the middle of the tank, two 3/4" threaded outlets. Side: 6" handhole 2" flanged nipple 3/4" threaded outlet Bottom: 3/4" threaded outlet Manufacturer: Capacity: Chattanooga Boiler Vorks 20 ft.3 350 psig pressure Materials of Construction: 11/16" steel plate lots: Fabricated in accordance with ASME code for unfired pressure vessels. Location: Located la compressor room. References: Drawings Monsanto Hydrogen Compressor Tanks C-7367-3 OSw462505 WATER PCB-SD0000050532 It-- 117; Beazol Return Pump Taak (1-Rcqulred) 27. August 1957 Fumctiom: Operation: Mstsrtals Handled: Sit* & Type: Ope*lags: Ms*usctur*r: Capacity: Material of Comstractlom: Hot*: Locatiem: References: To collect the condensed beaxol frost th* receivers aad the beatol trap. The benzol frost the collecting taak is continuously run back to the pump taak aad the beazol from the receivers is periodically blova back iato the puap taak. The collected beazol is periodically pusped back to the beazol feed taak. Approx. 4600# or 620 gal. of beazol recovered per day (max.). 3'-0" I.D. x 6'-0" high vertical taak with dished heads. Top: 1%" threaded outlet Two 3/4" threaded outlets Side: Five 3/4" threaded outlets Oae 6" haadhole Botton: 1%" threaded outlet Chattaaoogs Boiler Works 45 ft.3 50 pslg pressure 3/16" steel plate Fabricated ia accordance with ASME code for unfired pressure vessels. Located ia hydrogea compressor room. Drawings Monsanto Hydrogea Compressor Taaks C-7367-3 OSW 462506 WATER_PCB-SD0000050533 August 1957 It 118: Recovered Bemzol Retnrm Pump (2-Reqaired) . Fumctiom: Operstiom: Comtrols: Services: Size & Type: To ratura the recovered bemzol im the pump tmak to the bemzol feed teak. Periodic. Manually comtrolled by motor etertimg switch. Estimated 15 KWH per dmy (max.) Ome Micro-Westco emd ome Worthimgtom pump commected im parallel. Theme are old pumpa repossessed from smother process amd the idemtificatiom marks are illegible. DSW 462507 WATER_PCB-SD0000050534 c Itt 119: Crude Diphenyl Catch Tasks (2-Required) 29. August 1957 Function: Operation: Materials Handled: Controls: Services: Comments: To cstch the crude diphenyl fro* the diphenyl units and store it prior to batch distilling or delivery to crude diphenyl storage tank. The catch tanka receive the sump product, crude diphenyl, from the columns as a continu ous overflew from the carbon trap. The crude diphenyl is periodically withdrawn from the catch tanks for batch distilling. No definite schedule is followed as the catch tanks become filled at indefinite intervals depending upon the number of units in operation. Crude diphenyl of the following approximate composition: Diphenyl Hi-boiler Benzol Head & Tails Oil Fraction eventually lost 60.87Z 14.01Z 22.49Z 0.10Z 2.53Z 100.001 Oper. Temp. 120-130C. Oper. Pressure 2-5 psig Provisions are made for indicating the temperature of the crude diphenyl. An enclosed tape is provided for Indicating the level in the tank. An explosion disk (Protectoseal) is provided to prevent excessive pressure in the tank. Steam coils are provided in the bottom of the tank. Considerable benzol flasks out of these tanks through a vent line connect to the hydrogen vapor system. ( WATER PCB-SD0000050535 I tea 119 Coatlmued: Sire & Type: Openings: Manufacturer: Capacity: Material Comatractlorn: Imaalmtiom: Steaa Coila: 30. 8'-0M I.D. x 16'-0" lomg horizomtal tamk with diahed heads. Top: Ome 3*-0" manhole cemtrally located amd containing three openings; ome for the imatmllmtiom of the soap pump, ome for the pomp discharge amd ome & r the Protectoseei connection amd vest lime. Four steaa coil mozzles are im the ertlcml side of the 3 mamhole mozzles. Ome 2'-0" aamhole cemtered 6*-0" from the alddle of the tamk vlth the cover drilled for the imatmllmtiom of the "Varec" gage for aeasurlmg the level la the tamk. Three 3n slip om veldimg fImages are provided 1*-0" apart 4'-6" from the middle of the tamk. The outside mozzle ia for fillimg the tamk, the cemter for a vemt (which is mow sealed), amd the imside ome for the theraowell comaectioa. Bottom: A 2" plugged pipe couplimg drala is pro vided lm the pump well. Chattaaooga B. & T. Compamy (tamk) Crame (steaa coils) 6,000 gal. ea. - tamk, tested for 25 pslg 3/8" steel plate The eatire tamk is covered by a 2" blamket imsulatlom, followed by a %" layer of Eagle 66, amd a V Imsulseal, amd with a aetal jacket protective sheetimg. Two 2" (irom pipe size) extra heavy seamless steel pipe coils approximately 64' amd 56' long are provided ia the bottom of the tamk with ialets amd outlets through the side of the cemter aiozzle for the sump pump. Each coll comslsts of four halrplm turms 6'-0" lomg, 4n pitch amd lmstalled flat. The two inside coils for the nVarec" gage emd of the tamk are 2' short to clear the gage. DSW 462509 WATER PCB-SD0000050536 I Cm 119 Continued: Location: Auxiliary Equipment: References: 31. Located in a relaforced coacrete pit, 4'-6" deep, with a 3'-6" vail between taaka vlth a drala uader Che vail which caa be cloaed off with a atopper from either aide. The pit ia located east of the dipheayl building aad has a high brick vail abield to protect the taaka agaiaat fire front the buildiag. The H.W. coraer of the pit coataiaa a sump pump manually coatrolled. The pump is a Taber Ho. 2 - Fig. B-148 sump pump with \ HP,'1750 RPH motor. The pit also contains a 1500 gal. catch tank for benzol. The pit ia surrounded by a handrail and provided with haadrailiag and valkvays over the tanks. Drawings Moasaato Layout of Crude Jiphenyl Catch Tanks Layout of Pit and Foundations Crude Dipheayl Catch Tank Pit-Details 6000 Gal. Catch Tank Pit Handrail Platform (Sheet 1) Piping Walkway aad Stairs (Platform Sh.2) Bill of Material 9C-8193 9C-8196 9C-8197 9C-8192 9C-8197 9C-8198 9C-8194 9C-8199 9BM-54 DSVV 4C2510 WATER_PCB-SD0000050537 August 1957 Item 120: Still Charging Pumps-(2-Requlred) Function: Operatioa: Materials Haadled: Controls: Services: Sire & Type: Manufacturer: Capacity: Materials of Construction: Drive: Location: Reference: To deliver the crude diphenyl from the catch teaks to the still. Periodically operated whenever the catch teak becomes almost filled. Crude diphenyl - sp.gr. approx. 1.041 Controlled annually by a motor starting switch. Approximately 20 KWH per day (max.) Vertical submerged type sump pump. Taber Pump Company 100 GFM vs. 50' TDH 5 HP, 1750 RPM, 3 phase, 60 cycle, 220/440 v. vertical explosion proof motor with ring base. Direct connected with flexible coupling. Installed on crude dipheayl catch tank. Bill of Material 9BM-54 DSW 462511 WATER_PCB-SD0000050538 33. August 1957 Item 121: Hl-Boller Collecting Tank (1-Requirad) Fusetlorn: Operation: Materials Haadled: Services: Sire & Type: Opeaiags: Steam Coil: Capacity: Materials o Coastructlom: Note: Refereace: To provide a receiviag aad coollag taak for the distilled hi-boiler. At the completioa of the crude dlpheayl distillatioa, the hl-boller fonalag the residue ia the still is pumped by the still circulatiag pump to the Jil-boiler collectiag taak. The hl-boiler is allowed to cool aad at iatervals reheated aad poured iato drums for coaveylag to the crude Saatovax storage area. Also, the hi-boiler may be pumped to the Saatovax plaat for use, depeadiag upoa requiremeats. Hi-boiler coaslstlag malaly of terpheayl. Steam to steam coll vhea seeded. 5'-6" I.D. x 5'-6" high vertical taak with flat top aad dished bottom. 4" islet 4" vest 4" gaglag hatch 22" maahole 2" bottom outlet 1V1 diameter seamless pipe coll approximately 80* loag. 1000 gal. 1/4" steel plate Oae taak is sow coaaected to service both stills. Drawlags Koasaato Hi-Boiler Taak 9C-7876 OS****'2 WATER PCB-SD0000050539 34. August 1957 Item 122: High Boiler Pump (1-Rcquired) Fuactloa: Operatlom: Materials Hamdled: Comtrola: Serricea: Sire & Type: Kaaufacturer: Motor: Drive: Locatioa: To deliver hi-boiler from the bi-boiler taak to tbe Saatowax storage taak or tbe Saatowax still pot. Periodically Hl-Boiler Maaually operated by motor startiag switch. A aegligible smouat of power coasuaptioa per day. Sump pump Taber Pump Compaay 7*& HP, 1735 rpm, 3 phase, 60 cycle, 220/440 v. Geaeral Electric vertical motor Direct coaaected with flexible coupliag. Kouated oa bi-boiler collectiag taak. DSW 462513 WATER PCB-SD0000050540 35. August 1957 I tea 123: Distilled Bearol Collectlag Taak (1 Required) Fusetlorn: Operatioa: Hsterisls Hsadled: Services: Sire & Type: Opeaiags: Maaufacturer: Capacity: To provide s catch taak for the bemrol fractioa distilled froat the crude diphemyl. The first fractioa distilled over from the crude diphemyl comes over at 80C. sad is rua by gravity lato the bearol taak. The bearol is aot rua back directly to the feed taak because of the possibility of makiag a mistake aad alloviag some of the heads to rua back with the bearol. Therefore, it is accessary to check the color of the bearol for clearaess before it is periodically puaped back to the bearol feed taak. Bearol distilled from the crude dipheayl. Steam to steam coll. 7*-0" I.D. x 4*-5" high vertical taak with dished heads. Top: 21%M I.D. maahole ceatrally located. Three 2" staadard pipe coup1lags. Side: Four morales fabricated as follows: Oae piece of 4" die. staadard pipe x 3%" loag welded all arouad outside to shell plate. Oae staadard 3/4" pipe coupllag (seamless) welded to shell plate aad hole cut. 3/4" pipe is coaceatric to 4" pipe. (Norxles are preseatly closed off). Bottom: 2" pipe aipple ceatrally located Joha Hooter Boiler Works, St. Louis, Missouri 1500 Galloas - Workiag pressure 3# gas. Givea Hydo. test @ 10# DSW 462514 WATER PCB-SD0000050541 123 Continued: Materials of Construction: Insulation: Steam Coll: Locatlom: Reference: 36. Mild ateel plate - structural quality A.S.T.M. A10-34 The aldea aad bottom are laaulated with 2%" blanket Insulation, %" Eagle "66" Insulation and covered with a 22 gage blank Iron jacket. The steam coll Is a removable unit fabricated to the manhole cover. The coll consists of 8 turns @ 4" pitch and is made from IV seamless steel pipe. The overall length of the coll measured from the bottom of the cover plate is 6'-4". Coll by Crane. Located in the crude diphenyl sump pit. Drawings Monsanto Details of Sump Tank Detail of Coil 9C-81S2 9C-7874 Bill of Material 9BM-48 oSv\J 462515 WATER_PCB-SD0000050542 ( Item 124: Distilled Benzol Returm Pump (1-Raquired) 37. August 1957 Function: To deliver the recovered beazol from the distilled beazol collectiag task to the beazol feed taak. Operation: Periodic Materials Handled: Beazol recovered fan the crude dipheayl. Controls: Maaually coatrolled by motor starting switch. Services: Estimated 2 KWH per day. Size & Type: Figure 3004, size 2", single stage, ead suction centrifugal pump mounted on bedplate. HuaftcCarer: Gould Pump Company Material of Comstructioa: Standard except for stainless steel shaft. ( Motor: 3 HP, 1750 rpm, 220/440 v., 60 cycle, 3 phase, enclosed fan cooled, class 1, group D, type K, General Electric induction motor. Frame 225. Drive: Direct connection with flexible coupling. Locatioa: Located on concrete foundation in crude diphenyl sump tank pit. Refereaces: Bill of Material 9BM-48 ( Osvv 462516 WATER_PCB-SD0000050543 C Item 125: Diphenyl Storage Tsmks (2-Requlred) 38. Angust 1957 Function: To store distilled diphenyl prior to shipping. Operatloa: Continuous Materials Handled: Distilled diphenyl at 71C. minimum temp. Controls: A thermometer veil is provided for use in determining the temperature of the diphenyl. Services: Steam for steam coils. Size & Type: 10'-6n O.D. x 37'-4" long horizontal tank with dished heads. Openlags: Top: Steaa coil inlet, 3" sch. 80 pipe nozzle Measuring port, 2" sch. 80 pipe v/cap. Thermometer veil, 3n sch. 80 pipe nozzle Pump opening, l'-9V' I.D. flanged nozzle Diphenyl inlet, 2%" sch.80 pipe nozzle c Mairiiola and relief opening, 2'-0" I.D. flanged nozzle Vent, 3n sch. 80 pipe Bottom: Steam coil outlet, 2" steam coll pipe velded Drain, 3" flanged nozzle v/cover plate Steaa Colls: Hairpin type flat coil 36'-0" long vith eight runs wm of 2n sch. 80 seamless steel pipe spaced at 6". A pump veil is provided surrounded by tvo turns of %" copper tubing vith separate steam con nections. Manufacturer: Rogers and Wright, Incorporated Capacity: 25,000 gallons. Shell tested vith 25# hydrostatic pressure Materials of Construction: 3/8" steel plate. ( 462&l7 os^1 WATER PCB-SD0000050544 ( Item 125 Continued: Insulation: Locatioa: References: 39. Tank la insulated with 1%" Eagle blamket insulation type 201 with Eagle 66 (E2) applied at all butt joiata of blamket lnsulatlom where necessary to fill up cracka. Eatire aurface ia covered vith 20 gage galvamized from jacket. All the jolmta oa top half are made water tight by aolderiag. Tamka are located 31'-6n apart ceatcrs amd imatalled lemgthwiae ia a NS direction. The cemter of the eaat task la 61'-2-3/8" eaat of the center lime of the diphemyl building weat column row. The tamka are 30'-0" aouth of the marlatlc acid atorage tanks neasured from end to end. Elevations: centerline of tanks grade top of dike 768' 4-3/16" 758'-0" 761'-0" Drawings Monsanto Location plan diphenyl storage tanks Details storage tanks Foundation details Diphenyl piping to and from tanks 9C-9076 9C-9057 9C-9081 9Ct9083 Procurement Record 9PR-87 ( DSW 462518 WATER PCB-SD0000050545 40. August 1957 Item 126: Dipfaemyl Loading Pumps (2-Ragaired) Function: To deliver diphenyl from the diphenyl storage tanks to tank cars for shipping. Operstlon: Periodic Materials Handled: Distilled diphenyl Controls: Manually operated by motor starting switch. Services: Estimated 15 KWH per day (max.) Sire fx Type: Figure S 1790-No. 2-type F sump pump measuring 11'-8-3/8" from bottom suction to underside of cover plate. Manufacturer: Rumsey Pump Company Materials of ( Construction: Iron Motor: 5 HP, 1750 rpm. General Electric vertical motor. Drive: Direct drive with flexible coupling. Location: Mounted on storage tanks (Item 125) Reference: Drawings Monsanto Pumps for storage tanks 9C-9088 < svv 462519 WATER PCB-SD0000050546 C SERIES 200 - BIPHENYL UNITS ltd 201: Benzol Vaporiser (1-Requlred per Unit) 41. August 1957 Function: 1. To vaporize the benzol feed to each diphenyl unit. 2. To recover sensible bent from the exhaust gases used in heating the preheater and converter pots. Operation: Continuous. The benzol makes a single pass through the vaporizer, flowing countercurrent to the hot flue gas. Materials Handled: Benzol - Rate: 1700#/hr. 170 GPH Temperature-In: 30C. approx. In feed tanks 0ut:200oC. approx. Pressure: Out: 100 psig approx. Exhause gas - Rate: Flue gas 1250#/hr. approx. ( Excess air 220#/hr. Temperature-In: 780C. Out: 400C. Approximate Heat Balance: Benzol: 1. Heating liquid to B.P. 1700 (136-30)(1.8)(0.34) = 110,000 BTU/hr. 2. Vaporizing benzol 1700 (150) = 255,000 3. Super-heating vapor 1700 (200-136)(1.8)(0.39) = 8.000 Total 373,000 BTU/hr. Some of this heat load is absorbed by passing the benzene through the small coil in the column before it enters the vaporizer. No temperature data are available to determine the exact load ou the vaporizer coil. ( DSVJ 462520 WATER PCB-SD0000050547 42. ICot 201 Continued: Controls: Services: Size & Type: Units Outside Area. Ft.^ 2,3 4,5 6,7,8,10 123 186 180 9 11,12,13 180 240 Normally no controls sre needed. However, it is necessary to avoid overheating the vaporiser when benzol is not being fed during start-ups and shut-downs. To prevent overheating during start-ups, the exhaust gas is diverted from the vpi>iir by exhausting through a special by-pass stack. During shut-downs, cool air is vented into the exhaust stack to cool the vaporizer. The benzol feed outlet temperature, the ex haust gas inlet temperature, and the exhaust gas outlet temperature are recorded on the 12 point temperature recorded. None required. The housing for the vaporizer coil is described separately (Item 209). The coils are all essentially the same in regards to purpose but the details of con struction vary as follows: Sunsaary of Vaporizer Design No. Colls No. Turns Dla. Pipe Dia. Coil Pitch Length Single Single Single Single Single 36 38 37 39 37 52 U"xH 2'6" 2\" 90' 2 "xH 2'6" 3" 95' 2 "xH 2 "xH 2'6" 1'llVii 3n 2M 92.5' 78' 2 "xH 2'6" 3" 92.5' 2 ''xH 2'6" 3 " 130* Manufacturer Nos. 6,7,8, 9, and 10 units originally had a double coil but the inner <coil burned out and is disconnected. Crane Company "SW 462521 WATER PCB-SD0000050548 Iten 201 Continued: Materials of Conetraction: Location: References: 43. Extra heavy standard steel pipe The vaporizer coil is located in a vertical stack lined with insulating refractory brick and containing a stainless steel inner shell designed to give a maximum exhaust gas velocity over the pipe coil. Drawings Monsanto Vaporizer Vaporizer Vaporizer Vaporizer Assembly,Units 11,12, for Ho. 1 Unit for Ho. 4 Unit for Units 6,7,8,9,10 13 9C-9026 9C-6841 9C-7840 9C-8150 o=>,,N 162&22 WATER PCB-SD0000050549 44. August 1957 ( Item 202: Heat Exchanger (1-Rcquired) Installed on Dnits 4 & 5 Only Comment: The use of s heat exchanger on units 4 and 5 deviated from the prevailing design. The heat exchanger replaces the preheater and conserves fuel by recovering sensible heat from the converter vapors. Function: 1. To further super-heat the benzol vapor from the vaporizer. 2. To recover some of the heat from the vapors leaving the converter. Operation: Continuous. The converter vapors make a single pass through the tubes, countercurrent to the benzol vapor making a single pass through seg mental baffles on the shell side. Materials Handled: (The conditions stated were taken from Phosphate Division Engineering Report No. 117. Actually, ( the units may be operated up to a 240 gal./hr. Benzene Feed Rate.) Shell fluid: Benzol vapor - 1200#/hr. Tube fluid: Converter vapors - 1200#/hr. (benzol vapor) (diphenyl vapor) (hi-boiler vapor) (hydrogen gas) Heat Balance: Shell fluidtemperature: In - 160C. Out - 525C. Tube fluidtemperature: In - 720C. Out - 405C. LHTD: 220C. Duty: 405,000 BTO/hr. Heat transfer coefficients (outside surface) Tube film: 11 BTU/hr.sq.f t.F. Tube scale: 400 " Tube vail: 3300 " ( Shell film: Shell scale: 28 500 " " DSW 462523 WATER PCB-SD0000050550 ( Item 202 Continued: 45. ( . ( Heat Balance Contd: Type: Size: Nozzle*: Manufacturer Design: Materials of Construction Insulation: References: Overall U-theo: Overall 0: 7.56 5.44 Total effective surface: 188 ft.^ 10'-0" eff. length Rote: Source of above data is report by D. A. Rober on Design of No. 4 Unit. Vertical packed expansion joint, removable tube bundle. Single section with 16" O.D. shell, with seventy-two (72) 1" O.D. #12 BWG tubes at lfc" square pitch, and with twenty-one (21) 3/16" thick transverse baffles spaced at 5" centers. Shell Nozzles - inlet: 3" T&G outlet: 3" T&G Series 30 Series 30 Tube Nozzles - inlet: 4" T&G outlet: 4" T&G Struthers-Wells Series 30 Series 30 Operating pressures - tubes: 5# ga. Shell: 45# ga. Max. Working Pres. - tubes: 50# ga. Shell: 50# ga. Max. Temperatures - tubes: 1400F. Shell: 1000F. Shell: Tubes: Baffles: Steel 4-6 chr. 0.5 mo. Steel The exchanger is Insulated with 3" of Eagle #88 rock wool, with bolted flanges exposed. Drawing 9SC-2577 Bill of Material 9BM-29 9BM-35 DSW 462524 WATER PCB-SD0000050551 46. August 1957 Item 203: Preheater (1-Regalred) #4 and #5 Only Fauction: Operation: Materials Handled: Heat Balance: Controls: Services: To further super-heat the bensol vapor coming from the heat exchanger to the reaction temperature necessary for pyrolysis. Continuous. The benzol vapor passes through a distributor pipe with the end emersed in molten lead in the preheater pot. The vapor babbles up through the molten lead and is discharged through a gooseneck pipe to the converter. The pot is suspended in a firebrick setting and the temperature of the lead maintained by burning natural gas la burners extending through the firebrick. In addition, the hot flue gases from the converter are used to heat this preheater. (The conditions stated vere taken from Phosphate Engineering Report Ho. 117. Actually, these units may be operated up to a 240 gal./hr. benzene feed rate.) Benzol Vapor - 1200#/hr. Benzol vapor temperature: Flue gas temperature: In: Out: In: Out: 525C. 675C. 1800C. 1150C. LMTD: 850C. Duty: 374,000 BTU/hr. Overall 0: 7.0 BTU/hr., ft.2, F. Total effective aurface: 35 ft.2 Temperature of lead recorded on 12 point recorder. Hatural gas, approximately 350# CFH. Make-up lead has to be added periodically. DSW 462525 WATER_PCB-SD0000050552 Item 203 Continued: Sire & Type: Manufacturer: Capacity: Materials of Construction: References: Comments: 47. 24" O.D z 72" long dished bottom pot filled with 37" to 42" of molten lead and suspended in a firebrick setting. The distributor pipe is a straight 4" O.D. x 3" I.D. tube located in the center of the pot. A small baffle covers the vapor outlet to prevent lead being splashed directly into the outlet pipe. The outlet pipe is 4" XH pipe. The top of the pot is welded carbon steel plate and is bolted to the pot. Blew-Knox Company 100 lbs. of lead adds 1%" to the level of the lead in the pot. Type 309 stainless steel plate 5/8" thick. Drawings Monsanto 9SC-2852 9SC-2575 The firebrick setting consist of one unit for both the preheater and the converter partitioned by a firebrick wall with an opening left for the flue gas to pass from the converter side to the preheater side. DSVV 462526 WATER PCB-SD0000050553 August 1957 Item 204: So. 1 Preheater (1-Requlred per Unit) All Units Except #4 sad #5 Function: Operation: Materials Handled: Controls: Services: Type & Size: Consents: To further super-heat the benzol vapor from the vaporizer to a mid-point temperature between the vaporizer temperature and the re action temperature. Continuous. The benzol vapor passes through a distributor pipe vlth the end emersed in molten lead in the preheater pot. The vapor bubbles up through the molten lead and is discharged through a gooseneck pipe to the No. 2 pre heater. The pot is suspended in a firebrick setting and the temperature of the lead main tained by burning natural gas in burners ex tending through the firebrick. In addition, the hot flue gases from the converter and the No. 2 preheater are used for heating the No. 1 preheater. (The conditions stated were taken from Phos phate Engineering Report No. 117. Actually, these units are operated at benzene feed rates greater than 1200#/hr.) Benzol vapor - rate: 1200#/hr. Temperature: In: Out: 140C. 425C. Temperature of lead recorded on 12 point temperature recorder. Natural gas. Make-up lead added periodically. Identical to Item 203. The firebrick setting consists of one unit for Items 210, 211, and 212, partitioned by a firebrick wall wth an opening left for the flue gases to pass from the No. 1 preheater and converter to the No. 2 preheater. 0SW 462527 WATER FcB-SD0000050554 49. August 1957 Item 205: Wo. 2 Preheater (1-Requlred per Oalt) All Onlts Except #4 and #5 Function: Operation: Materials Handled: Controls: Services: Type & Size: Comments: To super-heat the benzol vapor from the Ho. 1 preheater outlet temperature to the reaction temperature for conversion. Continuous. The benzol vapor from Ho. 1 preheater passes through a distributor pipe with the end eiaersed in siolten lead in the pre heater pot. The vapor bubbles up through the molten lead and is discharged through a jumper pipe to the converter. The pot is suspended in a firebrick setting and the temperature of the lead maintained by burning fuel gas in burners extending through the firebrick. In addition, the hot flue gases from the converter are used for heating the Ho. 2 preheater. (The conditions stated were taken from Phos phate Div. Engineering Report Ho. 117. Actually, these units are operated at benzene feed rates greater than 1200#/hr.) Benzol vapor - rate: 1200#/hr. Temperature: In: Out: 425C. 700C. Temperature of lead recorded on 12 point recorder. Hatural gas Hake-up lead added periodically. Identical to Item 203. The firebrick setting consists of one unit for Items 204, 205, and 206 partitioned by a firebrick vail vith an opening left for the flue gases to pass from the Ho. 1 preheater and converter to the Ho. 2 preheater. DSVV 462528 WATER PCB-SD0000050555 50. , August 1957 Item 206: Converter (1-Requlred per Unit) Function: To maintain the benzol vapor at the reaction temperature for a short sojourn time sufficient for about 201 conversion to diphenyl. Operation: Continuous. The benzol vapor passes through a distributor pipe with the end emersed la molten lead in the converter pot. The vapor bubbles up through the molten lead and la discharged through a pipe to the lead trap. The pot is suspended in a firebrick setting by burning natural gas in burners extending through the firebrick. The exhaust flue gas passes through an opening in the firebrick partition to the chamber surrounding the No. 2 preheater. Materials Handled: (The conditions stated were taken from Phos phate Div. Engineering Report No. 117. Actually, these units are operated at benzene feed rates greater Chan 1200#/hr.) ( Material In: Material Out icmpcribuie, i benzol vapor - 974#/hr. diphenyl - 181#/hr. Hi-boiler - 42#/hr. hydrogen diphenyl - 3#/hr. - 4344#/day Temperature : 750-810C. Controls: The temperature of the lead la the pot must be Mintained exactly at 750-810C. This is done by a temperature recorder controller control ling the gas burners. Size & Type: Identical to Item 203 on all units except Units Nos. 4 and 11. The converts on Units 4 and 11 have a standard vertical pot section welded to the top of the standard pot to provide additional sojourn time. An extensive report has been prepared on the materials of construction of the converter pot. See Research Report #2211, Interim Report on Alloy Testing and ( Biphenyl Pot Corroalon. Constructive criticism is presented which may be of value in future construction. DSW 462529 WATER PCB-SD0000050556 51. August 1957 Its* 207: Burners (18-Requirad on Units 2,3) (14 Required on Units 4,5) (19 Required on Units 6,7,8,9,10) (24 Required on Units 11,12,13) Function: To provide for the combustion of natural in the firebrick setting housing the lead pots (Items 203, 204, 205, and 206). Operstion: Continuous. Nozzles operate with 1# to 1-1/8# back pressure with 15# gas on the burner. Meterinis Handled: (The conditions stated were taken from Phosphate Dlv. Engineering Report No. 117. Actually, the burners are presently operated at approximately 25 psig. The actual quantity of gas being burned is not known.) Natural gas with about 15X excess air. (Ap proximately 2000 CFH @ 25C. and 760 ss of gas is required for each unit.) ( Controls: The burners servicing the converter pot are automatically regulated by a single point temperature recorder and controller activated by the temperature of the molten lead in the converter pot. The gas flow is also auto matically cut down when the benzol flow is cut down (Units 11, 12, and 13 only). The burners servicing the preheater are manually regulated by the operator to maintain the molten lead within the desired temperature range. The temperatures are recorded on a 12 point temperature recorder. Pressure gages are provided for indicating the gas pressure. Type: Surface Combustion tunnel burners with high pressure Inspirators. Size: \ #1333 tunnel burners. It" nozzle #1333 TN alloy tunnel retainers #224-B, type 1, burner adapter castings #N-54 high pressure inspirator sets #405 lighting hole assemblies DSV\f 462530 WATER PCB-SD0000050557 ICaa 207 Continued: Manufacturer: . Capacity: Materials of Construction: Reference: 52. Surface Conbustion, Toledo, Ohio 2850 CFH when burning natural gas at 20 psig Standard Bill of Material 5SM-87 DSW 462531 WATER PCB-SD0000050558 Ita* 208: Start-up By-Pass Stack (1-Repuired par Unit) 53. August 1957 Fanettan: Operation: Materials Handled: Controls: Size & Type: Manufacturer: Materials of Construction: Location: Reference: To provide a naans of by-passing the hot flue gases around the cold vaporizer prior to beginning the benzol feed. Used only daring start-ap periods. Hot flue gases fron the preheater and con verter units. The flue gases are diverted fron the exhaust stack to the start-up by-pass stack by aeans of a butterfly type valve. The stack is constructed in two sections, a lover stack and an upper stack. The lover stack is 2'-6n I.D. x ll'-O" high and has an adjustable damper over the top. It is voided vertically to the horizontal header betveen the converter units and the exhaust stack (Item 209). A butterfly type valve is installed in the horizontal header betveen the by-pass stack and the exhaust stack. The upper stack is 2'-0" I.D. x 29'-6" high vith a 4'-0*' I.D. x 2'-6" high funnel at the lover end over the lover stack. Southern Car & Manufacturing Co., Birmingham, Ala. The lover stack is 1/4" steel plate and the upper stack 3/16" steel plate. The stack is installed vertically vith its center 4'-ll" from the center of the final preheater. Drawing Monsanto Detail of Stack 9C-7845 DSW 462532 ...WATER'PCB-SD0000050559 I tea 209: Exhaust Stack (1-Required per Omit) 54. August 1957 Function: Operation: Materials Handled: Controls: Size & Type: Manufacturer: Materials ef Construction: Insulation: Location: 1. To provide s aeans for exhausting the flue gas frog the preheaters and con verter to the atmosphere. 2. To provide a means for passing the gas around vaporizer colls for heat recovery. Continuous except during start-up periods. Exhaust flue gases from the preheaters and converter. A door Is provided at the bottom of the stack for venting la air to cool the vaporizer coll when shutting down the diphenyl unit. Vertical stack lined with Insulating refractory and containing a stainless steel Inner shell, designed to give a maximum gas velocity over the vaporizer colls. The housing for the vaporizer Is split and hinged for access to the coll. Outer Shell: Inner Shell: Upper Stack: Snyder Tank Company Birmingham, Alabama Decatur Iron & Steel Company Decatur, Alabama Southern Car & Mfg. Company Birmingham, Alabama All mild steel with the exception of the Inner shell which Is Type 304 stainless. The horizontal gas header between the exhaust stack and the converter shell Is lined with 4%" of firebrick and the vertical vaporizer shell with 4" of Carey HI-temperature #19 cement. The center of the stack is 9'-ln from the center of the final preheater. DSW 462533 WATER PCB-SD0000050560 Item 209 Continued: Reference*: Insulation: Drawings Monsanto Detail of Stack Details of Vaporiser Shell 9C-7845 9C-9025 The horizontal gas header between the exhaast stack and the converter shell is lined vith 4%" of firebrick and the vertical vaporizer shell with 4" of Carey-Hi-temperature #19 cenent. DSW 462534 WATER PCB-SD0000050561 August 1957 Item 210: Lead Trap (1-Requlred par Pnlt) Function: Operation: Materials Handled: Size & Type: Manufacturer: Materials of Construction: References: To trap entrained lead coming over with the v benzol vapor from the converter. X Continuous. The trap is periodically cleaned out when necessary while the unit is shut down. Benzol and reaction products from the converter. X Entrained lead. Mew Design 24" dia. welded steel pipe 3'-l" long. Outlet is a 3" Crane #1545 fig. to a 8" x 3" E.X. reducer with an 8" 309 S.S. nozzle extending 1_4 into trap. Inlet is a 3" E.X. W.S. pipe, opening tangential to the trap and 9-9/16" down from top. Old Design 24" dia. W.S. pipe with 3" E.X. nipple on top for outlet with 3" Crane #1545 flange. Inlet is 3" E.X. pipe opening tangential to trap 9" down from top - 3" Crane #1545 flange. Callahan Grinding & Machine Company Anniston, Alabama Hew Design: 5/8" sides. %" bottom 3/4" top 309 S.S. outlet cylinder Old Design: 3/8" side. %" bottom 3/4" top Drawings Monsanto Lead Trap Details 9C-8143-4 OSW 462535 WATER PCB-SD0000050562 57. August 1957 I ten 211: Fractionating Column (1-Requlred per Quit) Function: Operatloa: Haterials Handled: 1. To function as a cool lag criluan to condense the vapors from the converter. 2. To utilise the heat in the vapors from the coaverter to effect a partial separation of the benzol frost the converted products. Continuous. The benzol fractionating column is a 12 plate bubble cap rectifying section with the feed la oa the bottom plate as super-heated vapor. The liquid crude diphenyl coatalaiag hi-boiler and liquid benzol is discharged from the bottom and benzol vapor and hydrogen from the top. The reflux is returned to the top plate. The column is operated vlth the top temperature below 100C. (The conditions stated were taken from Phos phate Div. Engineering Report Ho. 117. Actually, these columns are operated at rates greater than 1200#/hr.) Benzol vapor Diphenyl vapor Hi-boiler vapor Hydrogen gas 974 181 42 3 1200#/hr. Controls: Bottom - Liquid benzol Liquid diphenyl Liquid Hi-boiler Top - Benzol vapor . Hydrogen gas 14#/hr181 42 960 3 1200#/hr. The temperature of the top of the column and the sump are recorded oa the 12 point tempera ture recorder. The column is controlled by the operation of the condenser and split flow box. DSW 462536 WATER PCB-SD0000050563 211 Continued: Sire & Type: Manufacturer: Materials of Construction: References: 12 piste bubble cap rectifying column, 3'-0" dia. with 12" tray spacing. (Units 4,5 column is 2*-6" dis.) Plate spacing Ho. of plates Ho. of bubble caps per plate Cap diameter Slot area/cap. Total slot area/plate 12 in. 12 28 3" 3.43 in.2 0.666 sq.ft. Riser pipe - 2" O.D. x 10 BWG Riser pipe area/riser - 2.35 in.2 Total Riser Area^- 0.45 sq. ft. Liquid depth on plates Liquid height above slots Tower height 1.5" 0.5" 18' Hooter Boiler Works, St. Louis, Missouri <11, 12, 13) Leader Iron Works (6, 7, 8, 9, 10) A.S.T.M. specification A-283-46T Crace C (A-10) steel. Drawings Monsanto Fractionating column (Unit Ho. 2) Fractionating column (Unit Ho. 3) Fractionating column (Units Ho. 6 thru Ho. 12) 9C-5582 9SC-7279 9C-8131 DSW 462537 WATER PCB-SD0000050564 August 1957 Item 212: Benzol Condenser (1-Requlred per Unit) Function: Operation: Materials Handled: 1. To partially condense the benzol vapor from the top of the column. 2. To control the top temperature of the column at 100C. by sub-cooling the con densed benzol which Is refluxed to the column. Continuous. (The conditions stated were taken from Phos phate Dlv. Engineering Report No. 117. Actually, this equipment Is operated at higher rates than those stated.) Shell fluid - benzol vapor: 2900#/hr. (Usual rate under favorable conditions) Tube fluid - water: Usually operated at max. available pressure. DSW 462538 WATER PCB-SD0000050565 Item 212 Continued: 60. Beat Balance: Controls: Size & Type: The condenser duty for all the units should be substantially the same and should consist approximately of the amount of super-heat in the vapors from the converter less the amount of heat loss from the surface of the fractiona ting column. This duty has been calculated to be about 625,000 BTU/hr. average based on a study as reported in a memo to Hr. J. F. Reeves, 5/25/48 written by Hr. G. W. Jordan. The present system of control is to run the condenser with the water valve wide open and the split flow box adjusted to maintain the top of the column at 100C. The temperature of the cooling water and the efficiency of the condenser therefore deter mine the rate of benzol flow through the shell and the cooling water outlet temperature. This system of controlling has the advantage of simplicity but does not provide the most effective use of the condenser and cooling water. Summary Units Type Eff. Surface Shell Dla. No. Tubes Tube Dia. (O.D.) Pitch Tube Length 3 2,5 4,6,8,9 11.13 7.10,12 Vertical 70 14" Horizontal Horizontal Vertical 113 162 90 20" 14" 132 139 1" 5/8" triangle 13/16"sq. 72" 97-7/8" Vertical 207 10-3/4" 88 3/4" - - Kanufacturer: Andale Callahan Callahan Andale Struthers Wells qSW 462539 WATER PCB-SD0000050566 Itta 212 Continued: Units 32.5 4.6.8.9 11.13 7.10.12 Capacity: Opcr. Pres. - Tcbe? - Shell Max. Vk.Press.: - Tubes - Shell Max.Testp.: - Tubas - Shell 75# ga. 1# ga. 75# ga. 75# ga. 130F. 176F. 15# ga. 100# ga. 150# ga. 150# ga. 150# ga. 150# ga. 500F. 61. Materials o Construction: Shell Tubes Steel #10 BWG Steel #12 BWG Steel #12 BUG Steel #10 BUG Steel #16 BUG References: Drawings Monsanto Condenser Details, Sheet 1 Condenser Details, Sheet 2 (4,6,8,?) 9C-8157 9C-8158 Foreign Andals Condenser #13 X-A-36 type 206X Sketch #1261 Dug. #5845 Struthers-Uella Type H Group 3 Size 10 N12 DSVV 462540 WATER PCB-SD0000050567 Item 212 Continued: 62. The operating conditions of these condensers after physical cleaning in 19S6 vere as follows: Unit Ho. Benzene Feed Bate gal./hr. & Reflux Benzene Reflux Tamp. 2 3 4 5 6 7 8 9 it* 10 11 12 13 175 165 245 245 230 210 220 220 245 330 250 180 701 78C. 75 34 60 66 40 41 75 40 90 40 75 50 70 73 60 28 48 24* 75 42 85 42 Approximate Overall Vater, GPM Coefficient 0. (Old data frosi Rpt.117) (Old data from Report Ho.117) 80 90 35 170 95 65 80 90 95 65 -- 95 65 95 65 -- 75 250 -- 75 250 with column coll Ho. 9 condenser is mounted vertically dSNN 462541 WATER PCB-SD0000050568 63. August 1957 Item 213: Split Flow Box (1-Requlred par Unit) Function: To control the mount of liquid benzol returned to the column as reflux. Operation: Continuous. Ratio adjusted as necessary to maintain the top of the fractionating column below 100C. Materials Haadled: Liquid benzol. Controls: Mechanically indicated ratio adjusted manually by operator to maintain temperature of top of fractionating column below 100C. Temperature of runback indicated by thermo meter well. Sight glasses provided in reflux and runback lines for checking flow. Size & Type: The split flow boxes for Units 2 thru 5 are identical to the biphenyl still split flow boxes. Units 11-13 are provided with standard manu factured rotswelrs, figure 192-special, size 10 with one 2" horizontal inlet connection and two 2n vertical outlet connections. Units 6-10 are slightly dissimilar. Manufacturer: Units 6-13 furnished by Fischer & Porter Company, Hatboro, Pennsylvania Capacity: Outlets Capacities: Forward: Min. 100 GPH Horn. 150 GPH Max. 250 GPH Reflux: Min. 200 GPH Horm. 420 GPH Max. 750 GPH Materials of Construction: Cast iron fittings, stainless steel weir tubes and gears, and steel shells. DSW 462542 WATER PCB-SD0000050569 Itea 213 Continued: Location: References: 64. Located near top of column on condenser platform. Drawings Monsanto Layout Rotawelr & Condenser Split Flow 5u& Details Piping at Rotsvsir & Condenser Piping at Rotawelr & Condenser Details 9C-9055 9C-7836 9C-8163 9C-8164 Foreign 13" Rotaveir with netal shell Rotaveir Rotawelr 5-6727 6-11591 S-4228 DSW 462543 WATER PCB-SD0000050570 65. August 1957 Item 214: Carbarn Trap (1-Required per Halt) Function: Operatic*: Size & Type: Opening*: Manufacturer: Material* of Construction: Location: References: To trap any carbon and sludge in the sump product from the fractionating column. Continuous. The crude diphenyl is decanted through a side outlet in the trap and the carbon and sludge settled to the bottom from where it is drained periodically when necessary. A steel tank 18" O.D. x 3'-l-3/4" long with flat bottom and top. Top: 6" dia. XH nipple with flange, inlet. Side: 2" XH coupling, overflow. Bottom: 2" XH coupling, drain. Callahan Grinding & Machine Company Anniston, Alabama 3/4" steel plate, top 1/2" steel plate, bottom 18" O.D. x 3/8" thick W.S. pipe, side wall Bolted to bottom outlet of fractionating column. Drawings Monsanto Lead trap details 9C-8145 OS'N 462544 WATER PCB-SD0000050571 SERIES 300 - B1PHEHYL STILLS 66. August 1957 Item 301: Diphenyl Still (1-Requlred per Still) Function: Operation: Materials Handled: Controls: Services: Size & Type: Openings: Manufacturer: Capacity: Materials of Construction: Insulation: To provide a reservoir for heating the charge of crude diphenyl vhich is being distilled. Batchwise - tine required for distilling one batch is approximately 10 hours, depending on operator. Approximately 30,350# or 4,120 gal. of crude diphenyl per batch. A thermowell is provided for recording the temperature of the crude diphenyl. Steam to steam coils. (Biphenyl must be in liquid state before it can be circulated through still heater.) 7'-0" O.D. x 14'-0" long horizontal tank with dished heads. Par. 0-69 ASME construc tion. 3" opening for thermoveil 3" charging inlet 4" inlet from heating coil 10" vapor outlet 2n reflux inlet 22" opening for circulating pomp 22" opening for steam heating coll R. D. Cole Manufacturing Company 4300 gals. Tested for 50# pressure at 750F. 1/2" steel plate The still is insulated with 4" of rock wool, %" of Eagle 66 and covered with a sheet metal jacket. DSW 462545 WATER_PCB-SD0000050572 Item 301 Continued: Steam Coil: Reference*: 67. 1-1/4" pipe coil Drawing# Diphenyl Still Diphenyl Still Body Bill of Material Monsanto 9C-7873 9SC-2526 9BM-55 ( ( DSW 462546 WATER_PCB-SD0000050573 68. August 1957 Itw 302: Crude Diphenyl C Ironist lag Pump (1-Requlred per Still) Function: Operation: Materials Handled: Controls: Services: Size & Type: Manufacturer: Capacity: Motor: To cycle the crude diphenyl through the still and the heating coil of the gas fired heater. Continuous, during batch distilling operation. The crude diphenyl is returned to the still fro* the heating coil aad is recycled until the distilling operation is completed. Crude diphenyl Controlled manually by motor starting switch. The rate of flow is not controlled but al lowed to seek its maximum. Estimated 80 KWH per day (max.) Ho. 1 Still: Special Ho. 2, figure S1790 vertical, all iron, Rumsey soap pump with a 96" set length and provided with special water cooled stuffing boxes. Ho. 2 Still: 3" inlet x 2%" outlet, CV-5 vertical pump, figure 19,435 with cast iron water jacketed stuffing box where shaft passes through cover plate. Discharge pipe has stuffing box not water jacketed. Pump is of iron, 96" long from bottom of cover plate to end of pump inlet with inter mediate cast iron bearings in the column. Shaft is of steel. Impeller of cast steel. Ho. 1 Still: Rumsey Pump Company Ho. 2 Still: Taber Pump Company Ho. 2 Still: 200 GPM vs. 70' TDH Ho. 1 Still: Ho. 2 Still: 5 HP, 1750 RPM, 3 phase, 60 cycle, 220 v., vertical explosion proof 7% HP, 1750 RPM, 3 phase, 60 cycle, 220 v., vertical explosion proof motor. DSW 462547 WATER_PCB-SD0000050574 Item 302 Continued: Drive: Location: Reference: 69. Direct connected with flexible coupling. Located on diphenyl still. Drawings No. 1 Still Pump No. 2 Still Pump Bill of Material Taber F-246A 901203 9BM-55 DSW 462548 WATER_PCB-SD0000050575 C Item 303t Gas Fired Heater (1-Required per Still) 70. August 1957 Function: To supply the heat required for distilling the crude diphenyl. Operation: Continuous during batch operation. Materials Haadled: Crude diphenyl - rate: 200 GFM approx. Heat Duty: 400.000 BTU/hr. is the average net heat available from the still heater for heating and vaporising charge. Controls: The combustion rate of the fuel gas is con trolled automatically so as to raise the temperature of the liquid passing through the coil approximately 20 to 25C. (difference betveen inlet and outlet temperatures in the coil). ( Services: Natural gas - estimated requirement is 1.000 CFH @ 30C. and 760 mm (avg.) max. capacity approx. 3,200 CFH Site & Type: 4'-0" I.D. x 8'-3" high shell with an inner core and stack. Manufacturer: Chattanooga Boiler Works Materials of Construction: Steel outer shell, 304 S.S. inner shell Heating Coil: The heating coil consists of 18 turns of 2" W.I. pipe l'-6" in dia. (approx. 53 sq.ft, of outside heating surface). Gas Burners: The heater is fired with four Surface Com bustion #55 H.P. Inspirators with each inspirator supplying the mixture for two #1345 tunnel burners. Insulation: The steel shell ia lined vith 9" of H&W #111 firebrick. Location: Located at second floor level in the diphenyl plant machine shop immediately outside of ( the distilling rooms. DSW 462549 WATER_PCB-SD0000050576 Item 303 Continued: References: 71. Drawings Monsanto Diphenyl Still Heater Shell, #1 Still 9C-6372 Diphenyl Still Heater Shell, #2 Still 9C-8211 Stack Cover & Heater Core 9C-8078 Stack 9C-7939 Heater Shell Base SC-8230 Platforms & Supports 9C-8217 Bill of Material 9BM-55 < OSW 462550 WATER_PCB-SD0000050577 72. August 1957 Item 304: Still Column (1-Raqulrad per Still) Function: Operation: Materials Handled: Site & Type: To separate the crude diphenyl Into benzol, hi-boller, heads aad tails, and diphenyl. Continuous during batch operation. The vapors Iron the still enter the bottom of the column. The lover boiling fraction passes overhead to the total condenser and part re turned as reflux above the top plate. The high boiling fractions are returned to the still. The first product from the coluan is benzol, with the top of the column at 80C. The second product cut is taken until the crystallizing point of the distillate reaches 68.6C. The next fraction, diphenyl, is collected until the still pot temperature reaches 340-350C. and then the balance is diverted into the heads and tails tank. The high boiler, remaining in the still as residue, is pimped to the high boiler catch tank. Crude diphenyl vhich is separated approxi mately into the following fractions: Diphenyl High Boiler Benzol Heads & Tails Oil Material Lost 60.871 14.01 22.49 0.10 2.53 100.001 The still column is a 20 plate, bubble cap, rectifying column, 3'-0" I.D. x 25*-2" high. The plates are spaced 12" apart and each tray contains thirty-six (36) 3n dla. pressed steel bubble caps and two 4n dla. downspouts. DSW 462551 WATER_PCB-SD0000050578 Item 304 Continued: Openings: Manufacturer: Materials of Construction: Insulation: Reference: 73- Each plate la provided with two 10" die. hamdholea lm the ahell. The vapora from the atlll eater the column below the bottom plate through a 20" dla. combination man hole and vapor Inlet. The lover boiling producta leave the top of the column through a 16" dla. manhole which la reduced to a 6" dla. vapor pipe. Reflux eaters through a 3" nozzle above the top plate and the over flow from the bottom tray is returned to the still through a 3" line. Leader Iron Works Company Steel The column la insulated with 4" of rock wool, of Eagle 66, and covered with a sheet steel jacket. Drawings Monsanto Diphenyl Still Column 9C-7870 Bill of Material 9BM-55 DSW 462552 WATER_PCB-SD0000050579 74. August 1957 It-- 305; Diphenyl Still Condenser (1-Requlred par Still) Function: Operation: Hater1*1s Handled: Heat Duty: Site A Type: Hoxxles: Manufacturer: Materials of Construction: Insulation: References: To condense the overhead vapors from the still col--n. Continuous during batch distilling operation. The cooling water makes 8 passes through the tubes and vapors condensed outside of the tubes. Tubes Shell 70 GPK City Water 4080#/hr. benzol. Shell fluid temp. - In: 176F. Out: 176F. Tube fluid temp. - In: 130F. Out: 150F. LHTD: 34F. Daty: 690,000 8TU/hr. Overall heat transfer coefficient: 100 Total effective surface: 200 ft.2 200 sq.ft, horizontal, floating head, re movable tube bundle condenser with 25" O.D. shell and 152 tubes 1" O.D. constructed of #12 BWG tubing and pitched li". The shell has been enlarged to the same size as the floating head bonnet and a special outlet added to insure complete drainage of each product from the condenser. Shell: Inlet 6" Outlet 2" Tubes: Inlet 3" Outlet 3" R. D. Cole Manufacturing Company Steel Shell Insulated with 2" rock wool, %" of 66, and covered with a sheet metal jacket. Drawings Monsanto Condenser Bill of Material 9C-7872 9EK-55 DSW 462553 WATER_PCB-SD0000050580 75. August 1957 It-- 306: Split Flow Box (1-Requlred psr Still) Function: Operation: Katerlals Handled: Controls: Services: Size & Type: To control the mount of condensate re turned to the columa as reflux. Continuous during batch distilling operation. The condensed vapor frost the condenser Is dis charged into a basket Installed inside of a container with the bottom partitioned into 2 outlets. The basket has holes drilled in the side so that by rotating the basket the discharge from the holes auy be directed to either side of the bottom partition in the shell. The split flow box la usually operated on a 1:1 reflux ratio. Heat is supplied from a snail heating coil when the diphenyl fraction is being distilled. All of the overhead products from the column pass through the split flow box. The reflux ratio is controlled by a selector lever setting the position of the basket in relation to the partition between the 2 out lets. The control of the basket is extended to the still operating floor by neans of a shaft and gears so that the reflux ratio may be changed during a distillation without ascend ing to the condenser platform. Steam for the heating coil. Shell casing: Basket: 18" O.D. x 18" high gas tight casing with dished heads. 12" I.D. x 6^" deep vith a 9" I.D. concentric screen parti tion. The basket has 19 equally spaced ^;n dia. holes 7 apart. DSW 462554 WATER_PCB-SD0000050581 Item 306 Continued: Openings: Manufacturer: Capacity: Materials of Construction: Gaskets: References: 76. August 1957 Two 2" X.H.W.S. pipe outlets in the bottom, one for reflux and the other for the product. A 5/16" plate partitions the reflux side of the shell casing from the product side. One 2" X.H.W.S. pipe side inlet for the con densed vapors from the condenser. One 2" X.H.W.S. pipe side nozzle for vent through flame arrestor and conservation vent. Three 5-5/8" I.D. sight nozzles using Pyxex glass. Two located on top and one on the side for observing the flow from the basket. Stuffing box and gland 1-3/4" I.D. centrally located on top for selector lever shaft. Fischer and Porter Company 800 GPH normal capacity 1600 GPH maxi sum capacity The split flow box is made of steel except basket, screen, and packing gland which are made of monel metal. Gaskets are #901 Garlock, ring type, 1/16" thick and must not swell when handling hot diphenyl or benzol. Drawings Monsanto Split Flow Box Details 9C-7836 Bill of Material 9BM-55 DSW 462555 WATER_PCB-SD0000050582 77. August 1957 Item 307: Head & Tails Catch Tank (1-Rcquircd per Still) Function: Operation: Materiala Handled: Controls: Servlcea: Sire & Type: To provide a catch tank and storage for the heads and tails distilled front the crude diphenyl. After the bersol fraction has been distilled off the crude diphenyl, the next fraction distilling between 80, a held point of 68.6C. is diverted to the heads and tails catch tank. After most of the diphenyl has been distilled and the temperature in the still reaches about 30QC., the flow is changed again to feed into the heads and tails tank. The heads and tails that were collected are returned to the diphenyl still for re distillation with the next batch. The small amount of heads and tails oil left over is discarded. The "heads" are light oils with boiling points nearing that of diphenyl and the "tails" is diphenyl containing a little hi-boiler fraction. The heads and tails as collected is mainly diphenyl, which is recovered on redistillatiom. The amount of heads and tails oil produced is very small, consisting of only about 0.1X of the crude diphenyl. The heads and tails tank is provided with a 4" gaging hatch for measuring the level in the tank. Steam for heating coll. 5'-0" O.D. x 5*-0" high vertical tank with flat top and dished bottom. OSVN ^2656 WATER_PCB-SD0000050583 Item 307 Continued: Opeaiaga: Steam Coll: Capacity: Iaaulatloa: Referaace: 78. The task la provided with a 4n imlet aozzle, a 4" vest, a 22" I.D. aozzle for a aump pomp, a 4" gaglag hatch, aad a ateam heatlag coll lalet aad outlet. The ateam coll coagistf of about 30' of 1%" dla. ataadard aeamleaa pipe. 800 galloaa The aldea aad bottom of the taak are iaaulated with 2n of rock wool, a of Eagle 66, aad covered with a aheet metal jacket. Dravlaga Moasaato Heada & Telia Catch Taak 9C-7876 DSW 462557 WATER_PCB-SD0000050584 79. August 1957 Item 308: Head sad Tails Retura Pump (l-Rcquired per Still) Fuactloa: Operatloa: Materials Haadled: Coatrols: Services: Sire & Type: Kaaufactursr: Materials of Coastructioa: Motor: Drive: Lecatlem: Refereace: To returm the hesds sad tails frost the catch taak to the still for redistllletloa. Periodic Heads aad tails fractloa from crude dipheayl distillatloa. Kaaually comtrolled by motor startlag switch. Estimated 3 KWH per day (maximum) 2%n x 2" CL-4 vertical sump pump, 5'-6" loag Taber Pomp Compaay Iroa casiag with steel shaft aad cast steel impeller. 3 HP, 1750 RFM, 3 phase, 60 cycle, 220/440 v., TEFC explosioa proof vertical motor with riag base. Direct drive with flexible coupllag. lastailed la heads aad tails taak. Bill of Material 9BM-55 os\N 462558 WATER_PCB-SD0000050585 80. August 1957 I teat 309: Diphenyl Catch Tank (1-Requlred per Still) Function: Operation: Materials Haadled: Controls: Services: Sire & Type: Openings: Capacity: Materials of Construction: Insulation: Reference: To receive the diphenyl fraction from the crude diphenyl distillation. The operator sets the swivel flow box to deliver to the diphenyl catch tank after the hold point of the distillate reaches 68.6C. The flow is changed again from the diphenyl catch tank to the heads and tails catch tank after the temperature in the still reaches 300C. Distilled diphenyl The tank contains a thief hatch for sampling the diphenyl. Steam to steam coll. 7'-6" I.D. x 6'-0" high vertical tank with a flat top and dished bottom. The tank is provided with a 4" inlet, a 4" vent, a 22V1 I.D* nozzle for a sump pump, a 16'* dla. manhole, and a 6" thief hatch. 2100 gallons. 1/4" steel tank The sides and bottom of the tank are insula ted with 2" rock wool, a 1/2" of Eagle 66 and covered with a sheet metal jacket. Drawings Monsanto Diphenyl Catch Tank 9C-7877 DSW 462559 WATER_PCB-SD0000050586 81. ( August 1957 Itaa 310: Distilled Diphenyl Transfer Pump (1-Required per Still) Function: To deliver the distilled diphenyl from the diphenyl catch tank to the diphenyl storage tanks. Operation: Operated at the completion of the batch distillation. Materials Handled: Distilled diphenyl at approx. 100C. Controls: Manually controlled by motor starting switch. Services: Estimated 15 CWH per day (maximum) Size & Type: No. l^B, figure S 1790 vertical sump pump with a length of 7'-3M. Manufacturer: Rumsey Pump Company ( Materials of Construction: Iron Motor: 3 HP, 1750 RPM, 3 phase, 60 cycle, 220 volt, vertical explosion proof General Electric motor. Drive: Direct connected by flexible coupling. Location: Installed in diphenyl catch tank. Reference: Drawing Foreign Rumsey Pump F-246-A ( DSW 462560 WATER_PCB-SD0000050587 SERIES 400 - IHSTROMEKTATIOK 82. August 1957 Item 401; Automatic Let-Dow Level Comtrol (1 Oait For Each Feud Tuk) Fuactioa: Operatloa: Type: Haaufacturer: To automatically maiatain a supply of beazol la the feed task aad to souad aa alarm la case of high or lov level. The operator must naaually select one of the five storage tasks from which to feed. A five-poiat pump switch located at the feed task is provided for this purpose which places the system ia automatic coatrol to feed from that particular storage teak selected. The automatic coatrol system maiataias the level of the beazol ia the feed task withia a raage of 6" with the high level'9" below the top of the task. "If the system fails iad the high or lov level exceeds this raage by 3", aaalanaii souaded by a separate level coatrol system. Special TF-2 EP taadem magaetrol coatrol with glass float. Twb'uaits'are required, oae for coatrol aad oae for the alarm. Fred H. Schaub Eagiaeeriag Compaay, lac. Chicago, Illiaois DSW 462561 WATER_PCB-SD0000050588 c Item 402: Benzol Feed Comtrol 83. August 1957 Fumctiom: Ramge: Type: Maaufacturer: To automatically meter a specified quaatlty of bemzol to each uait. 0-400 GPH - Oaita 4 through 13 0-250 GPH - Omits 2 ad 3 Each comtrol comsists of: 1 - 12" M/10 Stabilog flow comtroller type 7115 1 - S.l. orifice plate for 1" lime 1 - 1" A6A S 30 orifice flamge 1 - Set liquid meter pipimg 1 - V* comtrol valve, code 32110 BA 1 - Set liquid seal chambers Poxboro ( ( DSW 462562 WATER_PCB-SD0000050589 84. August 1957 I teal 403: Twelve Point Temperature Recorder Function: Range: Type: Manufacturer: To record the following temperetures: 1 - vaporizer coil outlet, inaer and outer coils (if double coil unit) 2 - exhaust flue gas to vaporizer - islet asd outlet 3 - No. 1 preheater pot 4 -No. 2 preheater pot 5 - top of fractiomatimg column 6 - condenser water outlet 7 - benzol "run-back" from condenser 8 - bottom of fractionating column sump 0-1000C. #40362-17-special model microraax tempera ture 12 point indicating recorder. Iron - Constantin #8759-S thermocouples Leeds and Northrop DSW 462563 WATER_PCB-SD0000050590 85. ( August 1957 Item 404: Slagle Polat Temperature Recorder sad Costroller Fuactioa: Raage: Type: Maaufacturer: To ladlcate, record, amd comtrol the temperature of the converter by regulstlmg the sstursl gss burners. 100-1100C. #40617-A2-H-83 Model S Microaax tempera ture ladlesttag aad recordlag coatroller. Paeoaatic coatrol - Automatic droop correctloa - Motor 110 v. 60 cycles 3/4" Masoa-Heilaa paeurnstic valves Masoa-Heilaa valve reposltioaers with air sets aad parts. Ho. 8755 Iroa-Coastaatia pipe type thermo couples with staadard 778A elemeat aad P1-181A head, 66" loag Leeds aad Horthrup 0SW WATER_PCB-SD0000050591 86. August 1957 Item 405: Natural Gas Meter Function: Typ: Manufacturer: To record the quantity of gas consumed per ualt er still. Ho. 35 B Metric iroa case meter for matural gas service. Top coaaectioas. Maximum working pressure 100#. Americas Meter Company OSW 462565 WATER_PCB-SD0000050592 87. ( August 1957 Iteai 406; Temperature Recorder - Dlphemyl Still (1-Rcqulred per Still) Fumctiom: Type; Kamufacturer; To record the following temperatures: 1 - still body 2 - still imlet 3 - outlet - circulating 1Lme 4 - top of columm 5 - reflux to coluaa 6 - comdexaer vater-out. #40356-55M-special Micromax 6 poimt 115 . 60 cycle temperature recorder Leeds amd Horthrup f ( DSW 462566 WATER_PCB-SD0000050593 88. August 1957 Item 407: Temperature Control Still Beater Function: Type: Kanufacturer: To control the temperature dtffereace between the heater lmlet aad outlet by regulatlag the gaa burners. #40617 A3 - Model S Micromax single point recording temperature controller Mnson-Heilam #30 valve repoeltioners vith 3/4" pneumatic valves, air sets and parts. Leeds and Horthrup DSW 462567 WATER_PCB-SD0000050594 89. ( August 1957 I test 408: Blphearl Palt - Automatic Safety Switches for Hatural Gss (1-Rsqulred par Oalt) Fumet to*: Maaufacturer: To protect the equipmeat la the eveat of aa eaergeacy, by topptag the flow of astural gas to the Ho. 2 preheater whea the temperature exceeds a predetarataed maximum. Foxfccro - Foteatiometer Coatroller ( ( DSW 462568 WATER_PCB-SD0000050595 SERIES 500 - UTILITIES 90. August 1957 Item 501: Lightiag The dlpheayl bulldlag housiag the coaversioa uaita is provided with slightly better them geaeral lightleg. The lights ere stamdard lights with reflectors. The two still rooms are provided vith geseral lightiag utillzlag Appletoa Electric Compaay Cat. #26537 explosioa proof peadamt fixtures vith shallow done reflector. V* hub size, 200 vatt lamps. The hydrogea compressor room has ao lightiag facilities la the room but receives its lightiag from the outside from special explosioa proof lights shlaiag through the vIadova. DSW 462569 WATER_PCB-SD0000050596 C Itesi 502: Power Wlriag 91. August 19S7 The smxIjbusi coaaected horsepower Is shout 180 HP sad the dally power coasuaptioa about 1845 Etf average at full productioa capacity. Wiriag, relay switches, traasfoners, etc., are provided eccordiag to staadard electrical practices. The coatrel paael is located outside the buildiag ia a special eaclosere. ( ( DSW 462570 WATER_PCB-SD0000050597 t Itea 502 Coatlaaed: oe m <L $8 o M o --i --U< l *o O.W 8M' 8 $? t-l H<-> HWaOw ,13 to .a a w cn 33o i > a. o at cl ACL O 9 V. u A >r. ri AA a. cl --< QQ W K 5 M5 ^ M X E *o 01 M u0 rM o > pa o as m o H r-l o Hd o -3- o St CM CM O o o in r <C o r- r>. r-* r** H co H < n H H H o--^ >M r-M MO CM 0 O1 CO O mT mJ* o^ CM O CM CM CM OO mm r* r*^ HH oo CM CM CM CM oO *r* m r-4 r- CM m t--n4 m H o <* Oo O CM CM CM CM CM CM O oo O n iO *> m d r-. rH rW^~t ( A21.! n /-V /*N n CM o * o O C-- r- ir> in \r\ co CO CO m -m r- cm co 0 -< cm cm <o i, CL o. 9 CL CL A9, B9 o PL to a w pL n 3a3 M o --Ooa< Hawa N Aft ao a CL B o a to e aa eKa - aa 9 CL > 6 o pi H o M m A CaL 9 Cl tao rC to a 9o CaL r-l * m9 cw/5 CaL 9 04 to a cl as a cl H 0M U0 U -4 >t4 oo m H r4 jd 4o1 itd4 CaL 9 CL a 9 Ums CL Cl > #-4 bo r4 0 Cl o. f5i * fgc* 9 0 H P* Pi V< * 0 <0 HoN00 A *Col A 04 0 0 u H 0 r4 A 0o J c Ot-< Oco Or- CM *- O CM co -h n co o ^ ChM On nH ChM 92 DSW 462571 WATER_PCB-SD0000050598 Item 503: Product Plplmg The bemrol amlomdlmg plplmg *md tramsfer plplmg Is steam traced sad Imsalated. All prodact plplmg lmcladlmg crude dipheayl, high boiler, smd distilled dlphemyl are steam jacketed amd provided vith "homemade" diaphragm expeastos jolmts betwees all comaectloms. The prodact plplmg from the cmrbom traps amd the split flow boxes are comstracted to form a deep liquid trap to prevemt hydrogem from vestlag lmto the feed or catch tamks from the colomm. Plplmg Is provided for the hydrogem gas from the split flow boxes amd comdemser to the hydrogea coolers amd compressor room. 93. DSW 462572 WATER_PCB-SD0000050599 94. August 1957 Item 504: Water Piplag Coollag water piplag is provided from the Pleat water mala pump to the coadeaaera aad the hydrogea coolers. The return piplag from the various ualts termlaate la a cooanoa header for dralaage back to the geaeral pleat coollag poadY The water from the coollag poad Is stralaed aad pumped back to a coollag tower. The water from the coollag tower Is piped back to a booster pump for reuse. City water pipli^g is provided for driakiag purposes aad for the eaergaacy showers placed at strategic poiats throughout the bulldiag. DSW 4625^3 WATER_PCB-SD0000050600 Item 505: Fuel Gas Piplug Fuel gee pipLeg is provided to the preheaters aed coaverters aed to the gas fired heaters. Ae iudividual gas meter is provided la each liae. 95. August 1957 Item 506; Steam Llees Steam llees are provided to all the jacketed product llees aed to the coils le the catch aed storage tasks, aed to the split flow box. Also, a coeeectloe is provided to the recirculated vater system. Steam is provided at 90-100# pressure. Qcyy 462574 WATER_PCB-SD0000050601 96. August 1957 Item 507: Bulldlmg The dlphemyl omits, crude dlphemyl stills, compressor room, Aroclor plmmt, comtrol roams, offices mmd mmchlme shop mre mil located la m 3-story stmmdmrd mill bulldiag with m ome-story lesm-to om each side. The malm buildimg sectiom measures 60' z 220', total area 110' x 220' ` accoumted for by a 20' leam-to om the vest side amd 10' camopy om the east side over the loadimg platform. Am area measur lag 100' x 180' at the south emd Is allocated to dlphemyl operatioms. Comstructlom is of steel throughout with hollov tile amd stucco outside vails.' Fire wills sad fire doors separate the dlphemyl umits lmto three groups amd separate the dlphemyl stills from each other amd from the rest of the plamt. DSW 462575 WATER_PCB-SD0000050602 i Item 508: Sewers 97. August 1957 .. Item 509: Fire Protectiom Equlpaeat ( Itf" 510: Grouads d Gemersl Ares_ ( DSW 462576 WATER PCB-SD0000050603 98. August 1957 Item 511: Painting The control piping is painted with distinguishing colors: blue for water, green for natural gas, and orange for benzol. Storage tanks are painted with one shop coat (outside only) of blue lead as per Monsanto specification #1007. Iten 512: Insulation Item 513: CO? Piping DSW 462577 WATER_PCB-SD0000050604 P /p /I/{,: S / 'P P f r f / l A/YD. i itrZ-s-?' DSW 462579 I` WATER_PCB-SD0000050606 99. t August 1957 1: Flowsheets sad Diagrams B-5114 C-5240 C-5440 C-6258 C-6374 C-6830 -*>831 A-7812 9C-7850 9C-7851 9C-7875 9C-8466 9C-8546 Biphenyl Plant Flow Sheet Diagrammatic Layout Temperature Pressure Curves for Mercury, Diphenyl Diphenyl Plant Layout Diphenyl Plant Layout General Layout June 1935 Diagramaatic Flow Sheet Heat Balance on Ho. 3 Unit Diagrassatic Flow Sheet for 4 Pot Unit Diagrammatic Flow Sheet for 2 Pot Unit Diphenyl Still Diagrammatic Flow Sheet Diagrammatic Flow Sheet Showing Prin. Equipment and Control System Map Diphenyl Area Vater 2: General Plant Details of Steam Jacket Expansion Joint 9AA-9058 Thermo-well Detail 9AA-8832 Preheater Pot and Head Reaction Pot C-4092 ( Preheater Terminal Bars Cast Alloy Reaction Pot B-4012 B-4052 Typical Diphenyl Unit C-4061 Detail Reaction Pot B-5205 Detail Pot Cover and Flange C-5233 Chrome Steel Fittings for Lead Pots C-5234 Detail Beams and Counter Fortes C-5235 Lead Pot Setting C-5236 Details of Fractionating Colons C-5237 Converter Unit - Plate Structure Work C-5238 Converter Unit Structure Frame Diph. Col. & Condenser C-5239 Hanger for Lead Pot Flange AA-5299 Gooseneck for Still Connection AA-5541 Hlne Pass Expt. Tubular Converter Unit Brickwork C-5760 Reaction Cover C-5883 Diphenyl Distributor Pipe AA-6333 Gasket for Benzol Still A-6497 Stainless Steel Distributor Cup for Converter AA-6699 Cover for Reaction Pot C-6714 Lead Bath and Ser. Converter Units C-6815 Vater Piping at Top Platform for 4 Units C-7861 Fire Protection for Still and Benzol Tanks C-7893 Fan for Diphenyl AA-8061 Detail Cast Steel Pot Cover 9C-8166 ( DSV'J 462580 WATER_PCB-SD0000050607 100. All Welded Pipeline Insulation end Jackets for Goosenecks Detail of Goosenecks Cover Plate Detail for Reaction Pots AA-8531 9C-9085 9C-8147 9C-9019 3: Benzol Storage Benzol Underground Storage, Wooden Pump House Benzol Storage Tank Relocated Above Ground Detail benzol Storage Tank Above Ground Benzol Storage - Pomp Platform, Piping at Tank Benzol Storage Tanks, Cyclone Fence Benzol Storage Tank, Hev Layout Benzol Storage Tank, Detail Benzol Storage Tanks 3, 4, 5 C-6259 C-6668 C-6669 C-6685 C-6691 9C-7960 9C-7961 9C-8252 4: Benzol Feeding Feed Tank and Pump Foundation Sump Tank Feed Tank Cover, Pipe Trough and Supports & Misc. Steel Benzol Feed Tanks, Piping Layout Benzol Feed Tanka, Piping, Supports & Jacket Benzol Feed Pumps, Piping and Fence Handrail for Benzol Feed Tank Alterations to Pump Plate at Benzol Feed Tanks Fence for Benzol Tanks Piping for'Benzol Pumps 5 and 6 Benzol Feed Tank Platform Benzol Piping Inside of Building Detail Housing Detail Housing Benzol Feed Tanks, Layout Benzol Feed Tanks, Detail Piping from Building to Tanks Piping at Control Room Piping at Building Line Benzol Feed Tank Foundation, Sheet 1 Benzol Feed Tank Foundation, Sheet 2 9C-7857 9C-7858 9C-7859 9C-7862 9C-7863 9C-7864 9C-7898 9C-8149 9C-8153 9C-8154 9C-8200 9C-8201 9C-8202 9C-8203 9C-8205 9C-8206 9C-8207 9C-8208 9C-8209 9C-8250 9C-8251 5: Units 1 and 2 ' C-5241 C-5580 AA-5581 C-5582 C-5583 Preheating and Vaporizing Coils Diphenyl Plant 2nd Unit - Reactor Pots Diphenyl Plant 2nd Unit - Detail Special Brick for Converter Unit and Traps Diphenyl Plant 2nd Unit - Detail of Fractionating Column Diphenyl Plant 2nd Unit - Setting for Converter Unit DSW 462581 WATER_PCB-SD0000050608 101. C-5584 C-5585 B-5586 C-5587 C-5588 C-5589 B-5590 C-5591 C-5592 C-5593 C-5594 C-5595 C-5596 C-6841 AA-7337 9C-7551 9C-7900 Diphenyl Plant 2nd Dnlt - Door and Burner Castings Diphenyl Plant 2nd Unit - Steel for Converter Unit Diphenyl Plant 2nd Unit - Stack for Coav. Salt and Location Burners Diphenyl Plant 2nd Unit - Stainless Steel Piping at Coav. Unit Diphenyl Plant 2nd Unit - Elev. Steel Work Around Coav. Unit Diphenyl Plant 2nd Unit - Plan Steel Work Around Coav. Dnlt Diphenyl Ple-t 2nd Dait - Foundation for Conv. Unit and Steel Platform Diphenyl Plant 2nd Dait - Layout of Subway Grating and Handrail on S. G. Diphenyl Plant 2nd Dait - Inside Fittings for Frac tionating Column Diphenyl Plant 2nd Dnlt - Gas Piping for Conv. Dnits Diphenyl Plant 2nd Dait - Hot Water Storage and Heating System Diphenyl Plant 2nd Dait - Layout of Auxiliary Piping Diphenyl Plant 2nd Dnlt - General Layout Diphenyl Plant 2nd Dnlt - Benzol Vaporizer for No. 1 Dnlt Dlpheayl Plant No. 1 Dnlt - Conn, to Lead Trap Diphenyl Plant No. 2 Dnlt - Detail Supports for Cond. and Flow Box Diphenyl Plant No. 1 Dnlt - Piping at Lead Trap 6: Unit No. 3 C-7279 C-7280 C-7281 C-7282 C-7283 C-7284 C-7285 C-7286 C-7287 AA-7322 9C-7335 9C-8139 Fractionating Column for Dnlt No. 3 Dnlt No. 3 - Diphenyl Still Dlpheayl Plant - Dait No. 3 Dlpheayl Plant - Dait No. 3 Steel Elev. Dlpheayl Plant - Dait No. 3 Steel Sections Dlpheayl Plant - Dait No. 3 Evaporator sad Stack Dlpheayl Plant - Dait No. 3 Lead Traps Dlpheayl Plant - Dait No. 3 Assembly Plana Dlpheayl Plant - Dnlt No. 3 Assembly Elev. Dlpheayl Plant - Dnlt No. 3 Adapter Flange - Coad. to Split Flow Box Diphenyl Plant Split Flow Box Installation oa Diphenyl Still Column Dlpheayl Plant - Dait No. 3 Cooling Colls for Column 7: Halt No. 4 9C-7830 9C-7831 9C-7832 Dait No. 4 General Assembly Dnlt No. 4 Burner Setting Dait No. 4 30" Dia. 12 Plate Fractionating Column DSW 462582 WATER_PCB-SD0000050609 102. 9C-7833 9C-7834 9C-7835 9C-7836 9C-7837 9C-7838 9C-7839 9C-7840 9C-7841 9C-7842 9C-7843 9C-7844 9C-7845 9C-7846 9C-7847 9C-7848 9C-7849 9C-7852 9C-7855 9C-7856 9AA-7860 9AA-7865 C-7866 C-7867 C-7869 C-7935 7936 7937 9AA-7955 8: Unit Mo. 9C-7970 9C-7971 9C-7972 9C-7973 9C-7974 9C-7975 9C-7976 9C-7977 9C-7978 9C-7979 9C-7980 Unit Ho. 4 Shell for Converter Ualt Ho. 4 Gee Piplag to Burners Ualt Ho. 4 Pip lag at Top of Cola. 1 and 4 Ualt Ho. 4 Split Flow Box Details Ualt Ho. 4 Fire BrickSettlag Unit Ho. 4 Lead Traps Ualt Ho. 4 Heat Exchaagar Ualt Ho. 4 Vaporiser Ualt Ho. 4 Section aad 2nd Floor Plan Ualt No. 4 Section aad 3rd Floor Plaa Ualt He. 4 Floor Gratlag Ualt Ho. 4 Holes for Burners In Shell Unit Ho. 4 Stack & Connection to Vaporizer Ualt Ho. 4 Reaction Pot Asseably Ualt No. 4 Reaction Pot Detalla Ualt No. 4 Carbon Trap Ualt No. 4 Piping at Converter Ualt Ualt Ho. 4 Piping at Suap Tank Unit Ho. 4 Condenser, "Trap, aad Flow Box Support Unit Ho. 4 Foundations Unit Ho. 4 Condenser Support Ualt Ho. 4 Burner Adapter Unit Ho. 4 6" dla. Coll. Main for Ventilating Suap Tanks Unit Ho. 4 Gas and Benzol Feed Unit Ho. 4 Support for Vaporizer Unit No. 4 Fractionating Col. Jacket Unit No. 4 Eaerg. Pipe Conn. Carbon Trap to Col. Unit No. 4 Alterations to Reaction Pot Ualt No. 4 C. Steel Pipe Flanges Unit Ho. 5 Layout Ualt Ho. 5 Steel Supports Ualt Ho. S Steel Supports Unit Ho. 5 Floor Gratlag Ualt Ho. 5 Detail Sheel For Converter Ualt Ho. S Burner 4 Lighting Holes Converter Unit Ho. 5 Pipe froa Converter Ualt Ho. 5 Detail Pipe - Cols, to Suap Taak Unit Ho. 5 Gas Piping to Burner Unit Ho. S Detail of Piping Unit Ho. 5 Benzol Feed Control Piping nsW 462583 WATER_PCB-SD0000050610 103. 9: Unit Ho. 6 9C-8131 9C-8140 9C-8141 9C-8142 9C-8143 9C-8144 9C-8145 9C-8146 9C-8147 9C-8148 9C-8150 9C-8151 9C-8152 9C-8155 908156 9C-8157 9C-8158 9C-8159 9C-8160 908161 908162 9C-8163 9C-8164 Unit Ho. 6 Detail of Fractionating Colon Unit Ho. 6 Layout Unit Ho. 6 Foundation Unit Ho. 6 Structural Steel Unit Ho. 6 Lead Traps Unit Ho. 6 Piping at Col. and Cond., etc. Unit Ho. 6 Detail Converter Shell Unit Ho. 6 Layout S.S. Piping at Converter Unit Ho. 6 Detail S.S. Piping at Converter Unit Ho. 6 Assembly of Preheater Unit Ho. 6 Vaporizer Details Unit Ho. 6 Firebrick Setting Unit Ho. 6 Detail of Sump Tank Unit Ho. 6 Burner Setting Unit Ho. 6 Gas Piping to Burners Unit Ho. 6 Condenser Unit Ho. 6 Condenser and Covers Unit Ho. 6 Vaporizer Manhole Frame and Cover Unit Ho. 6 Piping and Layout for Sump Tank Unit Ho. 6 Detail of Vaporizer Coils Unit Ho. 6 Diphenyl Line to Sump Tank Unit Ho. 6 Piping at Rotaweir and Condenser Unit Ho. 6 Piping at Rotaweir and Condenser Details 10. Units 7. 8. 9. 10 9C-8190 9C-8191 9C-8192 9C-8193 9C-8194 9C-8195 9C-8196 9C-8197 9C-8198 9C-8199 9C-8202 9C-8203 9C-8467 Units 7, 8, 9, 10 Layout Units 7, 8, 9, 10 Details of Vaporizer Shell Units 7, 8, 9, 10 6000 Gal. Catch Tank Units 7, 8, 9, 10 Layout Crude Catch Tanks Units 7, 8, 9, 10 Layout Diphenyl Piping Units 7, 8, 9, 10 Details Diphenyl Piping Units 7, 8. 9, 10 6000 Gal. Catch Tank Foundation Units 7, 8, 9, 10 6000 Gal. Catch Tank Pit H.R. Units 7, 8, 9, 10 Platform Sheet 1 ' Units 7, 8, 9, 10 Platform Sheet 2 Units 7, 8, 9, 10 Detail Housing Units 7, 8, 9, 10 Detail Housing Dlpheayl Units 6, 7, 8, 9, 10 11. Pnlts 11. 12. 13 9C-9021 9C-9022 9C-9023 9C-9024 Diphenyl Onits 12 and 13 Details Col. Fdas. Diphenyl Onits 11, 12, & 13 Converter Shell Det. Diphenyl Unit 11 Structural Framing Vaporizer Coil Detail SVV462584 WATER PCB-SD0000050611 104. i 9C-9025 Vaporizer Shell Detail 9C-9026 Vaporizer Assembly Units 11, 12, and 13 9C-9054 11, 12, and 13 Gaa Piping to Burners 9C-9055 Layout Rotaveir and Condenser 9C-9056 Diphenyl Piping Lead Trap to StorageTank 9C-9059 Units 11, 12, and 13 Pipe & Support Details-Rotaweirs and Cond. 9C-9069 11, 12, and 13 Layout Benzol Runback Lines 9C-9014 Plot Plan Units 1, 11, and 12 9C-9015 Layout Units 1, 11, and 12 9C-9017 12 and 13 Structural Steel Framing 9C-9018 12 and 13 Structural Steel Framing 9C-9019 Unit Assembly and Details Preheater 12: Hydrogen Compressor C-7363 Layout of Hydrogen Compressor C-7364 Hydrogen Compressor Structural Steel for Building C-7365 Hydrogen Compressor Room C-7366 Hydrogen Compressor Room Wiring & Control Piping Diag. C-7367 Hydrogen Compressor Tanks C-7370 Compressor Room Foundation Flan C-7901 Relocating Hydrogen Condensers C-8014 Layout of Hydrogen Compressor Platform ( C-8040 C-8132 Layout and Detail Hydrogen Pipe from Cond. Ext. to Hydrogen Compressor Room Plans & Elev. of Bldg. C-8133 Ext. to Hydrogen Compressor Room Struc. Steel for Bldg. C-8134 Ext. to Hydrogen Compressor Room Layout C-8165 Hydrogen Compressor Wiring and Piping Diagram C-8179 Hydrogen Compressor Plan and Elev. Bldg. C-8180 Hydrogen Compressor Floor Plan Sec. and Detail C-8181 Hydrogen Compressor Detail Door Frames C-8182 Hydrogen Compressor Foundation Plan and Sections C-8188 Hydrogen Compressor Layout and Piping C-8189 Hydrogen Compressor Details and Bill of Material C-8279 Units 7, 8, 9, 10 Layout of Hydrogen Piping 13: Crude Diphenyl Storage 9C-8152 9C-8160 9C-8162 9C-8174 9C-8175 9C-8176 9C-8192 9C-8193 9C-8194 9C-8195 Detail of Sump Tank Piping and Layout for Sump Tank Diphenyl Line to Sump Tank Steel Support & Platform for Crude Diphenyl Storage Storage Tank Steam Coils & Thermowell Crude Diphenyl Storage Tank 6000 Gal. Catch Tank Layout Crude Catch Tank Layout Diphenyl Piping Details Diphenyl Piping ( 0stv^535 WATER PCB-SD0000050612 105. 9C-8196 9C-8197 9C-8198 9C-8199 9C-8249 9C-8276 9C-8277 9C-8278 6000 Gal. Catch Tank Foundation 6000 Gal. Catch Tank Pit Platform, Sheet 1 Platform, Sheet 2 Sprinkler System for Crude Diphenyl Storage Sprinkler System for Crude Diphenyl Catch Tank Vent Piping for Crude Diphenyl Catch Tanks Crude Catch Tanks, Varec Gage 14: Diphenyl Distillation 9C-7870 9C-7871 9C-7872 9C-7873 9C-7876 9C-7877 9C-7878 9C-7879 9C-7880 9C-7881 9C-7883 9C-7884 9C-7885 9C-7886 9C-7887 9C-7888 9C-7889 9C-7890 9C-7891 9C-7892 9C-7895 9C-7896 9C-7897 9C-7939 9C-7940 9AA-7941 9C-7943 9C-7944 9C-8076 9C-8077 9C-8078 9C-8079 9C-8081 9C-8264 Fractionating Column Hew Layout Still and Auxiliary Equipment Detail Condenser Still Detail Details Heads and Tails Tank and High Boiler Details Diphenyl Catch Tank Still Foundation Still Supports, Sheet 1 Still Supports, Sheet 2 Still Supports, Sheet 3 Misc. Pipe Details, Sheet 1 Floor Grating Misc. Pipe Details, Sheet 2 Swivel Split Flow Box and Hisc. Steel Misc. Pipe Details, Sheet 3 Condenser Details Misc. Pipe Details, Sheet 4 Misc. Pipe Details, Sheet 5 Detail of Vents Misc. Details Assembly of Flow Box Control Details of Split Flow Box Control Vent Fan for Swivel Flow Box 6 High Boiler Drum Fill Detail Still Heater, Sheet 1 Detail Still Heater," Sheet 2 Flanges for Still Piping As send)ly of Heater Detail of Heater Inner Core Still Heater, Assembly Still Heater, Details Sheet 1 Still Heater, Details Sheet 2 Diphenyl Still Revision to Heater Platform Diphenyl Still, Heater Gas Piping Hew Stairs at Ho. 1 Diphenyl Still DSW 462586 WATER_PCB-SD0000050613 106. 9C-8210 9C-8211 9C-8212 9C-8213 9C-8214 9C-8215 9C-8216 9C-8217 9C-8218 9C-8219 9C-8220 9C-8221 9C-8222 9C-8223 9C-8224 9C-8225 9C-8226 9C-8227 9C-8228 9C-8229 9C-8230 9C-8254 9C-8262 9C-8263 Layout of Ho. 2 Dipheayl Still Ho. 2 Still Heater Shell Ho. 2 Still Heater Assembly Ho. 2 Still Catch Tasks Ho. 2 Still Heads sad Tails Task Ho. 2 Still, Layout Pipiag Sump Taak to Still Ho. 2 Still, Detail Pipimg Sump Task to Still Ho. 2 Still, Heater Platform Ho. 2 Still, Heater Platform Plam Ho. 2 Still, Platform, FI. L. aad Gratimg Ho. 2 Still Platform - Sectioa aad Details Ho. 2 Still Platform - Stairs amd H.R. Ho. 2 Still Fouadatioa Ho. 2 Still Layout of Rotaveir Ho. 2 Still Detail of Rotaveir Ho. 2 Still, Details Vests aad Piplag. Sheet 1 Ho. 2 Still, Details Veats aad Pipiag, Sheet 2 Ho. 2 Still, Details Vests aad Pipiag, Sheet 3 Ho. 2 Still, Details Veats aad Pipiag, Sheet 4 Ho. 2 Still, Details Veats aad Pipiag, Sheet 5 Ho. 2 Still, Heater Detail Maahole Frame aad Cover Ho. 2 Still, Layout of Pipiag Ho. 2 Still, Stair Details Ho. 2 Still, Stair Details 15: Distilled Dipheayl Storage 9C-9057 9C-7882 9C-7894 9C-9071 9C-9082 9C-9071 9C-9083 9C-9076 90-9088 9C-9087 Storage Taak 10'-6" x 37'-4" Detail Fouadatioa for Dipheayl Storage Taak Storage Task, Detail Loadlag Liae Supports Pipeliae to Storage Teaks Steel Platforms over Dipheayl Taaks Pipe Liae Supports aad Fouadatioa! Pipiag to aad From Dipheayl Storage Taaks Locatioa Plaa, 2 - 25,000 Gal. Taaks Pumps for Sta: age Taaks Steam Pipiag to Storage Taaks 16: Buildlag C-5418 C-6378 C-7853 C-7868 9AA-7899 C-8183 C-8184 C-8185 C-8186 C-8187 C-8264 Bulldlags - Elevatloas of Dipheayl Buildlag Dipheayl Buildlag - Asbestos Roof, S.E. Coraer 2ad aad Top Floor Plaas Shovlag Daits, 1, 2, 3, aad 4 Roof Truss Reiaforciag Dipheayl Developmeat Bldg. Areas - Floor Llghtlag Dipheayl Buildlag 40' Exteasloa - Fouadatioa Dipheayl Buildlag 40' Exteasloa - Floor Dralaa Dipheayl Buildlag 40* Exteasloa - Leaa-to Still Dipheayl Buildlag 40' Exteasloa - Fraalag for Oalts 7. 8, 9, 10 Dipheayl Buildlag 40' Exteasloa - Fraalag for Uaits 7. 8, 9, 10 Hev Stairs at Ho. 1 Dipheayl Still DSVv 462587 WATER_PCB-SD0000050614 107. 17: Control* 9C-8754 9C-7942 907949 9C-8204 90-8208 9C-9060 9C-9061 Walls & Instrument Panels - Control Room Diphenyl Plant Coatrol Roan Diphenyl Plant Control Panel - Detail Coatrol Rooa Units 7, 8, 9, 10 Panel Benzol Feed Tanks - Piping at Coatrol Roan . Process Control - Instrumentation Diagram General Plant, 1947 Additions - Power and Control 18: Power 9AA-8265 9C-8266 9C-8269 9C-8539 9C-8540 9C-8881 Diphenyl Plant - Power, Crude Diphenyl Power Panel Diphenyl Plant Service Room - Gas 4 Elec. Con. Diphenyl Power Transformer Guard Electrical - Electric Services in Diphenyl Area Electrical - Power in Diphenyl Bldg. - One Line Diagram Power Distr. - Power Panels & Layouts & Schedules 19: Bills of Material 9BM-26 9BM-27 9BM-28 9BM-29 9BM-35 9BM-36 9BM-44 9BM-47 9BM-48 9BM-50 9BM-51 9BM-52 9BM-53 9BM-54 9BM-55 9BK-56 9BH-57 9BM-63 9BM-74 9BH-87 Benzol Feed Tanks Diphenyl Units 1-2 Hew Still and Accessories (Ho. 1 Diphenyl Still) 4th Diphenyl Unit 5th Diphenyl Unit Benzol Storage (9C-7960) Diphenyl Still Heater (9C-8076) Hydrogen Compressor 6th Diphenyl Unit Crude Diphenyl Storage Diphenyl Units - Extension to Building Relocating Hydrogen Compressor Benzol Storage Four Diphenyl Units Diphenyl Still No. 2 Water Supply . Power Supply High Boiler Line to Storage Pit Steam Line to Diphenyl Building Diphenyl Units 11, 12, 13 DSW 462588 WATER PCB-SD0000050615 KQP1PMSHT HUMBER LIST OF M5cK IS DEPT. 20 - BIPHKMYL Equipment jmhgr 17-7 17-10 17-15 17-16 17-17 17-20 17-21 17-22 17-23 17-24 17-25 17-31 17-32 17-33 20-1 20-64 20-107 20-110 20-113 20-126 20-220 20-226 20-230 20-234 20-235 20-247 20-263 20-264 20-274 20-275 20-276 20-285 20-286 20-287 20-288 20-289 20-290 20-291 20-292 20-293 20-296 20-298 20-335 ____________________ Description Converter #2 Converter #3 Converter #4 Converter #5 Still Hester #1 Converter #6 Converter #7 Converter #8 Converter #9 Converter #10 Coil Hester #2 Still Converter #11 Converter #12 Converter #13 Split Flow BOx #5 Unit Storage Tank, Heads and Tails Catch #2 Still Storage Tank, Heads and Tails Catch #1 Still Water Tank #1 Still Hi-Boiler #2 Still Tank Benzol Storage Tank - Yard Benzol Feed Tank Air Receiver 24" x 6* Inter Cooler - Receiver #2 Split Flow Box #1 Still Split Flow Box #3 Unit Split Flow Box #2 Onit Split Flow Box #4 Unit Benzol Storage Tank 10'-0" x 18' Receiver After Cooler #1 Comp. Receiver Inter Cooler #1 Comp. Samp Tank #3 Benzol Storage Tank Benzol 8torage Tank Benzol Storage Tank Biphenyl Catch Tank Still #1 Biphenyl Catch Tank Still #2 #2 Biphenyl Sump Tank Sooth #1 Biphenyl Soap Tank Horth Benzol Catch Tank #1 - Comp. Room Vacuum Receiver - Comp. Room #3 Benzol Feed Tank Sump Tank - Cooling Water Biphenyl Storage Tank 108. DSW 462589 WATER_PCB-SD0000050616 Equipment Humber List Continued: Equipment Humber Description 20-236 20-516 20-517 20-518 20-528 Biphenyl Storage Tank Benzol Recovery - Comp. Room Benzol Recovery - Comp. Room Benzol Feed Tank & Platform Isopropyl Alcohol Tank 26-13 26-18 26-22 28-80 28-81 28-82 28-83 28-84 28-85 28-140 28-141 28-142 Sump at Benzol Storage Tank - Yard Concrete Catch Basin - #3 Benzol Feed Tank Safety Dike - #2 Biphenyl Storage Tank Rotaveir - #6 Unit Rotaveir - #7 Unit Rotaveir - #8 Unit Rotaveir - #2 Still Rotaveir - #9 Unit Rotaveir - #10 Unit Rotaveir - #11 Unit Rotaveir - #12 Unit Rotaveir - #13 Unit 33-60 33-79 33-84 33-129 33-135 33-137 33-138 33-145 33-156 33-157 33-158 33-165 33-166 33-167 33-168 33-169 33-170 33-171 33-177 33-215 33-216 33-218 33-246 33-261 Pump - Ramsey 26/37 Benzol Storage Tank Pump - Gould - Crude Storage Pump - Viking 1189619 - Benzol Storage #1 Pump - Ramsey 26811 - Biphenyl Storage Pomp - Worthington - Still Room #1 Still Pump - Ramsey - #1 H&T Tank Pomp - Viking - #2 Benzol Storage Pomp - Worthington - Comp. Room Pump - Worthington - #2 Still Pump - Blackmer 246737 - Benzol Storage #3 Pump - Blackmer 246738 - Benzol Storage #5 Pump - Taber 395 - #2 Still Pump - Taber 249 - Pit Pump Pump - Taber 384 - Catch Tank Pump - Taber 384 - Catch Tank Pump - Westco BR507 - Comp. Room Pump - Taber 37764 - Crude Storage Pump - Taber 37765 - Crude Storage Pump - Westco 43036 - Benzol Unloading Dock Pvsap - Taber 45132 - #1 Biphenyl Still Pump - Taber 45497 - Biphenyl Still (Spare) Pump - Viking - Benzol Storage #1 Pump - Gould 290AO48 - Benzol Feed (Yard) (3) Benzol Feed Ptapa 109. DSW 462590 WATER_PCB-SD0000050617 Equipment Number List Continued: Equlpemt Hunber 34-74 34-98 Description Pomp - Gould 176415 - Benzol Feed (1) Puap - Gould 185143 - Benzol Feed (2) 35-22 35-33 35-34 35-37 35-45 Compressor #1 Hydrogen Compressor #2 Air Compressor #3 Air Compressor #2 Hydrogen Compressor #3 Hydrogen 51-17 51-24 Biphenyl Still #1 Biphenyl Still #2 52-6 52-17 52-22 52-23 52-27 52-28 52-29 52-30 52-32 52-33 52-34 52-36 52-37 52-42 52-43 52-44 52-45 52-53 52-54 52-55 52-56 52-57 52-58 52-59 52-60 52-61 52-62 52-76 52-77 52-78 52-80 52-81 Vaporizer #2 Unit Vaporizer #3 Unit Vaporizer #4 Unit Condenser #3 Unit Condenser #2 Converter Heat Exchanger #1 Still Heat Exchanger #4 Unit Condenser #4 Unit Condenser #1 Still Heat Exchanger #5 Converter Condenser #5 Converter Vaporizer #5 Unit Benzol Condenser - above Deck Sled Vaporizer #6 Unit Condenser #6 Unit Inter Cooler #1 After Cooler #1 Condenser #7 Condenser #8 Condenser #9 Condenser #10 Vaporizer #7 Unit Vaporizer #8 Unit Vaporizer #9 Unit Vaporizer #10 Unit (in stack) Heat Exchanger #2 (Still) Condenser #2 (still) Vaporizer #11Unit Vaporizer #12 Unit Vaporizer #13 Unit Condenser #11 Unit Condenser #12 Unit ( 110. d5NN 46259A WATER_PCB-SD0000050618 Equipment Humber List Continued: Equipment Humber Description 52-82 52-88 52-91 52-92 52-147 52-148 52-149 52-150 52-151 52-155 52-157 Condenser #13 After Cooler Inter Cooler - Comp. Roan After Cooler - Comp. Roan Condenser - Conp. Roan Condenser - Conp. Roan Hent Exchanger - Hydrogen Cooling Heat Exchanger - Hydrogen Cooling Preheater Coll - Biphenyl Column Heat Exchanger Heat Exchanger 53-13 53-14 53-15 53-17 53-18 53-19 53-20 53-21 53-22 53-23 53-24 53-26 53-27 53-28 Fractionating Column #1 Biphenyl Still Fractionating Column #4 Converter Fractionating Column #2 Unit Fractionating Column #5 Converter Fractionating Column #6 Converter Fractionating Column #2 Biphenyl Still Fractionating Column #3 Converter Fractionating Column #7 Converter Fractionating Column #8 Converter Fractionating Column #9 Converter Fractionating Column #10 Converter Fractionating Column #11 Converter Fractionating Column #12 Converter Fractionating Column #13 Converter 55-177 55-291 55-295 Man Cooler Fan Fan, Utility Blower - Hydrogen Comp. Room 61-157 Hand Truck - for Pots and Traps 63-93 63-134 Gear Box on Controller Speed Reducer - Flaker 64-40 64-41 64-47 64-48 64-57 64-58 64-66 Jacketed Process Piping Steam Feeder Piping - Storage and Loading Piping - Instrument Service Piping - Units Piping Benzol Recovery Piping Benzol Unloading and Storage 65-21 65-74 65-75 Hydrogen Compressor Control Lines Process Piping Benzol Feed Tank Water Cooling Tracer 111. DSW 462592 WATER_PCB-SD0000050619 I ( ( 112. Equipment Number List Continued: Equipment Humber___ ________________ Description 73-49 73-84 73-94 73-95 73-96 73-99 73-104 73-105 73-106 73-107 73-108 73-109 73-123 73-124 73-125 75-21 75-66 75-67 Chein Hoist #2 Converter Chain Hoist #3 Converter - Trolley Chain Hoist #4 Converter - Trolley Chain Hoist #5 Converter - Trolley Chain Holst #5 Converter Chain Hoist #4 Converter Chain Hoist Chain Hoist - Trolley Chain Hoist - Trolley Chain Hoist - Trolley Chain Hoist - Trolley Chain Hoist - Trolley Chain Hoist #11 Converter Chain Holst #12 Converter Chain Hoist #13 Converter Power Feeder - Underground to Biphenyl Storage Pumps Temperature Control Wiring - Units Motor Wiring 78-170 78-171 78-174 78-177 78-178 78-189 78-190 78-197 78-242 78-243 Power Panel #1 Converter Motor Control Cabinet #1 Converter Heat Control Board #1 Motor Control Board - Benzol Storage Pumps Motor Control Board - Compressor Room Control Cabinet - Compressor Room Control Cabinet - Control Room Motor Control Board #2 - #1 Converter Room Power Cabinet - Benzol Feed & Hydrogen Compressor Motor Control Frame - Storage Tank Motors 79-18 79-106 79-152 79-157 79-301 79-308 79-414 79-519 79-531 79-561 79-571 79-589 79-593 79-610 Motor - C.E. 5560247 - 40 HP - #2 Hydrogen Comp. Motor -LA 311416 - 1% HP - on Viking Pump Motor -LA 3648018 - 1% HP - Benzol Storage Motor - Howell 5132 J 1 - 15 HP - Benzol Feed Motor - G.E. - 5 HP - Biphenyl Motor - G.E. - 5 HP - Biphenyl Motor - G.E. - 1% HP Motor - Howell 5131 J2 - 10 HP - Feed Pump Motor - G.E. - 30 HP - #1 Hydrogen Comp. Motor - Allis Chalmers 52694 -2 HP - Yd 5 Bid. 27 Motor - G.E. 6768195 - 40 HP - #3Hydrogen Comp. Motor - L A - 7% HP - #1 Still Motor - G.E. - 3 HP - Yard Motor - GE - EM 2900 - 5 HP - Biphenyl Storage QSW 462593 WATER_PCB-SD0000050620 113. Equipment Number List Continued: Equipment Humber 79-612 79-614 79-642 79-683 79-712 79-758 79-824 79-878 79-914 79-922 79-923 79-926 79-927 79-963 79-975 79-976 79-978 79-979 79-980 79-987 79-1139 79-1192 ___________________Description Kotor -LA 368542 - 1 HP - Aroclor Boiler - Hyd. Comp.Room Motor - GE - Ml314 - 5 HP - Biphenyl Storage Motor - GE - FW879 - 5 HP - Circ. Water #1 Still Motor - GE - EW2292 - 5 HP - Air Comp. Motor - Courtney - 1/6 HP Motor - GE- AP1990 - 3 HP - Flake D. Dryer Motor - GE - EP2055 - 3 HP - Biphenyl Tank Kotor Reducer - Foxboro - 1/6 HP - Control Room Motor - G.E. - 3 HP - Sump Tank Motor - G.E. - 5 HP - Catch Tank #2 Still Motor - G.E. - 5 HP Motor - G.E. - MR2065 - 3 HP - (on Gould pump) Motor - G.E. - MR2067 - 3 HP - (on Gould pump) Motor -LA- 7VHP Motor - L A - 7% HP - #2 Biphenyl Still Motor - 1/2 HP - Sump Tank Motor - Howell 296186- 2 HP - Blackmer Pump Motor - Howell 287229 - 2 HP - Blackmer Pump Motor - Howell 306991- 2 HP - Blackmer Pump Motor - W'hae - 7 HP - on Hartzell Fan Motor -LA 1827991 - 15 HP - on Benzol Pump 33-246 Benzol Feed Pump and Motor 82-226 82-227 82-228 83-11 83-13 83-17 83-33 83-34 83-35 83-40 83-44 83-60 83-114 83-116 83-117 83-118 83-119 83-124 83-125 83-126 83-127 83-128 Watt Hour Meter G.E. 19366523 in Panel 76-170 Current Trans. G.E. 400/5 - in Panel 78-170 Current Trans. G.E. - in Panel 78-170 Controller - Benzol Comp. Ind. Recorder - L&H 293220 Temp. Indicator - L&H 292382 - Control Room Temp. Controller - Wllsoa-Macalen Temp. Controller - Wilson-Macalen Temp. Controller - Wilson-Macalen Temp. Controller - Wilson-Macalen - 9575 H47A Temp. Controller - Wllsoa-Macalen - Crows Nest Temp. Controller - Wllsoa-Macalen lad. Recorder - L&H 329967 Gas Coatrol Valve Coatrol Valve - Foxboro 490478 Control Valve - Foxboro 563776 Benzol Valve - Foxboro 563781 Temp. Recorder - L&H 350456 Temp. Recorder - L&H 338835 Gas Valve - L&H - #5 Converter Control Valve - Foxboro 619301 Control Valve - Foxboro 619302 DSW 462594 WATER_PCB-SD0000050621 114. Equipment Huaber List Continued: Equipment Huaber J Description 83-132 83-136 83-142 83-145 83-146 83-147 83-148 83-149 83-150 83-151 83-152 83-153 83-154 83-155 83-156 83-166 83-168 83-169 83-170 83-171 83-172 83-174 83-175 83-176 83-177 83-179 83-180 83-181 83-182 83-183 83-185 83-186 83-187 83-188 83-189 83-190 83-191 83-192 83-193 83-194 83-196 83-197 83-198 83-253 83-256 Magnetic Valve - On Preheater #5 Pressure Balance Valve - L&N Teap. Controller - L&H 350682 Pneumatic Recorder - L&N 366481 Control Valve - Foxboro Potentiometer Controller - Foxboro C58872 - Hydrogen Coap.Rm. Potentioaeter Controller-Foxboro C-58873Gas Valve - L&N Teap. Recorder - L&H 350738 Teap. Recorder - L&N 350744 Gas Valve - L&H Control Valve - Foxboro 697076 Control Valve- Foxboro 697077 Control Valve- Foxboro 697078 Control Valve- Foxboro 645409 Gas Valve - #2 Still Teap. Recorder - L&N 350802 Teap. Recorder - L&H 350803 Teap. Recorder - L&H 350805 Teap. Recorder - L&H 350796 Teap. Recorder - L&N 350784 Teap. Recorder - L&N 381506 Teap. Recorder - L&H 381509 Teap. Recorder - L&N 381528 Teap. Recorder - L&N 381541 Teap. Recorder - L&N 350806 Teap. Recorder - L&N 381525 Teap. Recorder - L&N 350800 Potentiometer Recorder - L&H 381467 Potentiometer Recorder - L&N 381419 Potentiometer Controller - Foxboro C-63869 Potentiometer Controller - Foxboro C-63870 Potentiometer Controller - Foxboro C-63871 Potentiometer Controller - Foxboro C-63872 Control Valve - L&H - W/AB Air Set Control Valve - L&H - W/AB Air Set Control Valve - L&H - W/AB Air Set Control Valve - L&H - W/AB Air Set Control Valve - L&H - W/AB Air Set Control Valve - L&H - W/AB Air Set Ratox Press Controller - Foxboro C93641 Diff. Press Controller - Foxboro C66930 Motor Controlled Valve - Foxboro 470763 Pressure Valve - L&N Rec. Teap. Controller - L&N 576007 DSVV 462595 WATER_PCB-SD0000050622 115. Equipment Humber List Continued: Equipment Huaber Description 83-257 83-258 83-259 83-260 83-261 83-262 83-263 83-265 83-266 83-267 83-268 83-269 83-270 83-271 83-272 83-328 Rec. Temp. Controller - L&H 576010 Rec. Temp. Controller - L&H 576015 Rec. Temp. Controller - L&M 690411 Temp. Recorder - L&H 690470 Temp. Recorder - L&N 690473 Potentiometer - Foxboro F83911 Potentiometer - Foxboro F83912 Ind. Press Controller - Foxboro 95626 - Hyd. Comp. Room Cont. Benzol Valve - Foxboro 1619914 Control Benzol Valve - Foxboro 1619963 Control Benzol Valve - Foxboro 1619976 Control Gas Valve-Mason-Heilan J-29871C8276 Control Gas Valve-Mason-Heilan J29872C8276 Control Gas Valve-Mason-Heilan J-29873C8278 Controlled Valve-Foxboro F25FB-Hydrogen Compressor Gas Controller - Foxboro J19649 84-18 84-19 84-20 84-23 84-24 84-28 84-29 84-30 84-31 84-32 84-53 84-54 84-55 84-56 84-57 84-58 84-59 84-60 84-61 84-62 84-63 84-64 84-65 84-70 84-71 84-72 Biphenyl Flow Controller - Foxboro - #4 Converter Biphenyl Flow Controller - Foxboro C33473 Biphenyl Flow Controller - Foxboro C32422 Biphenyl Flow Controller - Foxboro C37533 Biphenyl Flow Controller - Foxboro C37534 Biphenyl Flow Controller - Foxboro C55147 Biphenyl Flow Controller - Foxboro C63568 Biphenyl Flow Controller - Foxboro C-63569 Biphenyl Flow Controller - Foxboro C63570 Biphenyl Flow Controller - Foxboro C-63571 Pneumatic Transmitter-Foxboro F75356 Pneumatic Transmitter-Foxboro F75357 Pneumatic Transmitter-Foxboro F75358 Pneumatic Transmitter-Foxboro F45926 Pneumatic Transmitter-Foxboro F45927 Pneumatic Transmitter-Foxboro F45928 Pneumatic Transmitter-Foxboro F45929 Pneumatic Transmitter-Foxboro F45930 Pneumatic Transmitter-Foxboro F45931 Pneumatic Transmitter-Foxboro F45932 Pneumatic Transmitter-Foxboro F45933 Pneumatic Transmitter-Foxboro F45934 Pneumatic Transmitter-Foxboro F45935 Intergrating Flow Controller-Foxboro F75359 Intergrating Flow Controller-Foxboro F75360 Intergrating Flow Controller-Foxboro F75361 DSW 462596 WATER_PCB-SD0000050623 116. Equipment Humber List Continued: Equipment Humber 86-2 86-5 86-7 86-17 86-24 86-29 86-30 86-31 86-32 86-33 86-49 86-50 86-51 Description Gas Meter - 016398 - #5 Unit Gas Meter - 016463 - #11 Unit Gas Meter - 016489 -#13 Converter Gas Meter - 829070 - Biphenyl Still Gas Meter - 016397 - #12 Unit Gas Meter - 027352 - #7 Converter Gas Meter - 028002 - #4 Converter Gas Meter - 028003 - #6 Converter Gas Meter - 028004 - #2 Converter Gas Meter - 028265 - #3 Converter Gas Meter - 051935 - #10 Unit Gas Meter - 051936 - #9 Unit Gas Meter - 051936 - #8 Unit 99-20 99-26 Fence - at Benzol Storage Tank Fence - Storage Pit 106-132 106-253 106-276 106-283 106-365 106-377 106-391 106-525 106-533 Flood Lights - Feed Tank Clock Synchonous High Boiler Storage Pit - "Lake Clegora" Benzol Unloading Dome Transmitter Stand - Meter Room Pneumatic Wrench High Boiler Storage Pit - Storage Crude Santowax Pipe and Coils for #12 and #13 Units Conversion Measurement System 107-16 107-33 Fire Extinguisher - on 2-Wheel Truck Emergency Foam Line - at Benzol Feed Tank 110-39 110-42 110-56 110-68 110-69 110-70 110-82 110-83 110-84 110-85 110-95 110-99 Platform at Storage & Shipping Tank - S.E. Corner Bldg. 27 Platform #2 to #6, and #11 Units - Mid. Conv. Room Supports for Benzol Feed Piping - S.W. Bldg. 27 Platform at #1 Still Platform at Biphenyl Still Heater Walking Platform, above Deck Shed Roof-Benzol Loading Platform 7,8,9,10 Units Platform #2 Biphenyl Still Platform Benzol Feed Tank Unloading Platform Platform #12 and #13 Units Platform, Including Grating & Stairs, Tovers to Handle Sub. Pump 112-16 Control and Alarm System . DSW 462597 WATER_PCB-SD0000050624 Equipment Number List Continued: Equipment Number Description 116-98 Aroclor Hester (From CC Job - At No Value) 117-201 Tool snd Supply Locker (4) 206-57 206-72 Feed Pump Structure (Fence snd Concrete Floor) Operstlng Structure-Biphenyl Sump Tsnk (Catch Basin, Fire Wall, Platform) DSW 462598 WATER PCB-S00000050625 x c ( c 118. August 1957 MAINTENANCE SURVEY SERIES 100 - GENERAL PLANT Item 101: Benzol Tank Car Unloading Pump (1 Required) Fuactioa: Maintenance Required: To unload benzol from railway tank cars to the benzol storage tanks. Hone I ten 102: Benzol Storage Tanks (5 Required) Function: Maintenance Required: To provide Benzol raw material buffer storage between receipt and use. None Itea 103: Benzol Transfer Pumps (5 Required) Function: Maintenance Required: To transfer benzol from the benzol storage tanks to the benzol feed tanks. Maintenance will be done on MRO - proposal has been made to test suction of pumps to determine if a fever nunber of pumps can be used. Item 104: Isopropyl Alcohol Storage Tank (1 Required) Function: Maintenance Required: To provide buffer storage for Isopropyl alcohol. None DSW 462599 WATER_PCB-SD0000050626 Item 105: Isopropyl Alcohol Transfer Pump 119. August 1957 Function: Maintenance Required: To transfer isopropyl alcohol to the isopropyl alcohol feed tank. Hone Item 106: Benzol Feed Taak (2 Required) Fuactloa: Maintenance Required: 1. To provide a source of benzol for feeding the Biphenyl units. 2. To provide a catch tank for the benzol returned from the Biphenyl process. None I ten 107: Benzol Feed Pumps (3 Required) Fuactloa: Maintenance Required: To deliver the benzol feed from the benzol feed tank to the benzol vaporizer coll of each Biphenyl unit. None Item 108: Isopropyl Alcohol Feed Taak Function: Maintenance Required: To provide a source of isopropyl alcohol for feeding to the benzene feed. None ( OSW46260 WATER_PCB-SD0000050627 Item 109: Isopropyl Alcohol Feed Pump 120. August 1957 Fraction: Maintenance Required: To transfer Isopropyl Alcohol to the auctioa of the benzol feed pumps. Hone Item 110: Hydrogen Coolers (6 Required) Fraction: Maintenance Required: 1. To cool the gas and vapors from the benzol condenser in order to decrease the vapor load on the hydrogen compres sors . 2. To condense some of the benzol vapor from the hydrogen gas. Clean each cooler on the vater side. This cleaning should consist of acid vashing and inspection to determine if physical clean ing is. necessary. Item 111: Benzol Catch Tank (1 Required) Function: Maintenance Required: To trap condensed benzol from the hydrogen gas. Hone Item 112: Hydrogen Compressors (3 Required) Function: Maintenance Required: To compress the hydrogen and condense the benzol vapors contained in the hydrogen. Hone oSnN 462601 WATER_PCB-SD0000050628 Item 113; Inter Coolers (3 Required) 121. August 1957 Function: Maintenance Required: To condense benzol from the hydrogem gee after the first compression stage. Hone Item 114: Low Pressure Receiver (3 Required) Function: Maintenance Required: To provide a trap and collecting tank for the benzol condensed from the hydrogen gas after the first compression stage. Hone Item 115: After Coolers (3 Required) Function: Maintenance Required: To condense beazol from the hydrogen gas after the second compression stage. Hone Item 116: High Pressure Receiver (3 Required) Function: Maintenance Required: To provide a trap and collecting tank for benzol condensed from the hydrogen gas after the second compression stage. Visual inspection indicate no maintenance required. However, thickness of these tanks should be checked. DSW 462602 WATER_PCB-SD0000050629 Item 117: Benzol Return Pump Tank (1 Required) 122. August 1957 Function: Maintenance Required: To collect the condensed benzol from the receivers and the benzol catch tank. Rone Item 118: Recovered Benzol Return Pump Function: Maintenance Required: To return the recovered benzol in the pump tank to the benzol feed tank. Hone (Larger benzol pumps are needed.) (A separate project is being submitted.) Item 119: Crude Biphenyl Catch Tanks (Sump Tanks) (2 Required) Function: Maintenance Required: To catch the crude Biphenyl from the Biphenyl units and store it prior to batch distillation. Repair sheet metal weather-proofing over insulation on Ho. 1 Sump Tank. Item 120: Still Charging Pumpa (2 Required) Function: Maintenance Required: To deliver the crude Biphenyl from the catch tanks to the still. Hone SIV 462603 WATER PCB-SD0000050630 Itan 121: High Boiler Collecting Tank (1 Required) 123. August 1957 Fauction: Maintenance Required: To provide * receiving end cooling tank for the distilled high boiler (Santowax C). The insulation on this tank is saturated with Biphenyl. Remove old Insulation and re insulate. Provide new weather-proofing. Item 122: High Boiler Pump (1 Required) Function: Maintenance Required: To deliver high boiler from the high boiler tank to the Santowax C Storage Tank. None Item 123: Distilled Benzol Collection Tank (1 Required) Function: Maintenance Required: To provide a catch tank for the benzol fraction distilled from the crude Biphenyl. None Item 124; Distilled Benzol Return Pump (1 Required) Function: Maintenance Required: To deliver the recovered benzol from the distilled benzol collection tank to the benzol feed tank. Repair motor casing where it has corroded through. DSW 462604 WATER PCB-SD0000050631 C Item 125: Biphenyl Storage Tanks (2 Required) 124. August 1957 Function: Maintenance Required: To store distilled Biphenyl prior to shipping. Hone Itea 126: Biphenyl Loading Pumps (2 Required) Function: Maintenance Required: To deliver Biphenyl from the Biphenyl storage tanks to tank cars for shipping. Hone ( c 0SW 462605 WATER_PCB-SD0000050632 125. August 1957 SERIES 200 - BIPHENYL UNITS It* 201: Benzol Vaporizer (1 Required par Putt) Function: Maintenance Required: 1. To vaporize the benzol feed to each Biphenyl unit. 2. To recover sensible heat from the exhaust gases used in heating the preheater and converter pots. Unit Ho. 2 through 13: Check each vaporizer coil core and coil support. Suspend all vaporizer coils from the top and support each turn of the coil. Replace the S.S. coil cores as required. Item 202: Heat Exchanger (1 Required on Units 4 and 5 Only) Function: Maintenance Required: 1. To further super-heat the benzol vapor from the vaporizer. 2. To recover heat from the vapors leaving the converter. Unit No. 4 and 5: Hone os* *606 WATER PCB-SD0000050633 126. August 1957 Items 203, 204. 205, 206, and 207; Fire Box and Associated Preheater Pots. Converter Pot, Burnart, stc. Function: Maintenance Required: To super-heat the benzol vapors to the pyrolysis temperature. Firebox: Check brickwork in firebox of Units 2 through 13 and repair as required. Burners: Unit Ho. 4: Replace broken Inspirator on preheater. Unit No. 5: Replace missing burners on converter. Unit No. 7: Replace missing burners on converter. Replace broken Inspirator on Ho. 1 preheater. Unit Ho. 8: Replace missing burner on No. 2 preheater. Unit Ho. 9: Replace broken Inspirator on No. 2 preheater. Unit No. 10: Replace broken Inspirator on con verter and Ho. 2 preheater. Unit No. 11: Replace broken Inspirator on Ho. 2 . preheater. Unit No. 12: Replace broken Inspirator on converter. DSW 462607 WATER_PCB-SD0000050634 c Item 208: Start-Up By-Pass Stack (1 Required per Unit) 127. August 1957 Function: Maintenance Required: To provide a means of by-passing the hot flue gases around the cold vaporizer prior to beginning the benzol feed. Check the butterfly type valve in the horizontal header between the by-pass stack and exhaust stack of Units 2 through 13. Repair as required. Item 209: Exhaust Stack (1 Required per Unit) Function: 1. To provide a means for exhausting the flue gas from the preheater and converter to the atmosphere. 2. To provide a housing for the vaporizer coil. ( Maintenance Required: Check the flrebrock in the exhaust stacks of Units 2 through 13 and repair as required. Repair all holes in these stacks. Itea 210: Lead Trap (1 Required per Unit Except Unit Hos. 4 and 11) Function: Maintenance Required: To trap entrained lead coming over with the benzol vapor from the converter. Ho maintenance required. (These lead traps will be eliminated as soujourn pot sections are installed on the converter pots.) ( DSW 46260& WATER_PCB-SD0000050635 128. August 1957 Items 211. 212. 213 end 214: Fractionating Column Carbon Trap. Condenser and Split Flov Box (1 Required per Unit Function: Maintenance Required: 1. To function as a cooling system to condense the vapors from the converter. 2. To effect a partial separation of the benzol from the converted products. Check the supports on the #2 Unit column and provide additional supports as necessary. These supports should be adequate to support the column and associated equipment when the colvna is filled with water. DSW 462609 WATER PCB-SD0000050636 SERIES 300 - BIPHENYL STILLS 129. August 1957 ltd 301: Biphenyl Still Pot (1 Required per Still) Function: Maintenance Required: To provide a reservoiY for heating the charge of crude Biphenyl which is being distilled. Still Ho. 1: Hone Still Ho. 2: Hone Itan 302: Biphenyl Still Circulating Pump (1 Required per Still) Function: Maintenance Required: 1. To circulate the crude Biphenyl in the still pot through the heating coil of the gas fired heater and back to the still pot. 2. To pimp the residue in the still to the high boiler collecting tank. Still Ho. 1: Hone Still Ho. 2: Hone ltd 303: Gas Fired Heater (1 Required per Still-) Function: Maintenance Required: To supply the heat required for distilling the crude Biphenyl. Still Ho. 1: Recondition or replace two bad inspiratora and reconnect to gas line. Still Ho. 2: Hone DSW 462610 WATER PCB-SD0000050637 130. August 1957 Itest 304. 305, and 306: Biphenyl Still Column. Condenser, and Split Flow Box (1 Set Required per Still) Function: Maintenance Required: To separate and condense the crude Biphenyl vapors into benzol, high boiler, end Biphenyl. Still Ho. 1: Hone Still Ho. 2: Hone Item 307: Heeds snd Tells Cetch Tank Function: Maintenance Required: To provide e cetch tank end storage for the heeds end tails distilled from the crude Biphenyl. Still Ho. 1: Hone Still Ho. 2: Hone Item 308: Heeds end Tells Retnra Pomp (1 Required per Still) Function: Maintenance Reqnlred: To return the heeds end tells from the cetch tank to the still pot. Still Ho. 1: None Still Ho. 2: None Item 309: Biphenyl Cetch Tank (1 Required per Still) Function: Maintenance Required: To receive the Biphenyl fraction end temporarily store the Biphenyl during . the distillation. Still No. 1: Hone Still Ho. 2: Hone DSW 462611 WATER PCB-SD0000050638 It-- 310: Piitlllsd Biphenyl Transfer Ptaap (l Required per Still) 131. August 1957 Function: Maintenance Required: To deliver the distilled Biphenyl fro* the Biphenyl catch tank to the Biphenyl storage tanka. Still Ho. 1: None Still Ho. 2: Hone C DSW 462612 < WATER PCB-SD0000050639 SERIES 400 - IHSTROMEKTATION AMD CONTROLS 132. August 1957 Item 401: Automatic Let-Down Level Control (1 Required on Primary Feed Tank Only) Function: Maintenance Required: To automatically maintain a supply of benzol In the feed tank and to sound an alarm in case of high or low level. None Item 402: Benzene Feed Control (1 Required per Unit) Function: Maintenance Required: 1. To automatically meter a specified quantity of benzene to each unit. 2. To automatically shut off the natural gas flow when the feed stops. None Item 403: Twelve Point Temperature Recorder (1 Required per Onlt) Function: Maintenance Required: To record the critical temperatures. Check the instrument on each unit and repair as required. Each instrument is to record: 1. The condenser water outlet temperature. 2. The vapor temperature on the top plate. 3. The flue gas temperature leaving the vaporizer coll section of the exhaust stack. 4. The temperature of the material flowing through the sump line. DSW 462613 WATER PCB-SD0000050640 Item 403 Continued: Maintenance Required Continued: 133. 5. The temperature of material leaving the vaporizer coil. 6. The temperature of the lead in the Ho. 1 preheater. 7. The temperature of the lead in the No. 2 preheater. 8. The temperature of the flue gaa entering the vaporizer coil section of the exhaust stack. Item 404: Single Point Temperature Recording Controller (1 Required per Unit) Function: Maintenance Required: To indicate, record, and control the temperature of the converter by regula ting the natural gas to the burners. None Item 405: Natural Gaa Meters (1 Required per Unit and 1 Required per Still) Function: Maintenance Required: To record the quantity of natural gas used on each Biphenyl Unit and each Biphenyl Still. Clean, recondition, and check all gas meters. Relocate one of the two meters nov on No. 12 Unit to Ho. 7 Unit. DSW 462614 WATER_PCB-SD0000050641 134. August 1957 Item 406: Biphenyl Still Twelve Point Temperature Recordar Function: Maintenance Required: To record the critical temperature* on the Biphenyl Stills. Still Mo. 1: Mone Still No. 2: None Itea 407: Biphenyl Still Furnace Temperature Recording Controller Function: Maintenance Required: To control the temperature differential betveen the heater inlet and outlet by regulating the flow of gas to the burners. None Item 408: Biphenyl Unit Automatic Safety Switches for Natural Gas (1 Required per Pnlt) Function: Maintenance Required: To protect the equipment in the event of an emergency, by stopping the flow of natural gas to the No. 2 preheater when the temperature exceeds a predetermined maximum. Check, clean, recondition and repair as required. DSW 462615 WATER PCB-SD0000050642 Item 501: Lighting Maintenance Required: SERIES 500 - UTILITIES 135. August 1957 1. Install adequate lighting in benzene unloading dock area. .2 Provide adequate lighting in Biphenyl Unit rooms, 1st, 2nd, and 3rd floors. Lighting should be of the flood light type and should be located near walls and windows so that the lights do not overheat. Item 502: Power Wiring Maintenance Required: 1. Install iasulated switch buttons on benzol unloading pump switch. 2. Replace the insulation button on the high boiler catch tank pump starter switch. 3. Replace the insulation buttons on both the Ho. 1 and Ho. 2 still heads and tails return pump starter switches. 4. Replace the insulation buttons on the Ho. 1 still Biphenyl transfer pump starter switch. 5. Replace the eanymerable conduit covers throughout the entire area. DSW 462616 WATER PCB-SD0000050643 Item S03; Process Piplag Maintenance Required: 136. August 1957 1. Extend the leg in the benzene run-beck ' line from the roof cooler to mske leg 8* high. (Completed) 2. Remove the swivel flow box from ench still end install la their piece e sight glass (stesm jacketed) and a 3-way, "Y" type, valve. Provide a sample port in the line. (This change will reduce Biphenyl sublima tion in the area and eliminate a aource of product contamination.) 3. Repair eanumerable steam leaks through out the area. 4. Replace the bent sump tank vent header so that condensed benzene can run back to both sump tanks. Item 504: Plant Water Piping Maintenance Required: Dismantle copper tubing to benzol feed pump bearings and Install 1/4" steel piping. Item 505: Hatural Gas Piping Maintenance Required: Ho maintenance is required except for general renovation of unusable valves, gauges, and general wandering pipe runs. DSW 462617 WATER PCB-SD0000050644 137. August 1957 I teat 506: Stem Piping - Bensol Loadlag Pock Ares Maintenance Required: 1. laetell steam trap oa teak car ualoedlag llae tracer aear pump. Supply steam to thla tracer aear base of poap aad trap aear this point. Condensate will drala back down the tracer to trap. 2. Dismantle copper tublag feedlag tracers oa beasol feed pump discharge llae aad lastall la scbemetrical fashion. 3. Survey all steam traps la the ace a aad repair or replace those aot operatlag. Item 507: Building Malateaaace Required: Removal of the vails la the Bipheayl Unit area is desperately seeded. This report Is by ao mesas presenting the design for that undertaking because It is beyond the scope of this survey. However, the author does encourage those concerned to act upon the removal of these vails at their earliest opportunity. Item 508: Severs Maintenance Required: Provide sewer for beaaol feed tank drain. Dsiv <(=,<, WATER PCB-SD0000050645 138. August 1957 ltd 509: Fire Protection Equipment Iacludlag Sprinklers Malnteaaace Required: This equlpaeat is la fslrly good conditio* but some of the equipaeat should be replaced with up-to-date equlpaeat. Item 510: Grounds aad Geaeral Area Beazol Ualoadlmg Dock Area: Halateaaace Required: 1. Remew guard rail arouad task car dome silag. 2. Reaev the 2 heazeae pipe liae supports due south of hydrogea compressor room aearest the Muriatic Acid area. 3. Extead feace arouad beazol storage taaks to ladude Isopropyl alcohol storage task. 4. Repair steps to aorth Beazol feed teak. 5. Repair beazol feed task dike. 6. Remove the float valve from the suap pump at the coacrete dikes arouad sump taaks aad beazol receiver. Provide a maaual switch so the water caa be dralaed from this dike. (A project has beea submitted for the reaewal of the Bipheayl traasfer liae aad the pipe supports.) Item 511: Palatlag Halateaaace Required: Palatlag of the Bipheayl Pleat is, la geaeral. aeeded. This, however, is beyoad the scope of this survey. Palatlag la this area should be oa a scheduled basis aad should begin immediately. DSW 462619 WATER PCB-SD0000050646 Itea 512: Imsulstiom Maintenance Required: Item 513: CO^ Plpimg Maimtemamce Required: 139. August 1957 Insulate: 1. *11 limes betweem vaporizer coils amd Mo. 1 preheater 2. all limes betveem the No. 1 preheater amd the No. 2 preheater 3. all limes betveem the No. 2 preheaters amd the converters, amd 4. all limes betweem the comverters amd the coltmms. Insulate all steam jacket plpimg. (A project has beem approved for the installation of CO2 distribution piping. Consequently, mo recosamemdetloms for im proving the present system will be made.) DSW 462620 WATER PCB-SD0000050647