Document ga3184J0z0YVLYkZVYDbzgMNJ

DOWLEX OPERATING MANUAL JANUARY, 1981 DOW CONFIDENTIAL DO A 056701 CONFTDFNTTAL INDEX 1. INTRODUCTION r 2. DOWLEX DEFINITIONS AND EQUIPMENT NUMBERING 3. EMERGENCY SYSTEMS 4. RAW MATERIALS 5. THEORY OF PROCESS 6. ETHYLENE PURIFICATION AND COMPRESSION 7. CATALYST 8. REACTION 9. CALCIUM STEARATE 10. DEVOLATILIZATION AND VACUUM SYSTEM 11. SOLVENT RECOVERY AND PURIFICATION 12. RECYCLE ETHYLENE COMPRESSION 13. SOLVENT AND OCTENE STORAGE 14. ADDITIVE SYSTEMS 15. GEAR PUMPS AND PELLETIZER 16. PELLET WATER SYSTEM 17. MATERIAL HANDLING 18. DOWTHERM SYSTEM 19. CHILLED WATER SYSTEM 20. COOLING TOWER 21. OTHER UTILITIES 22. ELECTRICAL SYSTEMS 23. MISCELLANEOUS SYSTEMS 24. QUALITY ASSURANCE AND PROCESS ANALYZERS 25. COMPUTER AND CONTROL SYSTEMS 26. INDUSTRIAL HYGIENE AND ECOLOGY ^ 27. EQUIPMENT LIST 28. SIMPLIFIED FLOW SHEETS, MATERIAL AND ENERGY BALANCE DO A 050700 CONFIDFNTTAl 1. INTRODUCTION The Dowlex plant is designed to produce linear low density polyethy lene, a tough, flexible plastic used in packaging film, trash cans, houseware, trash bags, and many other applications. The plant can also produce high density polyethylene. The design capacity of the plant is 400 million pounds per year of Dowlex resin produced in two trains. Ethylene from the Light Hydrocarbon plants at 400 psig is purified and compressed to 650 psig and is mixed with a solvent (Isopar E). This solution is chilled to 10C and is fed to a reactor. Catalyst injected to the reactor causes the ethylene to polymerize to polyethylene. The reactor runs at 450 psig and 200C and is liquid full. The polyethylene density is controlled by adding octene to the solvent and the melt,index is controlled by adding hydrogen to the ethylene. About 85% of the ethylene feed is converted to polyethylene in the first reactor. A further 7% con version is obtained in a second reactor at 220C. The polyethylene - solvent solution from the reactors is heated to 2606C by a Dowtherm vapor heat exchanger. The solution then flows to a M first stage devolatilizer at 20 psig where 99% of the solvent is vaporized. lO% A gear pump transfers the concentrated polyethylene through a Dowtherm liquid plate heat exchanger to heat it back to 260C. The mixture then flows to a second stage devolatilizer at 5 mmHg vacuum where the remainder of the solvent is removed. A second gear pump pumps the molten polyethy lene to a pelletizer. Solvent vapor from the first stage devolatilizer flows to the bottom of a scrubber column to remove entrained polyethylene. The vapor from the col umn is used to generate 15 psig steam. 00 A 056703 CONF T DFNT T Al Unreacted ethylene is separated from the condensed solvent. The solvent is purified in silica gel and molecular sieve beds and is recycled back to the reactor. The ethylene is compressed in three stages from 10 psig to 650 psig and is returned to L.H.C. or it can be recycled back to the reactor. Additive systems can inject four separate additives; calcium stearate in solvent, two separate hot melt additives and pellet concentrate using a sidearm extruder. Auxilliary systems include three absorption refrigeration units (ARU) for reactor feed cooling, a cooling tower, pellet water system, Freon refri geration for the vacuum system and a Dowtherm furnace. The material handling system for the final product has six blenders and 11 million pounds of storage capacity. DO A 056704 CONFIDFNTTAl 2. DOWLEX DEFINITIONS AND EQUIPMENT NUMBERING 2.1 DEFINITIONS 1. Additive - certain raw materials that are injected into the process to modify polyethylene properties. 2. ARU - absorption refrigeration unit. 3. Agitator - a motor driven shaft that has blades attached. Used for mixing. Usually has a gearbox. A. Catalyst - a substance used in the reactor to initiate and maintain a chemical reaction (maintain a set temperature in the reactor). 5. Density - the mass of a substance per unit volume. 6. Devolatilization - that part of the process where solvent, unreacted ethylene and hydrogen are removed from the polyethylene. 7. Dowtherm - a liquid or vapor used for heating. 8. Diverter valve - a three way valve used in the material handling system. 9. Heat exchanger - a vessel used for removing or adding heat. 10. Furnace - an enclosed structure in which heat is produced. 11. Fin-Fan - an air cooled heat exchanger 12. Hopper - a storage vessel for polyethylene pellets. 13. Pelletizer - a piece of equipment that converts molten polymer into small round spheres. 14. Palletizer - a piece of equipment used in the bagging area that takes bags of polyethylene pellets and stacks them on pallets. 15. Reactor - a spherical vessel in which the product is made. 16. Rotary feeder - an air lock chamber with a paddle wheel-like assembly DO A 056705 CONFIDENT T Al that turns 360 to feed polyethylene into a transfer line at a controlled rate. 17. Melt Index - the amount of polymer that passes through a given opening in a given time with a constant force. A measure of molten polymer viscosity. 18. Material Handling - the moving, storage, and shipping of the poly pellets. 19. Screen Pack - a fine mesh screen that filters out impurities in the poly stream. 20. Specks - black or gray spots on the pellets. 21. Gels - a hard lump or other imperfection that sometimes forms in film. 22. Regenerate - to renew a bed that has been exhausted. 23. Purge - to remove undesirable elements. 24. Sidestream - an injection point other than the mainstream. In this process ATE is a sidestream. 25. Static Mixer - a series of baffles that makes the poly change direction for blending. 26. Molecular Sieve - a fine sand-like granular substance with a large surface area to remove water and other impurities. 27. Silica Gels - a fine sand-like granular substance with a large sur face area to adsorb water and other impurities. 28. Solvent - a liquid substance used in Dowlex to absorb the heat of reaction and keep polymer in solution. Also known as Isopar-E. 29. Film - a thin flexible transparent sheet. 30. Polyethylene - the ethylene after it has been changed to plastic. 31. u.P.S. - an uninterruptable power supply. Provides emergency power DO A 056706 CONFIOFNTIAL for certain lights, plant intercom, and critical instruments. 32. Substation - the housing for the electrical switchgear in the block. 33. Level control - any device (pump speed, control valves) used to maintain a liquid level In a vessel. 34. Pressure control - any device (speed control, pressure control valves) used to maintain a certain pressure in a vessel. 35. Granulation - the size or shape of the polyethylene pellets. 36. Cross contamination - when two different product types are mixed together, unintentionally. 37. Classlfer - a piece of equipment used to separate small or large polyethylene pellets from the desired size pellets. 38. Cooling Tower - a large vertical construction open to atmosphere with water falling down and air being pulled up to cool the water. 39. Catalyst Kill - any of a number of elements that will stop the poly merization process. Calcium stearate is used in the process. 2.2 VOWLEK NUMBERING The block number for Dowlex is Block 86. The equipment numbering system for Dowlex follows a systematic pattern. It is the same as that used for Trains "C" and "D" at Polyethylene III in Texas Division and other Dowlex plants built throughout the world. Major equipment is numbered as follows: XX NNN A/B XX - equipment type abbreviation, list below NNN - equipment number; first digit describes the area of the plant, second digit the train, third digit the actual number. DO A 056707 CONFI DENT I Al A/B - used for two identical pieces of equipment serving same purpose on the same train. DO A 056708 CONFTDFNTTAl EQUIPMENT ABBREVIATIONS (cont'd) c Compressor CH Check Hopper CL Classifer CT Cooling Tower D Drum or Tank DPW Drum for Pellet Water DV Diverter Valve E Heat Exchanger F Furnace FACP/FACV Air Conveying Filter FL Filter FN Fin-Fan FV Flare Stack H Hopper HA, HAS Additive Hopper HB Bagging Hopper HL Car Loading Hopper HMB Make-Blend Hopper HS Storage Hopper HUH Hold-Up Hopper K Pelletizer M Motor MX Static Mixer NSV Automatic Slide Valve P Pump POC Oil Pump on Air Compressor POX PR PS PW R RAC RF SACP/SACV SAM SD VP WS XS Y YB YE YD YH Oil Pump on Extruder Refrigerant Pump on ARU Solution Pump on ARU Pump for Pellet Water Reactor Receiver in Air Conveying - also acts as a Deduster Rotary Feeder Silencer Sample Collector Spin Dryer Vacuum Pump Weigh Scale Additive Extruder Adsorption Bed Blower on regeneration system for adsorption beds Heat Exchanger on regeneration system for adsorption beds Drum on regeneration system for adsorption beds Electric heater on regeneration system for adsorption beds Throughout the operating manual the numbers shown in the text are those for Train I. The same explanation or description applies for Train II. 2.5 PLANT MODEL For the engineering of this plant, a model was built using the modular concept. That means Train I and Train II are modelled as identical modules and the one model applies to both trains. In the areas around the pelletizing building, including the devolatizers, T611 and T621, both trains are modelled DO A 05A71C confidfntia: because in these areas the trains 'mirror' in to the pelletizing building. The common equipment - solvent storage, catalyst mixing and storage, ARU's, air compressors, Dowtherm furnace are modelled. The model scale used is 3/4" l'O". DO A 056711 CONFTDFNTIAl 3. EMERGENCY SYSTEMS 3.7 SAFETY SHOWER MW EYEWASH SYSTEM Potable water is used for the safety shower system. Potable water is received from the Division's water treating plant and enters the block in a four inch header at about 70 psig. There is a flow and pressure transmitter located on the incoming line that indicates and alarms on TDC 2000. The alarms are low pressure and high and low flow. The incoming line goes to all buildings, the pellet water system, and E-906. (Fig. 3.1) E-906 is a heater designed to heat gpm of water 100F above the in let cold water temperature. The temperature will be controlled on a field mounted controller. 15# steam will be used for temperature control. The con densed steam will be returned to the condensate return header going back to D-908 (condensate storage).(Fig. 3.2) The safety shower system is a closed recirculating system requiring make up water only if potable water in the safety shower is used. P-906 A&B are the recirculating pumps and get suction from the safety shower return header, dis charging into E-906 and returning to the supply header. On the discharge of the P-906 pumps is a low pressure switch. On low header pressure, this switch automatically starts the P-906 pump that is not running. Low pressure also alarms on TDC 2000. P-206 A&B should always be left in the automatic field position with suction and discharge valves open. There are 42 safety shower and eyewash stations located throughout the plant. The alarms on each station is a field mounted push button type. Push the button and the alarm activates. Pull the button out and the alarm deacti vates. In the control room each safety shower has its own alarm light on a graphical display of the block. DO A 05671? CONFIDENTIAL The board operator will have to acknowledge any safety shower alarm, even if the alarm has been deactivated in the field. The list of safety shower lo cations are located on Figure 3.2. 3.2 FIRE PROTECTION The Dowlex plant will have several different types of fire protection sys tems. All systems will use the rate of rise method (5 temperature rapid rise will trip the system involved). These deluge systems can be tripped remotely in the control room and manually at the deluge valve. Several systems will have an optional foam system than can be manually tripped in the control room or in the plant. (Fig. 3.3) The foam can be injected along with the water and sprayed throughout the system. Storage area - deluge system and will have a connection for mobile foam equipment from the fire department. Warehouse - Wet-filled system. Sprinkler heads will be fused and only those heads unfused by fire will be activated. Catalyst Storage & Mixing - Deluge system only. Dowtherm Area - Deluge system. Also in the pipeway directly north of the Dowtherm area will be a water curtain to isolate the Dowtherm furnace from the process area. Process Area - Deluge system with foam option. Truck & Rail Unloading - Deluge system only. Collection Pond - Foam system only. All of the fire protection systems will have alarms in the control room to show that they have been activated. No deluge valves can be reset by any of the trip methods. They have to be reset manually at the valves. Close the valve, reset, open the valve. DO A 056713 conftdfntta:. Deluge systems will be designed for directional and area coverage. Di rectional coverage is direct spraying on one piece of equipment, and area coverage is a specified area. The directional coverage is calculated as .35 gallons per minute water per square foot of surface area. Example: D-811 diameter is 16 feet X 16 feet 16 X 16 equals 1,056 square feet of area 1056 X .35 = 369.6 gallons of water per minute Area coverage is calculated the same way using .2 gallons per minute instead of .35. Area coverage would be like spraying the entire storage area. Fire protection water comes from the division looped process fire water system. This encircles the block at the block limits. These lines are de signed to give Dowlex (Block 86) the total demand of all systems flowing at the same time. The block is also looped internally to supply the deluge sys tems, fire monitors, and fire hydrants. The system inside the block is not a boosted system and runs at division pressure which would be approximately 85 psig at the block limits. The deluge system inside the block is designed for 55 psig at a deluge valve. (Fig. 3.7) 1) Location of the plant monitor guns (Fig 3.4) NUMBERS LOCATION 1 Southeast of cooling tower CT901 2 West of substation #1 3 East of T-611 4 North of substation #2 5 North of Catalyst mix tanks 6 West of C-721 7 South of Y-122 A/B DO A 056714 OONFIDFNTTAL o 1) Location of the plant monitor guns (cont'd.) NUMBERS LOCATION 8 West of E-221 9 Southeast of E-627 10 Northwest of E-621 11 South of C-902 12 Southwest corner of storage area 13 Northwest corner of storage area 14 Southwest corner of pallet storage 15 North of Catalyst storage 16 Northeast of cooling tower CT901 2) Hydrant Locations (Fig. 3.6) a. Southwest corner of pallet storage. b. East of Substation #2 c. Northwest corner of storage area d. Northwest of cooling tower CT901 3) Location of Deluge Valves (Fig. 3.5) NUMBERS LOCATION 1 South wall of storage, southwest of D-801 2 South wall of storage, southeast of D-802 3 South of Catalyst mix tank 4 East of C-lll 5 East of C-121 6 Northwest of Y-211 A/B 7 West of Y-211 A/B Northwest of Y-211 A/B DO A 056715 CONFTDFNTTAl 3) Location of Deluge Valves (cont'd) NUMBERS LOCATION 9 West of E-627 10 Southwest of VP-512 A/B 11 North of E-261 12 West of C-903 3.3 PIKES AWP PRAINAGE The storm sewer system is designed to handle the full flow of deluge systems when set off on trains one through four, solvent storage area, and the cooling tower area. Fire and rain water will be carried by. the storm sewer system from the process areas to the collection pond. The collection pond is sized to handle the first 3/4 inch of rainfall on the areas described above. The plant drainage system is divided up in small areas in order to size the system. The areas that flow into the collection pond are divided into three sections. Fig. 3.11 will show drainage areas. The solvent/comonomer storage area is diked for containment of spills. A valve box is located outside the diked area so this area can be drained to the collection unit. The valves must remain closed at all times except to drain rainwater. An operator must remain at the valves all the time they are open. Also tied into this area's drainage is the rail and tank car unloading drains and Catalyst storage drains. The pelletizer buildings drains tie into the sewer going to the collection pond, but before going into the sewer, the water flows through a pellet trap to remove pellets before entering the sewer. The area of the plant south of the south-most entrance road does not drain to the storm sewer system except the drains around the flare system DO A 056716 CONFIDFNT T At (D-904, FV-904). The flare drains do tie into the storm sewer system. The hopper car loading, pellet storage, warehouse, and pallet storage areas all flow into a pellet trap then out on the east side of the block. Another diked area is the Dowtherm system consisting of F-501, D-500, D-502, and associated pumps. The area is diked to prevent Dowtherm from escaping into other areas. This area drains into the storm sewer system. The plant's ground level is sloped in such a manner that all pipe racks and instrument/electrical trenches are on the high points. The reasoning behind this is to minimize the possibility of fires under the piperacks and keep liquid out of the trenches. On both outlet trenches on the storm sewer system there are weirs to maintain a liquid-full level in the sewer system at all times. This is done to prevent hydrocarbon gases from forming an explosive mixture in the sewer piping. 3.4 EMERGENCE BLOCK VALVES Emergency block valves are located throughout the plant in different pro cess lines to enable areas of the plant to be shutdown in an emergency situation to protect both people and equipment. On train one, there are 25 block valves (HV) and 9 flow, level, temperature, and pressure control valves that can serve as emergency block valves. There are equivalent valves on Train 2. (Fig. 3.12) The 25 block valves are of different sizes and some require more pressure to operate than others. Our plant air pressure is not sufficient to operate some valves so 200 psig nitrogen will be used. Also some will have reservoirs installed to aid in closing the valves. On the next page is a list of these 22 valves and information on each. DO A 056717 CONFIDENTIAL HV 1141 - Located on the incoming propylene line near the block limit. This is a 3 inch gate valve and can be operated from the control room only. Fail safe position is closed. HV 1003 - Located on the incoming ethylene line near the block limit. This is an 8 inch gate valve and can be operated from the control room only. Fail safe position is closed. HV 2240 - This valve is located on the incoming feed line to R-211. This is a 6 inch gate valve requiring 200 PSIG nitrogen to operate. This valve can be operated from the control room only. Fail safe position is closed. HV 2242 - Located on the bottom outlet of R-211. This is a 6 inch gate valve requiring 200 PSIG nitrogen to operate. This valve can be operated from the control room only. Fail safe position is to fail in place. HV 2246 - Located on the top outlet of R-211. This is a 12 inch gate valve requiring 200 PSIG nitrogen to operate from the con trol room only. Fail safe position is to fail in place. HV 2278 - Located on the top outlet of R-212. This is a 12 inch gate valve requiring 200 PSIG nitrogen to operate. This valve can be operated from the control room only. Fail safe posi tion is to fail in place. HV 2280 - Located on the bottom inlet of R-212 from P211's. This is a A inch gate valve that will operate off of plant air pres sure. This valve can be operated from the control room only. Fail safe position is closed. 00 A 05671 8 cnftdfnttai safe position is closed. HV 9005 - Located on the incoming chlorine to CT 901. This is a 2 inch gate valve that will operate off plant air. This valve can be operated from the control room only. Fail safe position is closed. HV 9026 - Located on the incoming hydrochloric acid header going to CT901. This is a 2 inch Teflon--lined plug valve that will operate off plant air. This valve can be operated from the control room only. Fail safe position is closed. HV 2317 - Located on R211 bottom to dump to D212. Air operated 3 inch gate valve with air reservoir to enable operation in an air failure. On power failure will fail in place, HV 2318 - Located on R212 bottom to dump to D212. Same as HV 2317. HV 5024 - Located on bottom outlet of D-500 going to P-500 A/B/C to Dowtherm liquid system. This is a 20 inch gate valve re quiring 200 PS1G nitrogen to operate. This valve can be operated from the field and from the control room. Fail safe position is to fail in place. HV 5115 - Located on the Dowtherm vapor inlet line to E-511. This is a 14 inch gate valve requiring 200 PSIG nitrogen to operate. This valve is furnished with an override hand wheel operator and can be operated from the control room. Fail safe position is to slowly close. HV 5253 - Located on D-500 outlet to P-501 A/B/C suction going to F-501. This is a 24 inch gate valve requiring 200 PSIG nitrogen to operate. This valve can be operated from the field and from the control room. Fail safe position is to fail in place. DO A 056719 CONFIDENTIAL HV 2281 - Located on bottom inlet of R-212 from R-211. This is a 12 inch gate valve requiring 200 PSIG nitrogen to operate. This valve can be operated from the control room only. Fall safe position is to fall in place. HV 5086 - Located between MX212 and E511. Nitrogen operated 12 inch gate valve. Fail safe in place. Operate from the control room. HV 3094 - Located on the discharge of P-311 A, B, & C. These are one & 3095 half inch 3 way plug valves. Upon tripping these valves, the flow is diverted from going to R-211, back to D-311. P-311 A/B/C are positive displacement pumps so they cannot be dead headed.. Valves can be operated from the control room only. Fail safe position is to D-311. EV 5001 - These valves are located on the fuel gas inlet lines to F-501 A,B,C,D, (Dowtherm furnace). These valves are electronic Maxon valves. E&F The block valves fail closed. The bleed valves fail open. EV-5001 D, E, & F are located on the pilot gas line. EV-5001 A, B, & C are located on the main gas line. HV 6005 - Located on the bottom outlet of T-611. This is a 10 inch gate valve requiring 200 PSIG nitrogen to operate. This valve is furnished with an override handwheel operator. Can be operated from control room also. Fail safe position is fail in place. This valve also has a reservoir tank to aid in operating. HV 7019 - Located on the recycle ethylene line back to LHC. This is a 3 inch gate valve that will operate off plant air. This valve can be operated from the control room only. Fail DO A 056770 CONFTDFNTTAl This valve also has a reservoir tank to help operate this valve. The above valves are operated by switches on a graphic panel in the con trol room. They all have limit switches and lights on the panel to indicate whether opened or closed. There are 10 control valves that can be used as Emergency Block Valves during an emergency. The following is a list of the valves, location, and fail safe position. FV 1123 - Ethylene flow control located downstream of E--111. Fail safe position is closed. FV 2227 - Solvent/octene flow control valve to R-211 located between P-211 A/B/C and EJ-211. Fail safe closed. PV 2248 - Reactor pressure control valve. Located between E-511 and D-511. Fail safe is closed, LV 5243 - D-500 level control valves. These are split range valves. EV AS.B 5243 A is on the return header from trains 1 and 2. LV-5243 B is on the make-up from D-502 to D-500. TV 5252 - Temperature control valves that control the temperature of the A&B Dowtherm liquid to train 1. TV 5252 A is on the train 1 return header going to D-500. TV 5252 B is on the line going from train 1 return to the suction of P-500 A/B/C. Fail safe on TV5252A is open, for TV 5252B is closed. FV 6000 - Wax flow from T-611 bottoms to D-511. Fail safe position is closed. FV 8038 - Flow control valve for octene makeup. This valve is located downstream of P-803 A/B. Fail safe position is closed. 00 A 0567? CONFTDFNTTAl 3.5 GAS DETECTORS The gas detectors in the Dowlex plant will be Rexnord brand detectors. 'UA.uf' We have an extensive gas detector system, locations are shown on Figure 3r*>. Dowlex has both single channel and eight-channel units. The single chan nel units are used for combustible gas measurements which are input to the TDC 2000 so gas concentration can be trended. The eight-channel units are used for area gas detectors. Do A 0567?? CONFTDFTNtt^i TABLE 3.1 GAS DETECTOR LOCATIONS The following Is the location of gas detectors in train 1 and equipment common to both trains. Train two has the same detector locations as train 1 1. Near F501 2. Near P500 A/B/C 3. Near P501 A/B/C 4. Flare area 5. Near C902 6. Near C903 7. Check Hopper 1A 8. " IB 9. HMB (blinders) 1A 10. " IB 11. " 1C 12-19 Hoppers 1-8 20-25 Hopper silos 1-6 26-27 Hopper bagging 1-2 28-35 Hopper loading 1-8 36. Near Dill 37, Near Cl11 38. Near Elll 39. Near YB211 40. Near P211A 41. Near P211B 42. Near P211C 43. Near FV2227 64. Near T611 44. Near R211 65. Near P611 A/B 45. Near A211 66. Near P612 A/B 46. Near R212 67. Near YB611 47. Near A212 68. Near P802 A/B 48. Near D301C 69. Near P809 49. Near D305 70. Near P811 A/B 50. Near D308 71. Near P806 A/B 51. Near D311 72. D202 Vent 52. Near D312 53. Near P312 A/B/C 54. Near P511 55. Near D511 56. Near P519A 57. Near P519B 58. Near E512 59. Near D512 60. Near VP512A 61. Near VP512B 62. Hold Up Hopper #1 63. Near P614 A/B 0^ <X DO A 056-7 OONFTDFNTT EMERGENCY SYSTEMS FIGURE INDEX FIGURE NUMBER 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 3.9 3.10 3.11 3.12 3.13 DESCRIPTION Potable Water System Potable Water Heater Block Layout for Fire Protection Plant Monitor Gun Locations (overview) Deluge Valve Locations (overview) Hydrant Locations (overview) Underground Fire Water Wet Filled Sprinkler Head Deluge Valve Foam Tank Storm Sewer Drainage Emergency Block Valves Pneumatic Cylinder Gate Valve Operations DO A 056774 CGNFTDFNTIAi DO A 0 5 6 7 ? OONFTDFNTTA POTAfiLE WATER SYSTEM I r f *. v*r#. SS aO STEAM CONDENSATE adjust steam pressure to the heater shell . . . ad mitting steam as the load or demand for hot water increases . . . and reducing it as the demand de creases. Even if the blender plug is held open by an object, and movement of the'valve is restricted, a yielding arrangement comes into play to auto matically permit shutdown of the steam to the heater. DIFFERENTIAL sensing head 6LEN0ED WATER OUT COLO WATER IN SAFETY DESIGN Even if something should go wrong with either unit ... it would produce only cooler water, or no water at all. A safety system designed'to help protect per sonnel and process from scalding. TEMPERATURE ADJUSTMENTS Temperature settings are easily made on the Leslie-Constantemp by using the adjusting rod located on the stem of the blending valve. A simple movement of the rod in one direction of the other allows outlet water temperature to be preset. As an added precaution, the adjusting rod locks with a lock ring and set screw ... a deterrent to tampering ... the blending device, however, re mains free to move in response to demand. In climates where the cold water supply tem perature varies greatly from summer to winter, a quick seasonal adjustment is easily made with the adjusting rod to keep temperature differential within the desired operating range. BLENDED water out 3.2 DO A 056726 CONFIDENT T Ai T FOAM OR WATER WATER ONLY y NOPIHQ BOflO I. *14333'-FT BA. N.l0 80*-0 'l BA. N.BBOS' ABA. l3BH*-6* '1V11NJGIJNOO zzz9yo v oa AA FIRE PROTECTION 8-i Q- 0*'* Q*-' ' 0-4 Om tU- lonoirn no* B /L N .B 805' DO A 0 5 6 7 7 8 C0NFTDFNTTA1 C cm 7 a p C FIR. 3 B DO A 0 5 6 7 3 0 C 0N FID FN 7TAI DO A 0 5 6 7 3 1 CONFTDFNTTAL FIR. 3.7 UNDERGROUND FIRE WATER () /8 l N.eeos- DO A 0 5 6 7 3 ? CO NFIDFNTTAL e/t iiMii' P| A 44 DRAINAGE g- Q*-* g O'*-' .0^.-1__ n-i o- o. iwm aim m*t DO A 0 5 6 ,7 3 3 CO NFIDENTIAL FIG. 3.12 EMERGENCY BLOCK VALVES SOLENOID PIPING TYPES ARE AS FOLLOWS: OPERATOR (TYP) SOLENOID B L XX r3*r >/i 4-WAY OUAL SOLENOID SEE SPECIFICATION NO. A6-6352-722B9 *JA1R SUPPLY GATE VA rJL(TYP) TYPE 1 (FAIL IN PLACE) BUG SCREEN SOLENOID A f-- 4-WAY SOLENOID j-J SEE SPECIFICATION NO. A6-6351-72289 AIR SUPPLY BUG SCREEN TYPE 3 (NORMALLY OPEN) TYPE 2 (NORMALLY CLOSED) R SUPPLY BUG SCREEN 4-WAY SOLENOID SEE SPECIFICATION NO. A6-6351-72289 CONTROL VALVES ON-OFF CYLINDER OPERATED FIG. 3.13 DO A 056734 CONFTDFNTTAl 4. RAW MATERIALS The following materials are used either directly or indirectly at Dowlex Octene-1 Isopar E Slip Superfloss Ethylene Mineral Oil Propylene Dowtherm A Hydrogen Silica Gel Magnesium Alkyl Molecular Sieve Triethyl Aluminum Chlorine Tetraisopropyl Titanate moc HC1 - anhydrous Fuel Gas Nitrogen Calcium Stearate Steam Irganox 1010 Condensate Weston 619 -Jraoft-- UV531 Lithium Bromide Activated Alumina it^SCSCSO&Jt 'Bapfesfie Betz DLTDP jm Lithium Chromate Octanol This section describes the important information relating to the above mat erials. Table 4-1 lists some properties. The raw material specification sheets and other useful data are included at the end of this section.* * DO A 056735 CONFIDENTIAL 4.1 RAW MATERIALS Ethylene (CjHj,) Flammable gas received by pipeline at 400 psig from the LHC plants (X, II, and III). Usage is 406 million pounds per year. It has a characteristic sweet odor, is not toxic but acts as an anesthestic. Explosive limits are 3% to 34% in air. It has about the same density as air. In an ethylene fire the best action is to shut off the fuel supply and activate the plant deluge system. Small fires such as valve packing can be extinguished using a dry chemical ex tinguisher. About 8% of this ethylene is recycled back to L.H.C. unreacted. Octene (CeH16) Flammable liquid received in tank cars or tank trucks from Gulf, Shell, and Ethyl. Usage is about 39 million pounds per year and it depends on the type of products that are made. Octene is used to control polymer density and densities are varied between products. It will be stored in two nitrogen padded, 100,000 gallon tanks. It has a characteristic sweet odor and is non-toxic. Fire fight ing should consist of deluge water and foam or dry chemical on small fires. Propylene (C3H6) This is a flammable gas at ambient temperature and pressure. It is re ceived as a liquid from LHC under 250 psig pressure. Propylene is used if high or intermediate density polyethylene is made. It is not used to make Dowlex. It is used to control density. It is similar to ethylene in odor and toxicity. Propylene is heavier than air so a leak will stay at ground level. In case of a large leak and fire, the fuel should be shut off before extin guishing the fire to avoid a 'flash back'. The deluge system will cool metal DO A 056736 CONFIDENTIAL but probably won't extinguish a fire. Dry chemical should be used on small fires. Hydrogen (H2) A very light, flammable gas received by pipeline from LHC III or in high pressure tube trailers. Usage will be 100,000 pounds per year. It is used to control polymer melt index. It is odorless and non-toxic. Explosive limits are 4.1% to 74.2% in air. The only way to reliably extinguish a hydrogen fire is to shut off the fuel source. Dry chemical may work on small fires. 4.2 PROCESS SUPPLIES Isopar E Flammable liquid received in tank cars or tank trucks from Exxon. Usage is 4.6 million pounds per year with 3.6 million pounds of that returned as waste solvent. Isopar E is stored in a 20,000 gallon API type tank. An ad ditional 50,000 gallons is stored in other in-process vessels. Isopar E is a <X mixture of iso-oct^ne, iso-nonane(C8 and C*) and small amounts of other paraf fins. It is not toxic and has FDA approval for food contact applications. Flammability limits are 0.9% to 7.0%. Fire fighting should include foam or dry chemical on small fires. Isopar E is the principal solvent in the plant; the catalyst is slurried in it and the reaction takes place in it. It is of ten called 'solvent'. Heptane Flammable liquid used for solvent by magnesium alkyl suppliers. The magnesium alkyl is a 10% to 20% solution in heptane. Properties are similar to those for Isopar E. DO A 05A737 CONFIDFNTTAL Triethyl Aluminum Commonly known as ATE (aluminum triethyl) or TEA. Received as a 15% solution in isopar E in tank trucks from Ethyl or Texas Alkyls. 100% ATE is pyrophoric - it ignites on contact with air and reacts violently with water. When diluted to 15% it is non-pyrophoric, however, it should be still treated as pyrophoric, because it becomes pyrophoric as the solvent evaporates. Latest fire fighting techniques recommend using a fine mist water spray. Dry chemical is also effective on small fires. ATE is hazard ous to personnel because it will cause severe burns. Usage is 48,000 pounds per year of contained ATE. It is used in catalyst preparation. Tetraisopropyl Titanate Trade name is Tyzor TPT. Received in 55 gallon drums from Dupont. Usage is 6000 pounds per year for catalyst preparation. It decomposes slowly on con tact with air and moisture to form isopropanol which is a flammable liquid. Dry chemical is effective for the quantities that are used. Magnesium Alkyl Magnesium alkyl is a general name for di-n-sec-butyl magnesium (DBM) sup plied by Lithium Corporation and butyl ethyl magnesium (BEM) supplied by Texas Alkyls. Both chemicals are used interchangeably for mixing catalyst. They are received in tank trucks diluted in heptane or isopar E to a 10% to 20% con centration. At 100% concentration both chemicals are solid. Magnesium alkyl is stored in a 3-compartment tank to keep shipments separated. Usage will be 82,000 pounds per year of contained magnesium alkyl. Magnesium alkyl is a pyrophoric solid, that is, if exposed to air it will ignite spontaneously. It also reacts violently with water. When dilut'd to DO A 056738 CONFTDFNTIAL 20% or below in a solvent it is considered non-pyrophoric although it must still be treated as pyrophoric because it can be concentrated if the solvent evaporates. Fire-fighting should be similar to that used for ATE. HC1 - anhydrous hydrogen chloride A highly corrosive gas when mixed with water. Supplied in 600 pounds net cylinders. Usage is 60,000 pounds per year. It is not flammable. It is corrosive to the eyes, skin, and respiratory tract. HC1 is used to mix catalyst. Diethyl zinc Also DEZ. Same properties and comments as triethyl aluminum. Usage de pends on catalyst research. It is used to mix catalyst. Mineral Oil (MO) Received in tank trucks. Usage is about 100,000 pounds per year. A typical oil is Exxon 'Primol' 355. It is used as a barrier fluid on the re actor seals. It is only moderately flammable. Silica Gel Received in drums or bags. Usage is about 220,000 pounds per year de pending on how often the silica gel is dumped from the beds. It is supplied as clear granules when new but may turn black or brown after being in service. It has a very high surface area that will adsorb many impurities in ethylene and solvent. It is not toxic except that the dust may cause silicosis - a lung disorder. Dust masks must be worn. Silica gel is non-flammable. DO A 056739 CONFIDENTIAL Molecular sieve Received in drums or bags. Dowlex uses two types: 5A molecular sieve and 13X molecular sieve. Usage will depend on how often beds are changed out. Its form is that of off-white solid regular shaped granules. It has a very high surface area per unit weight like silica gel and is used to purify ethy lene and solvent. It is not toxic except that dust may cause lung disorders. Dust masks must be worn. Molecular sieve is non-flammable, however it can cause a violent reaction if mixed with ethylene too quickly. Freon 22 Used in a closed mechanical refrigeration system on both trains. Usage should be zero after initial charging of units. It is non-toxic and non-flam mable but is an asphyxiation hazard. Also known as R22 refrigerant. Lithium bromide/lithium chromate/octetta These chemicals are used in the absorption refrigeration units. After initial charging, lithium bromide usage should be zero. Small amounts of lithium chromate and octanol (corrosion inhibitors) are needed. All three chemicals are moderately toxic. Dowtherm A --------------- 4 Received in tank truck ok drums for a closed loop heating system. It is a clear liquid when new but degradation may cause it to turn black or brown over several months. It is moderately flammable but it has a low vapor pres sure at high temperature. Its normal boiling point is 257C or 495F. The flammability limits are 0.5% to 6.2% at 500F. Dowtherm A is a mixture of di phenyl and diphenyloxide. It is mildly toxic and not corrosive. It has a DO A 056740 CONFIDFNTTAL o DO A 0567 CONFTOFNTI <x characteristic unpleasant odor. Its freezing point of 54F requires all equipment be steam traced. 4.3 POLYMER AWIT1VES Calcium Stearate (CaSt) A 'soapy* feeling white powder used to neutralize or kill the catalyst. It is received in 2200 pound tote bins. Usage is 600,000 pounds per year. It is non-toxic and approved for food contact applications. It is flammable and calcium stearate dust in air is a dust explosion hazard. Irganox 1010 A high molecular weight antioxidant that inhibits degradation of poly ethylene due to heat and air. It is received in 120 pound fiberpacks. Usage is 96,000 pounds per year. Irganox 1010 is a white, free flowing crystalline powder. It is FDA approved for polyethylene with food contact. It is slightly flammable. Irganox 1076 Like Irganox 1010 except lower molecular weight. Usage depends on pro duct mix. It is used in the hot melt additive system instead of Irganox 1010 because it has a lower melting temperature. Weston 619 A secondary antioxidant used in the hot melt additive system. It is received in fiberpacks and usage is 24,000 pounds per year depending on pro duct mix. It is supposed to provide additional processing stability of poly mer for customers. C50 A 05674? OONFIDFNTTAL DLTDP Full name is dilauryl thiodipropionate. It is a secondary antioxidant and is used in the hot melt additive system. It is a 'soapy' feeling solid received in flberpacks. Usage depends on the product mix. BHA Chemical name is Butylated Hydroxy Anisole. Another primary antioxidant. Received in flberpacks, it is a white powder. It is approved for use in food contact applications. UV531/TBS TBS (tert butyl salicylate) and UV531 are both ultra-violet light stab- alizers for the polyethylene. TBS is FDA approved for food contact polyethy lene but UV531 is not. Usage is 120,000 pounds per year and depends on pro duct mix. Both chemicals are received in flberpacks. They are used in the hot melt additive system. They are off-white (yellow) powdery solids. Dust masks should be used when handling them. Sli Other names are erucamide, Kenamide E, erucylamide, oleamide. It is an off-white waxy solid used in the hot melt additive system. It reduces the co efficient or friction of the polyethylene and allows polyethylene films to be more slippery. Usage is 60,000 pounds per year and depends on product mix. Received in flberpacks. DO A 056743 CONFTDFNTTAl Superfloss Also known as anti-block. It is a blend of polyethylene (7S%) and silica (25%). Silica is like sand. It is received in bulk hopper cars and stored in silos. It is added using a side-arm extruder. Usage is 320,000 pounds per year. It reduces the tendency of polyethylene film to stick together. 4.4 UTILITIES Chlorine (Cla) Green-yellow gas received by pipeline. Usage is about 15,000 pounds per year to control the growth of algae and bacteria in the cooling tower system. It is highly corrosive and harmful to all body systems especially lungs and eyes. Chlorine is non-flammable but can react with steel and titanium under certain conditions. Fuel Gas Colorless, odorless gas received by pipeline from the Division system. Consists mainly of methane and hydrogen and is highly flammable. It is non toxic. It is used to heat the Dowtherm furnace and to keep the flare pilot lit. Usage is about 840 million BTU per day. Nitrogen (Na) Colorless, odorless, inert gas received by pipeline from the Division 400 psig system. Its main use is to pad vessels to keep oxygen from the air from getting in. It is non-flammable and non-toxic; however, a special hazard exists from asphyxiation due to lack of oxygen. DO A 05A744 CONFIDENTIAL Steam and Condensate Steam is supplied in two systems: 235 pslg and 15 psig. The hazard of steam and condensate is their high temperature causing severe burns. 235 psig steam is used to jacket and trace all polymer and Dovtherm lines. DO A 056745 C0NFTD5NTTAI DO A 056746 CONFTDFNT I At. MATERIAL TABLE 4-1 SPECIFIC GRAVITY 2 0C DENSITY LB/GAL LB/SCF MELTING POINT C BOILING POINT C MOLECULAR WEIGHT Ethylene 0.97 Oct ne-1 0.71 Propylene (gas) 1.45 Propylene (liquid) 0.52 Hydrogen 0.069 Isopar E 0.715 Heptane 0.685 Triethyl aluminum 0.835 15% ATE in isopar E 0.735 Tetraisopropyl titanate 0.955 50% TPT in isopar E 0.84 Dibutyl magnesium SOLID Butyl ethyl magnesium SOLID 10% BEM in heptane 0.72 Anhydrous HC1 (gas) 1.18 Diethyl zinc Calcium stearate SOLID -- Irganox 1010 Irganox 1076 Weston 619 (liquid) UV531 0.920 to 0.935 TBS (liquid) 1.06 Slip (erucamide) Mineral oil 0.079 5.93 0.12 4.35 0.0056 5.96 5.71 6.96 6.13 7.97 6.97 SOLID SOLID 6.0 0.095 SOLID 13 to 33 LB/FT3 o vO V1 -169 -104 122.5 -185 - 48 -185 - 48 -259 -253 116 to 143 - 91 98 - 58 DECOMPOSES <C- 60 -- ~ 20 -- -- UNSTABLE -- UNSTABLE -- -- -114 - 85 UNSTABLE 156 120 -- -- -- 50 -- 40 -- 48 -- 63 -- 70-85 -- 28.05 112 42.1 42.1 2.0 123 AVG. 100.2 114.2 -- 284.2 -- 138 110.5 -- 36.5 147.4 607 1178 305 WESTON 618 732 326 335 DO A 056747 CONFIDENTIAL MATERIAL Chlorine (gas) Fuel gas (methane) Nitrogen Freon 22 Dowtherm A DLTDP BHA TABLE 4-1 (CONT'D) SPECIFIC GRAVITY 2 0C DENSITY LB/GAL LB/SCF MELTING POINT C 2.32 0.51 0.90 0.187 0.041 0.073 -102 -183 -210 BOILING POINT C - 35 -161 -196 MOLECULAR WEIGHT 71 ~16 28 1.06 8.85 12 257 166 50 -- 514 -- 180 DO A 056748 CONFTDFNTTAt 5. THEORY OF THE PROCESS 5.1 INTRODUCTION Polyethylene Is simply ethylene molecules combined with one another to form a distribution of longer, higher molecular weight chains. The chain lengths vary from 2 to over 200,000 ethylene units. This variance is known as the molecular weight distribution. 5.2 DENSITY Linear low density polyethylene (Dowlex) is characterized by a density range of 0.935 to 0.915. Octene can be incorporated into the ethylene chains resulting in side chains branching. The polymer chains try to fold upon solidification into a uniform structure called a crystal. This crystalline structure determines, to a large extent, the density of the polymer. Extensive branching hinders other chains from taking their preferred crystallinity, molten and solid densities are not equal quantities. These side chains can also affect the melt index of the product. Fig. 5.1 shows how these octene side chains at tach to the ethylene chain. Propylene also reduces density but more is re quired to give the same effect as octene because the side chains are shorter. 5.3 MELT INDEX Melt index is a measured property of the polymer and is useful in sepa rating the various grades of products. The melt index is the amount of poly mer in grams that will flow through an orifice of 0.0825 inches at 190C with a 2.16 kg weight as the driving force. The larger the molecular weight of DO A 056749 CONFIDENTIAL DO A 05,6750 OONFTDFNTT Al. chains, the lower the melt index. Melt index is also an indirect way of measuring the viscosity of this non-Newtonian fluid at one shear rate. The melt index can be controlled and affected in several ways. The ad dition of hydrogen causes the chains to terminate. So the addition of hydro gen to the reactors causes the smaller polymer chains to form resulting in a higher melt index. The reactor temperature also directly affects the melt index due to thermal chain termination (i.e. the higher the temperature the higher the melt index). Other factors affecting the melt index include im purities in the system, catalyst formations, and reaction conversions. Fig. 5.1 also shows how hydrogen terminates ethylene chain growth. 5.4 CATALYST M7X1HG The four major catalyst components are ATE (aluminum triethyl), HC1 (hydrogen chloride), MgR (magnesium alkyl), and Ti(OiPr),, (tetraisopropyl titanate). The following reactions occur during premix. 1. MgRa + 2 HC1 --------- MgCla + 2 RH Mg Cl a serves as the substrate on which the active ingredient is adsorbed. It has a high surface area ( 250 square meters per gram). 2. Ti(OiPr) <, + 2 HC1--------- Ti(OiPr)aCla + 2 ROH 3. --H--X HC1 '----------- Al(Et) ---- --x EtH The proposed reaction mechanism is as follows: (SEE NEXT PAGE) DO A 056751 CONFTDFNTTAl REACTION 2. RO^ ^,RO /T\ RO RO + 2 HC1 .Ti /\ RO Cl + 2 ROH REACTION 3. MgCl2 (Support) \ / \ /RO. .Et Et Ti Al m xci' ^ Et C1 * ads. HgCla A1(Et)3_xclx RO Cl \/ Ti---- ,, Adsorption / X ^ MgCla RO Cl ETHYLENE POLYMERIZATION CH2=CH a RO Et I Et \ X\/ Ti Al /|\ X \ RO I Cl Et Cl RO CHj-CHa------------ Et V FN.--'" Cl Et tX Et CH 2=CH 2 RO CHa"CH2-Et Et `AT \ Et Cl I. RO * CHa-CHa-R \.y' ,Ti: Al / RO 1 Cl' Cl Et xEt CHa=CHa R\ Ti Al RO | Cl Cl \ Et *. * RO H Et \ /\ / Ti. Al + CHj-CH-R RO Cl DO A 05675? CONFIDFNTIAL The titanium alkoxy-chloride and the aluminum alkyl chloride form a com plex which is adsorbed on MgCl2. The titanium contains an active site for the ethylene molecule and temporarily bonds to it. The ethylene double bond then forms a bond with the ethyl group attached to the aluminum molecule. A new bond forms between the aluminum molecule and the terminal carbon in the chain. This procedure is repeated until Ha reacts with the aluminum molecule thus terminating the chain. The chain can also be terminated thermally or by the addition of octene (or some other monomer). High reaction temperatures result in the hydrogen atom migrating from the ethylene 0 carbon atom to the aluminum molecule. The octene terminates the chain by sterically hindering the catalyst active site. 5.5 CALCIUM STEARATE The catalyst can be killed by the addition of calcium stearate. Calcium stearate contains about 3% water and both of these components result in the fol lowing catalyst kill reactions: rMgCla + HaO MgCla + HjO MgCla X H20; -^MgCl(OH) + HC1 + Ha0 *MgO + 2HC1 + Ha0 CaSta + MgCla ----------* MgSta + CaCla 2ATE + 3Ha0 ---------- * AlaOs + 6EtH Ti(OiPr) aCla + 2H20 ---------- ? Ti02 + 2PrOH + 2HC 'Tj ^ 2 s CaSta + 2HC1 ---------- CaCla + 2StH The catalyst substrate (MgCla) and ATE are destroyed by oxidation while HCl formation is inhibited by the formation of CaCla DO A 056753 CONFIDENTIAL Other polar compounds such as water, carbon monoxide, and carbon dioxide have the ability to deactivate the catalyst. DO A CONF TO 'H O H HH H H H \/ \/ i C = C + C = C -- H - C - C - C = C X C2 H4 -> /\ / H HH \ H t H 'h H H-C I H H i C i H H,H HX X = 0 T0> 200,000 ETHYLENE MOLECULES HHHHH H n H rH H H H - 'c - 'c C< c* - ct 4< c = C + H2-> H - c - c - c-4 c - c - I t/I I c H Hc H H X nh I I lI I < ( I H H HXH H H H/H H#H H-C-C<C-c4c ll/l|4 H Hv H H X R- C - H H H H H H H , H H H , H,, ,| H / ii / iiSiiivil / = C +H-C`C = C->H-C-C4C-C-C4C-C = C \I \ I I C I I ill S HH H H H H H HXH C3 Hg PROPYLENE HOPE & IDPE H H H nH (, Hn H H 1 H 1 H 1 H 1 H H 1 H 1 H-C 1 l\ + H C-C 1 C C 1 C-C C H H H HX H H H H H H H H N CB h16 OCTENE--1 H-C- -c -c=c HXH H LLDPE HCH I HCH H c1 H H cI H H cI H C H cI H I H FIG. 5.1 POLYETHYLENE AND ITS COMONOMER REACTIONS fJO A 056755 CONFTDFNTT At 6. ETHYLENE PURIFICATION AND COMPRESSION This portion of the plant is used to purify ethylene from the Light Hydrocarbon plants and to increase the incoming ethylene pressure from 400 psig to 650 psig for feed to the reactor. The normal flow path for the ethylene is first through a knock out pot (D-lll) which removes "heavies" (generally oil) that may be in the ethylene. The knock out pot is equipped with a high level switch that alarms in the control room. The oil, if not removed, will cause problems in the purification beds such as fouling and plugging. The purification beds remove impurities such as water, carbon mon oxide, carbon dioxide, and methanol. Analyzers before and after the beds measure the impurities which, even in small quantities, will cause the reactor to shut down. (Section 24.2) There are two sets of purification beds which are Y-lll A/B (silica gel) and the Y-112 A/B (molecular sieve). While 'A' bed say, is in service (absorption cycle) the other 'B' will be in a phase of regeneration. After the ethylene is purified it then goes through FL-111 which will remove any molecular sieve particles that would cause problems in the compressor. 6.1 ETHYLENE PURIFICATION (Y-lll A/B and Y-112 A/B The Y-lll A/B are silica gel beds designed to remove impurities from the ethylene. Silica gel is a clear granule with a high surface area for absorption. The regeneration of a silica gel bed consists of 4 cycles which are: A. Depressuring - this is removing the unit from service and bleeding the ethylene pressure off to the recycle ethylene drum, D-711, or DO A 056756 CONFIDENTIAL to the flare header. B. Heating - this is accomplished by blowing hot nitrogen at 45 psig (which is heated by steam and electric heaters) through the bed in the same direction of normal ethylene flow (downward). This process will dry out the bed and remove the impurities trapped during the absorption cycle. The operating temperature for this phase of regen eration for a silica gel bed is 260C. The amount of time required for heating will be hours. During the heating cycle a vent valve will open automatically at preset intervals of every 20 minutes, and will remain open for one minute. This is done to purge out any ethylene and impurities remaining in the bed and maintain a high purity of circulated nitrogen. C. Cooling - the purpose of this step is to get the bed temperature down to 50C which is the maximum temperature it would be safe to start the pre-load. Nitrogen will be circulated through the unit the same as in the heating cycle but steam and electric heaters will be bypassed. D. Preloading - this means to slowly start to adsorb the ethylene on the bed at a controlled rate so as not to exceed 100C at any point in the bed. NOTE: After preload is complete the bed is pressured up to 400 psig manually. NOTE: All beds have temperature readings at the top, middle, and bottom These will alarm at 300C during heating and cooling they will alarm at 100C during absorption and preload. DO A 056757 CONFIDENTIAL A typical flow path for regeneration is shown in Figure 6.5. The Y-112 A/B are molecular sieve beds designed to remove impurities from ethylene not removed by silica gel. Molecular sieve has a very high surface area (greater than silica gel). The regeneration of Y-112 A/B is exactly the same as for the Y-lll A/B with the following exception: The regeneration temperature during the heating cycle will be approximately 290C. Molecular sieve and silica gel beds may have a violent reaction if mixed too rapidly with ethylene. Both Y-lll A/B and the Y-lll A/B have re generation system isolation safety valves that will close in the event ex cessive pressure is on the system. Example would be if a bed in service at 400 psig was mistakingly lined up for regeneration. 6.2 E-111 (FIN FAN COOLER) When a gas is compressed its temperature will rise. Ethylene coming out of C-lll will be at 650 psi and approximately 100C. To lower this temperature it will pass through E-111 which is a fin fan cooler. The gas leaving the cooler will be 50C maximum which will allow for a lower feed temperature (and higher production rates) to the reactors. E-111 will shut down on high vibration and alarm in the control room. 6.3 ETHVLEHE FEEV COMPRESSOR (C-111) The compressor is an Ingersoll Rand, reciprocating, single stage, dual piston, double acting, design. C-lll operates with a 400 psig suction pres sure and discharges at 650 psig with a maximum rate of 30,000 pounds per hour and minimum of 7500 pounds per hour at 25% speed. Below a 25% speed a re cycle valve will open to control the discharge pressure. There are no un- 3SO loaders or pockets on these compressors. The compressor is driven by a DO A 056758 CONFTDFNTTAl hp. electric motor that is variable frequency speed controlled from 25% (125 RPM's) to 100% (500 RPM's). The speed is controlled by the discharge pressure. The motors are totally enclosed water and air cooled. (T.E.W.A.C.). C-lll will shut down automatically on high vibration, low oil pressure, low suction pressure, high discharge or high motor temperature. (See Table 6.4 for settings). DO A 0567 CONFTOFNTI ifi <1 TABLE INDEX FOR ETHYLENE PURIFICATION & COMPRESSION TABLE NUMBER 6.1 6.2 6.3 6.4 6.5 DESCRIPTION C-lll loop controls C-lll data and performance sheet C-lll electric motor data sheet C-lll trips & alarms Purification beds capacity chart FIGURE INDEX FOR ETHYLENE PURIFICATION & COMPRESSION TABLE NUMBER 6.1 6.2 6.3 6.4 6.5 DESCRIPTION Ethylene purification & compression flow sheet C-lll capacity/speed chart C-lll crankcase C-lll cylinder head Regeneration basic flow sheet DO A 05r>760 CONFTDFNTIAL ETHYLENE COMPRESSION & PURIFICATION CONTROLLERS LOOP CONTROL // PURPOSE OPERATION FIC 1004 Flow Ind. & Control To control recycle ethylene gas back into the feed system. By operating flow con trol valve FV1004 FIC 1123 Flow Ind. & Control To control ethylene feed flow to reactor By operating flow con trol valve FV1123 SIC 1126 Speed Ind. & Control To control the speed of C-lll thus discharge pressure By sensing a pressure change from PIC-1127A PIC 1127A Press. Ind. & Control To control discharge pres sure on C-lll thru SIC-1126A By sensing a pressure change in C-lll dis charge it will operate SIC 1126. PIC 1127B To control discharge pres sure of C-lll once C-lll has reached minimum RPM's By operating recycle valve PV 1127 TABLE 6.1 DO A 056761 CONFIDFNTTAl INGER50LL-RAND* GAS COMPRESSORS - OPERATING CHARACTERISTICS AND GENERAL DATA - COMPRESSOR TYPE: (2) 6*" 5 6V1 X 9M HSE-1-NL2 CYLINDER DATA AND PERFORMANCE (U.S. CUSTOMARY UNITS) Service Stage Cylinder or Liner I.D. (in.) Stroke (in.) Cylinder Type Cylinder Pattern Number Liner Thickness (in.) ETHYLENE FEED GAS COMPRESSORS 1 (2)6* 9 DA F-25900 3/8 Percent of Full Load 100 Intake Pressure (psig) Intake Temperature (F) 376.3 107 Discharge Pressure (psig) 657 Discharge Temperature (F)* 172 . Piston Displacement (cfm) 306.25 Capacity at Inlet (cfm) . 249.83 Dry Cubic feet per min, ref.14.7 psiA & 60 F 7082.3 Dry Pounds Per Hour 31,400 Safety Valve Setting (psig) 740 il BHP per Stage 309.3 Total BHP 309.3 RPM 505 Barometric Pressure (psiA) -14.7___________________________________________________________________ * Discharge temperature is estimated as an adiabatic rise. Key to abbreviations: SA -- Single Acting FE -- Frame End or Crank End OE - Outer End DA -- Double Acting TO _ Tall OnH TABLE 6.2 C-lll DATA SPECIFICATIONS DO A 05676? OONFIDFNTTAl INGERSOLL-RAND GAS COMPRESSORS - OPERATING CHARACTERISTICS AND GENERAL DATA - Make & Type ELECTRIC MOTOR DRIVER FUJI ELECTRIC COMPANY_____________________________________________________ BHP 350kW 261RPM 150 to 500 Voltage_iZi___ Phase 3Frequency 60 HzPower/Service Factor 10 Special Features TEWC. EXTERNAL COOLING FAN. CLASS 'F' INSULATION. 80 RISE BY RESISTANCE OVER 40 AMBIENT RTD'S LOW SPEED COUPLING (IF USED) THOMAS 5S0 CMR HIGH SPEED COUPLING (IF USED) NONE GEAR REDUCER MAKE & MODEL (IF USED) N0NE TABLE 6.3 MOTOR SPECIFICATIONS DO A 056763 CONFTDFNTTAl C-lll ALARMS/SHUTDOWNS CONDITION High vibration Low oil pressure Low suction pressure High discharge temperature ALARMS Mils /S psi 300 psi \fcoc SHUTDOWN Mils 10 psi 100 psi \2,0 C TABLE 6.4 DO A 056764 CONFIDFNTTAl ABSORPTION BED CAPACITY CHART BED # VOLUME EACH Y-lll A/B 315 cu. ft. Y-112 A/B 315 cu. ft. Y-211 A/B 285 cu. ft. Y-611 A/B 285 cu. ft. Y-801 70 cu. ft. Y-802 70 cu. ft. WT. OF MEDIA EACH 14,500 lbs. 13,500 lbs. 11,000 lbs. 13,000 lbs. 3,300 lbs. 3.300 lbs. TYPE OF MEDIA SERVICE Grade 05 Silica Gel Ethylene 5A Molecular Seive Ethylene 13X Molecular Seive Solvent Grade 05 Silica Gel Solvent Grade 05 Silica Gel Solvent Grade 05 Silica Gel Solvent NOTE: Bulk density of Grade 05 Silica Gel is 46 lbs. per cubic foot. Bulk density of Type 13X Molecular Sieve is 38 lbs. per cubic foot. Bulk density of Type 5A Molecular Sieve is 43 lbs. per cubic foot. TABLE 6.5 DO A 056765 CONFIDENTIAL r FROM REGEN. FROM REGEN. - smpi jt TO REGEN. SYSTEM TO REGEN. SYSTEM INCOMING ETHYLENE PURIFICATION AND COMPRESSION DO A 0 5 6 7 CO NFIDENT! FIG. 6.1 3> ^ CA~c.o i c.u rLnrunnHi\ot C- I I I &C- I 2 I FEED CAPACITY LB/HR- nr e o CAPACITY VS SPEED C- I II DO A 056767 CONFIDENTIAL PISTON ROD CRANKPIN BEARING CRANKSHAFT CROSSHEAD WITH REMOVABLE SHOES CROSSHEAD PIN AND BUSHING CONNECTING ROD OIL WIPER RINGS DISTANCE PIECE WITH BORED CROSSHEAD GUIDE jTP-121 FIGURE 6.3 C-lll CRANKCASE D0 A 056768 OONFTDFNTIAL OIL WIPER RINGS VALVE COVER CYLINDER OUTER HEAD DISCHARGE VALVE FIGURE 6.4 C-lll CYLINDER HEAD TP-904 DO A 0S67A CONFIDENT!A n2 supply TYPICAL FLOW PATH DURING REGENERATION FIG. 6.5 DO A 056770 CONFIDENTIAL 7. CATALYST The catalyst used in the Dowlex process is a Dow developed high effi ciency catalyst. Under ideal conditions the process uses two pounds of titanium per 1,000,000 pounds of ethylene. This catalyst is made from four different chemicals; magnesium alkyl, triethyl aluminum, tetraisopropyl titanate, hydrogen chloride and is mixed in solvent. 7.1 CATALYST STORAGE The chemicals used to make catalyst will react violently with air or water, therefore they must be stored under nitrogen pad. Magnesium alkyls are stored in D-301, which has three compartments; A, B, and C. Each com partment has level, pressure and temperature transmitters, with a high tem perature alarm. Magnesium alkyl is received by tank truck in a 10-20Z solution. Each truck of magnesium alkyls is of a different concentration and the catalyst mix quantities depend on this concentration, so therefore it must be stored separately. This is the reason D-301 has three compartments. D-301 is equipped with a pressure relief valve set to relieve at 102 psig to D-308 (See Section 7.3) Triethyl aluminum is also stored under nitrogen pad in D-302. D-302 is equipped with a level, pressure, temperature transmitter, and a pressure re lief valve set to relieve at 102 psig to D-303. Triethyl aluminum is also received by tank truck as a 15% solution. Titanate is received in 55 gallon drums. Titanate will decompose on contact with water so it is transferred to D-304 for storage which is also nitrogen padded. The titanate is diluted with solvent to prevent it freezing. D-304 pressure relief valve relieves to D-308 at 102 psig. DO A 056771 CONFIDENTIAL Hydrogen chloride is received in cylinders. 7.2 CATALYST MIX Each component of the catalyst is carefully weighed and transferred by computer into D-305 for mixing. D-305 rests on load cells, which give the net weight of each component. There are level, pressure, and temper ature indications for the mix tank. Hydrogen chloride is weighed in D-300 then transferred to D-305. D-300 is designed for 1500 psig. Its PSV relieves to the atmosphere. Titanate is weighed in D-309 then transferred to D-305. Magnesium alkyl, triethyl aluminum and solvent are weighed in D-305. D-309 relieves to D-308. In the catalyst mixing procedure heat is generated by chemical reaction so D-305 is jacketed. Cooling tower water is used on the jacket to remove this heat. The first step in the mixing procedure is to add hydrogen chloride to magnesium alkyl. This forms finely divided solid magnesium chloride which acts as the catalyst support. The catalyst at this point is pale-yellow in color. This step in the catalyst mixing process is where most heat is gen erated. This heat must be removed before the next chemical is added, which is titanate. If the temperature is not below 30C, the titanate will be de activated. After the titanate is added, the catalyst is a titanate complex supported on the magnesium chloride and is tan-yellow in color. The next step is to add triethyl aluminum which forms a titanate alum inum complex on the magnesium chloride support. At this point the catalyst DO A 05677? CONFIDENTIAL is complete and is tan in color. To insure the catalyst is thoroughly mixed, D-305 is equipped with a 1 hp agitator. This agitator is started and stopped automatically by the computer and the motor current is monitored by the computer. During the catalyst mixing procedure it is very important that the hydrogen chloride weights be as accurate as possible. If the catalyst has too little hydrogen chloride it w'ill not run, the catalyst will age rapidly and will give very poor efficiency. If the catalyst has too much hydrogen chloride extra triethyl aluminum will be needed to make the catalyst work. This will cause lower reactor temperatures which cause lower production rates, or will cause catalyst plugging problems. All catalyst components have flow control valves going to D-305. The pressure relief valve on D-305 is set to relieve at 120 psig to D-308. After the catalyst has been mixed it is transferred to D-306 or D-307 hold tanks. Here the premixed catalyst is stored until it is needed in the process. To keep the catalyst mixed D-306 and D-307 are equipped with 2 hp agitators. The agitator amps are indicated on the TDC2000. D-305, D-306, and D-307 are equipped with automatic block valves to al low mixing and transferring procedures to be carried out from the control room. These automatic block valves have limit switches to indicate if they are in the open or closed position. D-306 and D-307 have temperature and level indications. The pressure relief valves on D-306 and D-307 are set to relieve at 120 psig to D-308. When catalyst is needed in the process it is transferred from D-306 or D-307 to D-311 day tank. D-311 rests on load cells and is equipped with a % hp agitator. 00 A 056773 CONFIQFNT T Al The pressure relief valve on D-311 is set to relieve at 120 psi and re lieves to D-212 which is the dump tank for the reactors. The catalyst is pumped from D-311 by Milton-Roy duplex variable speed pumps (P-311A, B, and C) to R-211 and/or R-212. Normally the P-311's are set up to pump to one reactor using two pumps with one as a spare. This de pends on the catalyst efficiency and pump capacity. The Milton-Roy duplex pumps are adjustable stroke and variable speed. The stroke adjustment is usually on maximum. The speed of the P-311's is controlled by the reactor temperature. A flow indicator is installed in the P-311's discharge line to show the catalyst flow to the reactor. The P-311's also have an air operated three way valve on the discharge for recycling back to D-311. 7.3 WASTE CATALYST If for any reason the catalyst in D305, D306, D307, or D-311 is bad or gets contaminated it can be dumped to D308 which is the catalyst waste tank. The pressure relief valves on D305, D306, and D307 relieve into a header that empties into D308. D308 is vented to the flare header. There is a three way valve on this line to isolate D308 from the flare header if neces sary. The waste catalyst in D-308 is killed by adding process water to the tank and then is pumped from D308 to D809 using P-308. D-809 is used for waste solvent and bad catalyst. 7.4 SIDESTREAM CATALYST The sidestream catalyst is very important to the process. This side- CC A 056774 CONFIDENTTA1 stream catalyst is called triethyl aluminum or ATE. ATE is transferred from D-302 to D-312 which is on load cells. Triethyl aluminum is pumped from D-312 by Milton-Roy duplex variable speed pumps (P-312A, B, or C) to R-211 and/or R-212, normally one reactor R-211. Triethyl aluminum is used to activate the premix catalyst. If the tri ethyl aluminum is added too soon the premix catalyst will age rapidly, there fore the discharge lines from the P-311's and P-312's combine just before en tering the reactor. The stroke adjustment on the P-312's are normally on maximum with the speed ratio controlled from the speed of the P-311's. There is usually one P-312 running for each reactor with one as a com mon spare depending on the amount of triethyl aluminum needed and the pump capacity. The pressure relief valve on D-312 is set to relieve at 170 psig, and relieves to D-212 the same as D-311. The nitrogen pad and depad system on D-305, D-306, D-307, D-311, and D-312 allow the vessels to breathe during filling and transferring. Nitrogen pressure is used to make all chemical and catalyst transfers. 7.5 MILTON-ROY V1SC V1APHRAGM LIQUID b!V METERING PUMPS The Milton-Roy diaphragm pump is a seal-less pump suitable for pumping small flows of slurries like the premixed catalyst or calcium stearate. The diaphragm is hedraulically balanced between the process liquid on one side and the hydraulic oil on the other side. The hydraulic oil takes the place of a mechanical connection between pump plunger and diaphragm. In a disc diaphragm liquid end pump, the reciprocating pump plunger al- DO A 056775 CONFIDENTIAL ternately forces hydraulic oil against the diaphragm and then draws the oil back into the plunger bore. This action causes the diaphragm to flex between the limiting contour plates. Each stroke of the plunger pulls the diaphragm toward the oil side con tour plate so that process liquid flows into the displacement chamber through the suction ball-check valve. Each discharge stroke of the plunger pushes the diaphragm towards the process side contour plate to expel the process liquid from the displacement chamber through the discharge ball-check valve. On each suction stroke, the discharge ball-checks are seated, and on each discharge stroke, the suction ball-checks are seated. This mode of operation prevents back flow and ensures liquid movement from the suction port, through the dis placement chamber, and out the discharge port. Precise hydraulic oil volume is maintained by an automatic air-bleed valve and a refill valve. DO A 056776 OONFTDFNTTAl TABLE NUMBER 7.1 FIGURE NUMBER 7.1 7.2 7.3 7.A 7.5 7.6 TABLE INDEX FOR CATALYST DESCRIPTION Loop Controls for the Catalyst Pumps FIGURE INDEX FOR CATALYST DESCRIPTION Catalyst Mix Catalyst System Agitator Data for A-306 & 307 Agitator Data for A-311 & 321 Agitator Data for A-305 Milton-Roy Diaphragm Pump DO A 056777 CONFTDFNTTAL LOOP CONTROL NUMBER TIC-2249 TABLE 7.1 LOOP CONTROLS FOR THE CATALYST PUMPS PURPOSE Temperature controller for R-212 OPERATION Controls catalyst flow to R-212 by controlling the speed controller (SIC-3081) of P-311 A or B. TIC-2275 Temperature controller for R-212 Controls catalyst flow to R-212 by controlling the speed controller (SIC-3090) of P-311 B or C. FIC-3103 ATE flow controller for R-212 which is determined by the catalyst flow Controls ATE flow to R-211 by con trolling the speed controller (SIC3108) of P-312 A or B. FIC-3107 ATE flow controller for R-212 which is determined by the catalyst flow. Controls ATE flow to R-212 by con trolling the speed controller (SIC3104) of P-312 B or C. DO A 058778 CONFIDENTIAL ci r DO A 0 5 6 7 8 0 CONFTDFNTTAL FIG. 7.2 CATALYST SYSTEM FIGURE 7.3 TAG NO. : items asos i A307 LIOHTI\iii\i 7 1 S 2 MIXER AS COMMON PRACTICE. FLANCE BOLT HOLES ARE SHOMN STRADDLING TANK CENTERLINE. TANK BAFFLES ARE NOT FURNISHED BY UGHTHIH BLEANFOFTLHE., jo TABILJZINC FINS PLATE 5102ft NOZZLE design data IMPELLER DATA vertical DOMNNARD load (POUNDS)I TOROUE (INCH-LBS.) BENDING MOMENT (lNCH-LBS.il 1.100 3.380 ___ 23.600 TYPE l A200/A200 RPMi 56 QUANTITY OF BLAOESl 4/4 KEYNAY ON SHAFT ALLOWS FOR THE FOLLOWING IMPELLER ADJUSTMENT In 3* Increhentsi SEE NOTE 10 . 102 DESIGN LOADS ARE CREATE* THAN ACTUAL LOADS BY A SUITABLE FACTOR. CONSISTENT HITH CONSTRUCTION COOES ANO LICHTNIK EXPERIENCE. M1XIN0 EQUIPMENT CO. INC. DOES NOT WARRANT. OUARANTEE. OR ASSUME ANY RESPONSIBILITY FOR THE DESIGN OR CONSTRUCTION OF THE NOUNTJNO PLATFORM FOR THE MIXER. ______________ UNIT MOUNTING FLANGE DATA ISO LB. ANSI (ASA) SERIES DRILLING Ewm SB1.ZcEVl B 0.0.113-1/2 NO. OF EGU1-SPACED BOLTSiB 11-3/4 FLANGE THICKNESS FOR BOLTlNCl 2-3/4 mSoUNtVnC BOLTS HOT FURNISHED BT LI CHTNIV 1 NOTES 1. REFER TO INSTRUCTIONS FOR START-UP AND MAINTENANCE PROCEDURES. ANO SAFE LIFTING PRACTICES. 2. ALL DIMENSIONS ARE IN INCHES. 3.UNMLAETSESRIOATLHEORFWMISIEXERSPPEACRIFTIESDIK. THE TMNIC 1* STra4. TOTAL MIXER WEIGHT(LESS MOTOR) 624 POUNDS. 5. TANK HOST HAVE MINIMUM OPENING SIZE OF 9 DIAMETER TO PASS DISASSEMBLED MIXER PARTS. 6. CLEARANCE REQUIRED ABOVE MIXER AND ABOVE IMPELLER(SI TO PERMIT REMOVAL OF SEAL CARTR100E. 7. CLEARANCE REQUIRED FOR PULLER ASSEMBLY (OPTIONAL). B.CLEARANCE REQUIRED FOR OIPSTICK REMOVAL. B.MECHANICAL SEALl __ PER OMCi IT-820 STYLEi C COOEt T-3 INLET 4^UTLET^ONNECTIONS TO SEAL LUBRICANT l/S NPT 10.IMPELLERS ARE ADJUSTABLE ON A 48* CONTINUOUS KETNAY. Motor - 2 HP - 575 Volts DO A 056781 CONFIDENTIAL r> | iianGI qaia | 5121 0.0. l;C. NO. Of UH Of HOKS IOUS 5 10 l-i ? 6 II 4-1 '2 it 25 zzVa I'45 ii '/* IJ3 U. A5A 5UIIS fl>NCI OBIUING. HOifi snuoou ctNiuuNi as shown (mounting ions rutNiSHto y cusiomci) BAIH.C WIDTH 1/12 TANK 01 A. MOOll APPROX HP wT IBS A C Cr C V'JSOS-TS 1 l no I'l 1)0 '-.'r.os-so 1 'J ns "! ''.OS 75 )/. ns v>r.:5-icr 1 no n JC3S -1 SC 1-1/7 "Too moj-jco 7 ISO *JIC3S-J0_0 28*1 l-J/8 J-7/8 78-J/B 1 *S'8 k-J/l. 2 8-W2 TrT7r JJ-J/a ji.-1/i. 1-7/8 A-J'1- 2-1/7 10-7/8 TMFCLLSR QU/PPZ> vjrrn Stabjuz7^ FIGURE 7.4 "IVIINGCJIJNOO ee^9so v oa 1. All OIHIHS'OHS AAC IN INCHtS UNLESS OTHERWISE SflCIfllO 2. AH HIXER PARTS IN CONTACT WITH TANK CONTENTS ARC OTEL. UNIESS OTHERWISE SPCClTitO ). PROPS ARC NOT TO Bt RC10CATC0 FROM POSITION SHOWN SCAWFE-T/ VY COS/EKts-- * MuEnCitHAN*ICATLURSNCisA/l^.TOTPwCitTh-2aSdouble TANK BATTltS NOT TURNISHCO BT MIXING EQUIPMENT CO. IMPELLER R.P.M. a IMPELLER 01 AMI HR 7. MINIMUM OPINING KEQUIREO TO PASS IMPIUIA UUAlHIO I MOM SMAIt IS 9.Q PIAMtllN 8. SCRtALA/O. Q0/94309G, % H&\V/ESrW*ER T/ECE : (MOTOK) APP&OX. GO LBS. .1, A A IV UAM V ciamiivo l .0. TXW CHEMICAL INTER1L .A/33GDSicm> Z7FNI3 A3/1 f A32J >qm> 72Z8&-L50/2 MIXING fOUIPMINI CO. INC '.! . I * f ATt !- t<P>. DESIGA/ LOADS 1 UQHTNM WAUBtlON 3,s\ * - -7://-S3 943C&S>A 796 B-29 TORQUE - 200 TN. LBS. BCND/A/6 MOMENT - 7700 TM ESS. ' * ' -tv*, /< rn /riAn- Pt'c>O^IFrS. DO A 0 5 A 7 8 3 CO NFIDENTIAL 'D 1 FLANGE DATA \ SIZE 0.0. .c. NO. OF SIZE OF HOUS IOITS H* s <0 B-l-1 6 II <-l '2 16 ll io ?i//4 II V4 ISO U. ASA Sims KANGl DRILLING. HOUS ST1AODU CtNKIUNI AS SHOWN (MOUNTING IOITS fUlNlSHID IY CUSTOMER) T>3/V LOADS : 70not/E - 530 TM /bO. TSCND/M2 MOrtEMT-13.300 TN. /Z>3. S/CXTJCAL KWNWAXX) LOAD - JOQ ClA. 11 BAFTI.C WIDTH I/ll TANK 01 A. I"0FFWALL MOOEL APPROX HP wf LBS A c Er G MJCDS-1S 1 'A 110 VM33S*13 I'J 110 28* J'4 l-3'8 nr-s-sc 1 '7 ISS JJ'.CS-75 !/ IBS 29* JAB 1-5'B NJTSOS-ICC I 270 TFT7T nJ JGOS*1 SO i-l'l JoO HUGOS-TOO 2 * JSO JJ.J/A lA'I/A 1*7/8 N]]C0S-100 _L JiL TTTTT 3-7 '8 (,.)/!. A*)/A 2 2-1/1 8*1/2 10*7/8 FIGURE 7.5 \ 1. ALL DIMENSIONS ARC lli V<ChES UNLESS OTHERWISE SPECIFIED 2. ALL HIXER PARTS IN CONTACT WITH TANK CONTENTS ARE 5TEF~L UNLESS OTHERWISE SPECIFIEO ). PROPS ARE NOT TO BC RELOCATEO FROM POSITION SHOWN A. UNIT IS FURNKMEO WITH A DOUBLE . MECHANICAL SEAt.TTPC T-3________ 5. tank baffles not furnisheo sr MIXING EQUIPMENT CO. 6. IMPIUER R P M 230 IMPllllR PI AMU I R /4.Z. J. MINIMUM OPINING RIQUIRIO TO PASS IMPUIIN UlUCMIO IMUM SHAIT IS /3.0 PI AMT TIM O. SK/AL At7. 00/943005 9* t-fA V/ST rt/xert P/CC.: Aioro^ -appjcoa . to/as. l 120 It/ A /. A HI V If fWAVJS an*iioT . . | io DOW CHEMICAL JWEH'L *'*"*i A/J3GVS-/OQ__ >c~o TTF2M AJOS.____ o-o 722Q9rL2QlZ____ mi omi MIXING (QUI'MlMf CO . INC (to**to *wMrt.S(r--* |.* I *!a i * UabfTNIN' S&sJ * B 0*w 2zIQ:Q0 043C&5A 102 h B-iy DO A 0 5 6 7 8 4 CONF ID F N T I Al FIGURE 7.6 SUCTION BALL-CHECK VALVE Mllroyal Disc Diaphragm Liquid End 8.0 REACTION We have two identical reactors on each train, R-211 and R-212. The reactors are 10' diameter spheres with a 4500 gallon capacity. Each reactor runs liquid full and is continuously stirred by an agitator with four pitched blades. The agitator turns at RPM's and is driven by a 200 hp electric motor. Assisting the agitator for better mixing there are five evenly spaced baffles contoured to the walls of the reactor. The reactor is tem perature controlled at 200C by catalyst flow to the reactor. The reactors are pressure controlled at 450 psi by a pressure control valve that drops the pressure to 20 psi in the first devolatilizer. R-211 and R-212 have emergency isolation valves on the feed into the reactors, and the polymer in and out of the reactors. These valves will be operated from the control room. R-211 and R-212 have nine temperature indications and a high temperature alarm. The temperature control point comes from a temperature transmitter located at the top of the reactor. The temperature transmitter has high and low temperature alarms. The pressure control point for R-211 is located at the top of the reactor and has a high and low pressure alarm. 8.1 REACTANTS ANV CONTROLS Ethylene from LHC at 400 psi is compressed to 650 psi and flow controlled to the reactor. Prior to entering the reactor, ethylene is mixed with solvent (IS0PAR E) at 600 psi and cooled from 50C to 10C in a cooling water exchanger (E210) and chilled water exchangers (E211 A/B). The ethylene is mass flow controlled to the reactor based on production. The flow is compensated for DO A 056785 CONFIDENTIAL temperature and pressure changes in the ethylene feed stream so pounds per hour do not change if on computer. The solvent is ratio controlled (about 5 pounds solvent per pound of ethylene) to adsorb the heat of reaction. 85% of the ethylene is converted in the first reactor, 7% is converted in the se cond reactor with no additional feed flows. Conversion is controlled at 92-93% by the solvent/ethylene ratio; to increase conversion add more sol vent. This takes out more heat, and more catalyst is added to maintain the reactor temperature, this extra catalyst increases the conversion. (See Table 8.1 for various cause-effect relationships.) 8.2 VUAL REACTORS Some products require a 'dual' reactor set up. On dual reactor runs, additional feed and catalyst are added to the second reactor (R-212). A 10% portion of low melt index material is made in R-212 and a 90% portion of high melt index material in R-211. This allows us to make a broad molecular weight distribution. Reactor flows on dual reactor runs are in the bottom of R-212 and out the top to R-211 bottom for 10% of the production. The re maining 90% of ethylene and solvent enters R-211 along with R-212 product. The top off of R-211 goes to E-511. (See Fig. 8.1) 8.2 CATALYST Pre-mix catalyst and ATE are ratio controlled by variable speed Milton Roy duplex pumps to control reactor temperature at 200C. The ATE is used to activate the pre-mix catalyst. ATE to pre-mix catalyst ratio is very impor tant for good catalyst efficiency. Too much or not enough ATE will bring the catalyst efficiency down. The computer will constantly adjust the ATE ratio to get maximum catalyst efficiency. DO A 056780 CONFIDENTIAL i.4 MELT 1HVEX Hydrogen is mass flow controlled into the ethylene stream to the reactor for melt index control. The hydrogen stream is compensated for temperature and pressure changes so pounds per hour hydrogen does not change. More hy drogen produces a higher melt index. Less hydrogen produces a lower melt index. We have dual line viscosity probes on the outlets of both reactors. The viscosity probes show if the polymer is getting harder or softer. A downward trend on viscosity would indicate softer polymer or higher melt in dex. An upward trend on viscosity would show a harder polymer or lower melt index. Hydrogen concentration in the ethylene is analyzed by an on-stream gas chromotograph. The hydrogen to the reactor has a wide range of flows for different melt indexes. We have 3 different size flow meters and two different size control valves for more accurate flow control of hydrogen. (See Fig. 8.8.) #.5 VEUSITy Octene is flow controlled into the solvent stream before entering the re actor for density control. More octene produces a lower density. Less octene produces a higher density. Octene is used for linear low density polyethylene that has a density range from 0.915 to 0.935. However lower and higher den sities can be produced and still be classified as linear low density polyethy- WM|wi y (.930 to .945) and high density polyethylene (.945 to .970). Fig. 8.2 shows the den sity control scheme. Figures 8.3 and 8.4 show the relationships between den sity, percent octene and melt index. DO A 056787 CONFTDFNTIAI 8.6 REACTOR JACKET AWP BLOWDOWN The reactors are jacketed for heating and cooling of the reactor walls. 235 psi steam is used to keep the reactor warm when the train is down. Cool ing tower water is used to help absorb some of the heat of reaction when the train is running. The jacket is equipped with a PSV that relieves to the atmosphere at 275 psi. Each reactor has two PSV's that relieve at 750 psig into D-212 where poly mer is separated from ethylene and solvent vapors. (See Fig. 8.3) Polymer falls to the bottom with vapors going out the top into the flare header. To keep polymer from going out the top with vapors, quench water spray nozzles are used. D-212 also has a PSV that relieves to the atmosphere at 102 psig. D-212 is 235 psig steam jacketed to flash off vapors and keep poly molten so it can be padded out the bottom of D-212. A pancake blind would have to be installed in the vent line to do this. N2 lines tie into the top of both reactors so they can be padded out for maintenance. Both R-211 and R-212 can be padded out the bottom to D-511. There are flow alarms on each reactor safety valve discharge line to detect leaks. 8.7 REACTOR SEALS The seal on the reactor agitator shaft is a double mechanical seal. (See Fig. 8.6) Mineral oil at 20 psi to 50 psi above reactor pressure is supplied to the top of the seal through a level controlled seal oil pot. The seal pot is supplied from D905 and P907 (Section 23.2 ). The pressure on the seal pot is maintained by a N2 cylinder with a pressure regulator. (See Fig. 8.7) We have a low pressure alarm and a high flow alarm on the seal oil pot. We have a combustible gas alarm near the seal to detect leakage to the outside. If DO A 056788 CONFIDENTIAl the seal starts leaking to the inside we can by-pass the seal oil pot and use high pressure solvent from the P-211's. There is a flow indication on this solvent so the amount can be included in the solvent to ethylene ratio calculation. See Fig. 8.8 - Agitator Data See Table 8.2 - Reactor Control Loops. DO A 0F6789 conftdfntiai TABLE NUMBER 8.1 8.2 8.3 8.4 FIGURE NUMBER 8.1 8.2 8.3 8.4 8.5 8.6 8.7 TABLE INDEX FOR REACTOR SECTION DESCRIPTION Cause Effect Chart Reactor Control Loops A-211 Data Emergency Dump System FIGURE INDEX FOR REACTOR SECTION DESCRIPTION Dual Reactor Flows Density Control Scheme Relationships Between Density Percent Octene and Melt Index Reactor Blow Down A-211 Seal Diagram Seal Oil Pots DO A 056790 CONFIDENTIAL TABLE 8.1 - CAUSE EFFECT CHART INCREASE WOULD CAUSE GO UP - GO DOWN Hydrogen Octene % Solvent/ethylene ratio Solvent/ethylene ratio Solvent/ethylene ratio Melt Index Melt Index Melt Index Density ATE Premix ratio Temperature melt index density melt index conversion catalyst efficiency density Iio/Ia (MWD) viscosity I10/Ia (MWD) catalyst efficiency melt index go up go down go up go up go down go up go down go down go down or gsgoo down up go up DO A 056791 CONFIDFNTTAL LOOP FIC-2227 FIC-1123 FIC-2214 FIC-8039 PIC-2248 TIC-2249 TIC-2275 LIC-2301 LIC-2306 TABLE 8.2 REACTOR CONTROL LOOPS PURPOSE Flow control solvent to re actor. OPERATION Ratio controlled with ethylene to absorb heat. Ethylene flow control to the reactor. Flow control ethylene for production rate. Flow control Ha to the reactor. Flow control Ha for melt index. Flow control octene to the re actor . Flow control for density. Reactor pressure control. Let's down pressure into D-511. Reactor temperature control. Controls speed of catalyst pumps, P-311 A or B. R-212 temperature control. Control level in D-213 A. Temperature control on dual re actor runs. P-311 B or C speed. Seal oil pot level control on R-211. Control level in D-213 B. Seal oil pot level control on R-212. DO A 05679? CONFIDENTIAL MIXING EQUIPMENT CO.. INC. 0OX U?0 134 MT- "EAO Bl-VD. HOCHtSTER. *. Y. USOJ A UNIT OP OCNIRAL IIBNAL LIGHTISH 1ST MIXERS AND AERATORS . 0243016 1 DOW CHEMICAL CO. DOW CHEMICAL USA P. 0. BOX 150 PLAQUE MINE, LOUISIANA 70764 PLANT 86 IHIP TO--------- ATTN: M. E. BOURGEOIS irptl mO. co. no TAG: ITEMS A211, 212. 221 & 222 0DC MQ *ca no 72289-L5012 72289-L5012 . a no iwwr 4 invoice 0* 1C te*m} net )e date m pocmeite*. * t. MSI? iOTTS! mnnpi /SiSgUU 30 SHIPPED r:or*___ ~ ~PAir UAL (O O. 09445261-4 PREPAY & ADD RYDER IMSIAU Know. DATA uaunit IAACT tAf* 781 121.2 73 I LICnTnim 0C 944526 mOTOa ON C*"il -fC^TuU-- nOWPOMtH .pjm CmCLOMMH TssiTTrnrinraTcr UfOt RELIANCE 447T 200 1800 XP SPECIFICATION ssmOK -- -- Crais KIVI 575 60 hutf 3 foRNiXlD it UOUMltP ST LIG* TNIN IMifl MOMBAL B4 irauior Pttnm tact > Tank ccwTfan "UZ-lTiT Vp.V STEEL LCnCIm MOm MIC. MM 72" C0U*LMC TTM RIGID Aaovt mu UlO* MU Off OTTO*._Ql!_ HUM .APT EAl ADY \*IN TWTTBir Type NO. OF ALAMl lumtat ' ,Te I I HUB~.tO 0,sc""O fn 10>{I Ou 73" TYPE A201 mo. Of pulms to 4 HUB CD RMC DISC *to CD mtm cd 1n.11 va r;?5'b 23b 24" PSIG _c__ .UC*CaT0* FVLLt* AiHmMLf *tOA*<AL UAL - STYLf stuffmc ioj TANtUApj |nid* **eiw*f UAL CM fiUMC TTfl TTPf UVdMCihATtAlAL MM TAHt 0tMMCft(0 0. *UNK 120" OrfAU T oO*1 HiKXT JL ttumao CXeanTITT LiMCTtf. MlDTM _ 5 ss 18" EKIE \YA Off *ALL OfSTAMCC - SCHEDULED SHIPMENT \2-!'Z0 DATE TABLE 8.3 c DO A 056,793 CONFIDFNTTAl TABLE 8.4 EMERGENCY DUMP SYSTEM a. When to use ----- The Emergency Dump System is primarily designed for use in extreme emergencies when the plant is in imminent danger of severe damage and where this damage can be minimized by emptying any or all of the following vessels: R-211, R-212, R-221 and R-222. Operation of the system will be authorized by the shift supervisor. These emergencies are defined as: 1. Geniune pressure rise significantly above the pop valve set pressure. 2. A massive reactor leak where other normal control systems will not reduce the leak to a satisfactory level. b. How to operate ----- Turn the appropriate valves on the dump system panel to the "Open" position. The quench water valve to D-212 and D-222 will have to be opened manually. As soon as practical after activation of the system, the dump lines that were used should be purged with either steam, or nitrogen. This is to minimize cleanup problems and should not be attempted until it can be done safely. After the emergency is over it will be necessary to clean out the tanks. The shift supervisor will initiate the clean-out procedures after he has inspected them and satisfied himself that is is safe to work in the area. When there is an emergency requiring dumping any of the above mentioned vessels, the emergency horn will be sounded. 00 A 056794 CONFIDENTIAL ADDITIVES DO A 0 5 6 7 9 5 c o n f id e n t ia i nn n i REACTORS DUAL REACTOR FEED FLOWS TO 0-212 DUAL REACTOR FLOWS DO A 0 5 6 7 9 6 C O N FTD FN TIA l OCTENE/DENSITY CON ROL WITH ANALYZER TARGET FIG. 8.2 DENSITY CONTROL SCHEME DO A 056797 CONFTDFNTTAl n^ n PROCESS WATER REACTOR PSV BLOW DOWN DRUM DO A 0 5 6 8 0 0 CONFTDFNTTAl r TO VENT HEADER TO VENT HEADER DO A 0 5 6 3 0 1 c o n f id e n t ia l FIG. 8.7 SEAL OIL POTS FOR REACTORS Si^ -Z''\ 9. CALCIUM STEARATE Calcium stearate is pumped into the polymer stream after it leaves the reactor to neutralize the active catalyst components. A static mixer in the main polymer line improves the mixing of the calcium stearate and polymer sol ution. The calcium stearate stops the polymerization reaction. It also inhib its the formation of hydrochloric acid. (See Section 5). Calcium stearate is a powder and is slurried with solvent before it is metered into the product. The solvent is used only as a carrier for the cal cium stearate. Irganox 1010 is an additive we mix with calcium stearate to help keep the polymer from degrading. 9.7 MIX TANKS We have two mix tanks common to both trains. (D-401 and D-402) Each tank is continuously stirred by an agitator. The agitator turns at 56 RPM and has one impeller with four pitched blades. It is driven by a 2 hp el ectric motor. The motor has a high and low amp alarms. The mix tanks have a regulator to keep nitrogen pressure on the vessels. Na will have to be depadded to the flare when adding solvent and calcium stearate. The tanks are protected by a PSV that relieves to the flare at 150 psig. Each tank has a recirculation pump, P-401 and P-402. The seal flush for these pumps comes from P-611 or P-621. Both tanks have high and low level alarms. See Fig. 9.1 A-401 & A-402 Data. 9.2 VAV TANKS The day tank is continuously stirred by an agitator that has two impel- DO A 056803 CONFIDENTIAL lers with 3 pitched blades. The agitator turns 350 RPM and is driven by a 1 hp electric motor. The agitator has high and low amp alarms. The day tank has a Na pad and has a PSV that relieves to the flare at 150 psi. D-411 has a pressure relief regulator that relieves to the flare when transferring into the tank. D-411 has high and low level alarms. See Fig. 9.2 - A-411 and A-421 Data. See Fig. 9.1 - Calcium Stearate Control Loops. 9.3 MIXING Solvent from Y-611 or Y-621 is pumped through a totalizing valve-meter into mix tanks D-401 and D-402. The meter measures gallons and will automat ically close when the desired amount of solvent is added. 2300 pounds of cal cium stearate is used to mix one batch, giving a concentration of 12 weight percent. We receive calcium stearate in 2200 pound tote bins. The calcium stearate is transferred from the tote bin to the mix tank by a variable speed belt conveyor with 4400 pounds per hour capacity. There is a diverter valve and two automatic slide valves at the end of the conveyor to select which tank to unload to. Each tote bin will be weighed prior to transferring to the mix tanks. Irganox 1010 is mixed with calcium stearate in high and low concentra tions depending on product specifications. Low Irganox will be 100-300 PPM and high Irganox will be 400-800 PPM concentration in the polymer. This means 1.6% to 5% Irganox concentration in D-401. We receive Irganox in 110 pound fiberpacks. We will dump fiberpacks of Irganox into a hopper at the end of the belt conveyor to transfer Irganox to the mix tanks. Calcium stearate is transferred to the day tank D-411 remotely by operator command. D-411 is on weigh cells where calcium stearate is weighed and pumped into the polymer stream by variable D0 & OSr.804 confidential speed Milton-Roy duplex pumps, P-411 A/B. Approximately 11 pounds of 12% calcium stearate slurry per 1000 pounds of polymer is added at 750,000 cat alyst efficiency and depends on catalyst efficiency. This rate is controlled by a computer calculation based on the amount of premix catalyst used. There is a three-way automatic valve on the discharge of P-411 A and B which can be lined up to the static mixer, MX212, or to recirculate back to D-411. A high pressure solvent line from P-211's exists to flush the P-411's if needed. DO A 056805 CONFTDFNTTAL TABLE NUMBER 9.1 FIGURE NUMBER 9.1 9.2 TABLE INDEX FOR CALCIUM STEARATE DESCRIPTION Calcium Stearate Control Loop FIGURE INDEX FOR CALCIUM STEARATE DESCRIPTION A-401 and A-402 Agitator Data A-411 and A-421 Agitator Data DO A 0S&806 CONFIDENTIAL LOOP FIC-3134 TABLE 9.1 CALCIUM STEARATE CONTROLLERS PURPOSE Flow of calcium stearate to MX212. OPERATION Speed of P-411. DO A 056807 CONFIDENTIAL installation data for LtGHTiMilM 71 S 2 MIXER NO NOZZLE DESIGN DATA IMPELLER DATA v* 1A VERTICAL DONNHARO TYPE A200 RPMi 56 LOAO (POUNDS) l 1,100 OUANTITY OF BLADES I 4 KEYNAY ON SHAFT ALLONS FOR THE FOLLOWING ft. TOROUE IMPELLER ADJUSTMENT (INCH-LBS.) I 3,380 IN 3' loner INCREMENTSl Impellertis* ___ upward. BENDINC MOMENT (INCH-LBS.) i 23,S00 BY A OESICN LOADS ARE SUITABLE FACTOR, QR CO EATER THAN ACTUAL LOAOS MSISTENT NITH CONSTRUCTION COOES ANO LIBHTNIH EXP ERIENCE. NIXINO EQUIPMENT CO . INC. DOES NOT WARRANT. CUARANTEE, OR ASSUME ANY RESPONSIBILITY FOR THE DESIGN OR CONSTRUCTION 0 F THE MOUNT INO PLATFORM FOR THE MIXER. UNIT MOUNTING FLANK DATA 150 LB. ANSI (ASA) SERIES DRILLINC SIZEl t 0.0.13-1/2 NO. OF EQU1-SPACED BOLTSiS B.C.l 11-3/4 FLANCE THICKNESS FOR BOLTINCi 2-3/4 ?NOUNT1INOI BOLTS NOT FURNISHED BY LtCHTNttf ) NOTES 1.REFER TO INSTRUCTIONS FOR START-UP AND MAINTENANCE PROCEDURES, ANO SAFE LIFTINO PRACTICES. 2.ALL DIMENSIONS ARE IN INCHES. 3.MATERIAL OF MIXEA PARTS IN THE TANK IS STEEL UNLESS OTHERWISE SPECIFIED. 4.TOTAL MIXER HEICHT(LESS MOTOR) S22 POUNDS, 5.TANK MUST HAVE MINIMUM OPENINO SIZE OF 12-3/4 DIAMETER TO PASS DISASSEMBLED MIXER PARTS. S.CLEARANCE REOUIREO ABOVE MIXER ANO ABOVE IMPELLER(SI TO PERMIT REMOVAL OF SEAL CARTRIDGE. 7.CLEARANCE REOUIREO f6r PULLER ASSEMBLY (OPTIONAL). S.CLEARANCE REOUIREO FOR DIPSTICK REMOVAL. S.MECHANICAL SEALi PER ONGl IT-B20 STYLE l C COOEl T-3 1 N^Tl^UTLET^ONNECTIONS TO SEAL LUBRICANT 1/S NPT 10.UNIT IS FURNISHED NITH A LOAO LIMITER COUPLINO. Motor - 2 HP - 575 Volts FIGURE 9.1 DO A 058808 CONFIDENTIAL DO A 0 5 6 8 0 9 CO NFIDENT!AL L' -3 - roy"-^z - zoz xss. lbs. ZB\ **S AHW&/r- 7700 Xfit LBS. VSKtiCAL. Oowa/U/ARD LOAD- SSO L&S. f f lamgi data | SIZE 0.0. I.C. NO. Of SIZE Of HOLES IOL1S H* 1 10 o-l '2 ft II i-iv5 l& H 21 Hi. Sa 1 19 10 a. ASA SlilES HANOI DULLING. hClIS STlADOlf CENIEIlINE AS SHOWN (/cur.ting toils fCIINlSMEO IV CUSIOMEI) I DIA. 3b BAf f t,C WIOTH 1/12 TANK 01 A. X HOOEL APPROX HP WT LBS A* C Er C HC0S-2S 1 / c NJI'.OS- JJ t'3 **3 3005 - 50 1/2 xjy:s-;s 3/R i3j;;s-ic: 1 **j;:os-iso 1-17 sm :s-2c: 2 -;y^-3cc 3 110 120 15S 16S 290 300 3S0 3S0 28*1 '6 l-3'8 3-7/8 29-3/8 l-S'8 A-3/A 2 8-W2 TFT7T 3 3* 3 /* 3L-1 /L 1-7/0 I.-3/L 2-1/2 3A-3/L 10-7/8 SAFETY CovCf^id- | TA. I. ALL DIMENSIONS Alt IN INCHES unless oeheawisc spzcmco 2. ALL HIXER PARTS IN CONTACT WITH Tana contents are STE unless otherwise SPECtriCO ). PROPS ARE NOT TO BE RE10CATE0 fROH POSITION SriOwN It. UNIT IS fURNISHCO WITH A DOUBLE hechanical sealtTipe T-3 S. rana bArriES nor turniSheo it MIXING EQUIPHENI CO. fc. IHPEUER k p h 33Q _________ IHPIUEN PIAHiriM /3.I 7. HINIHUH OPININf. NIQUIREO 10 PASS IHPEllIN UEEAChIO IN0H SliAl I IS JZjlSL . UlAdEIEM fl. SERIAL A/O. 80/^45031 9, FrAV/F-jr wxe*: r/C<z; (A)07VR) APnCctf. 70LBS. Toso 48 dol % A. HI Mil | EMAMit T~ UlliNbit | ___ .O. TEA'S CHEMICAL INTER*i MlllMOMt , <*. ITEMS A41l<A4tl .om, _____ MIXING IOUIPMINV CO. INC * UMT QP OINIRAL k> t I UOhfTTtlirJ- S\ll,tH ,.A " U n. ** 7- //-ft->* OT'TF>7A - 10. DEVOLATILIZATION AND VACUUM SYSTEM 10.1 VEV0LAT1LJZATJON The polymer, solvent, and ethylene solution is heated to 260C in E-511 with Dowtherm vapor. The polymer solution flows through the tube side of E-511. Dowtherm enters E-511 shell side, is condensed, flows into a knock out drum, D-519 where liquid is level controlled back to the Dowtherm furnace feed drum, D-500 (See Fig. 10.1). The pressure drops from 450 psi to 20 psi before en tering D-511. (First devolatilizer) The polymer enters the side of D-511 tangentially which causes a spiral effect to help keep polymer from being carried overhead with the vapors. About 98% of the solvent is vaporized and flows out the top of D-511 to the bottom of T-611 (Wax Column Scrubber). D-511 is level controlled to the second devolatilizer (D-512) by a variable speed gear pump P-511. D-511 will hold about 2 hours of production. The reactors will not have to be shutdown because of minor problems in the pelletizer area. P-511 is a 34" inlet and 12" outlet. P-511 speed is from 2 RPM to 20 RPM and pumps 6000 pounds per hour to 40,000 pounds per hour of polymer. P-511 is designed for 4000 psig. The capacity and pressure will depend on melt index. The gear teeth fill efficiency, that is, the fraction of the teeth filled with polymer goes down with decreasing melt index and with increasing speed. The capacity is therefore not directly proportional to speed. If the discharge line is restricted, to protect pump and piping we have high discharge pressure and high gearbox torque shutdowns, other shutdowns on P-511 are high level in D-512. Low temperature on P-511 discharge line prevents P-511 startup. Polymer enters D-512 through a plate heat exchanger E-512, where polymer is heated to 260C with Dowtherm liquid. E-512 has hori- DO A 056810 CONFIDENTIAL zontal plates with vertical Dowtherm tubes (See Fig. 10.2). Poly enters the top of E-512 and flows across the plates and out the outside of the plates into D-512. D-512 runs under 5 millimeters of mercury absolute pressure. The re maining solvent is vaporized out of the top of D-512 into the vacuum system. Both D-511 and D-512 are jacketed with spiral pipe welded to the outside shell of the devolatilizers and heated with liquid Dowtherm. Dowtherm flow path to the jackets is the same on both devolatilizers. Dowtherm enters P-511 and P-512 housing through a devolatilizer temperature control valve into the bottom of the jacket of the devolatilizers and out the top of the jacket to the Dowtherm return header. Both D-511 and D-512 have PSV's on the jackets which relieve to the Dowtherm storage drum D-502. D-512 is level controlled manually by a variable speed gear pump (P-512) to the pelletizer. The level indicators on D-511 and D-512 are lead shielded devices that project radiation across the devolatilizer to read the level. Level can also be estimated by various temperature indications inside the devolatilizer. Both D-511 and D-512 have low, high, and high-high level alarms. If you get a high-high level alarm, shut down the reactors, before you overflow the devolatilizers. The flanges on D-512 vacuum system are ring joint flanges with a nitrogen purge. Nitrogen is used to keep air out of system in case of a leaking flange. Air causes specks and gels (due to oxidation) in the finished product and causes polymer to build up on the walls of the devolatilizer. 10.1 PEI/OLATILIZER LEVEL INDICATIONS Each devolatilizer has two radiation sources that project 1000 micro 00 A 056811 cNFrDFNTTAL curies. Each source is mounted to the outside wall of the devolatilizer in a safety source holder. The radiation outside of the source holder will not ex ceed 2 MR/hr at 12 inches. Each devolatilizer has two strip radiation detectors located on the op posite side of the devolatilizer radiation sources. As the polymer level rises the amount of radiation picked up by the detector decreases giving a level reading. See Fig. 10.5 - D-511 Level Indicator See Fig. 10.6 - D-512 Level Indicator 10.3 VACUUM SVSTEM The vapors out of D-512 are cooled by three exchangers in series. E-513A uses cooling tower water, E-513B uses chilled water, and E-514 uses freon re frigeration. Freon from C-911 is pumped into the bottom of E-514 where it is vaporized and returns. We have a high temperature alarm on the outlet of E-514 to C-911. E-514 is level controlled with Freon for maximum cooling. The solvent enters D-514 where liquid and vapor are separated. We have high and low level alarms on D-514. The liquid is level controlled to D-515. Solvent from D-515 is used to lubricate and provide the 'liquid ring' on vacuum pumps. The non-condensable vapor (mainly N2) is pulled out of the top of D-514 by a booster blower B-512. B-512 A and B are M. D. rotary positive displace ment, V-belt driven by a 10 hp electric motor that turns 1750 RPM. The blower turns 3115 RPM and is capable of pulling 1100 cubic feet a minute of non-con densables. On the outlet of the blower we have high temperature and high pres sure alarms. The vapor enters Nash vacuum pumps VP-512 A or B. VP-512 A and B and V-belt driven by a 60 hp electric motor that turns 1800 RPM. (See Fig. DO A 05681P CONFIDENTIAl 10.7 and 10.8 - Nash Vacuum Pump). The vacuum pumps are capable of pulling less than 5 millimeters of mercury absolute pressure. The vacuum pumps are two stage pumps with two suction inlets and one discharge. When the velo city is high through the pump the first stage does all the work. When the velocity is low, the second stage "kicks" in and helps the first stage to pull a higher vacuum. N2 is regulated to D-512 through a needle valve to keep a small flow through the vacuum pumps so they don't cavitate. Solvent from D-515 is cooled with chilled water in E-515 and Freon in E-516 and flow controlled for seal coolant and the liquid seal ring on the vacuum pump. This solvent flow is automatically shut off when the pump is shutdown. The vacuum pumps discharge into D-515. The liquid in D-515 is level controlled to T-611. Vapor goes out the top of D-515 into the flare header. We have a high pressure and high temperature alarm on the vapors out of D-515. We also have an oxygen analyzer on D-515 so we can tell if we have any air leaks into the system. (See Fig. 10.6 and 10.4 for a simplified diagram of the vacuum system.) See Table 10.1 - Devolatilization Control Loops See Table 10.2 - Vacuum System Control Loops DO A 056813 CONFIDENTIAL 10.A FREON COMPRESSOR We have a packaged refrigeration unit (Model //RWB AO) . The unit has its own factory mounted and wired control panel. The compressor is a positive displacement helical rotary screw compressor directly connected to a 125 hp, 1200 rpm electric motor. The compressor is capable of operat ing between 10% and 100% of capacity. Freon vapor from the suction (D-913) will enter the compressor at psi and C. Lubrication is achieved by pumping oil into the suction of the compressor with the freon vapor. The oil pump is a positive displacement gear type oil pump driven by a 3 hp, 1200 rpm electric motor. The unit has dual oil pumps. An electric heater located inside the discharge drum (D-911) heats the oil to operating temperature (C) for start-up. Freon R-22 is used as the refrigerant. (See Table 10.A for freon R-22 data.) The freon and oil are compressed to psi at C in C-911. The discharge of C-911 enters D-911, the oil separator/reservoir. D-911 is a 3 stage separator. The freon/oil separation is assisted by coalescing-type oil mist eliminators. The oil is temperature controlled at C by a cooling tower water exchanger. The oil is then filtered and pumped to the suction.of C-911 for lubrication and to the hydraulically actuated single slide valve for suction pressure control. The freon flows out the top of D-911 to E-911 where it is condensed with chilled water and gravity flows into D-912, the liquid vapor flash drum. The liquid freon is filtered and is flow controlled to E-51A and E-516 (solvent coolers on vacuum system). E-51A and E-516 are level controlled with liquid freon. The vaporized freon flow back to C-911 suction drum, D-913. A recycle line from D-912 (liquid flash drum) to D-913 (C-911 DO A 056814 OONFTDFNTTAl suction drumo with a pressure regulator will allow high discharge _____ psi to bleed back into the suction drum. See Table 10.3, C-911 Shut Downs. See Figure 10.10 and 10.11, Freon and Oil Flows. DO A 056815 CONFrDFNTTAL TABLE INDEX FOR DEVOLATILIZATION AND VACUUM SYSTEM TABLE NUMBER 10.1 10.2 10.3 10.4 10.5 DESCRIPTION Devolatilization Control Loops Vacuum System Control Loops C-911 Shutdowns Freon 22 Data Radiation Level Indicators FIGURE INDEX FOR DEVOLATILIZATION AND VACUUM SYSTEM FIGURE NUMBER 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 10.10 10.11 DESCRIPTION E-511 Diagram E-512 Diagram Simplified Drawing Vacuum System Simplified Drawing Vacuum System D-511 Level Indicator D-512 Level Indicator Nash Vacuum Pump Nash Vacuum Pump Diagram C-911 Freon Flow Oil Flow on Freon Compressor DO A 056B1A CONFIDENTIAL LOOP LIC-5093 LIC-5059 TIC-5088 TIC-5126 FIC-5138 TABLE 10.1 DEVOLATILIZATION CONTROL LOOPS PURPOSE OPERATION D-511 level control. Controls speed of P-511. D-519 level control. Controls flow of Dowtherm into the Dowtherm return header from D-519. Control D-511 jacket temperature. Control Dowtherm flow to jacket. Control D-512 jacket temperature. Control Dowtherm flow to jacket. Temperature control Dowtherm on E-512. Controls flow of Dowtherm to E-512. DO A 056817 CONFTDFNTIAL LOOP LIC-5176 LIC-5181 FIC-5222 LIC-5238 LIC-5253 TABLE 10.2 VACUUM SYSTEM CONTROL LOOPS PURPOSE Level control E-51A shell side. OPERATION Control Freon flow to E-514. Level control D-514. Controls solvent flow from D-514 to D-515. Flow control solvent to vacuum pump Controls solvent flow to liquid seal ring & seal coolent to VP-512 A&B. Level control E-516 shell side. Controls Freon flow to E-516. Control D-515 level. Level controls solvent flow from D-515 to T-611. A 056818 OONFIDFNTIAI 1 - High 2 - Low 3 - Low 4 - High 5 - High 6 - High'N TABLE 10.3 C-911 SHUTDOWNS Discharge Pressure Suction Pressure Oil Pressure Differential Discharge Temperature Oil Temperature Oil Temperature CONTROL SETTINGS 275 psig 10 psig 20 psig 220 F 150 F (/60'f> DO A 056.819 CONFTDENTT Al PRESSURE lb( in 2)/ j> \) C Table 10,4 Temperature versus Pressure Plot for Frecr 22 00 A 056>8 CONFTDFNTT TABLE 10.5 RADIATION SAFETY DEVOLATILIZER LEVEL INDICATORS A. Routine 1. Within sixty days after installation and semi-annual intervals thereafter, an inspection of all devices containing radioactive material shall be conducted by the Radiation Safety Committee to determine the general physical condition of the device, pro per shutter operation, and adequate posting of radiation caution signs. B. Personnel Protection 1. The source holder should be sealed locked and red tagged in the off or closed position when: a. The radiation device is physically moved away from the vessel including instation, relocation or storage. b. When individuals are working on or adjacent to a device during periods of shut down. c. Whenever an individual enters a vessel on which a device is located. d. Whenever a vessel or line is empty and an individual is working around the exterior of a vessel. Our Radiation Safety Officer is: Henry Hopper Phone #1877 Radio Page #8787-321 DO A 056801 CONFIDFNTTAl POLYMER OUT REACT. ' rRtSSURk C0NT7 /AL VE * TO D-511 CONFTOFNTT Al m; mi r C O N F ID F N T T A l o o 1> o On O' CD \> CO r i r* i o E-5 I 2 n FROM 0-512 I r> oo ZO _n D Z'n Con H O' -1 0) X> \) is. BOOSTER BLOWERS P-514B DO A 0 5 6 8 7 5 CONF TDFNT TAl o FROM B-512 __________________ VP-512A/B -----------------------o VACUUM PUMPS TO C-911 FIG. 10.4 SOLVENT CHILLER FREON - T-611 SOLVENT COOLER WATER FIGURE 10.5 7*1 ANT location 66 Louisiana Division manufacturer BLOC. NO. NO. UNITS FILE/JOLJB- N O-. TLA. 17*2. >ilo"9*, CHARGE NO. B/M N& P. 0. NO, ^r-.<"c=rs- 13'J'--1 _1_ 3 1 4 s * 7 1 f '0 II I 2 13 M IS '.l 17 II 19 JO lil a 77 24 23 21 27 21 29 JO 31 ? jj 34 JS 36 37 31 39 40 41 _42 43 43 47. 41 49 JO 31 32 33 34 spec r chcckcdi APP*Oi cps SERVICE THE DOW CHEMICAL COMPANY Radiation Level Instruments rwitinwnATF 1 4 1 ^ 11 1 r. 1 Do A 056826 CONFIDENTIAL CWI. M , B1--151/251 D--511/521 SPECIFICATIONS FIGURE 10.6 j?LANT FILE/JOB NO. LAi'll&i {location Louisiana Division BLOC. no. CHARGE NO. {manufacturer Ohmart NO. UNITS B/M NO. 1------------------------------------------------------------------------------------------------------ f. o. ho. sd>052 -- lo4"r3'^ I4 n n 3 1 31 l 3* tn i 3 UL HO 4) 43 43 1. Vessel wall is SA-516-70 steel 5/8 " thick on both the cone and straight side. 44 ' The iacket is A" SCH AO SA106B half pipe on 5 1/A" pitch. f 43 U 2. Vessel contents molten polyethylene 0.92 specific gravity. Jacket contents Iiovthenn A 0.81 specific gravity. # # 3. Operating temperature vessel contents 482 F, jacket 572 F. 49 5. Level devices will be mounted 8" from jacket wall. Vendor shall supply details S3 of supports required on vessel. D0 A 056827 ss CONFIDFNTTAL seeCBt cxec*EDi AFF*01 OATEi cps SERVICE THE DOW CHEMICAL COMPANY Radiation Level Instruments REVIUONOATE A | * C ' \. MO. D-512/522 SPECIFICATIONS s**ec. OONFTDFNTTAl Jash Type CL Vacuum Pump/Compressor FIGURE 10.7 O IN THIS SECTOR, LIQUID MOVES OUTWARD -- DRAWS GAS FROM INLET PORTS INTO ROTOR CHAMBERS 0IN THIS SECTOR, LIQUID MOVES INWARD--COMPRESSES GAS IN ROTOR CHAMBERS INLET CONNECTIONS ROTATING LIQUID COMPRESSANT LIQUID IN THIS SECTOR, w COMPRESSED GAS ESCAPES AT DISCHARGE PORTS Functional schematic of Nash unit. Disassembled view shows physical appearance of rotor, body and ported cones indicated on schematic. FIGURE 10.8 CONNECTIONS HOW IT WORKS The Nash compressor or vacuum pump has only one moving part -- a balanced rotor that runs without any metal-to-metal rubbing contact. Such simplicity is possible because all functions of mechanical pistons or vanes are actually performed by a rotating band of liquid compressant. While power to keep it rotating is transmitted by the rotor, this ring of liquid tends to center itself in the cylindrical body. Rotor axis is offset from body axis. As the schematic diagram shows, liquid compressant almost fills, then partly empties each rotor chamber during a single revolution. That sets up the piston action. Stationary cones inside the rotor blades have ported openings that separate gas inlet and dis charge flows. ABOUT LIQUID COMPRESSANTS A portion of the liquid compress ant flows through the Nash vacuum pump or compressor while it is operating. The liquid, which is dis charged along with the compressed gas, is usually taken out by a sep arator in the discharge line. Liquid compressant that accumu lates in the separator may be dis carded, and make-up liquid may be introduced to replace it. In a closed-circuit system, liquid com pressant may be cooled in a heat exchanger and recirculated through the system. Condensibles in the gas stream condense into the liquid compress ant. The accumulation may be dis carded -- as in the case of water vapor condensed out of humid air. Condensed liquid may also be re covered -- as in the case of sol vents drawn off during a drying operation. Flow rate of the liquid compress ant into a Nash vacuum pump or compressor is usually adjusted by a hand valve setting in combination with one or more fixed orifices. In a recirculated system, the Nash unit itself supplies pressure to main tain liquid flow. In a once-through system, the liquid should be sup plied at a moderate, fairly constant pressure. Water is the most common liquid compressant -- an obvious choice, for example, if the gas being com pressed or evacuated is air. A number of other compressants are used in various chemical proc essing applications. The choice can become a rather complex engineer ing problem. Nash applications en gineers have a mass of operating data on file, and they can advise you about liquid compressants that have proved successful with a wide variety of gases. Some of the considerations are compatibility with the gas, protec tion of equipment from corrosion, compatibility with any vapors to be condensed, vapor pressure, specific heat, specific gravity, viscosity and -- of course -- availability at a rea sonable cost A combination of processing ad vantages can often be gained by selecting the best liquid compress ant for a particular job, and this freedom of choice is one of the basic benefits that' the Nash prin ciple affords. DO A 0568P9 CONFIDENTIAL n -514 -516 r - 11 DO A 0 5 6 8 3 0 C O N F ID E N TIA L E-514 FROM -511 Fie**1 7 ) FIG. 10.10 C-911 FL 912 COOLING TOWER bL E-91? P-911A/B FL--911 A/B TO E-514 E-516 FREON FLOW FREON COMPRESSOR D0 A 056,831 C O N FID FN TTA L P E-514 ROM E-516 RECYCLE A i E-911 - - - - - - - - - *! CHILL WATER J E-514 E--51G DO A 0 S 6 B 3 ? CONFTDFNTTAL FIG. 10.11 OIL FLOW FREON COMPRESSOR 11. SOLVENT RECOVERY AND PURIFICATION The recovery and purification of the solvent after it has been through the system is an important part of the plant operation. 11.1 RECOVERY This portion of the plant is used to separate entrained polymer from the solvent (T-611), partially condense and cool the solvent while producing 15 psig steam in E-611, finish condensing the solvent in E-612, separate the ethylene from the solvent D-611, and mix in octene with the solvent. In nor mal operation solvent and unreacted ethylene vapors from D-511 enter the bot tom of the scrubber column, T-611, where the vapors rise up through two sets of Monel Pall ring beds. The rings are kept wet by liquid solvent being pumped over them from D-611 using the P-611 A/B pumps through a flow control valve and also by P-613 A/B that takes suction from the bottom of T-611 for recirculation of the solvent. T-611 bottoms is level controlled through the control valve on the discharge of the pumps P-611 A/B. A portion of the "bottoms" from T-611 is also pumped out by P-614 A/B through filters (FL-614) back to D-511. These filters help to reduce "specks" in the polymer. The P-614 A/B pumps take their suction from the discharge of the P-613 A/B pumps. Reboiler, RE-611, attached to the side of T-611, is a 235If steam heat exchanger that helps maintain the temperature and level in the bottom of T-611. Example: if the level in T-611 was too high, the re boiler (RE-611) steam control valve will start toward its open position to boil out more solvent from T-611. If the level continued to rise, the solvent flow from P-611 would cut back. The clean solvent and ethylene vapor exits the top of T-611 and enters DO A 056833 CONFIDENT T Al the tube side of E-611. Condensate is being pumped into the shell side of E-611 for the cooling of the solvent with the condensate being boiled off as 15 psig steam. The condensate level in E-611 is controlled by a control valve and has a direct relation between level and amount of steam being produced. The steam pressure is controlled by the condensate level. Some of the condensate is blown down to the condensate storage tank (D-908) through a flow control valve to prevent an accumulation of solids in the shell side of E-611. The 15 psig steam, generated in E-611, is utilized for tracing, to operate the ARU's, and for building heat. If the steam pressure becomes too high the header will be vented through a pressure control valve to a fin-fan cooler E-908, on D-908 the condensate storage drum. From E-611, the solvent and ethylene flow to an air cooled exchanger (E-612) for further cooling then to D-611. E-612 has a high vibration shut down switch. Octene analyzers are located at various points in the solvent flow path to analyze percent octene in the solvent. Octene is added, through a control valve, just down stream of the Y-611 A/B beds to compensate for what was con sumed in the reactor. It is possible also to add octene to the suction of the P-612 A/B pumps. D-611 separates the liquid (solvent) from the vapor (ethy lene) with the solvent being pumped out by P-612 A/B to E-617. 11.2 PURIFICATION This portion of the plant includes D-611, the solvent-ethylene separation DO A 056834 CONFTDFNTTAl tank, pumps P-612 A/B, filters FL-611 A/B, E-617, a cooling tower water ex changer, the silica gel beds Y-611 A/B, and the molecular sieve beds Y-211 A/B. In normal operation solvent is pumped from D-611 by P-612 A/B through E-617, which will cool the solvent to a lower temperature so that any poly mer still remaining in the solvent will come out of solution and can be re moved in the FL-611 filters. The FL-611 filters are the cartridge type which are in a single removable bundle. After passing through the filters the solvent flow through Y-611 (sil ica gel beds) then through Y-211 A/B (molecular sieve) and on to the suction / of the P-211 A/B/C and back into the reactor to start the cycle over again. P-211's are high speed Sundyne centrifugal pumps that rotate at 11,400 RPM with a capacity of 230 GPM at 650 psig discharge pressure. Normally two pumps will run at a time with one spare. A "Lark" three way check/bypass valve on the discharge of each pump maintains a minimum flow through them by sending some solvent back to D-611. Y-611's have a recirculation line from the outlet of the beds back to D-611 to maintain a constant flow through them. This recirculation is flow controlled. An important point is the level control of D-611. If a low level is reached in D-611 solvent will be made up from D-811, which is the solvent/mono mer storage tank, through a control valve on the discharge of the P-811 A/B pumps. On the other hand, if the level in D-611 is too high a control valve on the discharge of P-612 A/B will dump solvent back to D-811. For monitoring the effectiveness of the Y-611's and the Y-211's, water analyzers have been installed before and after the beds. The water concentration is monitored by the computer. DO A 056.835 CONFIDENTIAL II. 3 SOLVENT SILICA GEL BEVS (V-61J A/B) The solvent silica gel beds Y-611 A/B are designed to reduce water im purities from 100 PPM to 2 PPM. Other unknown impurities are also removed. Flow direction is downward during absorption and all phases of regeneration. Temperature of the bed is designed to reach 260C during the heating cycle. Thermowells are located at the top, middle, and bottom of each bed which are monitored by the TDC 2000. During absorption the high temperature alarm is 100C but during the heating and cooling cycle the high temperature alarm is 300C. Regeneration will be supervised by the computer. Any liquid that is removed in regeneration will be in the knockout pot YD-611. YD-611 is level controlled and will blow down any liquid to D-809 which is the waste solvent tank. The nitrogen regeneration system for these units operate the same as for the Y-lll's and the Y-112's. Padding out of the beds before regeneration is to D-611. II.4 SOLVENT MOLECULAR SIEVE BEVS [Y-211 A/B) The solvent molecular sieve beds are designed to reduce water impurities from 90 PPM to 2 PPM. Other unknown impurities are also removed. Flow direc tion is downward during absorption and all phases of regeneration. Tempera ture of the bed is designed to reach 290C during the heating cycle. Thermowells are located at the top, middle, and bottom of each unit which are monitored by the TDC 2000. During absorption the high temperature alarms is 100C but during heating and cooling the high temperature alarm is 300C. The nitrogen regeneration system for these units operates the same as for the Y-lll's and Y-lll's. Padding out of the beds is to D-611. DO A 05f>836 OONFTDFNTTAl Figures 11.1 and 11.2 are block diagrams of solvent recovery and puri fication. DO A 05A837 CONFTDFNTIAl TABLE INDEX FOR SOLVENT RECOVERY AND PURIFICATION TABLE NUMBER DESCRIPTION 11.1 Control Loops For Recovery FIGURE INDEX FOR SOLVENT RECOVERY AND PURIFICATION FIGURE NUMBER DESCRIPTION 11.1 11.2 Flow Path from T-611 to Y-611 Flow Path from Y-211 to E-211B O', <C DO A 056)B CONFTDFNTI TABLE 11.1 CONTROLLERS SOLVENT RECOVERY LOOP NUMBER PURPOSE OPERATION LIC-2195 Level Indica tion & Control To control the level in knock out pot YD-211 By opening blow down valve LV-2195 to the waste solvent tank D-809. FIC-2214 Flow Indica tion & control To control the flow of hydro gen to the ethylene feed stream. By opening one of the two flow control valves FV-2214A or FV-2214B. FIC-2227 Flow Indica tion & control To control the flow of sol vent feed to the reactor. By operating FV-2227. NOTE: the flow of solvent is dependent on the heat gener ated in reactor. FIC-6000 Flow Indica tion & control To flow control amount of sol vent back to D-511 through FL-614's. By operating the flow control valve FV-6000. FIC-6002 Flow Indica tion & Control To flow control the amount of solvent being pumped by P-613 A/B to T-611 Rashing Bed. LIC-6009 Level Indica tion & Control To control fer the level in T-611. By operating flow control valve FV-6002. <0ic. By operating FV-69G9 on the discharge of the P-611's and controlling the steam valve igr-6009 on RE-611. LIC-6036 Level Indica tion & Control To level control D-611 By opening a valve on discharge of P-811's to raise level LCV6036B and to open a valve dis charge of P-612's to D-811 LCV-6036. A 056839 CONFIOFNTTAl CONTROLLERS SOLVENT RECOVERY LOOP NUMBER PURPOSE OPERATION LIC-6028 Level Indica tion & Control To control level/steam pres sure in E-611. By operating LV-6028 a control valve on the discharge of the P-908 A/B. FIC-6027 Flow Indica tion & Control To maintain a blowdown flow on shell side of E-611 to prevent a sludge build up. By operating FV-6027 a blow down valve to D-908. FIC-6063 Flow Indica tion & Control To maintain a minimum flow on the Y-611 A/B to D-611 By operating flow control valve FV-6063 during periods of low flow through the Y-611 A/B beds LIC-6075 Level Indica tion & Control To blowdown the knock out pot on YD-611 regenerate system By operating level control valve LV-6075 to D-809 the waste solvent tank. FIC-8038 Flow Indica tion & Control To flow control the amount of octene being added to system. By operating flow control valve FV-8038. The set point of this controller is deter mined by the octene analyzers in the system. DO A 056840 CONFTDENTTAl 00 A 056841 C O N FID FN TIAL FIG. 11.1 SOLVENT RECOVERY .12 ETHYLENE RECYCLE COMPRESSION This portion of the Dowlex process is used to compress the unreacted ethylene from the reactors after it has passed through the devolatilization and solvent purification systems. The compressed ethylene is then sent back to the Light Hydrocarbon plant for cleanup. Unreacted ethylene gas is separated from the liquid solvent in D-611 and flows overhead to D-711. From there, the ethylene flows through the compressor first stage suction knockout bottle, into and out of the first stage of the compressor, into the first stage discharge bottle, through E-711 which is the discharge cooler and into D-712. At this point, the ethylene is at 89 psig. Any liquid accumulated in the bottom of D-711 is pumped to D-809 using D-711. From D-712, the ethylene flows into and out of the second stage of the compressor, into the second stage discharge bottle, through E-712 and into D-713. At this point, the ethylene is at 265 psig. From D-713, the ethylene flows into and out of the third stage of the compressor, into the third stage discharge bottle, then to the ethylene recycle line. At this point the eth ylene is at about 733 psig which is high enough pressure to get into the re cycle line to the Light Hydrocarbon plant. This pressure will vary depending on the LHC system pressure. Each stage of the compressor has a discharge bottle and the purpose of these suction and discharge bottles is to dampen the pulsations caused by the reciprocating compressor and to remove condensed solvent. The liquid level in D-711 is level controlled by a level controller and P-711 which comes on and shuts off automatically depending upon the level. The liquid level in D-712 and D-713 level cor oiled by a level control valve. The liquid in D-712 and D-/iJ is padded out using their drum pressure, DO A 05684? CONFIDFNTT Al to D-711. If there were a malfunction in this system or a large surge of liquid, a high level switch on D-711 will trip the recycle compressor (C--711). The first stage suction bottle is drained continually to D-711. D-711 pressure is primarily controlled by the speed of C-711. If the pressure in D-711 gets too high a control valve in the inlet line from D-611 will open relieving the pressure to the vent collection system. This would occur after the compressor is at maximum speed. If the pressure gets too low a control valve in the outlet line from C-711 will open allowing ethylene in. This would occur when the compressor is at minimum speed. A third suction pressure controller set lower than the other two, controls ethy lene from D--111 to D-711. If the pressure gets too low a low pressure switch will trip C-711. D-711 is equipped with high and low pressure and high and low level alarms. There is also level pressure and temperature indications. D-712 and D-713 are equipped with a high level alarm and pressure, level and temperature indications. The exchangers E-711 and E-712 are used to reduce the temperature of the ethylene after it has heated up due to compression of the gas in the first and second stages. The third stage discharge does not have a cooler. Cooling to wer water is used as a coolant in E-712 and E-713. A portion of the recycled ethylene can go back into the system at D--111 and the remainder goes to the Light Hydrocarbon plant. 12.1 C-711 C-711 is an Ingerso]-Hand reciprocating compressor. It is direct coupled DO A 056843 CONFTDFNTTAl to by a 350 hp AC motor with variable frequency speed control. The mini mum speed is 125 RPM and maximum speed is 500 RPM. C-711 is designed to pump 4600 pounds of ethylene per hour with 10 psig first stage inlet pres sure . There are three stages to C-711, first stage, second stage, and third stage. On the discharge of all three stages there is a pressure and tem perature indication, with a high temperature alarm, and a high temperature switch that will shut C-711 down should each stage discharge temperature exceed the maximum operating temperature of 120C. C-711 has a low pressure shut down on the lube oil system for crank case. The compressor cylinders, have a force feed lubrication system. This is to avoid damage to the compressor due to excessive heat. The discharge pressure of C-711 is determined by the pressure of the Light Hydrocarbon's ethylene recycle system. To keep C-711 from exceeding its designed pressure a safety relief valve is installed in the discharge line. A discharge pressure control valve is used to maintain a differential between both C-711 and C-721 and the line to LHC. This valve will prevent back flow. In order to reduce ethylene losses to the atmosphere and for ecological and safety reasons, the packing gland vent line for each stage is vented back to the first stage suction. The distance pieces are open to the atmosphere. The compressor itself is water cooled including the cylinders, packing areas, end pieces, and the oil cooler with cooling tower water. In case there is any problem C-711 can be shut down from the control room but must be started in the field. There is a high vibration switch that will shutdown C-711 as well. DO A 056844 CONFTDFNTIAL TABLE NUMBER 12.1 12.2 12.3 12.4 TABLE INDEX FOR ETHYLENE RECYCLE DESCRIPTION Loop Controls C-711 Data and Performance C-711 Electric Motor Data and Characteristics C-711 Trips and Alarms FIGURE NUMBER 12.1 12.2 12.3 12.4 12.5 FIGURE INDEX FOR ETHYLENE RECYCLE DESCRIPTION C-711 Ethylene Recycle Compression Flow C-711 Expected Performance C-711 Crankcase C-711 Compression Cylinder DO A 056845 CONFTDFNTIAL TABLE 12.1 LOOP CONTROLS FOR THE ETHYLENE RECYCLE SYSTEM LOOP CONTROL NUMBER PURPOSE OPERATION PIC-7003 Pressure controller for D-711. Increase or decrease speed of C-711 to control pressure on D-711. PIC-7020B Control of low suction pres sure. Opens allowing discharge flow into D-711. PIC-7024 Secondary pressure controller for D-711. Opens allowing ethylene into D-711 after C-711 has reached low speed. PIC-7024 Secondary control for high suction pressure. Opens allowing ethylene to the vent collection header after C-711 has reached high speed. LIC-7036 Level controller for D-712. Opens or closes allowing liquid back to D-711 depending on level. LIC-7042 Level controller for D-713. Opens or closes allowing liquid back to D-711 depending on level. DO A C5684A CONFIDENTIAl TABLE 12.2 INGERSOLL-RANDt GAS COMPRESSORS - OPERATING CHARACTERISTICS AND GENERAL DATA - ~ COMPRESSOR TYPE:16" g 7V 6 4-3/4" X 9" 2HSE-3 CYLINDER DATA AND PERFORMANCE (U.S. CUSTOMARY UNITS) Service Stage Cylinder or Liner I.D. (in.) Stroke (in.) Cylinder Type Cylinder Pattern Number Liner Thickness (in.) RECYCLE ETHYLENE COMPRESSORS 12 16 9 DA N-22121 7H 9 DA F-25900 h_____ Percent of Full Load 100 Intake Pressure (psig) Intake Temperature (F) Discharge Pressure (psig) 10.05 107 89.1 Discharge Temperature (F)* 261 Piston Displacement (cfm) 1039.02 Capacity at Inlet (cfm) 671 100 84.9 107 264.7 220 213.73 162.1 3 4 3/4 9 DA F-26174 3/8 100 253.5 107 733 228 84.11 56.77 Dry Pounds Per Hour 4635 4635 ____________ 1 4635 BHP per Stage 148 98 Total BHP 542 RPM 500 Barometric Pressure (psiA) 14.7 Discharge temperature is estimated as an adiabatic rise. 96 INGERSOLL-flAND GAS COMPRESSORS - OPERATING CHARACTERISTICS AND GENERAL DATA - ELECTRIC MOTOR DRIVER Make & Type_______ FUJI ELECTRIC COMPANY OF AMERICA____________________________ HHP350kW_________________________ 261RPM 1S0 t0 so Voltage__ Phase3Frequency60 HzPewter/Service Factor Special Features EXTERNAL COOLING FAN, CUSS F INSULATION, 80C RISE BY RESISTANCE OVER 40C AMBIENT, STATOR RTD'S, SOLEPLATE LOW SPEED COUPLING (IF USED) THOMAS 550 CMR HIGH SPEED COUPLING (IF USED) NONE GEAR REDUCER MAKE & MODEL (IF USED) NONE TABLE 12.3 00 A 05684B CONFIDENTIAL I TABLE 12.4 C-711 TRIPS 1. Vibration trips at g. 2. C-711 low oil pressure trips at 20 psi. 3. High discharge temperature's trips at 120C. (1st, 2nd, and 3rd stages) 4. Low suction pressure trips at 3 psi. 5. D-711 high level trips at 85%. 6. MC-711 high temperature trips at 125C. 7. MC-711 high current trips at amps. c C-711 ALARMS 1. D-711 high and low level. 2. C-711 low oil pressure. 3. 4. 5. High discharge temperature on all three stages. 6. C-711 low suction pressure. 7. D-711 pressure high and low. 8. C-711 high and low speed. 9. MC-711 high temperature. 10. MC-711 high cooling water level. 11. D-712 high level. 12. D-713 high level. DO A 056849 CONFIDENTIAL r FIGURE 12.1 C-711 DO A 0 5 6 8 5 0 C O N FID EN TIAL 10 lHC ETHYLENE RECYCLE COMPRESSOR EXPECTED PERFORMANCE C - 7 I I &72 I RECYCLE DO A 0568 CONF T DENT T CAPACITY LB/HR- PISTON ROD CRANKPIN BEARING CRANKSHAFT CROSSHEAD WITH REMOVABLE SHOES CROSSHEAD PIN AND BUSHING DISTANCE PIECE WITH BORED CROSSHEAD GUIDE OIL WIPER RINGS TPI212 FIGURE 12.4 C-711 CRANKCASE A 056853 CONFTDFNTTAL FIGURE 12.5 C-711 COMPRESION CYLINDER Do ^ 056{}s4 CONF jnttal 13. SOLVENT AND OCTENE STORAGE In the Dowlex process a large amount of solvent, (Isopar E) is used. The main function of solvent is to absorb heat from the reaction and be the carrier for the ethylene polyethylene and catalyst. It will take ap proximately 5 pounds of solvent per pound of ethylene to absorb the heat generated during the reaction process. 13.1 SOLVENT STORAGE Solvent is received by tank car or tank truck and is stored in D-801 which will hold 24,000 gallons. D-804 (sometimes referred to as the swing tank) can also be used to store solvent. D-804 can also be used for waste solvent (Section 13.5) or for a solvent and octene mixture coming from D-611. This is how it gets the name swing tank. The safety equipment for these two vessels (D-801 and D-804) are iden tical. They consist of level indications, low and high level alarms, and pressure indications with a low pressure alarm. To keep the pressure from getting too low or under vacuum, a nitrogen pad has been installed. They also have two pressure relieving devices to prevent the vessels from over pressuring. One device is a pressure-vacuum relief valve (PVRV) relieving to the vent header at 12 inches water or from the atmosphere at 2 ounces vacuum and another larger emergency relief valve (ERV) relieving at 24 inches water to the atmosphere. Other equipment associated with D-801 is P-806 A and B, P-801 and Y-801. Solvent is pumped from tank cars or tank trucks using P-806 A or B di rectly to D-801 or through Y-801 which is designed to remove water in the DO A 05685! CONFTDFNTI At solvent from 50 parts per million using silica gel. (See Fig. 6.6) The regeneration procedure is the same as Y-611's. Section 24.2 shows analyzers in this area. If a tank truck or car has to be unloaded while Y-801 is in the regen eration cycle, the solvent is unloaded directly to D-801. When Y-801 has completed the regeneration cycle, the solvent in D-801 is then recirculated through Y-801. As optimum flow is required through Y-801 in order for mois ture adsorption to be accomplished, therefore a flow control valve has been installed in the recycle line back into D-801. P-801 is used to recirculate solvent through Y-801 and also supply the different areas of the plant such as to D-305, D-311, D-312, D-804, D-811, and P-311's. 13.2 OCTEHE STORAGE Octene is received by tank car or tank truck and is stored in D-802 or D-803, which will hold 129,000 gallons or 5 tank cars each. P-806 A or B is used to pump the octene from the unload station through Y-802 to D-802 or D-803. Y-802 is a silica gel bed (See Fig. 6.6 for capa city). If Y-802 is being regenerated the octene is unloaded directly to D-802. When Y-802 has completed the regeneration cycle, (which is the same as Y-611's), octene in D-802 is then recirculated through Y-802 using P-802 A or B back to D-802 or D-803. An optimum flow is required through Y-802 in order for moisture absorp tion to be accomplished therefore a flow control valve has been installed in the recycle line to D-802 or D-803 to maintain the minimum flow. Section DO A OSfeB FA CONFTDF.NTT Al 24.2 shows analyzers in this area. Octene is pumped from D-803 using P-803 A or B to the inlet of Y-211's for further drying and to be mixed with the solvent-octene mixture coming from Y-611's. The amount of octene added depends on the amount needed for the correct octene percent in the solvent for the density target. This percent of octene in the solvent as determined by the on stream analyzer is controlled by the computer depending on the density required. The safety equipment for D-802 and D-803 are identical. They are equip ped with low and high level alarms, level and pressure indications, and a low pressure alarm. A nitrogen pad has been installed to keep air from entering the vessels. D-802 and D-803 also have two pressure relieving devices to prevent the vessels from over-pressuring or to prevent a vacuum on them. One device is a pressure vacuum relief valve (PVRV) relieving to the vent collection header at 12 inches of water and from the atmosphere at 2 ounces of vacuum, the other is a larger emergency relief valve (ERV) relieving to the atmosphere at 24 inches of water. 73.3 SOLVEHT/OCTENE MIXTURE In the Dowlex process ethylene is dissolved in a solvent/octene stream before it enters the reactor. After these components have gone through the reaction process, the solvent and unreacted octene are returned to D-611. Any accumulation of solvent in this solvent 'loop', from catalyst addition or sol vent content in the fresh octene (2-3%), will cause D-611 level to continually increase. The excess solvent is returned to D-811. If for some reason the DO COSjf? ? 056857 TCNTTfi,i level In D-811 gets too high this solvent/octene mixture can go to D-804 (swing tank) or D-809 (waste solvent). If the level gets too low, solvent can be added from D-801. 13.4 WASTE SOLVENT In the Dowlex process some of the solvent gets badly contaminated with moisture or other impurities such as, C-711 interstage solvent and regenerated solvent. This solvent can no longer be used and must be disposed of. It is sent to D-809 which is referred to as the waste solvent tank. D-809 is also used for 'killed' catalyst and solvent from D-308. (Excess solvent from D-811) Waste solvent is loaded on tank trucks for shipment and sold. The safety equipment and alarms for D-809 and D-811 are identical to the safety equipment and alarms on D-801, D-802, D-803, and D-804. The pressure vacuum relief valves (PVRV) on these vessels are dual act ing. The valves relieve positive pressure to the vent collection header. They are also capable of relieving on a negative pressure or vacuum by equal izing the vessel pressure with the atmosphere. 73.5 SOLVENT LOADING AMP UNLOADING Solvent and octene are received by tank truck or tank car. A tank truck is unloaded from the bottom. To prevent air or a vacuum in the tank truck a nitrogen line, open on one end, is attached to the tank truck to maintain at mospheric pressure on the tank and also provide a nitrogen atmosphere. The same applies when loading a tank truck, except the nitrogen line provides a means of venting the tank truck above ground level. A tank car is unloaded from the top. A nitrogen pad is used to pressure DO A 056,858 CONFIDENTIAL the solvent or octene to the pump suction, and to displace the liquid as it is taken out to prevent a vacuum on the tank. The nitrogen pad for the tank cars are pressure controlled by a pressure control valve to about 50 psig to prevent the tank from over pressuring and as a safety device a pressure safety valve is installed. Before a tank car or tank truck can be unloaded the car or truck must be grounded. The unloading pumps P-806A or B will not run if the ground cable has not been connected. This is for safety reasons. A ground indicator light is installed to indicate a proper ground. When waste solvent from D-809 is loaded, P-809 is used. DO A 056859 CONFTDFNTTAl TABLE NUMBER 13.1 TABLE INDEX FOR SOLVENT AND OCTENE DESCRIPTION Loop Controls FIGURE NUMBER 13.1 FIGURE INDEX FOR SOLVENT AND OCTENE DESCRIPTION Solvent and Octene storage and flow DO A 056860 CONFIDENTIAL LOOP CONTROL NUMBER TABLE 13.1 LOOP CONTROL FOR THE SOLVENT AND OCTENE STORAGE PURPOSE OPERATION FIC-8005 Control solvent flow through Y-801 Opens or closes to maintain minimum flow through Y-801 FIC-8048 Controls octene flow through Y-801 Opens or closes to maintain minimum flow through Y-802 LIC-8100 Controls level in YD-801 Opens or closes allowing liquid back to D-809 depend ing on the level in YD-801 DO A 056861 CONFTOFNTTAl SOLVENT AND OCTENE STORAGE HO A 05686? CONFTDFNTTAL ri n 14. U.l ADDITIVE SYSTEMS HOT MELT APPITIt/E SYSTEM The purpose of the hot melt additive system is to add substances to the final product to stabilize against oxidation or ultra violet light or to add slip (See Section 4.3). In this system, two vessels are available for melting and mixing of the additives (D-513 & 516). Each has an agitator to aid in the mixing process. Both vessels are jacketed and use hot water from the D-510 hot water system to heat the vessels. For low flow additive, generally 300 PPM or less in the finished product, D-516 will be used for melting and mixing. The additive can then be transferred to D-517 or D-518 by nitrogen padding. Normally D-517 and D-518 will be the additive feed drums. For high flow additives generally from 400-1200 PPM in the finish product, the additive will be melted and mixed in D-513 (D-513 is larger than D-516) then padded to D-517 where it will be level controlled into the process at D-512. For extreme high flow additive generally 1500-4500 PPM the additives will be melted and mixed in D-513, then padded out to D-516. From D-516 the additive will be flow controlled into D-512. A detailed description of how the rate of additives are controlled and injected into the process can be found in the Safe Operation Procedures. All of the additive lines to and from each of the vessels are so designed that they are hot water traced. Because of a certain amount of plugging problems in this system, the mineral oil system is tied into the additive line and will be used for flushing. The additive tanks are all jacketed and have hot water flowing to the jackets from D-510. 14.2 SIPEARM EXTRUDER AMP FEEP SySTEM The sidearm extruder (XS-511) is driven by a 75 hp AC variable speed motor J)0 A 056863 CONFID F.NTTAl 1750 RPM's maximum with a capacity of 25 pounds per hour minimum to 375 pounds per hour maximum. The purpose of the extruder is to inject additives (that cannot be added into the process with the hot melt additive system) into the process just ahead of the static mixer (MX-512). These additives are known as anti-block. Due to physical properties of the anti-block additives, being of a sandy type material, it has to be added after the gear pump, to protect the bearings in the gear pump. The feed for the sidearm extruder is a blend of polyethylene pellets and anti-block silica. The feed system is filled by the unloading rail cars using Bac-7 that air conveys the material from the rail car to either the additive storage hoppers (HAS-1 or HAS-2), or directly to the additive hoppers (HA-1A or HA-1B) located above the sidearm extruder that gravity feeds the extruder. XS-511 is a cold work extruder with a 3^" screw and L/D of 24, which simply mixes and melts the material as it passes through the barrel of the extruder. The barrel of the extruder has an outer shell that is divided into three sections and has 235 psig steam piped to each section. At the outlet of the barrel of XS-511 is a three way valve that can be diverted in the direction of the ground for purging of the extruder and then back to the process line. The three-way valve diverts to the ground automatically when XS-511 or P-512 shutdown. There is a nitrogen purge on the inlet to the extruder to keep air from causing black specks in the polyethy lene . 14.3 P-510 HOT WATER SYSTEM This system is used for supplying hot water to the jackets of D-513, D-516, D-517, D-518, and for tracing of all additives lines connected to these DO A 056864 CONFTDFNTTA! vessels. This is a closed water system in which "condensate" from the D-908 system is used in level controlling D-510. Hot water from D-510 is circulated to the various additive drums and lines mentioned above with P-510 and back to D-510. The water in this system is heated by a steam coil located inside of D-510. Steam from the 235 psig steam system flows through the coil. A tem perature control valve located in the inlet line to the coil regulates the amount of steam flow through the coil. This flow depends on the set point of the temperature controller versus the actual temperature of the water inside D-510. DO A 056865 CONFTDFNTTAL FIGURE NUMBER 14.1 14.2 HOT MELT ADDITIVE FIGURE INDEX DESCRIPTION Hot Melt Additives System Sidearm Extruder DO A 056866 CONFIDENTIAL n n2 system DO A 0 5 6 8 6 7 CO NFIDENTIAL FIG. 14.1 I l n t- i j r* i ii rFIGURE 14.2 SIDEARM EXTRUDER DO A 0 5 6 8 6 8 C O N FID EN TIAL 15. GEAR PUMP AND PELLETIZER 15. 7 GEAR PUMPS In this process there are two gear pumps on each train P-511, P-512, and P-521, P-522. Each are 34" Dow designed pumps driven through a gearbox by a 500 hp 1800 RPM AC variable speed motors. The motors are totally en closed water and air cooled (TEWAC). The pumps' capacity is from 6000 pounds per hour at 2 RPM minimum speed to 40,000 pounds per hour at 20 RPM maximum speed. P-511 pumps 98% polymer from D-511 through the plate exchanger, E-512, to D-512, (See Sec. 10.0). P-512 pumps polymer with less than 2000 ppm sol vent through static mixer, MX-512, to the pelletizer, K-511. The static mixer is 22 feet long with 11 mixing elements. It is designed for 4000 psig. There is a rupture disc upstream of the static mixer that relieves at 4000 psig to protect the pump. There is also a rupture disc on the pelletizer that relieves at 2560 psig to protect the pelletizer die. The static mixer is used to uni formly mix additives with the polymer. The speed of the pump is controlled from the control room or from the pelletizer control panel. The gear pumps have two herringbone gears which results in zero axial thrust. The pump body and gears are constructed of 4140 steel hardened to Rockwell 'C* of 32 to 36 hardness. The bearings are polymer lubricated and made of 4140 steel hardened to 36 to 40 hardness and plated with 0.005 inches of silver. The bearing surface is spiral-grooved to allow polymer to flow from the discharge side of the pump through the bearing to the seal cavity. From thorn the polymer flows through an Internally bored channel in the pump DO A 056869 CONFTDFNTTAl housing to the pump suction. An adjustable screw in the channel is used to set a certain back pressure in the seal area. The seal is asbestos packing in a conventional stuffing box arrangement. 15.2 GEAR BOX Each gear pump is driven by a speed reducer (G-511 and G-512) using both gear shafts. The speed reducers are 4 stage gearboxes made by Horsburgh and Scott. The gears are single helical and the teeth surfaces are carburized for hardness. The overall gear ratio is 90.3 to 1 and the torque rating is 131,300 foot-pounds with a service factor of 1.75. Torque sensing strain gauges are installed on one low speed output shaft. Output from these gauges shuts down the motor on high torque. There are strain gauges on the input shaft that can be used for torque measurements if needed. The gear pump and gear box are coupled on both shafts with 'Sier-Bath' couplings. The couplings are clamped to the shafts using 'Ringfeder' locking rings which expand onto the shaft and coupling. The oil system on each gearbox has the following features: 1. Two 2 hp, 1200 RPM gear type oil pumps. 2. Duplex oil filters. 3. Oil cooler requiring 20 GPM of cooling water. 4. Oil low flow switches for alarm and shutdown. 5. Two 2 KW electric oil heaters inside the gearbox. 6. All lubricated points have sight glass flow indicators. DO A 056870 CONFTDFNTIAL 75-3 PELLETIZER The pelletizer is driven by a 100 hp variable speed AC motor with the capacity of 35,000 pounds of polymer per hour. The purpose of the pelletizer is to convert the molten polymer into pellet form for handling purposes as a finished product. The polymer enters the pelletizer through a three way diverter dump valve. This valve is hydraulically operated. The polymer then goes through an arrangement of cylindrical screen pack elements. There are 27 of these screen elements giving 418 square inches of total screen area. The screen packs filter out black specks that may occur in this process. From the screen pack the polymer goes through a die plate which has approximately 900 holes that are 0.125 inches in diameter. The face of the die is 1/8" thick and covered with pie-shaped segments of tungsten carbide tile. After the polymer if forced through the small holes of the die it enters the water box. Here the polymer is cut into the pellets by a rotating cutter assembly positioned right at the die face. Simultaneously the polymer is rapidly cooled by water that enters through the bottom of the water box. Inside the water box, there is a shroud that directs some of the water flow directly at the disc. The flow of the pellet water transfers the pellets out the top of the water box and up to the spin dryer. The pellet size and shape which is refer red to as granulation, is important in the majority of the product types that are made. To achieve and maintain good granulation several things are to be considered: pelletizer speed, the flow rate from the gear pump, the amount of wear of the cutter knives, pellet water temperature, melt index and den sity of the polymer. The die, die housing, the diverter valve, and the screen changer are heated with liquid Dowtherm. DO A 056871 CONFIDFNTIA1 7 5.4 THE HWRAUL1C SYSTEM FOR K-511 SCREEN CHANGER AtW THREE WAV V1VERTER Wlve This system has a 40 gallon reservoir; 5 hp 1800 RPM hydraulic oil pump. There are two accumulators that hold 7.5 gallon of fluid each and maintain 1500 psig. A high and a low pressure switch monitor the pressure in the sys tem and start and stop the pump accordingly. There are two safety valves that relieve back into the reservoir. For the screen changer, hydraulic fluid flows through a 4-way solenoid operated valve that diverts the screen changer in or out. For the three way diverter valve the fluid flows through a 4-way solenoid operated valve to the diverter valve. In both cases operation of the 4-way solenoid valves is by push buttons on the pelletizer/gear pump control panel (CP-K511). Do A 05687? CONFIOFNTrAl. TABLE NUMBER 15. 1 15.2 TABLE INDEX FOR GEAR PUMPS AND PELLETIZER DESCRIPTION Control Panel and Name Plates P-511, 512/K--511/XS--511 Interlocks and Alarms TABLE NUMBER 15.1 15.2 15.3 15.4 FIGURE INDEX FOR GEAR PUMPS AND PELLETIZER DESCRIPTION Hydraulic System Pelletizer Spin Dryer and Classifier Flow Pelletizer Devolatilizer & Pelletizer Control Panel DO A 056873 CONFTDFNTIAL TABLE 15.1 CP-K-511 and NAMEPLATES i 2 7/flit 3 S, Hit II-1U7A 1 ii-uzia 4 Tt-HSSA 7 Ti-fl} 7A > TiZM-flf} PS-tiff id G-flfO // HOA'fffO >i as fin is a-fin /f HOA-tlfl if VS fill /< X-fHf /; MOA-fH f /< HOA-flfT r* G-flfS 20 moa firs 2/ sc-mt 22 TlC-K-fllA 23 7K-P-1H6 2V TlC-P-fllC 2r TlC-K-IIID 24 Sl-K-fll 27 ii-a- ina 22 px-ms 2 Pot-fill 30 Ji-x-ine 3/ 32 Mi-rso-ruB 33 a -so-rn 3 ms- so-fno ir G-BACP-tO 34 a -BACP-U 37 6-Cl-fII 38 ms-ci-me 3* 10 G-MK-fO *tf pe-n-fus 11 PS -K- fllA IS S C-M-fll 11 HS'K'fit If vs-x-ru it HOA-MfH 17 6 1117 It PS-1/f7A n pe-nna ro MOA-mg ft Cl-01-inA u Pt-Pi-fUA IS G-OV-TUB 11 PB-Ov-fUB If A-R-1HB n H-SC-fll 17 P8-SC-1UA ft PB-SC-fHB 11 Ti-e-rnc to T/-UPC-IA tl pi-K-niB *2 G-PV-H-fUA 4) ppi-Kfue 41 HS-R-fll 41 44 17 4$ 41 70 CP -X- fll MAMCPLA re PUr.MA VIMG r/psr aue see AMMUMC/A TOP eAJCPA VIAIG SCCOMO UMC D-f'Z p-uz o-m p-m o-m STMS TC/HX speeo Level AMMcrex CUTLCT TCMP Ml- HZ p-m p-m cuner tcmp. DR!vex TCMP. start / xeser guz aiix. cuee OIL PUMP RUM G-i/i aux cuee p-m GHZ MAIM LUBC OIL PUMP ernex stop OIL PUMP RUM c ut MAIM LUBC p-m G-m e-m p-m vAPiAste p-nt dpi vex p-m ox/vex p-m OIL PUMP poi/ex OM MPA Tex on MCA Tex COMTX sxeeo comtxol rummima comtxol seeeo comtxol DV-fll sen/ TCMP. TCMP. Die UOUSIMG Die PLATS R-1U TCMP. TCMP. speeo Kill (PfM-t) DV- fn /MIST DV-fll/ AttMerex ipcm-z) we Hoouue. Die MODSIMG Die MOUS/MA psd-rn psd-in mso-m MCLT TCMP XUMMIMG START XUMWMG MSD-rn START BACP-10 BACP-H ci -rn RUMMIMG XUMMlMg XUMMlMg Ct-fll PP-HUM-1 A-11/ p-m X-S/I START XUMMIMG xunwng start/xeser crnex. stop X-f/l BYPASS R-f/l SPeCD COMTXOL tNTXlOCK POMPR OM M-f/l DPIvex HYDRAULIC HYDRAULIC HYDRAULIC comtxol sysrex rum SYSTCM START srsrepi stop HYDRAULIC DV-fll SYSTCM COMTX. oump Postt/om Dv-fn DV-fll D*' fit DUMP ' pxocess pcs. xxocess M-fti kmnes pcs. SCPCPMMOT scxeeM'A' HVPOSir/OM ttt XOStTtOM scxeen e-rn cooumg t-sn pfutr peuer pv-K-tn pv-r- fn IMPOSIT/RM MATe-xeuner COOL HtOOUT COOL IMS MATex OPCM ciosre PV-KfU AMMUMCIA TOR AMUUMCIA TOX AHMUHCtA TOX A MMUMCIA TOR COMTXOL ACKHOMltPOe resr sneMce xeser MO SUGRAVine. -ACROMAG rack NO SAJC.X4VN6 ACXOMAc XACK C O N FID EN TIAL TABLE 15.2 P-511, 512; K-511 & XS-511 INTERLOCKS AND ALARMS SHUTDOWNS FOR P-511 & P-512 P-511 or P-512 will shut down if: 1. High level in D-512 (P-511 only) 2. High discharge pressure in process line. 3. Rupture of disk on pump is blown. 4. Low oil flow to gear box. 5. High motor temperature. 6. High torque on output shaft. 7. Pump will not start if the temperature of polymer is below set point for the following points: inside the pump, and the pipe downstream. Low temperature will not shutdown pumps once they are running. SHUTDOWNS ON P-512 ONLY: 1. Additive feed valve must be open to dump position for pump to start. 2. Low temperature of screen changer, diverter valve, die plate, die housing and after MX-512 will prevent start-up but does not shutdown. 3. Pelletizer diverter valve must be in dump position to start P-512 unless interlocks are in the by-pass position. 4. Spin dryer and classifier must be running. 5. Screen changer must be all the way in one position or the other. 6. High pressure before the screen changer or before the die. 7. If 3-way polymer valve does not divert to process or dump position within 10 seconds after initiation P-512 shuts down and alarms. 8. Low pelletizer speed or pelletizer shutdown. P-511 & P-512 ALARMS ONLY: 1. High or low speed. .2 High or low motor current. 3. High pressure in process line. 4. Low temperature in process line. 5. High bearing temperature of pump - four points. .6 Low oil flow to gear box. 7. High torque of output shaft. .8 High water level to motor cooler. 9. High motor temperature - starts auxilliary blower to cooler motor. .10 High or low pump body temperature. 1NNERL0CKS FOR K-511 AND DV-511 T. Water box attached tcTdie. 2. Die temperature - above minimum. 3. Pellet water pressure high or low. 4. Pellet water flow low. DO A 056875 CONFIDENTIAL 5. Knife speed - above minimum. 6. Knives against die - circuit between knives and die complete. 7. Spin dryer and classifier running. 8. HS-K511 not in bypass position. ALARMS FOR K-511: 1. High pressure before and after screen changer. 2. Low speed alarm. 3. High or low motor current. 4. Low temperature of diverter valve, screen changer, die plate, and housing. 5. High differential pressure across screen changer. 6. HS-K511 in by-pass position. SHUTDOWNS FOR XS-511: 1. Gear box oil pressure low. 2. High discharge pressure. 3. Rupture of disk. 4. Low temperatures in Zones 1, 2, 3 will prevent start-up only. 5. Low level in feed hoppers. 6. P-512 shutdown. If gear pump goes down and XS-511 is running, XS-511 will automatically shut down and 3-way valve switch to "dump" position. ALARMS FOR XS-511: 1. High or low motor current. 2. High discharge pressure. 3. High or low motor speed. 4. Low nitrogen purge flow to additive feed to XS-511. DO A 056,876 CONFIDENTIAL r '"Y WAY DIVERTER VALVE HYDRAULIC SYSTEM DO A 0 5 6 8 7 7 C O N FID EN TIAL [)Q A 0 5 6 8 7 B ICONF T OF NT A l CIP 1G O PELLETIZER, SPIN DRYER AND CLASSIFIER 1---------------------------------------------------------------------- ------------------------------------.7^- PELLETIZER DO A 056879 CONFIDENTIAL n '-n V /i FIGURE 15.4 DEVOLATILIZER AND PELLETIZER CONTROL, PANEL FRONT V/FW DO A 056880 CONFIDENTIAL 16. PELLET WATER SYSTEM The pellet water system is a closed system used in the pelletizing part oft the process. Water is stored in DPW-500. Makeup water is provided and level controlled from the condensate system. Pellets, fines, and flakes which float to the top of the water periodically spill over into a screened basket. DPW-501 and then to a sump, DPV-502. PW-501 pumps the sump water back to DPW500. PW-500 A, B, or C pump from DPW-500 through a filter FL-510 that filters out any remaining pellets fines. The filter has a high differential pressure switch. From the FL-510 the pellet water goes to the tube side of a heat ex changer, E-517. Cooling tower water flows through the shell side of the ex changer and is temperature controlled for removing heat from the pellet water. After leaving the heat exchanger, the water passes through a three way valve that can bypass the flow back to DPW-500 when the pelletizer is down. The water flow is measured. The water then flows to the bottom of the waterbox on the pelletizer K-511, contacts the pellets and conveys them out the top of the waterbox up to the spin dryer SD-511. Here the water is separated from the pellets in the dewatering section of the spin dryer and gravity flows back to DPW-500. DPW-500 and PW-500 A, B, and C are common to both trains. There is a separate filter and heat exchanger for Train 1 and Train 2. 16.1 SPIN VRVER AW ROTEX CLASSIFIER [SD-511 & CL-S11) The pellets and water enter the dryer through a perforated chute known as the dewatering section, where the major portion of the water is removed. The pellets and remaining water enters the bottom of the rotor which turns at RPM. This creates a centrifugal force slinging the pellets against cylindrical screens, removing the remaining water which drains out DO A 056881 CONFIDENTIAL the bottom. The pellets move in an upward spiral path and are discharged through an outlet at the top. Dry air, pulled through a filter at the top by the blower action of the rotor, passes through the pellets, through the cylindrical screens and out the top into an exhaust blower system that dis charges atop the roof. The tangential outlet at the top of SD-511 has a di verter valve that directs the flow of pellets either to a scrap bin for offgrade start-up material or to the rotex classifier. The normal flow will go to the classifier. The purpose of the rotex classifier is to separate the undersize and oversize pellets from the correct size pellets. The rejected pellets are also directed down to the scrap bin. The correct size pellets are then gravity fed from the classifier to a small hopper (HUH1). Directly beneath the HUH there is a rotary feeder, the purpose of which is to feed a certain amount of pellets into a line where the pellets are air conveyed to the check hoppers (CH1A; CHIB). Between the HUH and the check hoppers, a continuous sample of pellets is taken by an automatic sampler, SAM-1, and piped to a sample hopper (SHI) to be checked periodically for specks, color, granulation, etc.. These pellets are then air conveyed, downstream of the sample point using an ejector and plant air. DO A 056882 CONFIDFNTTAL r DO A 0 5 6 8 8 3 C O N FTD FN TIA L o ir i PELLET WATER FLOW i 17. MATERIAL HANDLING SYSTEM The purpose of the material handling system is to transfer polyethylene pellets from one place to another. In this process the pellets are air con veyed by certain blowers (BAC) through aluminum pipes at velocities of several thousand feet per minute. There are two basic conveying systems by which the polyethylene pellets are transferred through the plant: one being the pres sure system (Fig. 17.1), and the other is the vacuum - pressure (Fig. 17.2). On the pressure systems, to prevent air from blowing backwards into the stor age hopper, there is an air-lock rotary feeder (RF) which takes pellets into a rotating chamber turning downward and dumping the pellets into the flow of air. To avoid generating dust, fines, and streamers as the pellets travel through the lines at such high velocities, the inside of the lines have spiral grooves, 1/32 inch deep, every 3/8 inch which cause the pellets to bounce rather than skid or slide. These lines are referred to as transfer lines. Diverter valves (DV) are located in the transfer lines to direct the flow of pellets to the desired destinations. All diverter valves are equipped with limit switches to indicate in which direction the valve is diverted. The Modicon 584, which is a programmable controller, will control all transfers in the material handling system. The Modicon accepts inputs, and outputs from the various blowers, rotary feeders, slide valves, diverter valves, and levels of each vessels. Direct communication with this system is achieved by a connection with the PDP-11 computer which in turn has input/output communication with a CRT and a keyboard. When the correct sequence of entries are made to the com puter, the computer which supervises the Modicon, will do the following: 00 A 056884 CONFIDENTIAL 1. Align diverter valves to the correct position. 2. Verify diverter valve to correct position. 3. Start blower and rotary feeder. 4. Check blower pressure and determine if blower is running. 5. Open slide valve - when applicable. 6. Verify slide valve open. 7. Verify feed pressure, (PSH), to check if pellets are transferring. 8. Shut down system if system alignment is interrupted. 9. Shut doum system if system pressure increases enough to activate a high, high pressure switch on the blower discharge. 10. Shut down system on high level in destination hopper or receiver. 11. Shut down system on low blower pressure (transfer complete).' Of the two basic air conveying system, there are five individual systems used to transfer polyethylene to the desired destination. BACP 10 or BACP 11; Single Blower Pressure System This system transfers polymer from HUH1 (which is a small vessel known as a hold up hopper) to the check hoppers (CH1A, IB). Beneath HUHl there is a rotary feeder (RF HUHl). At a certain point in the transfer line between the HUH and the check hoppers, a sample line is piped to a sample hopper (SHI). A small continuous amount of pellets is directed to this sample hopper to be checked at various time intervals for specks, color, granulation, density and volatiles. There are two buttons located at the sample table, labelled 'prime' and 'off-grade'. Once the sample has been checked`at the predetermined time intervals one of these buttons will have to be pushed in order to start trans ferring that particular check hopper which was being filled during the prior DO A 05,6885 CONFTDFNTIAL time period. The sample pellets are air conveyed downstream of the sample line to the check hopper. BACP 10 and BACP 11 are centrifugal Hoffman blowers. The same system is on Train 2. BACP 1 or 12 Single Blower Pressure System This system transfers polymer from the check hoppers (CH1A;1B) to the make-blenders (HMB1A, B, C, or 2C). The capacity of each blender being 200,000 pounds. In this system, a pressure switch located in the transfer line just down stream of the blower, indicates if the blower is running (PSH). There is also a high temperature switch. Whenever the hopper becomes empty and the pres sure drops (PSL) the system automatically goes through a time out cycle and shuts down. The blowers in this system are centrifugal blowers. The TDC2000 monitors the motor current of each blower from the motor control center. There is a high motor current alarm on each blower. If a transfer line starts to plug, the motor current will go up. Each check hopper has a high level switch, if activated, the valve diverts to the other check hopper. If both hoppers become full, the system would have to shut down. The check hoppers are mounted on weigh cells. The PDP-11 calculates the amount of polymer in the check hop pers and displays it on the CRT. In the event the Modicon shuts down, there are manual switches for the blowers, rotary feeders and diverter valves, to line up and start a transfer. These switches are on a graphic panel in the control room. BACP-3 Single Blower Pressure System This system is used to blend and transfer polymer from the make blenders (HMB1A; IB or 1C). Once, a predetermined amount of polymers ( 180,000 pounds) (referred to as a lot) has been accumulated in one of the HMB's, the system is DO A 056886 CONFIDFNTIAL used to blend the polymer. The polymer is cycled from the bottom of the blenders back through the top of that same blender for about 2 hours. After the blend cycle is completed, the polymer can then be transferred to the stor age hoppers HS1 through HS6 (capacity of each is one million pounds) or to HI through H8 (capacity of 600,000 pounds each), or to the bulk car loading hop pers (HL1-HL4) or to a bagging hopper (HB-1) 200,000 pounds capacity. BACP-3 is a positive displacement M. D. rotary-lobe blower. It will shutdown on low oil pressure. It has an inlet and outlet silencer. The Modicon has inputs from a low pressure switch that indicates if the blower is running, a high pressure switch to indicate pellets are transferring and a high-high pressure switch that indicates if the transfer line plugs. When the feed pressure drops below the set pressure of the high pressure switch, the system will time out and shut down. If the high-high pressure switch is activated the system will shut down. There is a button located at the bottom of the blender that an operator must push to confirm that the blender is empty before the computer will allow a new lot to be started in that blender. There is also a high temperature switch located in the transfer line that will alarm if the air temperature from the blower (after it passes through a cooling tower water exchanger, EA-3) is too high. BACV-5 & BACP-5 Dual Vacuum - Pressure Blower System This system transfers polymer from H1-H8 to the bulk car loading hoppers (HL5-HL8) or to the #2 bagging hopper (HB-2). These are positive displacement blowers. There are pneumatic slide valves under each of the H1-H8. Once the transfer is lined up and the blowers are running, depending on which hopper is being transferred the slide valve opens and gravity feeds polymer into the transfer line which is one the vacuum of BACV-5. The poly is pulled to a de DO A 056887 CONFIDENTIAL duster receiver (RAC-5). The receiver is equipped with baffles that directs the polymer to the bottom. Fines and air flow through an annular space and out the top of the receiver-deduster to a filter (FACV-5) that filters out the polymer dust, fines and polyethylene pellets that may carry over. The air flows from the top of the filters through a silencer (SACV-5A) to the blower and is discharged through another silencer (SACV-5B) to the atmosphere. The polymer that is collected in the receiver is fed into a transfer line that is on the pressure side of BACP-5. The polymer is air conveyed to the desired destination. BACV-5 has a high vacuum switch that indicates when the blower is running; a low vacuum switch for the feed flow indication and a low-low va cuum switch to indicate if the transfer line plugs. BACP-5 pressure switches work the same as BACP-3. There is a high level switch on RAC-5 that alarms on the annunciator panel in the control room. Low oil pressure will shutdown the blower. BACV-6 & BACP-6 Dual Vacuum - Pressure Blower System This system transfers polymer from (HS1 - HS6) to the bulk car loading hoppers (HL5 - HL8) or to the //I bagging hopper. This system operates the same as BACV5 and BACP-5. BAC-7 Rail Car Unloading There is a separate system used for transferring additives from a rail car. This is a Single Vacuum - Pressure Blower System BAC-7. The blower in this sys tem is a positive displacement blower. With the vacuum side of the blower, the product is pulled from the rail car to a deduster receiver (RAC-7). Air is drawn out the top of the receiver through a filter (FACV-7), through another filter (FLT-7), then to a silencer (SACV-7) to the blower. The air flow from the discharge of the blower goes through a silencer (SACP-7), to an exchanger DO A 056888 CONFIDENTIAL EA-7 where the air is cooled. From the exchanger the flow is directed under the receiver. At this point the product from the receiver is fed into the line by a rotary feeder and conveyed either to the additive storage hoppers or the additive hoppers above the additive extruder. On the vacuum side of the blowers there is high level switch on RAC-7 and a high differential pres sure switch on (FLT-7). On the discharge side of the blower a low pressure switch indicates when the blower is running, a high pressure switch indicates a plugged line. There is a high temperature switch after EA-7. The blower has a low oil pressure shutdown switch. This system can be used to unload polymer to the blenders HMB-1A and HMB-2A if needed. 00 A 056889 CONFIDENTIAL CONF SYSTEM (LINE SIZE) BACP 10 & 20 11 & 21 (8") BACP 1, 2, & (8") BACP 3 & 4 (10") BACV-5 BACP-5 (10") BACV-6 BACP-6 (10") BAC-7 (8") TABLE 17.1 CONVEYING SYSTEM SUMMARY SOURCE (NO.) POLYMER & DESTINATION CAPACITY (NO.) ............ MAX. (///HR) From HUH 1 & 2 Check Hoppers 1A-B; TO 2A-B 1 Each Train 2 Each Train 35,000 From Check Hop pers 1A-B; 2A-B TO 2 Each Train Blenders to 1A, B, C & 2A, B, C 35,000 Recirculate blenders or from blenders Silos Car Loading TO to HL1-HL4 or bag ging Recirculate 120,000 Transfer 90,000 From Hi to H8 Car Loading HL5 TO HL8 or bagging HB2 90,000 From HS1-HS6 Car Loading HL5 TO HL8 or bagging HBl 90,000 From Car Load ing HAS1, 2 TO HA1A-B; 2A-B or HMB1A HMB2A 90,000 TYPE PRESSURE PRESSURE PRESSURE PRESSURE VACUUM PRESSURE VACUUM PRESSURE VACUUM REMARKS Spare blower for each Train BACP- 11 & 21 BACP1 also to HME2C BACP2 also to HMB1C BACP12 spare for both TR. Rotary feeder on HMBs are two speed; 24RPMs for recirculating 18 RPMs for transferring Unloads car of resin or additive concen trate 7 7.7 PURGE AIR SYSTEM This system includes three air blowers (BPA1, 2, &3) . These are Hoff man centrifugal blowers driven by 200 hp electric motors. The blowers are piped to all hoppers except the additive hoppers. Due to the fact that not all of the solvent is devolatilized from the polymer, various percentages are entrained in the polymer and carried over into the hoppers. This system keeps a constant air purge on the hoppers to eliminate a concentration of sol vent vapors. Low flow switches are installed in each of the purge lines to the various hoppers. In addition to the purge air, in the case of the check hoppers, there is an additional purge system; the low pressure nitrogen sys tem is piped separately to each of the hoppers. There is a high flow switch installed in the nitrogen line that will indicate when this system is in ser vice. The low pressure nitrogen system should only be used in cases where there is a high volatile level in a hopper (over 40% L. E. L.). If the nitro gen system was left open to a hopper, the gas detectors in the top will not de tect a flammable mixture until the nitrogen is turned off. Thus, transfers could be made out of the check hoppers, of high-volatiles polymer, causing an explosive mixture in the blenders. There are also carbon dioxide cylinders for each of the check hoppers to be used in case of a fire. Generally solvent in polyethylene pellets will diffuse to the air at 10% per hour. That is for 10,000 pounds of polymer with 1% solvent in it (100 pounds solvent), 10 pounds would diffuse out in one hour. The lower explosive limit (L. E. L.) and upper explosive limit (U. E. L.) of solvent in air are 1% and 7% by volume respective ly. Any source of ignition (static electricity) within these ranges would re sult in an explosion. Thus the need for purge air is very important. This sys tem must be in operation at all times on all hoppers. (Purge air flow is mea- DO A 056891 CONFTDENTIAl sured on the lines to all vessels and low flow is alarmed.) Combustible gas detectors are installed in each of the check hoppers and HUH's, with indica tors in the control room. At 20% of the L. E. L. the control room will get an alarm and a yellow warning light at 40% of the L.E.L., an alarm and a red light is displayed. DO A 05689? CONFIDENTIAL TABLE NUMBER 17.1 17.2 TABLE INDEX FOR MATERIAL HANDLING DESCRIPTION Conveying System Summary Purge Air Flow Summary FIGURE NUMBER 17.1 17.2 17.3 17.4 FIGURE INDEX FOR MATERIAL HANDLING DESCRIPTION Single Blower Pressure System Dual Blower Pressure System Single Blower Pressure - Vacuum System Receiver Separator and Deduster A 056893 CONFIDFNTIA! SUMMARY OF P URGE AIR FLOW ITEM NO. CH 1&2 j A&B ! HMB 1A, B, C | 2A, b, c; THEOR PURGE AIR FLOW 'uMel % L.E.L. USED PURGE RATE USED/i^ia 400 CFM 933 CFM l1 !i 15 % it 1 25 % i ! 400 CFM i1 1 ! 800 CFM i HI to H8 HS1 to HS6 i 329 CFM ; --------------------------- p 329 CFM 15 % 15 % 300 CFM ; 300 CFM HLl to HL6 329 CFM 15 % 300 CFM HB1 to HB2 329 CFM 15 % 300 CFM NUMBER OF HOPPERS 4 6 8 6 8 2 TOTAL FLOW REQUIRED j 1600 CFM 4800 CFM 2400 CFM 1800 CFM 2400 CFM 600 CFM 13600 CFM i 1 TOTAL TABLE 17.2 A 056894 CONF T DFNITIAL n DO A 0 5 6 8 9 5 CO NFTDFNTTAl. FIG. 17.1 SINGLE BLOWER PRESSURE SYSTEM Hi-H8 DO A 0 5 6 8 9 6 C0NFTDFNTTA1 FIG 17.2 DUAL BLOWER PRESSURE - VACUUM SYSTEM A 05F897 C O N F ID F N T TAL FIG. 17.3 WCT SINGLE BLOWER PRESSURE - VACUUM 12" INLET < c RECI EVER SEPARATOR DEDUSTER Do A 056898 CONF TDr N'T T Al 18. DOWTHERM SYSTEM The purpose for this section of the plant is to produce hot Dowtherm liquid and vapors for heating of the polymer in the devolatilization section of the plant. This is accomplished through a gas fired furnace, for heating the Dovthein and then extracting hot vapors and liquid for circulation through various hf.>! exchangers and jackets. The Dowt'nerm is then returned to the system. Oowt'tnv "A" when received is a clear, colorless, oily material with a very pungent oj.^r. Dowtherm boils at 257C at 0 psig. Dowtherm has a very high temperature ci-mi.-.u 1 to steam at the same pressure and this is the reason it is used at Dowlex. 235 psig steam temperature is approximately 310cC while 2b psig Dowtherm temperature will be 310C. 1&.1 PMTHERM FURNACE (F-501) The basic operation of the furnace consists of mixing fuel gas (methane) with air for combustion to heat the tubes in the tube section of the furnace. F-501 is a gas fired, forced draft, single pass, counterflow furnace. The normal operation of F-501 consists of air, supplied by B-501, being blown into the furnace through an air preheater, located in the stack, to the burner wind box for mixing with the fuel gas for combustion. The hot gases for combustion pass over the Dowtherm tubes, then over the air preheater sec tion and finally out the stack. The Dowtherm flows into the convection sec tion at the top first where it is heated by the hot flue gas. It then flows to the radiant section in the firebox where it is further heated by radiant heat from the flame. B-501 has a control valve on it's discharge that regulates the amount of DO A 056899 CONFTDFNTTAl. /Wc- If the stack temperature went below It is very impor tant to maintain proper air to gas ratios to the furnace. To do this, a sample of the hot gases leaving the furnace is extracted and analyzed for excess oxygen. The desirable control point is 2.0% excess oxygen in the flue gas. If air flow increases or gas flow decreases the oxygen in the flue gas will go up. High oxygen results in poor efficiency and heat being carried out the stack by too much air flow. Too low an oxygen will result in what is called chocking the furnace; not burning all the fuel due to not having enough air flow. A chocking furnace is an extremely dangerous condition that could result in a furnace explosion. The proper handling of this condition is discussed in detail in the safe operating procedures manual. Fuel gas to the block comes from the Division pipeline at 275 psig and is regulated down at the block limits to 100 psig. The fuel gas to F-501 at 100 psig is first regulated down to 50 psig by the field regulator. This 50 psig gas is pressure controlled to F-501 burner. The fuel gas pressure to the burner is controlled by the Dowtherm pressure in D-500. A portion of the 50 psig fuel gas is also regulated down to 20 psig for pilot gas. Both the burner gas line and the pilot gas line are equipped with double-block and bleed safety shut-off valves. There is a 1" 235 psig steam line that enters the bottom of F-501 for use in an emergency such as a furnace fire. This line is equipped with an emergency trip valve that can be operated from the control room. The furnace will trip DO A 056900 CONFTDFNTIAI (gas lines blocked) off if any of the following conditions occur: A. Low fuel gas pressure 10 psig B. High fuel gas pressure 30 psig C. Low air flow (redundant) 8,000 Ibs/hr D. High D.T. pressure D-500 60 psig E. Flame out (loss of fire) Loss of all 4 flame detectors F. Low D.T. Flow (on any pass) 200 KLlbs/hr G. Power failure to controls H. Low level D-500 25% I. High stack temperature 427C J. Main gas block valves Closed F-501 is supplied with liquid Dowtherm from D-500 by P-501-A-B-C. A small portion of the discharge of the P-501 *s is sent back to D-500 through a filter (FL-502) to remove impurities in the system. 18.2 DOWTHERM "A" FLOW PATH Tank trucks unload Dowtherm into D-502 which is the storage drum for the system. This vessel is under a nitrogen pad to prevent air from entering the system. The liquid Dowtherm is pumped from D-502 by P-502-A-B through a control valve for level control of D-500. There is a level control valve from Trains I and II liquid lines for high D-500 level. A small portion of the P-5021s discharge passes through E-501 and E-502 (cooling tower water exchangers) then through FL-503 (filter) for use on the packing glands on P-501's and P-500's. D-500 is where the liquid and vapor Dowtherm are separated for specific uses in the plant. E-502 is a fin-fan cooler located on top of D-502 and is used to condense any vapors in the storage drum. Dowtherm safety valves located in the process area are piped back to D-502. DO A 056901 CONFIDFNTTAl IS. 3 VAPOR CYCLE Hot Dowtherm liquid from F-501 enters D-500 and is extracted from the top of D-500 at 26 psi and 3103C. At full furnace capacity 30% of the Dowtherm flowing back to D-500 from F-501 flashes overhead into the vapor line. This vapor goes only to E-511 where it is used to heat the solvent/polymer solution. After passing through E-511 the vapor is condensed and drains from E-511 to D-519 which is a level controlled collection drum from which the liquid Dowtherm is pumped back to D-500 by P-519 A/B. There is an identical system on Train 2. IS.-I L10U1V CYCLE Hot liquid from D-500 is pumped by P-500 A/B/C to the gear pumps and jackets of the devolatilizers to keep the polymer hot. Hot Dowtherm flows first through a temperature control valve at each dev olatilizer and back to D-500 to start the cycle over again. Most of the Dow therm liquid is used for the plate heat exchangers E-512, and E-522 inside the second devolatilizers. This Dowtherm is flow controlled to the exchangers. The polvmer temperature out of E-512 is changed by controlling the Dowtherm liquid temperature on each train. If the Dowtherm liquid from D-500 is too hot, a portion of the cooler Dow therm from the train can be controlled directly to the suction of the P-500 A/B/C thus bvpassing D-500. Thus the Dowtherm liquid system temperature is controlled. DO A 05690; CONFIDFNTT Al TABLE NUMBER 18.1 TABLE INDEX FOR DOWTHERM SYSTEM DESCRIPTION Dowtherm System Control Loops FIGURE NUMBER 18.1 18.2 FIGURE INDEX FOR DOWTHERM SYSTEM DESCRIPTION Flow Path for Furnace Area Flow Path for Distribution DO A 056903 CONFTDFNTTAl TABLE 18.1 DOWTHERM SYSTEM CONTROLLERS LOOP CONTROL NUMBER AIC 5002 Air Indication and Control PURPOSE OPERATION To maintain an excess % air in By taking the air flow indication the flue gas leaving the fur (FIC-5004) and multiplying it by nace (F-501). a ratio between 0.8 and 12. PIC 5241 Pressure Indication and Control D-500 pressure By controlling the gas valve (PV-5241) and the air valve (PV-5004) to the furnace with relationship to Dowtherm pressure in D-500. LIC-5243 Level Indication and Control To maintain level in the Dowtherm flash drum (D-500). By making up from D-502 to D-500 (LV-5243-B) or by dumping to D-502 (LV-5243-A). TIC-5251 Temperature Indication and Control TIC-5252 Temperature Indication & Control To maintain a set temperature on Train I Dowtherm liquid. By recycling a portion of Train I return Dowtherm to pump suction through TV-5251-B. To maintain a set temperature on Train II Dowtherm liquid. By recycling a portion of Train I return Dowtherm to pump suction through TV-5252-B. FIC-5004 Air Indication and Controller To control air flow to the to the furnace. By controlling the air valve (PV-5004). FIC-5029 Fuel Indication and Controller To control fuel gas flow to the furnace. By controlling the gas valve (PV-5029). DO A 056904 CONFIDFNTTAL r nrc in i DO A 0 5 6 9 0 5 CONFTDFNTTAl D--502 PSV'S HEADER. OOWTHERM RETURN TO D-500 DOWTHERM VAPOR =m T r ] rDL cv 0-519 ---- P-519A/B FT XT -n*-PSV' PSV FCV a E-512 D-512 P-512 r -H) TCV ]H)tcv OOWTHERM FROM P-50Q'S i___i DO A 0 5 6 9 0 6 OONFTDFNTTAl FIG. 18.2 19. CHILLED WATER SYSTEM 19.1 ABSORPTION REFRIGERATION UNITS The chilled water system is a closed system which supplies cold water to various exchangers, equipment, and Bldg. 8601. Three absorption refrigeration units supply the cold water. These units are tied together and can be run in series or parallel with all or two machines running and one on standby (Fig. 19.2). Steam, cooling tower water, and condensate are needed to run to ARU's to make chilled water. The ARU's are physically made up of two sections -- upper and lower. Each of these sections is also divided internally into two more sections. These four sections are the evaporator, absorber, condenser, and generator. Water (condensate) is used as the refrigerant and lithium bromide is a water carrier. The unit is kept at a low vacuum ( 29.7 in Hg) because water at this pressure boils at 40C. Half of the lower section is an evaporator through which the chilled water flows and is cooled. The heat contained in the chilled water is given up to the refrigerant water in the evaporator, causing the refrigerant water to boil. There is also a pump on the evaporator. This pump's function is to circulate refrigerant water to spray the tubes through which the chilled water flows to help get better heat transfer. The absorber is the other half of the lower section. Its function is to absorb the water boiled in the evaporator in order to maintain the vacuum. The water is absorbed readily because of the properties of the lithium bromide solution in the absorber. In the process of absorbing the boiling water, the lithium bromide solution heats up (and also looses capacity to absorb at high DO A 056907 CONFIDENTIAL temperatures), therefore cooling tower water is flowing through this section at all times to cool the lithium bromide solution. There is a pump on the absorber also. This pump has three functions -- to pump solution to the gen erator, to provide the driving force to remove non-condensables from the unit by use of ejectors, and to provide the pressure to purge the unit. The generator is one half of the upper section. Its function is to re move the water from the lithium bromide solution which then returns by gravity feed to the absorber where it is sprayed over the tubes on entry. The water is boiled off using 15 psig steam. The condenser is the other half of the upper chamber. Its function is to condense the water boiled off by the generator. It does this by using cooling tower water which has previously cooled the absorber. This condensed water is then returned to the evaporator by gravity feed through a restricting orifice; thus the cycle of the refrigerant water is complete. The other part on the unit is a heat exchanger which heats the bromide sol ution going from the absorber to the generator by cooling the bromide solution coming from the generator going to the absorber. This is done to economize on the amount of steam needed in the generator while also requiring less cooling on the absorber. (Figure 19.3) The temperature of the outgoing chilled water is controlled by steam going into the machine. The capacity control valve (Chilled water temperature control ler) modulates steam to the generator and is positioned by a controller which senses leaving chilled water temperature. At full load conditions the control valve is wide open. As the load is reduced and the chilled water temperature drops below the temperature set point, the control valve will start closing. At no load conditions the control valve will be closed. D0 A 056908 CONFIDFNTTAL Low level control extender valve - when condensing water temperature is low, the refrigerant low level control extender valve limits dilution of the lithium bromide solution and maintains enough refrigerant in the evaporator circuit to prevent refrigerant pump cavitation. When the solution (lithium bromide) approaches over concentration the cycle guard transfer valve opens to transfer refrigerant into the solution circuit and reduce the concentration. A combination of 3 refrigerant level switches and 2 solution temperature switches sense solution concentration to provide step control by the cycle guard device. Cooling tower water temperature control valve - this valve is located on the cooling tower water outlet of the condenser section. The purpose of this valve is to control the cooling tower water temperature out of the ARU at about A0C. Too cold cooling tower water leaving the condenser will shut the machine down due to crystallization. Too high a temperature and the machine will not cool efficiently (too much steam used) and chilled water temperature will not be cool enough. Purge system - properly inhibited, leak tight absorption machines generate hydrogen in very small quantities due to corrosion. (A corrosion inhibitor, lithium chromate, is charged into the machine with the lithium bromide. The inhibitor is used in conjunction with alkalinity control to minimize the amount of non-condensables normally generated within the machine. Excessive non-conden sable generation interferes with machine performance. The inhibitor is graduall depleted during machine operation and occasional replenishment is necessary. Solution alkalinity also changes over a period of time and must be adjusted.) Some non-condensables are normally generated within the machine and need to be removed on a continuous basis. During machine operation, lithium bromide sol- A 056909 c0NF1DFNTTAL ution from the discharge of the solution pump flows through two ejectors. The absorber purge transfer device discharges directly into the secondary heat exchanger after drawing non-condensables from the absorber. The non condensables pass from there into the condenser. They are removed from the condenser by a second transfer device and are carried to the separation pot. From the separator pot, non-condensables flow into the storage chamber and solution passes back into the absorber. Purge evacuation is started by closing the solution return valve and purge valve. Solution from the pump discharge is thereby forced into the storage chamber, compressing the non-condensables to a pressure higher than atmospheric. The exhaust valve is opened to pass the non-condensables through the exhaust bottle, and is closed when the non condensables have been exhausted. To return to normal operation, the return valve is opened to allow the flow of solution back to the absorber and the purge valve is opened to resume purging. The purge operation is continuous, automatic, and motorless. The non-condensables are stored outside the machine, thus avoiding any flow back into the machine. Machines should be purged at least three times per day. (Fig 19.4) 19.3 OTHER EQUIPMENT IN THE SYSTEM D-202 - chilled water surge tank - capacity gallons D-908 - condensate makeup tank - capacity gallons ARU-201, 202, 203, - model 16JB068 - capacity 500 tons each P-202 A&B - chilled water header pumps Equipment chilled water is going to: C-91L & 921 - freon compressors E-211B & 221B - produce feed exchangers going to reactors E-515 & 525 - exchangers to chill solvent to vacuum pump seals E-513B & 523B - second cooling exchanger on vacuum system Building - control, office-air conditioning (See Figure 19.1) 00 CQNf A 056971 Tb?NTtAl TABLE NUMBER 19.1 19.2 19.3 19.4 19.5 TABLE INDEX FOR THE CHILLED WATER SYSTEM DESCRIPTION ARU Specifications ARU Instrumentation ARU 201 Control Loops ARU 202 Control Loops ARU 203 Control Loops FIGURE NUMBER 19.1 19.2 19.3 19.4 FIGURE INDEX FOR THE CHILLED WATER SYSTEM DESCRIPTION Chilled Water System ARU Chilled Water Flow Internals of an ARU ARU Purge System 00 A 05691p conf.td enttal 1.1 Absorption refrigeration units, Model 016JBO68, in accordance with this specification. Tags Units: ARU-201 ARU-202 ARU-203 1.2 Service conditions and design parameters are as follows: System Type Lithium Bromide/Vater Refrigeration Capacity 1500 tons total Evaporator: Chilled Water Flow Temperature in Temperature out Pressure drop Fouling factor 2278 GPM (Series Flow) 55.8 deg. F. 40 deg. F. 39.3 ft. Ha0 0.0005 hr.-sq.ft.-deg. F./BTU Absorber: Cooling Tower Water Flow Temperature in Temperature out Fouling factor Pressure supply Pressure return 2000 GPM/Unit (Parallel Flow) 90 deg. F 94.6 deg. F 0.001 hr.-sq.ft.-deg. F./BTU 60 psig 40 psig Condenser: Cooling Tower Water Flow Temperature in Temperature out Pressure drop Fouling factor 2000 GPM/Unit (Parallel Flow) 94.6 deg. F. 102.2 deg. F. 32.3 ft. Ha0 (Absorber plus Condenser) 0.001 hr.-sq.ft.-deg. F./BTU Generator: Steam Flow at full load Pressure 9925 lb./hr. 15 psig (saturated steam) Cooling water to flow thru absorber and condenser in series. TABLE 19.1 DO A 056913 CONFIDFNTTAL TABLE 19.2 - INSTRUMENTATION FOR ARU's The instrumentation on each ARU is identical but below is for ARU-201. 1) Field mounted instrumentation: A) PI 2021 - steam pressure downstream of the capacity control valve. B) Light for low chilled water inlet flow. C) Light for cycle guard being open. D) Light for low level in the absorber. E) Light on low chilled water temperature. G) Hand switch for PS-201. H) Hand switch for PR-201. I) Control panel for ARU-201. 2) Control Room Instrumentation: A) Steam: 1) TIC 2008 - capacity control valve - controls chilled water temper ature by controlling steam flow. B) Cooling tower water: 1) TIC 2009 - cooling water outlet temperature controller. Controls outlet temperature by restricting or opening control valve on the water inlet. 2) FI 2014 - indicates incoming flow. Alarms on high and low flow. 3) TI 2022 - indicates temperature leaving absorber. C) Chilled water: 1) TI 2015 - entering chilled water temperature. 2) TT 2008 - leaving chilled water temperature. Signal goes to TIC2008 which controls the capacity control valve. 3) FI 2016 - entering chilled water flow. Alarms on high and low flow will close the capacity control valve if flow gets too low. D) Refrigerant Section: 1) LSH 2029 - these switches sense 2 upper levels of refrigerant in LSH 2030 the evaporator. Each is tied into 2 temperature elements on the strong solution downstream of the heat exchanger. At a speci fic temperature and level they will activate the cycle guard valve and dump refrigerant into the suction of PS-201 thereby diluting the solution and lowering the level in the evaporator. 2) LSHH 2028 - this switch will activate the cycle guard valve no matter what the solution temperature is. This is the highest level point in the evaporator. 3) TI 2017F - temperature inside the evaporator. 4) TSL 2019 - low chilled water temperature cutout. When this switch is activated, the solution pump (PS 201) and capacity control valve (TV 2008) will close. OO A OQA//r os6914 FfJTIAi TABLE 19. 2 (CONT'D) E) Solution Section: 1) TI 2017A - solution temperature from the absorber to the suction of PS 201. 2) TI 2017B - solution temperature after heat exchanger going to the generator. 3) TI 2017C - strong solution temperature from generator. A) TI 2017D - strong solution temperature after heat exchanger. 5) TI 2017E - high level overflow line from generator (temperature increase on this line would indicate solution is solidifying in the heat exchangers) G) ARU 201 Control Panel: 1) Alarm when unit shuts down. 2) Indication when purge is needed. 3) Indication when cycle guard valve is energized. *' A 05691 'NF^DENTTAl LOOP CONTROL NUMBER TIC 2008 TIC 2009 LSLL 2031 LSHH 2028 LSH 2029 LSH 2030 TSL 2024 TSL 2025 TABLE 19.3 CHILLED WATER CONTROL LOOPS (FOR ARU-201) PURPOSE Controller for leaving chilled water temperature. Controller for leaving cooling tower water temperature. To prevent cavitation of refri gerant pump. To prevent over concentrations of the lithium bromide. OPERATION Receives signal from TT 2008. Temperature is controlled by operating TV 2008 and varying steam to the unit. Valve is air to open. Receives signal from TT 2009 on cooling water tower leaving the unit and controls the tem perature with TV 2009 on the incoming CWT header. Valve is air to close. On a low level in the refriger ant section, the low level con trol extender valve (LV 2031) will open, allowing solution to flow into the section. LSH 2029 and TSL 2024 operate LV 2028. At a given temperature and level they will, open the valve. LSH 2030 and TSL 2025 do the same but at a different temperature and level. LSHH 2028 alone opens LV 2028. CQDNO^A rZ6 LOOP CONTROL NUMBER TIC 2144 TIC 2142 LSLL 2160 LSHH 2157 LSH 2159 LSH 2158 TSL 2153 TSL 2154 TABLE 19.4 CHILLED WATER CONTROL LOOPS (FOR ARU-202) PURPOSE Controller for leaving chilled water temperature. Controller for leaving cooling tower water. To prevent cavitation of the refrigerant pump. To prevent over concentration of the lithium bromide. OPERATION Receives signal from TI 2144. Temperature is controlled by operating TV 2144 and varying steam to the unit. Valve is air to open. Receives signal from TI 2142 on the CTW leaving the unit and controls the temperature with TV 2142 on the incoming CTW header. Valve is air to close. On a low level in the refrigerant section, the low level control extender valve (LV 2160) will open allowing solution to flow into the section. On a given temperature and level TSL 2153 and LSH 2158 will open LV 2157. At another given tem perature and level TSL 2154 and LSH 2159 will open LV 2157. LSHH 2157 alone will open LV 2157. DO A 05A917 CONFIDENTIAL LOOP CONTROL NUMBER TIC 2341 TIC 2343 LSLL 2357 LSHH 2354 LSH 2355 LSH 2356 TSL 2350 TSL 2351 TABLE 19.5 CHILLED WATER CONTROL LOOPS (FOR ARU-203) PURPOSE Controller for leaving chilled water temperature. Controller for leaving cooling tower water. To prevent cavitation of the refrigerant pump. To prevent over concentration of the lithium bromide. OPERATION Receives signal from TT 2341. Temperature is controlled by operating TV 2341 and varying steam to the unit. Valve is air to open. Receives signal from TT 2343 on the CTW leaving the unit and con trols the temperature with TV 2343 on the incoming header. Valve is air to close. On a low level in the refrigerant section, the low level control extender valve (LV 2357) will open allowing solution to flow into the section. At a given temperature and level TSL 2350 and LSH 2356 will open LV 2354. At another given tem perature and level TSL 2341 and LSH 2355 will open LV 2354. LSHH2354 alone will open LV 2354. D-202 LIC 2003 Maintain desired level. Receives signal from LT 2003. LV2003 opens/closes and receives and from D-908. Valve is air to open. A 0569 3 8 confidential c\ DO A 0 5 6 9 1 9 CONFTDFNTTAl P-202A CHILLED WATER SYSTEM CHILLED WATER DISTRIBUTION - ARU S CHILLED WATER FLOW -WEAK, HOT SOLUTION TO GENERATOR CONDENSING WATER T7NT CONDENSING WATER -OUT -REFRIGERANT OVER-FLOW^ PIPE x FROM CONDENSER CAPACITY CONTROL VALVE HOT, STRONG SOLUTION FROM GENERATOR COOL, STRONG SOLUTION TO SPRAYS FIOTENDER VALVE- , (ON SOME MODELS)1 HEAT EXCHANGER ---OUT CHILLED ^ WATER IN "REFRIGERANT TO SPRAYS CYCLEGUARD VALVE HEAT EXCHANGER HERMETIC SOLUTION PUMP LEVEL CONTROL EXTENDER VALVE HERMETIC REFRIGERANT PUMP ' FIG. 19.3 INTERNALS OF AN ARU LEGEND A 1-ABSORBER TRANSFER DEVICE A2--CONDENSER TRANSFER DEVICE B -SECONDARY HEAT EXCHANGER C -SEPARATION POT D -STORAGE CHAMBER E -SOLUTION RETURN VALVE F -LEVEL INDICATOR 6-AUXILIARY EVACUATION VALVE H-EXHAUST VALVE J-EXHAUST BOTTLE H--HERMETIC SOLUTION PUMP J-PURGE VALVE (LATER MODELS ONLY) FIG. 19.4 ARU PURGE SYSTEM ARU DRAWING DO A 0569 CONFIDFNTI I> \) 20. COOLING TOWER This portion of the plant is a closed, recirculating cooling tower sys tem where hot water from exchangers and other water cooled equipment in the plant enters the top of the cooling tower and falls, in drops, to the bottoms of the tower. Air is drawn into the bottom of the tower and out the top by a fan, thus cooling the water as it falls through the tower (Fig. 20.3). 20.7 NORMAL FLOWS Cold water from the cooling tower sump is pumped with P-901 A, B, C through various pieces of equipment in the plant and returns to the top of the tower. Through spray nozzles, the hot water falls through the tower and is cooled. Water is evaporated as it falls through the tower. This is how the water is cooled but also represents a loss of water which must be made up. Process water is used to make up for the loss of water through evaporation and blowdown. The cooling tower sump is level controlled and opens the level control valve when the water level starts dropping. Process water contains a certain amount of dissolved solids. If we continued to add these dissolved sol ids without removing them, the system would soon fill up with solids, silt, scale, and foulants. The cooling tower must continually be blown down to the drain. Another way of removing undissolved solids, (mud, dirt, dead micro-organisms), is FL901, the cooling tower side stream filter. Approximately two percent of the cooling tower flow is filtered through FL901 and re-enters the cooling tower sump. The filter automatically backwashes itself when the differential pressure between the inlet and outlet reaches a given point (Fig. 20.2). DO A 0569?? OONFIDFNTTAL 20. 2 TREATING SYSTEM A properly treated cooling tower system is the only way to insure that the field equipment and piping doesn't corrode, and the tower operates pro perly without clogging, rotting, or filling up with silt. Proper treatment helps keep treatment costs down and minimizes down time due to the above pro blems. The pH of the system is controlled by adding 35% aqueous HC1 into the tower sump. The pH is monitored and controlled. pH should be maintained at 6.8 - 7.2, checked and recorded once per shift. High ph results in scale formation on metal, which results in poor heat transfer and increased corro sion due to scale formation. Low pH results in corrosion of metal and forma tion of foulants and scale, which again causes poor heat transfer in cooled equipment. Inhibitors are used to coat the metal with a film of protective material to reduce corrosion. Betz 2040 inhibitor is a special blend of organic and inorganic inhibitors which does not contain chromate. This product is designed to control corrosion and scale formations in open recirculating cooling water i systems. Because Betz 2040 does not contain heavy metals, it enables plants to comply with local water quality standards. A small amount of inhibitors is continuously added to the system to maintain protection. Samples should be taken daily, analyzed, and recorded. Rates should be adjusted to maintain PPM. Low concentration levels results in increased corrosion and scale formations. High level concentrations are unnecessary and result in higher cost of operating this system. Betz 2020 inhibitor is a special organic deposit control agent designed to control calcium phosphate formation in open recirculating cooling water DO A 0569 CONFTDFNTT <\ <r systems. This chemical promotes the formation of a passivating gamma iron oxide film to coat the walls of the piping and equipment. Betz 2040 also contains an organic dispersant to control fouling due to suspended solids and other calcium salts. The actual concentrations of Betz 2020 and 2040 will be determined by Betz Laboratories and technical personnel in the Dowlex plant. Chlorine is added to the tower to control micro-biological growth. Too little chlorine results in micro-biological growth (bug fouling) which in turn results in scale formation. Too much chlorine results in ecology and safety hazards. A sample should be taken daily to determine parts per million res idual chlorine. This should be maintained at PPM. Biocides are used to control bug growth and are added on a "slug" basis once and twice a week as prescribed by the cooling tower treatment representa tive. Insufficient control results in growth of micro-organisms, fouling, scale formation, and corrosion. Generally, biocides are hazardous to health and should be handled with extreme care. 20.3 EQUTPMEUT ASSOCIATE? WITH THE C00L7NG TOWER ARE: FN-901 A/B - (Cooling tower fans) 125 hp motors with two speed operation. P-901 A/B/C - Cooling tower water recirculating pumps. Each capable of pumping 9,250 gpm. Two will be in operation with one spare. D-901 A/B - Betz 2020 & 2040 storage tanks FL-901 - Cooling tower side stream filter Equipment cooling tower water flows to, is on Figure 20.1. For instrumentation on the tower see Table 19.1 and Figure 20.5. DO A 0569?4 CONFIDFNTTAL. TABLE NUMBER 20.2 TABLE INDEX FOR COOLING TOWER SYSTEM DESCRIPTION Cooling Tower Water Control Loops FIGURE NUMBER 20.1 20.2 20.3 20.4 20.5 FIGURE INDEX FOR COOLING TOWER SYSTEM DESCRIPTION Cooling Tower Water Flow Path FL-901 and Valve Arrangements Cooling Tower Chemical Addition Locations Cooling Tower System Instrumentation Locations no A 056905 CONFTDFNTTA! LOOP CONTROL NUMBER FIC 9007 PHIC 9017 LIC 9015 AIC 9019 FIC 9001 TABLE 20.1 COOLING TOWER CONTROL LOOPS PURPOSE Controls Cla flow to tower. Control tower water pH. Controls level in tower. Control tower water conduc tivity. Flow controller to FL-901. OPERATION Receives signal from FT 9007. Valve (FV-9007) is air to open. Valve will close on low cooling tower water flow reading on FT900j A/B. Increases or decreases HC1 addit ive depending on setpoint. Re ceives signal from PHE 9017 inside the tower. Air to open valve (PHV9017) Valve will close on low cool ing tower flow reading on FT 9000 A/B. Receives signal from LT 9015 and regulates makeup water from the process water header. Control valve (FV 9001) is air to open. Receives signal from AE 9019 and controls conductivity by setpoint. Control valve (AV 9019) is air to open. Receives signal from FT 9001 air to open valve (FV-9001). DO A 0S69P6 CONFIDENTIAL uu A 05692 CONFTDETNTTA COOLING TOWER DISTRIBUTION CT--901 BASIN r FIG. 20.2 h CONFIDFNTIAI FIG. 20.3 Research-Cottrell Hamon Coolingfewer Division O K rm KWCMW mm Ml Ml A 0569?9 CONFIDENTIAL CL; | CT 01 ST.I a o o ion 'COOL I NG TOWER ADD I T I VES CONFI n ML 9018 COOLING TOWER FAN ALARMS U MOTOR-HIGH VIBRATION 2.) GEARBOX-HIGH VIBRATION 3. ) MOTOR-SHUTDOWN IfahlI n 00 A 056931 C O N FID FN TTA l. L FIG 20.5 r i 21. OTHER UTILITIES 27.7 PROCESS WATER Process water enters the block from the division header and is used for cooling tower water makeup, utility stations, on D-300 (HC1 weight tank for catalyst mixing), D-308 (catalyst dump tank), D-212 and D-222 (reactor dump vessels). There is a flow transmitter on the incoming line with alarms to indicate low pressure and high flow. Normally the division header pressure runs between 60 and 80 pounds. (See figure 21.1) 21.2 NITROGEN Nitrogen is an inert gas used mainly for purging or padding equipment. Flow, temperature and pressure are recorded in the control room. There are also two oxygen analyzers. Nitrogen enters the block at 400 psig, goes through a restricting orifice where it tees off, one line going to the reactors and the other going to various pieces of equipment and utility stations. The lat ter line has a pressure control valve that steps 400 psig nitrogen down to 100 psig. N2 also keeps a purge on flare (vent) header. (See fig. 21.2) 21.3 STEAM ANV CONDENSATE There are two sources of steam in our plant. One internal and one exter nal supply. The internal source is steam generated from E-611 and E-621. Hot solvent (180C) flowing through the tubes heats condensate on the shell side pro ducing steam controlled at 15 psig. This steam's primary use is for absorption refrigeration units, steam tracing, potable water temperature controller, and building heating. The condensate returned from this system is collected in DO A 05693? CONFIDENTIAL D-908. There, condensate is sent to E-611, E-621, D-202 (chilled water surge drum), and DPW-500 (pellet water drum). Excess condensate is sent to the div ision power plant. P-908 A/B forwards the condensate to the above locations. (Figure 21.32) The 15 psig steam is controlled by the levels in E-611 and E-621 and by a pressure control valve (PV-9148) located downstream of D-907 (steam/conden sate surge drum). If the pressure rises above set point this control valve opens and allows the excess steam to flow into E-908 (fin-fan cooler) and be condensed. Steam condensed in E-908 gravity flows into D-908 (condensate storage tank). In case of a low level in D-908, condensate from the division header is used. There are two control valves on the condensate out header, one to send condensate out and one to receive condensate. These two valves are split range, both receiving their signals from D-908 level transmitter. There is also a conductivity probe on the condensate out header. This probe measures in MHOS, an indication of impurities in the condensate. (Rust, acid, caustic, etc.) On a high conductivity reading, a signal is sent to a three way valve downstream of the D-908 level control valve. This valve will dump the conden sate to the ditch. When the conductivity returns in range, around 10 MHOS, the three way valve will switch back to normal and send condensate out the block. On low 15 psig steam pressure, 235 psig steam can be introduced manually into D-907 to raise the pressure. 235 psig is our external source of steam and is received from the division power plant. This steam goes to all reactor jackets, regeneration systems, side-arm extruders, the flare, devolatilizer tracing, reactor blowdown jackets, D-510 (hot melt additive tanks), and poly mer solution pipe jacketing and tracing. The 235 psig steam is metered for pressure, temperature and flow. Alarms are set up on these variables (high DO A 056933 CONFIDENTTAD and low). Condensate trapped from the 235 psig steam system goes into D-907, where it flashes, the steam going into the 15 psig steam header, and the con densate, level controlled into D-908. (See fig. 21.31) All steam traps in the plant are the 'TLV' type with automatic internal venting and by-pass for start-up conditions. 21.4 PLANT AIR SYSTEM Air from Dowlex is supplied from two Joy air compressors (C-902 and C-903). These are three stage centrifugal compressors driven by 800 hp, 3600 RPM motors. The compressors are capable of putting out 3000 SCFM of air each. Normally one compressor will run with one as a spare. Associated equipment with C-902 are: 1) FLY-902 (coalescer - filter) to remove moisture before entering the dryers. 2) Y-902 (air dryers) - are loaded with activated alumina to absorb mois ture. There are two separate beds in this system, one on the line and the other in a regeneration cycle. These beds switch automatically every 10 minutes. When a dryer goes into a regeneration cycle, the dryer depressures to atmosphere, then dry air from the other dryer purges through this dryer. After this step, the dryer is pressured up and is switched back on the line with the other going through the regeneration cycle. 3) FL-902 A/B - From the dryers, the air goes through FL-902 A/B to re move any alumina, rust, etc., in the air. These filters have to b switched manually and should be switched when a 10 psig pressure dif ferential develops. From the filters the air goes to the air headers throughout the plant. Figure 21.41 shows the air network in the plant. Instrumentation on the air system are as follows: 1) FLY-902 - (PDT 9296) - measures differential pressure across the knock out pot. Alarms on high differential pressure. 2) FL-902 A/B - (PDT 9291) measures differential pressure across the fil ter. Alarms on high differential pressure. 3) Outlet of FL-902 A/B: a) AE 9295 - measures the dew point of the air going to the plant. Alarms on high reading. DO A 056934 OONFTDFNTTAL b) FT 9294 - measures total plant air use. Alarm on high and low flow. c) PT 9293 - measures pressure on air header. Alarms on high and low pressure. d) PSL 9289 - pressure switch that will start the spare air compres sor upon a given air pressure. Alarms on low pressure. Figure 21.42 shows the above instrumentation. The following is information on our air compressors. C-902 and C-903 are identical but the equipment and instrumentation listed below is for C-902. A) Oil System - this is a force feed lubrication system. The main oil pump (POC-902A) is gear driven from the compressor drive shaft. The auxilliary oil pump must be started and oil up to pressure before the main drive motor will start. The auxilliary oil pump (POC-902B) will have a hand-off-auto (HOA) switch which should be in the automatic position at all times. On low oil pressure, this pump will automat ically start. Also this pump has to be running in order for the air compressor to start automatically. From the discharge of the oil pump, the oil goes through a cooler (E-902D) then a filter (FL-902 A/B). These filters are full flow twin filters and use 10 micron filter elements. These filters have to be manually switched after a K) pound differential pressure. From the filter the oil goes to the compressor. From the compressor, the oil flows into a reservoir and is pumped through the system again. In the reservoir, there is a heater used to heat the oil during startup conditions. Normal op erations is for the oil temperature to run between 110F and 120F. The pressure inside the lube oil reservoir is kept low to minimize oil leaks. This is accomplished by using an ejector which vents the gasses and returns the entrapped oil to the reservoir. (Refer- to Fig. 21.43) Oil System Instrumentation: A) Field mounted instrumentation 1) Temperature indicators a) Before E-902D b) After E-902D c) After FL-902 A/B 2) Pressure indicators a) Before FL-902 A/B b) After FL-902 A/B c) Before C-902 inlet 3) Temperature controllers a) Lube oil temperature controllers B) Field panel mounted instrumentation 1) Light for POC-902B running 2) Light for low panel purge flow 3) Light for low oil pressure from (PSL 9268) 4) Light for high oil pressure from (PSL 9269) DO A 056935 OONFIDFNTTAl 5) H. 0. A. switch for PC-902B C) Instrumentation monitored in the control room 1) PAL 9236 - low oil pressure alarm 2) TSH 9235 - high temperature alarm The air compressor has two intercoolers (E-902 A & E-902B), and one aftercooler (E-902C). Cooling tower water is the cooling media for these exchangers. The leaving air from E-902C should be around 100F. The fol lowing is a list of instrumentation on the air compressor air system. (Re fer to Fig. 21.44) A) Field mounted instrumentation 1) Temperature indicators a) Inlet to E-902A b) Outlet from E-902A c) Inlet to E-902B d) Outlet from E-902B e) Inlet to E-902C f) Outlet from E-902C 2) Pressure indicators a) 3rd stage discharge b) downstream of E-902C B) Field panel mounted instrumentation 1) Light for high temperature from E-902C from a temperature switch 2) Light for high pressure from PSH 9225 3) Push button for MC-902 start 4) Push button for MC-902 stop 5) Lights for excessive vibration, high vibration, and vibra tion probe not okay 6) Light for okay to start 7) Light for power on C) Instrumentation monitored in the control room 1) PAH 9225 - high discharge pressure 2) CPA 9223 - preliminary alarms a) low purge pressure b) high vibration (alert) c) auxilliary lube oil pump running d) vibration probe not okay 3) SPA 9217 - shutdown alarms a) low oil pressure b) high oil temperature c) high air temperature d) excessive vibration (DANGER) 4) Control valves in air system a) FV 9219 - suction valve - position is controlled by MC902 amps DO A 056936 CONFTDFNTTAL 2) FV 9220 - discharge high pressure controller. On high dis charge pressure, PSH 9225 sends a signal to SOV 9225 (sole noid valve). SOV 9225 dumps the air to FV 9220 opening it. FV 9220 is an air to close valve. When FV 9220 opens, FV9219 closes. When discharge (air) pressure gets below PSH9225 setpoint, FV 9220 closes and FV 9219 opens back up. NOTE: Normally FV 9219 will be controlling in the throttled position depending upon air usage. DO A 056937 CONFIDENTIAL t(Jl riiPtUriPl. I XT AIR COMPRESSOR MANUAL I. BASIC DESCRIPTION II. MANUAL OPERATING CONDITIONS III. LUBRICATION IV. f CONTROLS V. INSTRUMENTATION -- ALARMS AND TRIPS VI.START-UP AND SHUTDOUN PROCEDURES VII. ROUND CHECKS VIII. TROUBLE-SHOOTING GUIDE PAGE 1 9/29/81 DO A 056938 CONFIDENTIAL nu i h . iai PAGE 2 I. BASIC DESCRIPTION C-902 AND C-903 ARE THREE-STAGE CENTRIFUGAL JOY AIR COMPRESSORS DESIGNED TO SUPPLY THE DOWLEX BLOCK WITH INSTRUMENT AND UTILITY AIR AT A PRESSURE OF 115 LBS. THESE COMPRESSORS ARE DRIVEN BY 2 GENERAL DYNAMICS 800 HP 3595 RPM MOTORS. ALSO SUPPLIED WITH THE UNIT IS A RECIRCULATING COOLED AND FILTERED OIL SYSTEM WITH AN AUXILIARY BACK-UP. THE CONTROL PACKAGE CONSISTS OF A PRESSURE CONTROL SYSTEM* SAFETY PROTECTION DEVICES* MOTOR OVERLOAD PROTECTION, VIBRATION MONITORS AND AUXILIARY OIL PUMP START-UP. iv / 9/29/81 DO A 056939 CONFIDENTIAL *_ t i"i 'f ^ * /\ | PAGE 3 II. NORMAL OPERATING CONDITIONS A. COMPRESSOR 1) FLOW - 3327 CFM 2) 1ST STAGE PRESSURE -- 40# 3) 2ND STAGE PRESSURE -- 70# 4) 3RD STAGE PRESSURE -- 114# 5) 1ST STAGE OUTLET TEMPERATURE 6) 2ND STAGE INLET TEMPERATURE -- 90 DEG F TO 110 DEG F 7) 2ND STAGE OUTLET TEMPERATURE > i 8) 3RD STAGE INLET TEMPERATURE - 90 DEG F TO 110 DEG F 9) 3RD STAGE OUTLET TEMPERATURE -- 340 DEG F 10) AFTER COOLER TEMPERATURE -- 90 DEG F TO 110 DEG F 11) 1ST AND 2ND STAGE -- 33000 RPM 12) 3RD STAGE -- 46000 RPM B. OIL SYSTEM 1> OIL TEMPERATURE TO BEARINGS 2) OIL RESERVOIR TEMPERATURE 3) MINIMUM OIL RESERVOIR TEMP 4) OIL VOLUME 5) OIL FLOW 6) OIL FILTER P = 10 PSIG 110 DEG F TO 120 DEG F 130 DEG F TO 140 DEG F 70 DEG F 171 GALLONS 266 PM CHANGE AT 10 PSIG C. COOLING SYSTEM 1) 1ST STAGE INTERCOOLER E--902--A - 104 GPM ( P = 10. 6 PSI ) 2) 2ND STAGE INTERCOOLER E--902--B - 85 GPM ( P = 7. 3 PSI) 3) AFTERCOOLER -- 66 GPM ( P = 2. 0 PSI) 4) OIL COOLER - 27 GPM ( P = 3. 0 PSI) 9/29/81 HO A 056940 CONFIDENTIAL LU I rtlKLUNKH . I A I III. LUBRICATION PAGE 4 IMPORTANT: UNLIKE SOME OTHER TYPES OF ROTATING EQUIPMENT HIGH SPEED# GEARED COMPRESSORS CANNOT OPERATE# EVEN FOR VERY BRIEF PERIODS, WITHOUT ADEQUATE LUBRICATION. NO DELAYS CAN BE PERMITTED IN THE LUBE OIL SUPPLY. v ' ' NEVER ATTEMPT TO START THE COMPRESSOR WITH OUT ADEQUATE LUBRICATION. THE LUBE OIL CONSOLE PROVIDES A CONSTANT SUPPLY OF COOLED AND FILTEF OIL TO THE COMPRESSOR THRUST BEARINGS, JOURNAL BEARINGS AND GEAR SPF ALSO SUPPLIED IS AN OIL IMMERSION HEATER WHICH IS THERMOSTATICALLY CONTROLLED TO MAINTAIN OIL TEMPERATURE AT 100 DEG F. A. DESCRIPTION AND PRINCIPLES OF OPERATION (REFER TO OIL FLOW DIAGRAM) THE LUBRICATION SYSTEM COMPRISES A COMPRESSOR MOTOR-DRIVEN MAIN OIL PUMP AND AN ELECTRIC-MOTOR-DRIVEN AUXILIARY PUMP. UNDER NORMAL CONDITIONS OF OPERATION, THE MAIN PUMP PROVIDES ALL THE OIL FOR THE COMPRESSOR. OIL ENTERS THE MANIFOLD OF THE COMPRESSOR GEAR CASE AND IS DISTRIBUTED THROUGH OIL PASSAGES TO THE JOURNAL BEARINGS AND THRUST BEARINGS. SOME OF THE OIL IS DIVERTED TO THE GEAR SPRAY NOZZLES WHICH ARE POSITIONED TO DIRECT A CONSTANT SPRAY OF OIL AT THE MESH POINTS OF THE GEARS. INSPECTION PLATES LOCATED ON THE MAIN HOUSING CAN BE REMOVED TO INSPECT THESE NOZZLES TO PREVENT OIL LEAKAGE TO THE COMPRESSOR CASING AND SURROUNDING EQUIPMENT A SLIGHT VACUUM IS MAINTAINED ON THE OIL RESERVOIR AND BEARING CASE. AIR FROM THE OUTLET OF THE AIR DRYERS IS SUPPLIED TO A 1/2 EJECTOR WHICH PULLS THE REQUIRED VACUUM. AIR" FROM THE OUTLET OF THE EJECTOR IS PASSED THROUGH AN OIL-AIR SEPARATOR AND THEN THROUGH A MIST ELIMINATOR. WHEN A MALFUNCTION IN THE MAIN PUMPING UNIT RESUTLS IN A LOSS OF OIL PRESSURE, NORMAL OIL PRESSURE WILL BE RESTARTED BY THE AUXILIARY PUMPING UNIT AND THE COMPRESSOR WILL CONTINUE OPERATIN WHEN THE AUXILIARY PUMPING UNIT FAILS TO RESTORE THE OIL PRESSUF TO THE NORMAL OPERATING LEVEL, THE COMPRESSOR WILL BE SHUT DOWN AUTOMATICALLY. DO A 056941 CONFIDENT TAL PAGE 5 II. NORMAL OPERATING CONDITIONS \ ) ) ) C ) ) ) B. START-UP PROCEDURE 1) START FLOW OF COOLING WATER THROUGH OIL COOLER. 2> OPEN AIR VENT ON TOP OF OIL FILTER. 3) START AUXILIARY LUBE OIL PUMP BY ACTIVATING POWER SUPPLY TO CABINET. j" I 4) CLOSE FILTER AIR VENT WHEN FILTER BECOMES FILLED WITH OIL. 5) INSPECT ALL FITTINGS AND CONNECTIONS FOR LEAKS. 6) CHECK OIL PRESSURE AND TEMPERATURE (18-20 PSIG AT 110 DEG TO 120 DEG F). C. SHUTDOWN PROCEDURE 1) AFTER COMPRESSOR SHUTDOWN, OPERATE MAIN LUBE OIL PUMP OR AUXILIARY LUBE OIL PUMP AND OIL COOLER FOR APPROXIMATELY ONE HOUR TO REMOVE HEAT FROM THE SYSTEM. D. FILTER ELEMENT REPLACEMENT PROCEDURE 1> TURN OFF OIL SUPPLY TO FILTER. 2) OPEN AIR VENT ON TOP OF FILTER. 3) OPEN FILTER DRAIN. 4) OPEN FILTER AIR VENT WHEN RECHARGING FILTER WITH OIL. 5) CLOSE AIR VENT WHEN FILTER BECOMES FILLED WITH OIL. ) 9/30/81 \ L 00 A 05A94? CONFIDFNTT Al LU I HiKLUi It'D. I A I PAGE 6 CONTROLS A. TOTAL CLOSURE DESCRIPTION -- PRESSURE CONTROL .- TOTAL CLOSURE CONTROL MAINTAINS THE SYSTEM PRESSURE BETWEEN 95# AND 105# AND KEEPS THE COMPRESSOR OPERATING WITHIN ITS STABLE OPERATING RANGE. LOAD DEMAND CHANGES ARE AUTOMATICALLV SATISFIED WITHIN CERTAIN LIMITS BY THE VARIABLE FLOW AND PRESS CHARACTERISTICS OF THE COMPRESSOR. TOTAL CLOSURE CONTROL ALLC THE COMPRESSOR TO OPERATE IN A FULL LOAD CONDITION BETWEEN THE TWO PRESSURES. I AS THE SYSTEM PRESSURE INCREASES, THE 105# PRESSURE POINT IS EVENTUALLY REACHED. AT THIS POINT A PRESSURE SWITCH IS TRIPPE TO UNLOAD THE COMPRESSOR. THE PRESSURE SWITCH ACTUATES A THREE-WAY SOLENOID VALVE, WHICH IN TURN VENTS THE AIR LINES TC THE BLOW-OFF VALVE ACTUATOR AND THE INLET BUTTERFLY VALVE ACTUATOR. THIS DROP IN SIGNAL PRESSURE CAUSES THE BLOW-OFF VALVE TO OPEN AND THE INLET BUTTERFLY VALVE TO CLOSE. IN THE EVENT THAT THE SYSTEM DEMAND HAS BEEN GREATLY REDUCED, THE COMPRESSOR WILL HAVE A CHANCE TO COMPLETELY UNLOAD. THIS HAS THE EFFECT OF COMPLETELY OPENING THE BLOW-OFF VALVE AND AL ROTATING THE INLET BUTTERFLY VALVE FROM A MAXIMUM OPENING OF 90 DEGREES PARALLEL TO THE INLET PIPE TO A MINIMUM OPENING OF 7 DEGREES. IN THE UNLOADED CONDITION THE COMPRESSOR IS RUNNIN IN A THROTTLED VACUUM AND HAS A RESULTING NO LOAD HORSEPOWER 0 10 TO. 157.. AS THE COMPRESSOR DISCHARGE PRESSURE DROPS DURING THE UNLOADIN CYCLE, THE DISCHARGE CHECK VALVE CLOSES TO ISOLATE THE COMPRES FROM THE PROCESS. THE RESIDUAL COMPRESSED AIR IN THE PIPING 0 RECEIVER THEN SUPPLIES THE AIR NECESSARY TO MEET THE PROCESS DEMAND UNTIL THE 95# PRESSURE POINT IS REACHED. AS THE SYSTEM PRESSURE DECREASES, THE 95# PRESSURE POINT IS EVENTUALLY REACHED. AT THIS POINT A PRESSURE SWITCH IS TRIPPE TO LOAD THE COMPRESSOR. THE PRESSURE SWITCH ACTIVATES A THREE WAY SOLENOID VALVE WHICH IN TURN PRESSURIZES THE AIR LINES TO THE INLET BUTTERFLY VALVE AND THE BLOW-OFF VALVE ACTUATORS. THIS INCREASES IN SIGNAL PRESSURE CAUSES THE INLET VALVE TO OP. AND THE BLOW-OFF VALVE TO CLOSE. THE COMPRESSOR WILL CONTINUE TO PROVIDE THE EXACT SYSTEM REQUIREMENT AND WILL NOT REPEAT THi UNLOAD/LOAD CYCLE AS LONG AS THE SYSTEM DEMAND REMAINS SOMEWHEBETWEEN 95# AND 105# PRESSURE SET POINTS ON THE COMPRESSOR LOA: CHARACTERISTIC CURVE. DO DO NF ^ OS6944 Td5NTT4L PAGE 7 IV. CONTROLS (CONTINUED) -- (CONTINUED) -- B.~ SURGE CONTROL DUE TO THE COMPRESSOR CHARACTERISTIC AND ITS RELATIONSHIP TO TP SURGE LINE, THE FOLLOWING INLET AND BLOW-OFF VALVE MOVEMENTS AR REQUIRED TO AVOID SURGE. TO LOAD: OPEN THE INLET BEFORE CLOSING THE BLOW-OFF. k TO UNLOAD: OPEN THE BLOW-OFF BEFORE CLOSING THE INLET. IN GENERAL, IF THE COMPRESSOR SURGES ASIT IS LOADED. THEN OPEN THE INLET VALVE FASTER, OR CLOSE THE BLOW-OFF VALVE SLOWER. IF THE COMPRESSOR SURGES AS IT IS UNLOADED, THEN OPEN THE BLOW-OFF VALVE FASTER OR CLOSE THE INLET VALVE SLOWER. OPEN CLOSE INLET BUTTERFLY VALVE: BLOW-OFF VALVE: 12 SECONDS 3 SECONDS 12 SECONDS 14 SECONDS FLOW CONTROL VALVES ARE USED TO CONTROL THE OPERATING SPEEDS OF THE INLET BUTTERFLY VALVE AND THE BLOW-OFF VALVE. IN MOST CASE TWO CONTROL VALVES ARE PLACED BACK-TO-BACK IN SERIES WITH THE SIGNAL AIR TO THE DIAPHRAGM ACTUATOR FOR ADJUSTING THE SPEED OF THE VALVE IN BOTH DIRECTIONS. EACH FLOW CONTROL VALVE RESTRICT AIR IN THE DIRECTION OF THE ARROW AND ALLOWS FREE FLOW IN THE OPPOSITE DIRECTION. (NOTE THE DIRECTION OF THE ARROW ON EACH FLOW CONTROL VALVE. ) SINCE THE INLET BUTTERFLY VALVE REQUIRES CONTROL AIR PRESSURE T OPEN (AIR--TO--OPEN TYPE VALVE) THEN IT FOLLOWS THAT: -------- THE INLET VALVE CAN BE ADJUSTED TO CLOSE SLOWER BY CLOSING THE FLOW CONTROL VALVE THAT HAS THE ARROW POINTED AWAY FROM THE INLET VALVE. THE INLET VALVE CAN BE ADJUSTED TO OPEN FASTER BY OPENING THE FLOW CONTROL VALVE THAT HAS THE ARROW POINTED TOWARD THE INLET VALVE. -------- SINCE THE BLOW-OFF VALVE REQUIRES CONTROL AIR PRESSURE TO CLOSE (AIR-TO-CLOSE TYPE VALVE) THEN IT FOLLOWS THAT: -------- THE BLOW-OFF VALVE CAN BE ADJUSTED TO CLOSE SLOWER BY CLOSING THE FLOW CONTROL VALVE THAT HAS THE ARROW POINTED TOWARD THE BLOW-OFF VALVE. -------- 00 A 056945 CONFIDENTIAL PAGE 8 IV. CONTROLS (CONTINUED) -- C. MOTOR OVERLOAD DESCRIPTION (TOTAL CLOSURE MODE) MOTOR OVERLOAD CONTROL PREVENTS EXCESSIVE COMPRESSOR LOADING WHICH CAN RESULT IN AN INADVERTENT SHUTDOWN AND/OR MOTOR DAMAGE. ,, EXCESSIVE COMPRESSOR LOADING IS MOST OFTEN CAUSED BY "OFF; ' DESIGN" COMPRESSOR OPERATION. THE MOTOR OVERLOAD CONTROL SENSES MOTOR LOAD, AND DURING OVERLOAD CONDITIONS, SENDS A SIGNAL TO THE COMPRESSOR INLET BUTTERFLY VALVE TO DECREASE THE OPENING OF THAT VALVE AND THEREBY THROTTLE THE MOTOR LOAD BACK TO A PRE-DETERMINED LOAD LIMIT. THE LOAD LIMITING CONTROLLER HAS TWO ADJUSTMENTS, THE PERCENT LOAD AND BAND WIDTH SET POINTS. THE PERCENT-LOAD ADJUSTMENT DETERMINES THE SET POINT FOR MAINTAINING MOTOR AMPERAGE BELOW A PRE-DETERMINED LOAD LIMIT. THE BAND-WIDTH ADJUSTMENT DETERMINES HOW RESPONSIVE OR HOW QUICKLY THE CONTROLLER WILL REACT TO CONTROL CHANGES. THE BAND-WIDTH ADJUSTMENT IS SET AS LOW AS POSSIBLE TO MAINTAIN GOOD CONTROL, BUT NOT SO LOW THAT CYCLING OCCURS. D. VIBRATION MONITOR 1. 1 GENERAL THE JOY 9000 SERIES RADIAL VIBRATION MONITORING SYSTEM, MANUFACTURED BY BENTLY NEVADA CORPORATION, IS AN ACCURATE AND HIGHLY RELIABLE MACHINE PROTECTION SYSTEM THAT CONTIN UOUSLY MONITORS THREE INDEPENDENT CHANNELS OF RADIAL VIBRATION. THE SYSTEM, AS SHOWN IN FIBURE 1-1, CONSISTS OF A PROBE AND PROXIMITOR FOR EACH MONITORED CHANNEL AND A RACK ASSEMBLY THAT CONTAINS A FRONT PANEL ANALOG DISPLAY, POWER SUPPLY, RELAY MODULE, AND ONE OR MORE MONITORS. A 3000 SERIES EDDY CURRENT TYPE PROBE AND PROXIMITOR GENERATES A VOLTAGE SIGNAL FOR EACH CHANNEL THAT VARIES PROPORTIONALLY TO THE VIBRATION LEVEL. THE VOLTAGE SIGNAL OF EACH CHANNEL IS RECEIVED AND CONDITIONED BY A MONITOR. THE MONITOR OUTPUTS ARE SWITCH SELECTED TO DRIVE A COMMON FRONT PANEL METER. THE METER (WITH DUAL ENGLISH/METRIC SCALE) DISPLAYS EITHER THE HIGHEST VIBRATION LEVEL OF ALL MONITORED CHANNELS OR THE ACTUAL VIBRATION OF EACH CHANNEL. AN OK CIRCUIT FOR EACH CHANN MONITORS THE PROXIMITOR INPUT VOLTAGE TO DETECT AND INDICATE FAULTY TRANSDUCER OPERATION BY EXTINGUISHING A GREEN OK LED INDICATOR AND ACTIVATING A RELAY. THE SYSTEM CONTAINS TWO ALARM CIRCUITS FOR EACH CHANNEL WITH INDIVIDUAL SET POINTS TO DETECT EXCESSIVE VIBRATION LEVELS (ALERT AND DANGER ALARMS). BY PRESSING FRONT PANEL SWITCHES DO A 056946 CONFIDFNTTAl PAGE 9 IV. CONTROLS (CONTINUED) -- D. VIBRATION MONITOR 1. 1 GENERAL (CONTINUED) -- THE ALARM SET POINTS CAN BE DISPLAYED ON THE FRONT PANEL METER IF THE VIBRATION LEVEL MONITORED BY ANY CHANNEL EXCEEDS AN ALA SET POINT LONGER THAN AN INTEGRATRING TIME DELAY PERIOD. THE APPROPRIATE FRONT PANEL ALARM LED IS ILLUMINATED AND A RELAY I THE RACK IS ACTIVATED. THE RELAY CONTACTS CAN BE USED TO ANNUNCIATE AN EXTERNAL VISIBLE OR AUDIBLE ALARM. A SPECIAL DANGER DISABLE FUNCTION INHIBITS DANGER ALARMS WHEN A NON-OK CONDITION EXISTS AND A TRIP MULTIPLIER CAPABILITY CAN BE REMOTELY ACTUATED TO DOUBLE THE SYSTEM ALARM SET POINTS. A COMMON RESET SWITCH IS PROVIDED TO SIMULTANEOUSLY RESET ALL SYSTEM ALARMS. 1.2 PHYSICAL DESCRIPTION A TYPICAL 9000 SERIES RADIAL VIBRATION SYSTEM IS SHOWN IN FIGU 1-3 WITH INDICATORS AND CONTROLS INDEXED TO THE DEFINITATIONS ) PROVIDED IN TABLE 1-3. EXCEPT FOR THE PROBES AND PROXIMITORS. THE SYSTEM IS INSTALLED IN A RACK ASSEMBLY DESIGNED FOR PANEL ( MOUNTING. EXTERNALLY MOUNTED PROBES AND PROXIMITORS PROVIDE INPUTS THROUGH REAR RACK TERMINAL STRIPS. i TABLE 1-3 9000 SERIES FRONT PANEL CALLOUT DESCRIPTION 1 9000 SERIES INSTRUMENT RACK ASSEMBLY ) 2 DUAL SCALE METER --- DISPLAYS HIGH READ. SIGNAL. AND ALARM SET LEVELS FROM THE MONITORS. ) 3 POWER ON (LED) ------ ILLUMINATES WHEN POWER IS APPLIED TO THE SYSTEM. 4 TRIP MULTIPLIER (LED) ILLUMINATES WHEN THE TRIP MULTIPLY FUNCTION IS SELECTED. 5 COMMON RESET (SWITCH) USED TO RESET MONITOR ALARM CIRCUITS. 6 HIGH READ/CHAN SELECT (SWITCH) ------ SELECTS HIGH READ FUNCTION. OR IN CONJUNCTION WITH MONITOR SWITCHES, THE INDIVIDUAL MONITOR SIGNAL OR ALARM SET POINT. 7 CALIBRATION COVER. PROVIDES ACCESS TO METER SPAN POTENTIOMETER. 3 KEY 0 (BNC CONNECTOR) ------ PROVIDES KEYPHASOR OUTPUT SIGNAL MONITORING. DO A 056947 CONFTDFNTTAl. PAGE 11 IV. CONTROLS (CONTINUED) -- D. VIBRATION MONITOR (CONTINUED) -- TABLE 1-3 9000 SERIES FRONT PANEL (CONTINUED) -- CALLOUT DESCRIPTION 9 COM (SIGNAL COMMON TEST POINTS) ------ USED AS REFERENCE FOR SYSTEM SIGNAL MEASUREMENTS. 10 OK (LED) ------ GREEN LED INDICATOR IS ILLUMINATED WHEN CHANNEL INPUT TRANDUCER IS OPERATING WITHIN NORMAL OPERATING LIMITS. IF LIT VIBRATION CIRCUIT IS FUNCTIONING. 11 DANGER (LED) ------ RED LED INDICATOR ILLUMINATES IF CHANNEL VIBRATION LEVEL EXCEEDS ALARM SET POINT. TRIPS COMPRESSOR. 12 ALERT (LED) ------ RED LED INDICATOR ILLUMINATES IF ) CHANNEL VIBRATION LEVEL EXCEEDS ALARM SET POINT - ALARM ONLY. > 13 SIGNAL (SWITCH) ------ USED IN CONJUNCTION WITH CHANNEL ( SELECT SWITCH ,,6M TO SELECT CHANNEL SIGNAL LEVEL FOR METER DISPLAY. i NOTE: LEFT SWITCH IS FOR COMPRESSOR STAGES 1 AND 2. LEFT SWITCH IN LEFT POSITION ACCESSES STAGE 1 ) IN RIGHT POSITION ACCESSES STAGE '2. RIGHT SWITCH IN LEFT POSITION ACCESSES STAGE 3. ) 14 DANGER (SWITCH) -r- USED IN CONJUNCTION WITH CHANNEL SELECT SWITCH "&M` TO SELECT CHANNEL DANGER SET POINT FOR METER DISPLAY. ) NOTE: LEFT SWITCH IS FOR COMPRESSOR STAGES 1 AND 2. LEFT SWITCH IN LEFT POSITION ACCESSES STAGE 1 IN RIGHT POSITION ACCESSES STAGE 2. RIGHT SWITCH IN LEFT POSITION ACCESSES STAGE 3. 15 ALERT (SWITCH) ------ USED IN CONJUNCTION WITH CHANNEL SELECT SWITCH ,,6M TO SELECT CHANNEL ALERT SET POINT FOR METER DISPLAY. NOTE: LEFT SWITCH IS FOR COMPRESSOR STAGES 1 AND 2. LEFT SWITCH IN LEFT POSITION ACCESSES STAGE 1 IN RIGHT POSITION ACCESSES STAGE 2. RIGHT SWITCH IN LEFT POSITION ACCESSES STAGE 3. 050948 DO A CONFTO p{s)T I Al- PAGE 11 IV. CONTROLS (CONTINUED) -- D. VIBRATION MONITOR (CONTINUED) -- TABLE1-3. 9000 SERIES FRONT PANEL (CONTINUED) -- CALLOUT DESCRIPTION 16 CALIBRATION COVER. PROVIDES ACCESS TO DANGER AND ALER SET POINT POTENTIOMETERS. THE COVER LABEL DEFINES THE MONITOR RANGE. 17 PROX OUT------BNC CONNECTOR PERMITS MONITORING OF UN PROCESSED CHANNEL PROXIMITOR SIGNAL. E. PROCEDURE FOR SETTING ALARM AND TRIP SET POINT 1) SET THE "HIGH READ/CHAN SELECT" SWITCH ON THE FRONT PANEL TO THE "CHAN SELECT" POSITION. 2) PRESS AND HOLD THE "ALERT" SWITCH ON THE MONITOR FRONT PANEL TO THE "READ" POSITION AND ADJUST THE "ALERT" POTENTIOMETER UNTIL THE DESIRED ALARM SET POINT IS INDICATED ON THE ANALOG DISPLAY METER. RELEASE THE "ALERT" SWITCH. 3) PRESS AND HOLD THE "DANGER" SWITCH ON THE MONITOR FRONT PANEL TO THE "READ" POSITION AND ADJUST THE "DANGER" POTENTIOMETER UNTIL THE DESIRED DANGER SET POINT IS INDICATED ON THE ANALOG DISPLAY METER. RELEASE THE "DANGER" SWITCH. NOTE: ON THE DISPLAY PANEL THERE ARE TWO SWITCHES FOR "ALERT" AND TWO FOR "DANGER". THE LEFT SWITCH IS FOR STAGE 1 AND 2; THE RIGHT SWITCH FOR STAGE 3. PUSHING THE LEFT HAND SWITCH TO THE LEFT WILL ALLOW ACCESS TO COMPRESSOR VIBRATION SIGNAL AND TO THE RIGHT ACCESS TO STAGE 2. PUSHING THE RIGHT SWITCH TO THE LEFT ACCESSES STAGE 3. 10/02/81 D0 A 056949 CONFIDFNTTA1 }I ( L DO A 056950 CONFIOFNTTAl RACK TERMINAL STRIP 3-WIRE SHIELDED CABLE 2-WIRE SHIELDED CABLE KMUBH JOY 9000 RV MONITORS if5* /EXTENSION--^ v\ I'/( RECORDER CABLE PROXIMITOR B \ Ll \ c-------- 7 -J . I 1 r* . . ; j H PROBE ----------^ i REMOTE RESET SHAFT INTEGRAL CABLE PROBE A REMOTE I RESET-] SWITCH I, L TRIP MULTR SIGNAL . TERMINAL STRIP TRIP MULTIPLIER SWITCH 0 r otnrT 01 e 0I 3000 PROXIMITOR DO A 05A951 CONFTDFNTIAl EDT AIRC0MP6.TXT PAGE 12 V. INSTRUMENTATION -- ALARMS AND TRIPS EQUIP NO. INSTRUMENT NUMSER DESCRIPTION P ?< ID NUMBER RANGE ALARM POINT TRIP POINT C-902 .< / TCV-9232 OIL TEMP CONTROL VALVE B1-035 CONTROLS BE TWEEN 110 & 120 C-902 PSL-9234 CONTACT 1 AUX 01 PUMP START-UP PRESSURE SWITCH B1-035 12# C-902 PSL-9234 CONTACT 2 LOW OIL PRESSURE TRIP B1-035 8# C-902 C-902 COMPRESSOR OVER-PRESS SWITCH 3RD STAGE HIGH TEMP SWITCH 105# - 105# C-902 TSH-9235 HIGH OIL TEMP TRIP SWITCH B1-035 140 DEG C-902 VTS VIBRATION TRANSMITTER SWITCH B1-035 1ST it 2ND STAGE 1. 3 MILS 3RD STAGE 1. 0 MILS 1ST & 2ND STAGE 1. 6 MILS 3RD STAGE 1. 3 MILS DO A 05695? CONFIDENTIAL PAGE i: EQUIP NO. INSTRUMENT NUMBER DESCRIPTION P&ID NUMBER RANGE ALARM POINT TRIP POINT C-903 TCV-9271 OIL TEMP CONTROL VALVE , B1-036 CON TROLS BE TWEEN 110 DEG F TO 120 DEG F C-903 PSL-9268 CONTACT 1 AUX OIL PUMP START-UP PRESS SWITCH B1-036 12# C-903 PSL-926S CONTACT 2 LOW OIL PRESSURE TRIP B1-036 8# C-903 TSH-9269 HIGH OIL TEMP TRIP SWITCH B1-036 140 DEG C-903 UTS VIBRATION TRANSMITTER SWITCH B1-036 1ST 2ND STAGE 1. 3 MILS 3RD STAGE 1. 0 MILS 1ST Se 2ND STAGE 1. 6 MILS 3RD STAGE 1. 3 MILS C-903 COMPRESSOR OVER-PRESS SWITCH 105# C-903 3RD STAGE HIGH TEMP SWITCH 140 DEG C-902 C-903 CONTROL BOX LOW AIR PURGE PRESS 0--. 5" 0--. 5" 10/02/81 DO A 050953 CONFIDENTIAL  EDT AIRC0MP7.TXT PAGE 14 VI. START-UP AND SHUT DOWN PROCEDURES START-UP PROCEDURE <SEE CHECK LIST AT BACK) ( 1) MANUAL START-UP A. OPEN THE INSTRUMENT AIR TO CONTROL PANEL. IF NO AIR IS AVAIL ABLE, OPEN AIR SUPPLY FROM BOTTLE. 'b: OPEN COOLING WATER VALVES TO OIL COOLER INTER-COOLER AND AFTER-COOLER. C. START THE PRE-LUBE PUMP AT LEAST 15 MINUTES PRIOR TO COMPRESSOR START-UP. D. CLOSE PANEL POWER SWITCH S-l. INDICATOR LIGHT W-l WILL ILLUMINATE. E. PUSH THE ALARM SILENCE PUSHBUTTON S-5 TO SILENCE THE ALARM HORN. F. PUSH THE CONTROL RESET PUSHBUTTON. IF THERE ARE NO MALFUNCTIONS AT THIS TIME, THE ALARM LIGHTS WILL BE DE-ENERGIZED, EXCEPT THE AUXILIARY PUMP OPERATING LIGHT. GREEN PERMISSIVE START LIGHT SHOULD BE ENERGIZED. G. SWITCH S-2 MUST BE IN "AUTO" POSITION TO LOAD THE COMPRESSOR. WHEN TDR-1 (20 SECONDS) TIMES OUT THE COMPRESSOR WILL BEGIN LOADING UP. FOR THE INITIAL 20 SECONDS THE COMPRESSOR IS IN UNLOAD CONDITION. H. START THE COMPRESSOR BY PUSHING THE "START" PUSHBUTTON LOCATED ON THE MOTOR STARTER. WHEN TDR-1 (20 SECONDS) TIMES OUT, THE AUXILIARY LUBE OIL PUMP IS AUTOMATICALLY SHUT DOWN. THE AUXILIARY PUMP OPERATING LIGHT WILL BE DE-ENERGIZED. I. THE COMPRESSOR WILL CONTINUE TO RUN UNTIL STOPPED MANUYALLY WITr THE COMPRESSOR "STOP" PUSHBUTTON OR UNTIL STOPPED AUTOMATICALLY BY ONE OF THE MALFUNCTIONS. INSPECT COMPRESSOR FOR AIR AND OIL LEAKAGE. ANY UNUSUAL SOUNDS AND EXCESSIVE VIBRATION MAY BE CAUSED BY INTERNAL RUBBING, WORN BEARINGS OR SHAFT MISALIGNMENT. J. PLACE UNLOAD/AUTO SELECTOR SWITCH IN THE "AUTO" POSITION IF NOT. IN THAT POSITION ALREADY. K. CHECK TO ENSURE THAT STAGE INLET AIR TEMPERATURES ARE MAINTAINED BETWEEN 90 DEG F AND 110 DEG F. ADJUST WATER FLOW CONTROL VALVE TO OBTAIN DESIRED AIR TEMPERATURES. DO A 056954 CONFIDENTTAl PAGE 15 VI. START-UP AND SHUT DOWN PROCEDURES (I) MANUAL START-UP (CONTINUED) -- L. CHECK OIL PRESSURE AND TEMPERATURE. THE TEMPERATURE WILL DE AUTOMATICALLY CONTROLLED BY WATER CONTROL VALVES. REGULAR k OIL COOLER WATER FLOW TO OBRTAIN REQUIRED OIL INLET TEMPERATURE ' OF 110 DEG F TO 120 DEG F. (II) BACK-UP COMPRESSOR AUTOMATIC START-UP THE AIR COMPRESSOR SYSTEM IS DESIGNED TO AUTOMATICALLY START UP THE BACK-UP COMPRESSOR IF THE AIR HEADER PRESSURE REACHES 80#. HOWEVER, THE COMPRESSOR WILL ONLY START AUTOMATICALLY IF THE FOLLOWING CRITEREA ARE MET: (A) "MANUAL OFF AUTO" KEY SWITCH ON THE CONTROL PANEL SHOULD BE IN "AUTO" POSITION. (B) AUXILIARY OIL PUMP SHOULD BE RUNNING. AN 8# PRESSURE SWITCH MUST BE SATISFIED FOR COMPRESSOR TO START. (C> OIL TEMPERATURE CANNOT EXCEED 140 DEG F. (D) VIBRATION PROBE CANNOT EXCEED TRIP LIMITS. (E) 3RD STAGE SUCTION PRESSURE CANNOT EXCEED 140 DEG F IN ORDER TO ENSURE A RELIABLE BACKUP COMPRESSOR SEVERAL ITEMS SHOULD BE CHECKED WHEN MAKING ROUNDS OF THE PLANT. THIS LIST IS UNDER ROUND CHECK (B). (Ill) SHUTDOWN PROCEDURE A. OPEN INTER-COOLER SHELL DRAINS PRIOR TO SHUTTING DOWN THE COMPRESSOR. B. TURN UNLOAD/AUTO SELECTOR SWITCH TO "UNLOAD" POSITION. C. DEPRESS "STOP" BUTTON ON CONTROL PANEL. D. ALLOW AUXILIARY LUBE OIL PUMP TO OPERATE FOR ONE HOUR, WITH COOLING WATER CIRCULATING THROUGH THE LUBE OIL COOLER, AFTER COMPRESSOR IS SHUT DOWN TO REMOVE HEAT FROM BEARINGS. E. OPEN PANEL POWER SWITCH. F. TURN OFF INSTRUMENT AIR SUPPLY. G. TURN OFF COOLING WATER SUPPLY. DO A 056955 CONFIDENTIAL PAGE 16 VI. START-UP AND SHUT DOWN PROCEDURES (CONTINUED) ---- (IV) NON-ROUTINE SHUTDOWN A. IN THE EVENT OF LOW OIL PRESSURE, PS1-1 WILL OPEN TO AUTO MATICALLY START THE AUXILIARY LUBE OIL PUMP. THE ALARM HORN WILL SOUND AND THE AUXILIARY LUBE OIL PUMP OPERATING LIGHT WILL BE ILLUMINATED. IF OIL PRESSURE CONTINUES TO DECREASE, PS1-2 WILL OPEN TO AUTOMATICALLY SHUT DOWN THE COMPRESSOR. THE LOW OIL PRESSURE LIGHT (R-2) WILL BE ILLUMINATED. B. IN THE EVENT OF HIGH LUBE OIL TEMPERATURE, TS-1 WILL OPEN TO SOUND THE ALARM HORN AND AUTOMATICALLY SHUT DOWN THE COMPRESSOR. THE ALARM HORN WILL SOUND AND THE HIGH AIR TEMPERATURE LIGHT (R-4) WILL BE ILLUNINATED. C. IN THE EVENT OF HIGH AIR TEMPERATURE, TS-2 WILL OPEN AND AUTOMATICALLY SHUT DOWN THE COMPRESSOR. THE ALARM HORN WILL SOUND AND THE HIGH AIR TEMPERATURE LIGHT (R-4) WILL BE ILLUMINATED. r D. IN THE EVENT OF HIGH VIBRATION, VS1-1 WILL CLOSE TO SOUND THE ALARM HORN AND THE "ALERT" LIGHT ON THE VIBRATION MONITOR WILL BE ILLUMINATED. /\ IF VIBRATION CONTINUES TO INCREASE VS-1-2A WILL OPEN TO AUTOMATICALLY SHUT DOWN THE COMPRESSOR. THE "DANGER" LIGHT WILL BE ILLUMINATED ON THE VIBRATION MONITOR. E. IN THE EVENT OF VIBRATION PROBE OUTPUT NOT OKAY, THE VIBRATION MONITOR OKAY CONTACT WILL CLOSE TO SOUND THE > ALARM HORN AND THE VIBRATION MONITOR OKAY LIGHT WILL GO OUT. F. IN THE EVENT OF A LOSS OF PRESSURE FOR PANEL PURGE, DPS WILL OPEN TO SOUND THE ALARM HORN AND ILLUMINATE THE LOW PANEL PURGE PRESSURE LIGHT AL. 10/02/31 e 00 A 05695( CONF TDFNT I Al EDI AIRC0MP8.TXT PAGE 17 VII. ROUND CHECK A. OIL LEVEL B. LUBE OIL TEMPERATURE C. LUBE OIL PRESSURE D. OIL FILTER (F-902 AND F-903) P E. AUXILIARY OIL PUMP RUNNING F. THIRD STAGE SUCTION TEMPERATURE G. SECOND STAGE SUCTION TEMPERATURE AIR DISCHARGE TEMPERATURE : i. BLOWDOWN 1ST AND 2ND STAGE INTER-COOLOER TRAPS j. BLOWDOWN AFTER-COOLER TRAPS K. BLOWDOWN PRE-FILTER (FLY-902) TRAPS - 1 L. FLY-902 P M. FL-902-A OR B IN SERVICE N. PURGE AIR FLOW 0. PURGE AIR PRESSURE BACK COMPRESSOR ROUND CHECK A. MANUAL-OFF AUTO SWITCH IN "AUTO" POSITION B. AUXILIARY OIL PUMP SHOULD BE RUNNING* CHECK PRESSURE C. CHECK OIL TEMPERATURE D. CHECK WATER FLOW THROUGH 1ST STAGE INTER-COOLER* 2ND STAGE INTER-COOLER. AFTER-COOLER AND OIL COOLER E. CHECK TO BE SURE OIL SUMP EJECTOR IS IN SERVICE F. CHECK VALVING FOR PROPER POSITION G. CHECK FOR AIR PURGE ON CONTROL BOX H. CONTROL POWER SHOULD BE LEFT ON I. GREEN PERMISSIVE START LIGHT MUST BE "ON" 10/05/31 X> U1 00 A 0569 CONFIOFNTT EDI A1kCCMPS.TXT PAGE IS VIII. SYSTEM TOUBLE ANALYSIS PRELIMINARY SET-UP A. TROUBLE: NO PRIMARY VOLTAGE PROBABLE CAUSE: DEFECTIVE PRIMARY POWER SOURCE ,, DEFECTIVE CIRCUIT BREAKER IN PRIMARY POWER SOURCE : ' DEFECTIVE INTERCONNECTING CABLING, OR LOOSE OR BROKEN CONNECTIC REMEDY: REPAIR OR REPLACE PRIMARY POWER SOURCE, AS NECESSARY. CHECK CIRCUIT BREAKERS IN PRIMARY POWER SOURCE. REPLACE IF DEFECTIVE. CHECK ALL CONNECTIONS. PERFORM CONTINUITY CHECK ON CABLING. REPAIR OR REPLACE AS NECESSARY. B. TROUBLE: NO INSTRUMENT AIR PRESSURE (OR LOW AIR PRESSUR PROBABLE CAUSE: DEFECTIVE INSTRUMENT AIR COMPRESSOR INSTRUMENT AIR SUPPLY VALVE CLOSED RUPTURED OR PINCHED AIR LINE LEAKS AROUND FITTINGS REMEDY: REPAIR OR REPLACE AIR COMPRESSOR AS NECESSARY. OPEN AIR SUPPLY VALVE. REPLACE AIR LINE. TIGHTEN OR REPLACE FITTINGS AS NECESSARY. C. TROUBLE: NO LUBE OIL PRESSURE (OR LOW OIL PRESSURE) PROBABLE CAUSE: DEFECTIVE MAIN LUBE OIL PUMP CLOGGED OR LEAKING OIL FILTER LEAKS AROUND FITTINGS RUPTURED OR PINCHED OIL LINE REMEDY: REPAIR OR REPLACE PUMP AS NECESSARY. CLEAN OR REPLACE FILTER AS NECESSARY. TIGHTEN OR REPLACE FITTINGS AS NECESSARY. REPLACE OIL LINE. DO A 056958 CONFIDFNT T Al PAGE 19 VIII. SYSTEM TROUBLE ANALYSIS (CONTINUED) -- OPERATING CYCLE D. TROUBLE: VIBRATION PROBABLE CAUSE: COMPRESSOR AND DRIVER SHAFTS MISALIGNED WORN OR DEFECTIVE SHAFT COUPLING WORN OR DEFECTIVE COMPRESSOR JOURNAL BEARING WORN OR DEFECTIVE COMPRESSOR THRUST BEARING DAMAGED BULL GEAR OR PINION LOOSE ANCHOR BOLTS . DEFECTIVE DRIVER REMEDY: REALIGN. REPLACE SHAFT COUPLING. REPLACE JOURNAL BEARING. REPLACE THRUST BEARING. REPLACE BULL GEAR OR PINION. TIGHTEN BOLTS. REPAIR OR REPLACE DRIVER AS NECESSARY. E. TROUBLE: HIGH LUBE OIL TEMPERATURE POSSIBLE CAUSE: WATER FLOW TO OIL COOLER INTERRUPTED REMEDY: CHECK COOLING WATER SYSTEM. F. TROUBLE: LOSS OF LUBE OIL PRESSURE (OR LOW PRESSURE) -- AUXILIARY PUMP OPERATING PROBABLE CAUSE: MAIN LUBE OIL PUMP DEFECTIVE MAIN LUBE OIL PUMP CLOGGED OR LEAKING OIL FILTER LEAKS AROUND FITTINGS RUPTURED OR PINCHED OIL LINE REMEDY: REPLACE COUPLING. REPAIR OR REPLACE PUMP AS NECESSARY. CLEAN OR REPLACE FILTER AS NECESSARY TIGHTEN OR REPLACE FITTINGS AS NECESSARY REPLACE OIL LINE. DO A 056959 CONFIDENTIAL PAGE 20 VIII. SYSTEM TROUBLE ANALYSIS (CONTINUED) -- G. TROUBLE: LOSS OF LUBE OIL PRESSURE (OR LOU PRESSURE) -- AUXILIARY PUMP NOT OPERATING PROBABLE CAUSE: DEFECTIVE INSTRUMENT AIR COMPRESOR ' DEFECTIVE AUXILIARY PUMP MOTOR DEFECTIVE AUXILIARY LUBE OIL PUMP LOU LUBE OIL LEVEL MAIN LUBE OIL PUMP DEFECTIVE MAIN LUBE OIL PUMP CLOGGED OR LEAKING OIL FILTER LEAKES AROUND FITTINGS RUPTURED OR PINCHED OIL LINE REMEDY: REPAIR OR REPLACE AIR COMPRESSOR AS NECESSARY. OPEN AIR SUPPLY VALVE. REPLACE AIR LINE. TIGHTEN OR REPLACE FITTINGS AS NECESSARY. REPALCE COUPLING. c REPAIR OR REPLACE PUMP AS NECESSARY. CLEAN OR REPLACE FILTER AS NECESSARY. TIGHTEN OR REPLACE FITTINGS AS NECESSARY. REPLACE OIL LINE. H. TROUBLE: HIGH BEARING TEMPERATURE PROBABLE CAUSE: LUBE OIL SYSTEM MALFUNCTIONING DEFECTIVE BEARING REMEDY: REPLACE COUPLING. REPAIR OR REPLACE PUMP AS NECESSARY. CLEAN OR REPLACE FILTER AS NECESSARY. TIGHTEN OR REPLACE FITTINGS AS NECESSARY. REPLACE OIL LINE. REPAIR OR REPLACE AIR COMPRESSOR AS NECESSARY. OPEN AIR SUPPLY VALVE. REPLACE AIR LINE. REPAIR OR REPLACE MOTOR AS NECESSARY. ADD OIL TO OIL TANK. REPLACE BEARING. I. TROUBLE: HIGH DISCHARGE AIR TEMPERATURE PROBABLE CAUSE: WATER FLOU TO INTER-COOLERS INTERRUPTED REMEDY: CHECK COOLING WATER SYSTEM. nn . ^ 00 A 056960 C0NFIDFNTTA1 EDT AIRC0MP10.TXT STARTING PROCEDURE CHECK LIST PAGE 21 10/05/81 1. CHECK LUBE OIL LEVEL. 2. APPLY INSTRUMENT AIR SUPPLY TO CONTROL PANEL AND CONTROL VALVES. 3. OPEN COOLING WATER SUPPLY VALVE TO OIL COOLER. INTER COOLERS AND AFTER-COOLER. 4. START AUXILIARY LUBE OIL PUMP. AMBER LIGHT INDICATES PUMP IS RUNNING. 5. CLOSE CONTROL PANEL POWER SWITCH. WHITE LIGHT INDICATES POWER IS ON. 6. DEPRESS CONTROL RESET PUSHBUTTON. 7. DEPRESS ALARM SILENCE PUSHBUTTON. 8. TURN UNLOAD/AUTO SLECTOR SWITCH TO "UNLOAD" POSITION. 9. CHECK LUBE OIL PRESSURE AND TEMPERATURE GAUGES. 10. PERMISSIVE START LIGHT (GREEN) SHOULD BE ON. COMPRESSOR IS NOW READY FOR STARTUP AND NONE OF THE MALFUNCTIONLIGHTS ON THE PANEL SHOULD BE ILLUMINATED. 11. START THE COMPRESSOR. 12. TURN UNLOAD/AUTO SWITCH TO "AUTO" POSITION. 13. CHECK COMPRESSOR STAGE AIR INLET TEMPERATURE. 14. CHECK LUBE OIL PRESSURE AND TEMPERATURE GAUGES. DO A 056961 00NFIDFNTIA1 OFrP.ATIOi' nW, -- Operatic:. STARTING ?~.OCcCl~E Init!*1 Starting Procedure To stare the compressor alter initial installation or overhaul, proceed as follows: Thoroughly clean and dry all piping. To protect the compressor fre-r. possible damage resulting from dirty inlet piping, install an ir.l;t duct screen as shown in Fig ure. 1. Locate the screen as close as possible to the compressor making certain that all piping downstream of the screen has been thoroughly cleaned. The screen must conform to the following specifications: Size S x S sq mesh, C.C63 dia wire, plain weave (C.C-62 sq opening) 10.x 10 sq mesh, 0.035 dia wire, plain weave (0.068 sq opening) Material: AISI 3C2 or 5C1 stainless steel Length of cone: 1.5 times inlet pipe diameter ' w AI-Pj Tj. OV; Remove the screen after iG to 50 hours of operation. / A\ Figure 1. I rile Screen Arrangement, N,''I / I rHrc // / j-d / 71 --l^-L DO A 05696? CONFIDENTIAL 1 C*HO11v, i ii 00 A 056963 CONFTDFNTTAl  EDT AIRC0MP11.TXT PAGE 22 OPERATION STARTING PROCEDURE INITIAL STARTING PROCEDURE TO START THE COMPRESSOR AFTER INITIAL INSTALLATION OR OVERHAUL/ PROCEED AS FOLLOWS: 1. THOROUGHLY CLEAN AND DRY ALL PIPING. 2. TO PROTECT THE COMPRESSOR FROM POSSIBLE DAMAGE RESULTING FROM DIRTY INLET PIPING, INSTALL AN INLET DUCT SCREEN AS SHOWN IN FIGURE 1. LOCATE THE SCREEN AS CLOSE AS POSSIBLE TO THE COMPRESSOR MAKING CERTAIN THAT ALL PIPING DOWNSTREAM OF THE SCREEN HAS BEEN THOROUGHLY CLEANED. THE SCREEN MUST CONFORM TO THE FOLLOWING SPECIFICATIONS: SIZE: 8 X 8 SG MESH, 0.063 DIA WIRE. PLAIN WEAVE (0.062 SO OPENING) 10 X 10 SQ MEXH, 0. 035 DIA WIRE, PLAIN WEAVE (O. 068 SQ OPENING) MATERIAL: AISI 3C2 OR 3C4 STAINLESS STEEL LENGTH OF CONE: 1. 5 TIMES INLET PIPE DIAMETER CAUTION: REMOVE THE SCREEN AFTER 40 TO 50 HOURS OF OPERATION. 10/05/81 FIGURE 1. INLET SCREEN ARRANGEMENT DO A 056964 CONFIDENTIAL 21.5 FUEL GAS Fuel gas enters the block at 275 psig and Is stepped down to 100 psig by a regulator. Fuel gas is fed to FV-904 (flare) and the Dovtherm furnace (F-501). The fuel gas flow, temperature, and pressure is measured for meter ing. There is a high and low pressure alarm. DO A 056965 CONFIDENTIAL TABLE NUMBER 21.1 FIGURE NUMBER 21.1 21.2 21.3 21.A 21.5 21.6 21.7 21.8 21.9 TABLE INDEX FOR UTILITY SYSTEMS DESCRIPTION 15 PSIG Control Loops FIGURE INDEX FOR UTILITY SYSTEMS DESCRIPTION Process Water Distribution and Instrumentation Nitrogen Distribution and Instrumentation 235 PSIG Steam Distribution and Instrumentation 15 PSIG Steam and Condensate System and Instru mentation Plant Air Distribution Equipment and Instrumentation After Air Com pressors Oil System on Air Compressors Air System on Air Compressors Fuel Gas Distribution and Instrumentation rnA 056966 CONr rOENTJAi LOOP CONTROL NUMBER PIC 9148 LIC 9149 LIC 9147 TABLE 21.1 15 PSIG STEAM AND CONDENSATE SYSTEM CONTROL LOOPS PURPOSE 15 psig header pressure controller. Control level in D-908. Controls level in D-907 OPERATION Receives signal from PT9148. Valve is air to close. (PV-9148) Receives signal from LT-9149 If level is above set point, a signal is sent to LV-9149A and condensate is sent to the division power plant. If level is below set point, a signal is sent to LV-9149B and condensate is received from the division power plant. Both valves are air to open. Receives signal from LT-9147 Valve (LV-9147) is air to open. n r ?i i PROCESS WATER SYSTEM r i r 01 0 NITROGEN DlSTRIBUTION TRAIN I r FLARE F--501 o Y--801 REGIN Y-113 REGIN NEAR ADDITIVE PLATFORM l TRAIN NQ. ..2. HEADER DO A 0 5 6 9 7 0 CO NFIDENTIAL FIG. 21.3 D-511 TRACE Y--611 REGIN Y-211 REGIN Y-112 REGIN r-m REGIN RE- E--511 611 TRACE 235# STEAM SYSTEM (CONDENSATE RETURNS TO 0-907) STEAM HEADER FIR 91 A 15# STEAM SYSTEM [)0 A 0 5 6 9 7 ? CO NFIDENTIAL DO A 0 5 6 9 7 3 CONFTDFNTTAi r FIG 21 .6 r>i STARTS OTHER' COMPRESSORJ AM FAHL PAL 9295 9294 9289 r - WCT OUT WCT IN /SHUTDOWN^ MC-902 TT yrx fcL-902d OIL SYSTEM A.) PRELIMINARY ALARMS 1.) AUXILIARY OIL PUMP RUNNING C O N F ropM j o o o Ln > ~l vO '3> ''J B.) SHUTDOWN ALARMS 1.) LOW OIL PRESSURE 2.) HIGH OIL TEMPERATURE FIG. 21.7 EJECTOF SEPERATOR- 0 IL SYSTEM ON C-902 uo A 056975 C O N F ID E N T IA L FIG 21 .8 START STOP AIR SYSTEM A. ) PRELIMINARY ALARMS 1.) LOW PURGE PRESSURE (CABINET) 2.) VIBRATION PROBE NOT OKAY 3.) HIGH VIBRATION (ALERT) B. ) SHUTDOWN ALARMS 1.) HIGH AIR TEMPERATURE 2.) EXCESSIVE VIBRATION (DANGER) AIR SYSTEM ON C-902 I DO A 0 5 6 9 7 6 CONFTDFNTTAI FLARE FV-904 DOWTHERM FURNACE FIG. 21.9 100 PSIG FUEL GAS DIVISION PIPE RACK 22. ELECTRICAL SYSTEM The Dowlex electrical system is unique in the division in that the vol tages being used are 575V and 4500V. There are two main feeders coming from the power plant that enter the block on the north-east side. These feeders supply the two substations and various transformers in the block. If neces sary the block can be run on either one of the feeders but under normal con ditions the electrical load will be shared. There are two substations: Num ber one is located on the north side of the control room and the other sub station, number two, is located just north of the warehouse. The substations house the 15KV, 4.5KV and 600V switch gear, and various motor control centers (MCC). With the exception of the variable speed drive motors (C--111, C-711, P-511, P-512), this system is designed so that it's pos sible to operate with a back-up feeder from either Bus. NOTE: The standby feeders operate automatically on loss of voltage. (See attached one line diagram, figure 22.1) Diagrams of each MCC are in cluded showing the equipment on each MCC bus. It should be noted that usually all of Train #l's equipment is on MCC 1A and IB, while Train #2's equipment is on MCC 2A and 2B. The 'A' equipment is on the 'A' bus. The single items are split evenly. MCC 120 basically carries what is common for both trains such as the sol vent storage area. Substation #2 carries mostly the Dowtherm pumps and product handling equipment such as blowers, rotary feeders, etc. Inside substation #1 is also MCC-VS A&B. These are for the variable speed equipment in the block. MCC-VS A MCC-VS B MP-511 MP-521 ^D0 A 05697? cqnfiDentjai MCC-VS-A MP-512 C-lll C-711 MCC-VS-B MP-522 C-121 C-721 Finally, there are two 4.5KV MCC's. These are MCC-5A and MCC-5B. The following equipment is on these MCC's. P-901A C-902 P-901B C-903 P-901C 22.1 V. C. SYSTEM The D. C. power in the block is basically for the operation of the unin- terruptable power supply and emergency lighting. Each substation has a 60 cell 125V battery bank. Sub #1 is equipped with 2-100 amps chargers while sub #2 has 2-50 amps chargers. Each system has it's own distribution panels, under voltage alarm, and test circuits. The uninterruptable power supply (U. P. S.) is located on 111 D. C. distri bution bus. The purpose of this equipment is to convert D. C. to A. C. for critical 110V A. C. equipment in the plant. Normal A. C. power for the critical equipment comes from a lighting transformer on MCC-2B. The equipment on the U. P. S. includes: Intercom system and radios TDC2000 control system (controllers and operator stations) Emergency block valve solenoids Gas detectors and their alarm panels There battery banks are sized for 30 minutes back-up time. DO A 056978 CONFIDENTIAL FIGURE NUMBER 22.1 22.2 22.3 22.4 22.5 22.6 22.7 22.8 22.9 22.10 22.11 22.12 22.13 22.14 22.15 22.16 22.17 FIGURE INDEX FOR ELECTRICAL DESCRIPTION Block Electrical one line MCC-1A MCC-1B MCC-2A MCC-2B MCC-120 MCC-1C MCC-1D MCC-2C MCC-2D MCC-VS A/B ROBICON A/B MCC-5A/B 13.8KV S.G U. P. S. Block Diagram Substation #1 (Bldg. #8602) Substation #2 (Bldg. #8605) DO A 056979 CONFTDFNTTAL PQWEROnlY- c c FIG. 22.1 4.U Kv BUSA A-U KVjUgB. .V. 1? < sy 5 CtQLd ACC-.2C. - o VO- Ou 3M rtcc-lb. 325 -- 4------------ aaJC---------- <332i5-4 4-- Yvr-jfc. a SUBSTATION NO. 2. __-- --J 2fKDjS! 6C.4 ncc-vs j-p Hk<^5> *rr-aA ACC- 2.B AK.-lZfl. ACC-.tl. ttC.C-.lB. M <& SUBSTATION NO J n oa 2"n o n 3> o mo 2 cn HO *0 J> CO FIG. 22.2 ri.! East MCC-U West Spar* P-BUA Solvent Monos*r P-514A D-514 Bottosa P-515A Chilled Solvent VP-512A Vacuus Puatp C-911 Refrig Spare Spar* FN-612A E-612 Fan A-211 Agitator P-611A T-611 Reflux P-711 D-711 Bottosa CR-311 Lube Oil Heater P-211A Solvent Feed LP-8603 Lighting Panel H--111 N2 Caa Heater P-211C Solvent Feed 0P-GR511A Oil Pusp CR311A MR-511 Motor Pelletizer OP-CR512A Oil Pusp CR312A XS-311 Motor-311 Extruder EF-MP-511 Fan MP-311 SCR-100 Raney Variable Speed CL-511 Classi fier r-319A DTA Return P-612A Solvent Recycle B-312A Vacuia Booster P-613A SD-511 T-611 Pellet Reclrculai- Dryer tlon TB-611 T-611 - N2 Blower P-614A T-611 Bottosa POX-311 XS-311 Oil Pusp HC LOP cm Spar* P-C MEF C-lll SC-311 MC-511 Screen Changer PSD-S11 SD-511 Fan RRR 9/2/81. I T-4 BREAKERS T-3 BREAKERS OC Relays Tie Breaker VP-512B Vacuum Pump P-613B T-6U Reclrculatlon FN-111 E-lll Fan CB-B601 HCC Power Panel P-519B OTA Return Spare GR-512 Lube Oil Heater A- 516 Agitator A-305 Agitator H-211 N2 Gas Heater A-311 A-411 A-513 Agitator Agitator A-306 Agitator 0P-GR512B 011 Pump GR-512B FN-6128 E-612 Fan BC-8602A Battery Charger EF-MP-512 Fan HP-512 OC Relays Tie Breaker f t 252-28 BKR MCC-1A 252-30 BKR MCC-1B ./HI P-514B D-514 Bottoms A-212 Agitator P-21IB Solvent Feed Pump P-510 0-510 Pump EF-MC-711 Fan KC-711 LP-B601 Lighting Panel P-515B Chilled Solvent H-112 N2 Gas Heater P-612B Solvent Recycle YB-111 YB-112 YB-211 V-lll Y-112 Y-211 N2 Blower N2 Blower N2 Blower H-611 N2 Gas Heater LOP-C-711 Lub* Oil Pump C-711 P0C-902A Lube Oil Pump C-902 B-512B Vacuum Pump Booster P-61 IB T-611 Reflux UPS-8602A Uninter- ruptlble Power Supply C-0H-902 Lube Oil Heater C-902 IP-8608 Instrument Panel P-8U8 P-614B Solvent/ T-611 Monomer Bottoms 0P-GR511B POC-911 Oil Pump Lube Oil GR-511B Pump C-911 i l *\1 6 \ -4 k 252-27 BKR MCC-1A i 1 f i ! t i i 252-29 BKR MCC-1B 1 i t t j i i t ! L' A 0 5 6 9 8 2 C O N F rD F N T lA l FIG. 22.3 * " East^ T-3 BREAKERS Ha-2 A Tie Breaker OC Relays SP-902A Septic Tank Spare B-522A Vacuum Booster A-221 Agitator P-525A Chilled Solvent POX-521 XS-521 Oil Pump SCR-20O Ramsy Variable Speed FN-622A E-622 Fan VP-522A Vacuum Pump P-621A T-621 Reflux P-524A 0-524 Bottoms P-624A T-621 Bottoms FSO-521 SD-521 Fan A-321 Agitator H-121 12 Gas Heater A-307 HP-801 Agitator HYD Pump P-221A Solvent Feed P-221C Solvent Feed H-122 Gas Heater EF-HC121 Fan HC121 PSC-521 SCRN Changer HYD Pump LP-8608 Lighting Panel Spare XS-521 Hotor 521 Extruder LP-2101 Lighting Panel West - -. T-4 BREAKERS n ou zo n io-i J> mo zm H O' M vO 1> a> r~ co Spare 1/81 FIG. 22.4 P-622A Solvent Recycle YB-621 Y-621 P-623A N2 Blower T-621 Recircula tion P-529A OTA Return P-821A Solvent Monoaer 0P-GR521A LP-4201 Oil Pump Lighting Pelletlxer GR-521A Panel 0P-GR522A Oil Pump GR-522A LP-3101 Lighting Panel EF-HP521 Fan HP-521 Spare LP-8604 Lighting Panel West T-4 BREAKERS MCC-2B East T-3 BREAKERS ! Tie Breaker OC Relays SP-9028 Septic Tank SD-521 Pellet Dryer B-522B Vacuum Pump Booster VP-522B Vacuum Pump FN-622B E-612 Fan YB-122 FH-121 Nz Blower E-iei Fan A-421 Agitator P-520 0-520 Pump A-222 Agitator P-525B C-921 Chilled Regrlgera- Solvent tlon Unit P-624i3 T-621 Bottoms YB-221 P-721 N2 Blower 0-721 Bottoms P-221B Solvent Feed jR-521 _ube Oil leater H-221 Heater BC-8602B Battery Charger P0C-903B Lube Oil Pump C-903 UPS-86026 Uninter ruptible Power Supply P-821B Solvent/ Monomer Pump POC-921 Lube Oil Pump C-921 OC Relays Tie Breaker P-803B 0P-GR521B LP-1101 Comonomer Oil Pump Lighting Feed GR-521B Panel 252-22 BKR MCC-2A 252-24 BKR MCC-2B P-622B Solvent Recycle P-529B DTA Return P-623J YB-121 T-621 N2 Blower Recircula tion GR-522 Lube Oil Heater a-521 Classified P-621B T-621 Reflux A-526 Agitator P-524B D-524 Bottoms Spare A-523 Agitator H-621 N, Gas Heater P-802B 0P-GR5228 LP-8602 Comonomer Oil Pump Lighting Feed GR-522B Panel P-804B Swing Solvent .Tank EF-MP522 IPT-U601 Fan MP-522 C-0H-903 Lube Oil Heater C-903 EF-MC721 Fan MC-721 LP-3201 Lighting Panel 252-21 BKR MCC-2A 252-23 BKR MCC-2B DO A 0 5 6 9 8 4 C O N F ID F N T T A l 'H FIG. 22.5 *- *- West Tie Breaker oc Relays 252-26 MCC-120 * 252-26 Breaker MCC 120 t_ RRR 8/12/81 r> oo zo "H H J> om o Z Ln H O' t-H O 3> CD ^m FIG. 22.6 ( OC Relays 252-25 East - Tie Breaker 252-25 ' Breaker MCC 120 MCC-120 8/12/81 FIG. 22.6 IJ r j. * North MCC-1D South * - - 1 1 '( Ij '1 Tie :l Breaker !|' ij. i j II: 1 i- ' f; >! ! !; RF-IIHB1A Rotary Feeder IIMB-1A BF-MMB2A Rotary Feeder IIHB-2A Spare OC Relays BACV-5 Blower II-1 thru H-8 BAC-7 Unload Blower BACP-3 Blower IHB-1A-181C BACP-4 til ower Itl-in - 2A-2B- 2C Spare H 252-15 MCC-1C .1 j J; :! |? ij \ !} i: i o ; 252-17 MCC-1D ft, n oo ZT1 O M J> mo Z Ln H O' --< *0 X> CD ~ Nl il ; RPR ' __H/i3/w V n- !i5l ' ' i --1---------mm BACV-G Blower IIS-1 thru IIS-6 I \UWi 1P-9101 % Lighting Panel BACP-21 Blower HUH-2 PW-502 Spare Pellet HjO Sump Pump P-502A OTA Make Up Rr-6 Rotary r eeder RAC-6 BACP-ll Blower IHIM- 1 RF-CII1A Rotary Feeder Cheek Hooper 1A nr-7 Rotary T eeder IIAC-7 AP-1C Local Panel Bagglng Line AP-10 Local Pa nc 1 Bagging Line OC Relays Tie Breaker AP-1F Local Panel Bagging Line ni-502 E-502 Fan 252-16 MCC-1C re?-1' Rr-IHIII-1 Rotary Feeder F eeder Check Hold Up llooperlB llooper-1 AP-1A Loca 1 Panel Bagging Line RF-5 Rotary Feeder RAC-5 BC-060SA Battery Charger AP-in Loral Panel Bagging line ------------l 1 2S2-I8 MCC-10 . 1 i ii t ' 11; ' Vile Trraiiri' ifitF"-------- 1 IS' 1 i \ V on n South (' MCC-2C North DO A 0 5 6 9 8 9 CONFIDFTNT TA( Tie Breaker oc Relays RF-HMB-1B Rotary Feeder IIMB-1B RFCK-2A BACP-2 Rotary Blower Feeder CH-2A-2B 2A LP-8401 Lighting Panel RF-CH-2B Rotary Feeder CII-2B RF-HMB-2B RF-MMB-2C A-402 Rotary Rotary Agitator Feeder Feeder Spare 1 IIMB-2B HMB-2C Spare I BPA-3 Punge Atr Blower BACP20 AP-2B Blower Local MUM-2 Panel Bagging Line AP-2C Local Panei lagging -Ine BACP10 Blower HUH-1 AP-20 Panel Oagglng Line 252-11 SKA MCC-2C 252-13 BKA MCC-20 22.10 P-2020 Chilled IIjO Pump BACP-12 Blower CM-1-2 P-501C F-501 Feed Spa re P-401 0-401 Circula tion AP-2F Local Panel Oagglng Line PR-203 Refrige ration Pump ARU-203 nr-mum-2 Rotary Feeder MUM-2 IP-BH05 AC-BbOSU Lighting Mr Panel Pondltlon PS-203 Solution Pump ARU-203 BC-B605B Battery Charger AP-2A Local Panel - OC Relays He Breaker 1 1 1 . r~ ( MCCVS (A) East '^ ( 600V Tie Breaker Tie Breaker Tie Breaker MCCVS (B) West Tie Breaker ( CKT BKR C-lll Compressor OC Relays CKT BKR C-711 Compressor CKT BKR C-121 Compressor OC Relays CKT BKR C-721 Compressor n CKT BKR P-511 Gear Pump RRR 9/2/81 FIG. 22.11 CKT BKR P-512 Gear Pump CKT BKR P-521 Gear Pump CKT BKR P-522 Gear Pump ( (A) ( ROBICON ( (B) HO A 0 5 6 9 9 1 CO NFIDENTIAL RRR 8/12/81 FIG. 22.12 if Eas^ ^ MCC 5A MP-901C MP-901B MP-901A 4.16KV MCC 5B West OC Relays Incomer T-2 Tie Breaker 152 Incomer T-l OC Relays MC-903 MC-902 DO A 0 5 6 9 9 ? C O N F ID F N T T A L ? > /in FIG. 22.13 t t l f ( 1 I t North 13.8KV South T-3 Load BKR Switch T-7 Load BM Switch T-3 Load BKR Switch T-l Load BKR Switch T-ll Load BKR Switch T-9 Load BKR Switch 52-1 % 52-T 52-2 T-4 toad BKR Switch T-8 Load BKR Switch T-6 Load BKR Switch T-2 Load BKR Switch T-12 Load BKR Switch T-10 Load BKR Switch *8 oO ~n o o rn 2 o in O' n* V0 CO FIG. 22.141 MR 9/2/81 J I I STATIC FIG. 22.15 D0 A 0 5 6 9 9 4 CONFTDFNTTA! NOTES: 1. Internally Mounted Circuit Breaker 'used with 120 VDC & 240 VDC Battery. 2. Externally Mounted Disconnect Device (by others) used with 360 VDC Battery. I' ' SYSTEM BLOCK DIAGRAM ( xSyl-a I0* * V. > 5?-H ir>> Ll> I /fCC - Zfi A\CC - ZB ni Ui CD v ^ iCAP vi avr>* AJCt - /ZO n h <e Cl/JlJ ZZ CD KA -0 iXi mcc.-if) %A /vice - /B 13.8 KV Xf/C.oneR {52.- 0 /3.F TIC BACPKrtC (52-TlN h> r % TR UP* IMIB vricv* ups/Rt-tr -f, svsTeA J. uPs/Jiecr, ! CfUTuRe) 1 13.8KU incohcR(52-2) yfQ.Mt 771 VFO'MPSZl VfO-nC 7// vrtnPn# -F cLr/*l VFD-M* #*/ t'FQ-MPS'ZlL V/FD-MC *// trmrru _______ VBIP1C 3PTfp FUTilBC d r co 0) ^ \ JCX*j C'o N m cwp 6N oLr/J.| Nclr/)l M DO F3 3iTS- 5~B -pi"f 3* =?-2C*rJ io? f*.v i'>o i 2os-3"fl * 3 3x> 3 ? E $* s o 45 O k *> c fPMCL. MS'*- **>*-* tel S 0U5> (a et to JB c> o w r~--*------- r__- '"s <-3t 3n*) ?c HP31* a3t1 - O A5 ) "* M^ " T<. B c - FIG, 22.16 DO A 056,995 confidfntia; FIG. 22.17 00 A 056996 Co'N'Frof~nTTaij r ii c FIG. 22.1 ___________ ELECTRICAL ONE LINE DIAGRAM HO A 056997 CONFIDFNT T AF STATIC SWITCH DO A 0 5 6 9 9 8 CO NFIDENTIAL NOTES: 1. INTERNALLY MOUNTED CIRCUIT BREAKER USED WITH 120 VDC & 240 VDC BATTERY. 2. EXTERNALLY MOUNTED DISCONNECT DEVICE (BY OTHERS) USED WITH 360 VDC BATTERY FIG. 22.15 U.P.S. SYSTEM BLOCK DIAGRAM 23. MISCELLANEOUS SYSTEM 23.1 PROPYLENE PURIFICATION Liquid propylene is supplied from LHC at 250 pounds psig and enters the block through an emergency block valve (see Section 4.1 for properties of propylene). It is used to control density when making high and interme diate density polyethylene. The propylene will pass through one of Y-113 A or B (propylene puri fication beds) which are filled with molecular sieve and silica gel for removal of any impurities. The clean propylene then goes to the suction of the P-113 A/B pumps where the pressure is increased to approximately 650 pounds for feed to the reactors on either train 1 or 2. The propylene is added to the ethylene just before it is mixed with the solvent. These pumps are speed controlled to control the propylene flow. Regeneration of the Y-113's is essentially the same as the Y-lll's and Y-112's described earlier, with these exceptions: A. There are no safety isolation valves on the regeneration system as none are needed. The PSV on YD-113 is large enough. B. The beds are preloaded with gaseous propylene which is added through a pressure reducing regulator to the blower loop. C. Pressuring up and filling the bed with liquid propylene will be discussed in detail in the safe work procedures manual. 23.2 MINERAL OIL SYSTEM Mineral oil is used on reactor seals and as a flushing agent for the DO A 056999 CONFIDFNTTAL hot melt additive system. D-905 is the storage tank and its capacity is gallons. Mineral oil can be recieved in either rail cars or tank trucks. There are three pumps on the mineral oil system pumping out of D-905. One pumps mineral oil to train //I reactor seal system, (P-907A to D-213 A&B), the other to train //2, (P-907B to D-233 A&B). There are air operated Graaco pumps capable of pumping 30 gallons per minute at 650 psig. P-907A and B have a tie-in on their discharge in case of a problem with either pump. One pump can pump to both sets of oil systems. P-909 is the other pump and its use is strictly for flushing out lines in the hot melt additive system. This pump is also air operated and capable of pumping 16 gallons per minute at 240 psig. (Figure Air operated pumps put up a constant pressure at all flow rates including zero flow. Therefore, the mineral oil headers are maintained at constant pressure. 23.3 HyVROGEN TRAILERS Hydrogen is supplied by three high pressure tube trailers. These trailers are grounded and monitored by a grounding indicator which will alarm if the trailer is not grounded. The hydrogen is stored at 2500 psi and is utilized in the plant at 650 psi. This step down in pressure is accomplished by two pressure control regulators in series. When the hydrogen in the trailer has been consumed, the pressure in the cylinders drops causing a low pressure switch to activate an alarm at the TDC terminal. Two pressure safety valves are located on the process line to guard excess hydrogen pressure. These valves relieve at 900 psig. DO A 057000 C0NFIDENTTA1 The hydrogen is piped into the ethylene feed lines to R-211 and R-212. The hydrogen is added to the polyethylene to raise the melt index by shorten ing the polyethylene chains. 23.4 FLARE SYSTEM DESCRIPTION From time to time in the Dowlex plant it will be necessary to vent the process equipment. For example: When a safety valve relieves; when filling a vessel; when maintenance is done (safety valve checks, agitator repairs), or during bed regeneration. These releases, whether intentional or accidental, obviously cannot be allowed to go to the atmosphere for both safety and eco logical reasons. It is for this reason that the flare system exists. 23.5 FLARE HEAVER SYSTEM The vent collection header is a 24" carbon steel line. Various size piping branching from different areas of the plant tie into this header. On the end of each branch of the header we have a nitrogen purge. Also referred to as sweep gas, it is used to prevent any leakage of air into the system. The presence of air is hazardous because of possible ignition or explosion in the header. All safety valves that discharge to this system are equipped with permanently installed swing type blinds in the discharge line. The line should be blinded prior to the removal of the safety valve. This minimizes the possibility of leaking air into the system and also protects personnel from blowback should any other valve in the system release. We have an oxygen analyzer on the flare to detect the presence of air. The header and collection piping, knock out drum, and flare were sized so that the combined pressure drop was less than 10 psi. This was done so DO A 057001 OONF T DFNT T Al. that there would be no flow reduction from any relief valve. The header was installed with a uniform slope down towards the knock out drum. This would allow any liquid admitted to the header to drain to the knock out drum (D-904) located at the flare (FV-904). Other drums associated with the flare header are: D-308 catalyst waste drum, and D-212& D-222 reactor safety knock out drums. The top of these knock-out drums are open to the flare header to vent vapors. Any liquid knocked out in D-904 is pumped to D-809 (waste solvent). The liquid level in D-904 is automatically pumped down by P-904. D-904 has a level transmitter with high and low level alarms. D-904 has a low pressure alarm. A small positive pressure should be kept on the flare header to minimize the possibility of air being sucked in. The vapor goes out the top of D-904 to the flare. We have a high flow alarm on vapor out of D-809 to indicate a safety valve release. 23.6 FLARE STACK FV-904 is designed to burn any gas releases that enter the flare system. It will burn 88,000 pounds per hour of hydrocarbon with an average molecular weight of 114. FV-904 has a molecular seal to prevent any air from entering the flare system via the flare stack. The flare has a pilot system to ignite the gases as they exit. The pilot should be lit at all times except when we have a high concentration of oxygen in the system. A low temperature alarm on the pilot signals that the pilot is out. We have an emergency block valve to block fuel gas to the pilot and to open the steam valves to the flare. These valves are operated by a hand switch in the control room and are used to snuff the flare in case of any outside 00 A 05700? CONFTDFNTTAl spill that could be ignited by our flare. A fuel gas and air mixture is ignited by a spark plug to light the pilot. The ignited mixture flows through any of three 1" pipes to the pilot. The pipes are located at different points around the pilot ring. The right point would be selected depending on wind direction. The gases enter the bottom of the flare stack and are bubbled up through water in the bottom of the stack. The water prevents flash back from the flare tip to the vent header. We have a high water level alarm. The flame of the flare is constantly monitored by a remote infra-red detector, which detects smoke intensity and sends a signal to a controller, opening the steam control valves as necessary to control smoke. We have three steam manifolds located near the top of the flare. 00 ft 057003 CONF T OF NT T Al- FIGURE NUMBER 23.1 23.2 23.3 23.4 23.5 MISCELLANEOUS SYSTEMS FIGURE INDEX DESCRIPTION Mineral Oil Storage, Pumps, and Instrumentation Hydrogen Trailers Flare (Vent) Header Distribution FV-904 and Instrumentation D-904 and Instrumentation TABLE NUMBER 23.1 23.2 MISCELLANEOUS SYSTEMS TABLE INDEX DESCRIPTION Propylene Purification Controllers Flare System Controllers DO A 057004 CONFIDENTIAL LOOP CONTROL NUMBER FIC 1162 SIC 1158 TABLE 23.1 PROPYLENE PURIFICATION CONTROLLERS PURPOSE To flow control the propylene to reactors OPERATION By operating speed con trollers SIC 1158 and SIC 1160 that operates pumps P-113 A/B To speed control P-113A By sensing signals from flow controller FIC 1162 SIC 1160 To speed control P-113B By sensing signals from flow controller FIC 1162 DO A 057005 CONFIDENT T Al. LOOP CONTROL NUMBER FIC 9066 HS 9056 TABLE 23.2 FLARE SYSTEM CONTROLLERS PURPOSE Control smoke emission from flare stack To snuff flare in an emergency OPERATION An 'eye' senses smoke coming from the stack and opens FV-9066 A, B, and C enough to control emission a) Closes EV-9056A (fuel gas) b) Opens EV-9056B (signal to FV-9066 A, B, and C) (235 PSIG steam) DO A 057006 CONFIDFNTTAt Lx DO A 0 5 7 0 0 7 C O N F ID E N T IA L ;| i*ccn Mocaii v<u w o w jci> i4 i i1 !* FIGURE 23.1 wt< bCw memial 05 a" n.imuki ^OH pin (-*- , i TRAILER 2 DO A 0 5 7 0 0 8 C0NFIDFNTTA1 cir *)^ o HYDROGEN TRAILERS 00 VENT HEADER DO A 0 5 7 0 0 9 CO NFIDENTIAL ( |PROCESS H20f c cir 4 DO A 057010 CONFrDFNT JA( ( FIG. 23.5 DO A 057011 CONFTDFNTTAL 24. QUALITY CONTROL AND PROCESS ANALYZERS 24.1 QUALITY CONTROL The Quality Assurance Manual of the Dow Chemical Company states in its introduction "The Dow Chemical Company's Quality Assurance Program supports a philosophy of strict adherance to our own production specifications and quality requirements to which we are committed. Our program also aims to develop a sense of personal responsibility in each employee." Quality Control is charged with the responsibility for doing the testing and analysis work in raw materials and finished products at each production site to determine compliance to specifications. A list of the tests follows. Melt Index The melt index of a polymer is the amount of polymer in grams that will flow through a 0.0825-in. diameter orifice in 10 minutes, at 190C with a 2.16 kg weight as the driving force. This value is called an 1^. When a 10 kg weight is used as the driving force and all other conditions remain the same the value is called an I10. The test serves to indicate the uniformity of the flow rat of a polymer as made by an individual process. As the molecular weight of a polymer increases, the melt index decreases. 5. ! I.* * I / I is the ratio of flow rates at the two conditions described aove. This value gives an indication of molecular weight distribution. As the molecular weight distribution broadens,* the I t a /I 2 ratio increases. Density The density of a polymer is defined as the mass per unit volume expressed in g/cms at 23C. Density is determined by liquid displacement of heptane and is calculated knowing the dry sample weight, the weight of the heptane displaced, and the heptane density at 23C. The density of a polymer is a property that can be measured conveniently to identify a material, to follow physical changes in a sample and to indicate degree of uniformity among different sampling units or specimens. Changes in density of a single specimen may be due to changes in crystallinity, thermal history, and composition. DO A 05701? CONFTDFNTTA1. 24.1 QUALITY CONTROL, continuzd Color The color of polyethylene is measured on a molded chip using a Gardiner XL 23 Colorimeter. Color is expressed in Whiteness index (WI) units as defined by ASTM E-313-78. To be considered prime material a resin must meet a minimum color specification set down in the product spec ification for that product. Color is most often adversely affected by catalyst inefficiencies. Contamination Pelletized polyethylene is visually inspected to determine levels of contamination in the product. A sample is spread out on a lighted table designed specifically for the test and inspected for a specified length of time. Inspection is done for abnormalities such as off color, poor granulation, oxidation, dirt, and cross contamination. Cross Contamination Cross contamination occurs when two different products are in advertently mixed. On visual inspection, it will often be evident when it appears as a mixture of granulation types or of granules of different opacity. Other tests for cross contamination include molded sheet, film preparation, melt index, iodine staining or melt scatter and infrared determination. Sieve Analysis A sieve analysis is a measurement of the particle size distribution of polyethylene pellets conducted with multiple sieves. Each product must meet a Granulation Number specified for that product on the product specification. A Granulation Number is the designation of a standard product as to the shape (type of cut) and size. A material will have to conform to a stated specification in order to qualify as a given Granulation Number. The specification includes type of cut and a maximum amount retained on each sieve. Apparent Density (Bulk Density) The bulk density of a product is the weight per unit volume. A cylinder of known weight and volume is filled with polyethylene p llets, leveled off, and weighed. The bulk density thus determined provides a useful index of performance of polyethylene pellets with respect to their handling in packaging and fabrication. DO A 057013 CONFIDFNTTAL 24.1 QUALITY CONTROL, continued Volatiles The volatiles content in polyethylene made by the solution process is mainly retained hydrocarbon reaction medium. Volatiles content is determined by weight loss after heating in vacuo at elevated temperatures. It is expressed as a weight Z. Gel Count In blown polyethylene film, gels are small globular masses that have not blended into the surrounding material. Gels affect appearance and production of film as well as physical properties and performance of the finished product. Film is blown on a lab film rig and inspected for gels. A gel specification as set down in the product specification must be met before material can be shipped to the customer. UV Analysis Products which contain UV inhibitor must be analyzed for levels of additive present. A sample is pressed into a thin film and analyzed on an instrument which measures UV absorption. The quantity of inhibitor present is read from a UV absorption VS concentration curve. X-Ray Fluorescence An x-ray fluorescence analyzer is used to detect levels of bi and Ca in polyethylene pellets. SiC>2 and CaC03 are used as anti-blocking agents in film grade resins. Differential Scanning Calorimetry Levels of antioxidant in polyethylene are estimated by a differential scanning calorimeter (DSC) isothermal induction time procedure. The presence of antioxidant suppresses the rate of oxidative degradation of the polymer at elevated temperatures in an oxygen atmosphere. Once the antioxidant is consumed, the onset of degradation of polymers is observable by DSC an exothermic peak on a time based isothermal plot. The elapsed time from the introduction of oxygen to the beginning of the polymer degradation exotherm is known as the oxidative induction time (UIT). The quantity of antioxidant is read from an OIT vs. concentration plot. DO A 057014 CONFIDENTIAL 24.1 QUALITY CONTROL, c.oyitLme.d Cooling Tower Water Tests Cooling tower water is tested to monitor effectiveness of the treatment and to adjust levels accordingly. The water is tested for Calcium, orthophosphate, total Chlorine, ph and conductivity. Raw Material Identification All purchased raw materials will be identified by inhouse lab analysis before being used in production. Records will be maintained on every lot of material used on the plant site. DO A 057015 CONFIDENTIAL 24.2 PROCESS ANALVIERS The following is a list of the various analyzers and their locations within the Dowlex process. TABLE 24.1 Tag AE 1008 Stream Analyzed Ethylene to and from silica gel and molecular Components C02/ Methanol Type Beckman Model 6750 Chromatograph AE 1009 Incoming ethylene H20 Ondyne Model DY-1405 Moisture Analyzer AE 1010 Ethylene after silica gel beds h2o Ondyne Model DY-1405 Moisture Analyzer AE 2184 AE 2179 Solvent to P-211 A/B/C Solvent to P-211 A/B/C h2o Octene Ondyne Model DY-1405 Moisture Analyzer Teledyne No. 514 Infrared Analyzer AE 2218 Ethylene to Reactor 1 AE 2232 Ethylene to Reactor 1 AE 2251A Reactor 1 effluent to static mixer or Reactor 2 h2 c3h6 Viscosity Beckman Model 6/50 Chromatograph Beckman Model 6750 Chromatograph Dynatrol CL-10DVT-4 Viscosity Detector AE 2251B Reactor 1 effluent to static mixer or Reactor 2 Viscosity Dynatrol CL-10DVT-4 Viscosity Detector DO A 057016 CONFIDENTIAL (Continued) TABLE 24.1 Tag AE 2285A AE 2285B AE 6033 AE 6050 AE 6062 AE 6064 AE 8002 AE 8006 AE 8027 AE 8041 AE 8049 PHE 9017 Stream Analyzed______ Reactor 2 effluent to static mixer Reactor 2 effluent to static mixer E-612 solvent stream to D-611 Solvent from Y-611 to Y-211 Solvent from FL-611 to Y-611 Solvent from Y-611 to Y-211 Solvent leaving D-801 Solvent leaving Y-801 Octene leaving D-802 Octene leaving D-803 Octene leaving Y-802 Cooling Tower water sump Components Viscosity Viscosity Octene H20 h2o Octene H20 h2o h2o h2o h2o ph _________ Type Dynatrol CL-10DVT-4 Viscosity Detector Dynatrol CL-10DVT-4 Viscosity Detector Teledyne No. 514 Infrared Analyzer Ondyne DY-1405 Moisture Analyzer Ondyne DY-1405 Moisture Analyzer Teledyne No. 514 Infrared Analyzer Ondyne DY-1405 Moisture Analyzer Ondyne DY-1405 Moisture Analyzer Ondyne DY-1405 Moisture Analyzer Ondyne DY-1405 Moisture Analyzer Ondyne DY-1405 Moisture Analyzer Leeds & Northrup Series 7079 ph Transmitter DO A 05701 CWFrOENTTAl (Continued) TABLE 24.1 Tag AE 9018 AE 9019 AE 9059 AE 9144 AE 9176 AE 9295 AE 5002 AE 2001 Stream Analyzed Cooling Tower water from header to Cooling Tower sump Components TyPe Corrosion Petrolite Model M-3011-E Corrosion Rate Instrument Cooling Tower water from sump to header Conductivity Leeds & Northrup No. 4909-10-33-091-7-01 Conductivity Measurement Cells Vent gas to flare Taylor OA-541AA10600-1(512)(701) Paramagnetic 02 Analyzer Condensate from D-908 to condensate return Conductivity Leeds & Northrup No. 4909-10-33-088-7-01 Conductivity Measurement Cells Nitrogen from division header Taylor OA-541AA10600-1 (512)(701) Paramagnetic 02 Analyzer Air from FL-902 to air header DTA stack gas to atmosphere Dew Point Ondyne DY-1405 Dew Point Analyzer Taylor OA-541AA10600-1 (512)(701) Paramagnetic 02 Analyzer Chill water to D-202 Petrolite Model M-3011-E Corrosion Rate Instrument DO A 057018 CQNFXDFNTTA1 25. COMPUTER AND CONTROL SYSTEMS 25.1 CONTROL SYSTEMS The control system Dowlex uses to monitor and control the process is the TDC 2000 by Honeywell. "TDC" means total distributed control which allows the actual control of the process to be distributed among the different components in the system. This is advantageous because communication between the operator station and the controller can fail, yet the controller will continue to perform its function. All of the Dowlex controllers are located in the controller file room. The five basic components of the TDC 2000 system are these: (See Figure 25.1) 1. Date Hiway 2. Hiway Traffic Director 3. Operator Station 4. Controllers 5. High and Low Level Process Interface Units (PIU's) The data hiway is a coaxial transmission cable which allows all of the hardware components to communicate with each other. The data hiway needs a means of controlling the flow of information so it has a Hiway Traffic Director. This director can handle 63 units connected to the hiway including the computer, controller, operator stations, etc. There are two data hiways and the system will switch automatically if one hiway cable is disconnected. Each controller can control 8 different control loops. DO A 057019 CONFIDFNTTAL The operator station is a keyboard and color CRT, primarily used to receive controller information concerning the process and display it to the operator. It also will allow the operator to tell the controller what changes to make in the process. Controller variables such as gain, reset and alarm points can also be changed at the operator station. The operator station replaces conventional control panels. High and low level PIU's are used for accepting inputs only such as thermocouples, flow indications, pressure indications, etc. Each PIU can accept 64 inputs and reads them 8 at a time in a multiplex mode. DO A 0570 CONFTDFNTT (m < COMPUTER/INSTRUMENTATION SYSTEM The control/information system at the Dowlex Plant consists of four components - a Honeywell TDC-2000 system, a PDP-11/44, a PDP-8E, and a Modi con 584. The operator interfaces directly to the TDC System and the two PDP computers by means of CRT's. All outputs and inputs to and from the field will come through the TDC System or the Modi con 584. The interconnections of these four components are shown in Figure 1. TDC-2000 The TDC-2000 will provide the basic instrumentation for the process. All continuous process information and continuous control will come through this system. The components of this system are four operator stations, three high level process interface units (HLPIU), three low level process interface units (LLPIU), twenty-eight controller files, two data hiways, a line printer, and three strip charts. The HLPIU's provide inputs from the process for all analog signals, except thermocouples, that are not used for control such as pressure indications, flow indications and analyzer indications. These units are also used for digital inputs to show status of limit switches and whether pumps are running or not. The LLPIU's are used to provide input from the process of all thermo couples. The controller files are used to provide all the continuous control for the process. These units provide the same type of control as conventional instrumentations with a process input signal, a control point, and a process output signal going to a valve. These files can also do some things in addition to conventional instrumentation - such as adding together two Computer/Instrumentation System -2- TDC-2000 (continued) -- signals, and allowing signals to be controlled automatically or manually. All these options are used in the system at the Dowlex Plant. The four operator stations are used to communicate to the HLPIU's, LLPIU's, and the' controller files. The data hiway is the link that connects the operator stations to these units. The operator stations are configured (set up) such that two units are dedicated to Train I and two units are dedicated to Train II. All systems that are common to both trains will be displayed on all operator stations. The operator can view the process through these operator stations; he can change set points for his control loops; and he can place his controllers on manual, automatic or computer control. Through the operator stations the board operator observes and controls the process. The strip charts are used to record any eight points that the operator selects from one of two operator stations, either Train I or Train II. The line printer is used to print alarms, if the operator chooses, from one of two operator stations. PDP-8E The PDP-8E provides some sophisticated process control which the TDC2000 is incapable of providing. This computer is connected to the data hiway of the TDC System and is capable of reading any information on the hiway. This means it can read any information in the HLPIU's, LLPIU's, and the controller files. The operator communicates to the PDP-8 through a black and white CRT - through which he enters set points for the loops he has on computer control. QQ A 057023 CONFIDFNTT Al Computer/Instrumentation System -3- PDP-8E (continued) -- Some of the items that are on computer control and the reason for them are as follows: THE DESCRIPTION FOLLOWING WILL ONLY BE OPERATIONAL IF THE CONTROLLER FILES ARE SET UP FOR COMPUTER CONTROL BY THE BOARD OPERATOR. 1) Ethylene Flow to the Reactors The operator will enter the pounds per hour flow which he wants for the reactor. The PDP-8 will read the temperature and pressure of the ethylene flow and calculate what reading on the flow orifice is needed to give the flow rate required. The PDP-8 will then send the set point required to the controller file. 2) Hydrogen Flow to the Reactor The control is identical to the ethylene flow to the reactor in that the board operator enters the pounds per hour hydrogen flow required. 3) Solvent Flow to the Reactor The operator will enter the amount of ethylene conversion he desires in the reactor. The computer will look at the ethylene flow rate, the reactor temperature, the reactor feed temperature, the water flow on the jacket and the temperature rise of the jacket water to determine the set points of the Solvent. This set point then can be sent to the controller file. 4) Octene Flow to the Reactor The PDP-8 will need the target density and target melt index from the PDP-11. The PDP-8 will look at target conversion in the reactor (from the solvent control program), production rate DO A 057074 CONFIDENTIAL Computer/Instrumentation System -4- PDP-8E (continued) -- Items on computer and reason for them (continued) 4) Octene Flow to the Reactor (continued) ~ of the reactor, concentration of Octene before and after the addition point, and temperature of the Octene and reactor, and then calculate the set point of the Octene. This set point will then be sent to the controller file. 5) ATE Ratio Control to Premix There is no operator entry. The PDP-8 will attempt to maximize catalyst efficiency by increasing or decreasing ATE pump speed based on production rate and catalyst usage. 6) Calcium Stearate/Irganox Control The PDP-8 will read from the PDP-11 the percent Calcium Stearate and percent Irganox in D-411 or D-421. The computer will read the catalyst usage (premix) on the train and calculate the amount of Calcium Stearate needed to neutralize this catalyst. It will then send a set point to the stearate pumps to pump the deisred level of stearate. The computer will also not let too little or too much Irganox be added to the product. 7) Hot Melt Additives The computer will read the target additive level for the type of material being produced from the PDP-11. The board operator will need to tell the PDP-8 which drum the hot melt additive will come from. The computer will then control the amount of DO A 057075 CONFIDENTIAL Computer/Instrumentation System -5- PDP-8E (continued) -- Items on computer and reason for them: 7) Hot Melt Additives (continued) -- additive based on the production rate of the polyethylene and level drop in additive tank. 8) Side Arm Extruder The PDP-8 will determine what the target level of additives is to be as well as from which hopper the additives are coming from the PDP-11. The PDP-8 will control the speed of the side arm extruder based on the production rate of poly ethylene and the weight drop in the additive hopper. 9) Shut Off Flows to Reactors On loss of Solvent or Ethylene flow to a reactor, the computer will shut off all Solvent, Ethylene, Hydrogen, Octene, Catalyst, and Stearate flows to the reactor. 10) Reduce Rates Quickly On the operator's command to the PDP-8, all flows to the reactor will be reduced quickly to the amount specified by the board operator. Quickly means less than five seconds. MODICON 584 The Modi con 584 is the control computer for all batch type operations in the Plant. There is no operator interface directly to the Modi con. All operator commands to the Modi con come from the PDP-11. DO A 0570? CONFIDENTTA Computer/Instrumentation System -6- Modicon 584 (continued) -- The Modi con controls all seven of the Material Handling (transfer) Systems from the emptying of the check hoppers through the loading of hopper car and bagging silos. The Modicon also controls the regeneration of the molecular sieve and silica gel beds, the mixing of catalyst, and the transfer of Stearate and Catalyst from the bulk tanks to the day tanks. A more detailed look at these systems follows in the PDP-11 discussion. PDP-11 i i The PDP-11 has two distinctly different functions. One is to gather and display information for the operator. The other is to be the operator's source of control for the batch-type control functions. The PDP-11 does no control directly. The operator needs to furnish certain information to the computer which then furnishes the information to the Modicon 584 to start the control action. The following systems are controlled by the Modicon through the PDP-11. 1) Transfer System The operator begins control action initially by setting up a lot of material in an HMB hopper. The board operator must give this lot a lot number, a type number, a target weight and a reactor. Each hour the board operator must tell the computer to which blender (HMB) the check hopper (CH's) on each train must be transferred. After each blender is filled, the operator must give commands to blend the hopper and to transfer the hopper to either a million pound hopper (HS), a half-million hopper (H), a bagging hopper (HB), or a hopper car loading hopper (HL). This transfer must be previously approved by a warehouse operator. 00 A 0570?? confidpnttai Computer/Instrumentation System -7- PDP-11 1) Transfer System (continued) -- The warehouse operator, in addition to giving approved destinations by means of the PDP-11, also has control of the transfers from the million pound hoppers and the half-million pound hoppers to the bagging and hopper car hoppers. These transfers can be made by the board operator if the warehouse operator has given approval. An additional transfer can be made by the board operator. He can unload hopper cars to the ddditive hoppers (HAS) or to certain blenders. He can also transfer additive from the HAS hoppers to the additive hoppers (HA) on each train. A more detailed procedure for the transfer systems can be found at the end of this section. 2) Regeneration System The board operator will initiate the regeneration system after the outside operator has approved the bed for regeneration. The regeneration will be initiated by entering which bed to regenerate. This will cause the computer to tell the Modicon to begin the heating cycle for the bed. After the heating cycle, the computer will start the cooling cycle. When the cooling cycle is finished on Solvent beds, the computer will check the level in the knock out drum and alarm that there is still level there, or, if no level, will alarm operator that the regeneration is finished. On ethylene and propylene beds after the cooling cycle, the computer will alarm that the pre-load cycle is ready. The outside operator will line up the pre-load line and the computer will continue through the pre-load cycle. When this is over, the computer will alarm that the regeneration is complete. DO A 057028 confidential. Computer/Instrumentation System -8- PDP-11 (continued) -- 3) Catalyst Mixing Before mixing can be started, the concentration of catalyst components (Magnesium Alkyl and Aluminum Alkyl) must be available to the PDP-11 as well as the order of addition of the Catalyst components. To start a batch of catalyst mixing, the board operator must enter which section of D-301 that the Magnesium Alkyl will come from. The PDP-11 will then instruct the Modicon on each step of the Catalyst mixing and alarm the operator when the mix is complete. 4) Transfer of Catalyst and Calcium Stearate The board operator must enter the vessel he wishes to come from and the vessel he wishes to go to. The PDP-11 will then instruct the Modicon to make that transfer. All these control from the PDP-11 will have checks and alarms not enunciated on these brief descriptions. A more detailed description follows at the end of this section. In addition to the control work, the PDP-11 will also process information for the board operator and others. Some of these items are: a) Paymeter Calculations The PDP-11 will calculate and store on an instantaneous, hourly, daily, and monthly basis all incoming raw material and utilities usage as well as polyethylene production. This information will be sent daily to the Division's computer by the Secretary. 0 A 0570P CONF XDENT TAi Computer/Instrumentation System PDP-11 -9- Information for the board operator (continued) -- b) Raw Material Balance The PDP-11 will calculate and display instantaneous, daily, hourly, and monthly ethylene yields, and the conversion energy for each train. It will also dis play instantaneous inventory levels and print out inventory at month's end. c) Status Sheets and Displays The status of different pieces of equipment, such as feed and recycle compressors, the pelletizers and gear pumps, the Dowtherm furnace, the ARU's and the reactors, will be displayed to enable the operator to determine in what state of readiness they are in for start-up. Also the Louisiana PICS system will be used to display areas of the Plant to show their status at any time. d) Status of Lots in Process There will be displays of all lots being produced at any time with their properties such as weight, melt index, density, additive level, etc. Also a status of all hoppers with their weight and types, will be displayed at any time. When a lot has been finished in a HMB (blender), all data for this lot will be printed out to be put in the lot folder. This data will include the physical properties of the lot (i.e. -- melt index, density, additive levels) and also the plant conditions during the production of the lot (.such as reactor conditions, devolatization conditions, catalyst efficiency). In addition to the DO A 057030 CONFIDENTIAL Computer/Instrumentation System -10- PDP-11 Information for the board operator: d) Status of Lots in Process (continued) -- printing of this data, the data will be stored in the computer for future reference. The lot data will also include identification of which manufacturers batches the additives came from that are in the polyethylene. 5) Type-Target File There will be a file in the PDP-11 which will show all products made in the Plant with the targets for all the phylical measurable parameters (melt index, density, color, additives, volatiles, etc.) 6) Operating Discipline The emergency procedures and job procedures will be in the PDP-11 for display and hard copy. There will also be text written to tell operators what to try in case of certain problems or alarm conditions. 7) Miscellaneous Duties There will be lists of activities to be done in the Plant at periodic intervals. These may be done weekly, monthly, quarterly, or yearly. Each week these duties will be printed out and the responsible person will check that they are done and then it will be enetered back into the computer that these jobs were completed. DO a OS7031 confioenttal Computer/Instrumentation -11- This is the essence of the computer/instrumentation system at Dow!ex. Ron Gast Production Supervisor Dowlex Plant 11/10/81 pb DO A 057032 CONFIDENTIAL 26. ECOLOGY Before permission was granted to build the Dowlex plant, certain requirements concerning pollutant emissions set by the Environmental Protection Agency (EPA) and administered by the Louisiana Air Quality Control Commission had to be met. These requirements are presented in the following text and tables. The bulk of the emissions from Dowlex will be hydrocarbon. This is due to the evaporative losses of residual hydrocarbons carried by the pellets. These emissions come from hoppers and storage silos, and are vented to the atmosphere using an air purge system to prevent hazardous build-up of flammable vapors. No current federal New Source Performance Standards are applicable to this process, but we will still be subject to emission regulations and compliance with federal requirements pertaining to the Prevention of Significant Air Quality Deterioration. Dowlex low pressure system along with its high efficiency cataJysts allows the plant to operate at reduced amounts of ethylene dissolved in the polymer. Ethylene losses will be less than one ton per year. Table 26.1 and Table 26.2 list where, what kind, and how much pollutants will be emitted. HO A 057033 CONFIDF.NTTAl TABLE NUMBER 26.1 26.2 26.3 ECOLOGY TABLE INDEX DESCRIPTION Potential Air Emissions Sources of Hydrocarbon Emissions at Dowlex Indentification of Emission Sources as Specified in Environmental Protection Agency's Air Permit DO A 057034 CONFIDENTIAL D-801 D-802 D-803 D-804 D-805 D-809 D-81I Y-lll Y-801 Y-802 TABLE 26.2 SOURCES OF HYDROCARBON EMISSIONS AT DOWLEX ROUTINE OPERATION Hydrocarbon (HC) Storage 3 in operation at one time Na pad HC vented due to fluctuation in vapor space vent connected to flare system Molecular Sieves HC vented only during regeneration Vent connected to flare system F-501 Dowtherm Furnace - 475 scfm natural gas D-502 DTA Storage Drum SD-511 CH-1A CH-1B HMB-lA HMB-1B HMB-1C H-l H-2 H-3 H-4 H-5 H-6 H-7 H-8 HS-1 HS-2 HS-3 HS-4 HS-5 HS-6 Process Equipment Handling Finished Polymer Amount of HC emission for each item will vary with operating conditions. However, total emissions from all items should be fairly constant and based on pounds of polymer produced. Best approximation show 480 ppm/lb. polymer DO A 057035 CONFIDENTIAL NON-ROUTINE OPERATION EMERGENCY VENTS All process vessels and equipment will be protected from over pressure by relief valves. The valves will discharge into a vent header system which connects to a flare (exception D-801 through D-804, D-809, D-811 ERV's vent to atmosphere). DO A 057036 CONFTDFNTTAl f TABLE 26.3 IDENTIFICATION OF EMISSION SOURCES AS SPECIFIED IN EPA AIR PERMIT IDENTIFICATION NUMBER 86-1 to 86-6 86-7 86-8 86-9 86-10 86-11 to 86-18 86-19 to 86-24 86-25 86-26 NAME AND DESCRIPTION OF SOURCE HMB-1 A/B/C and HMB-2 A/B/C Blender CH-1 A/B Check Hopper CH-2 A/B Check Hopper SD-511 Shaker Dryer SD-521 Shaker Dryer H-l to H-8 Maker Hopper HS-1 to HS-6 F-501 Storage Si' o Dowthern Furnace Flare C CO A 057037 CONFIDENTIAL r r c 27. EQUIPMENT LIST A-211 212 Agitator for R-211 - Lightnin PO# 5012 gear reduction ratio 20.7 to 1 output speed 84.4 RPM Driver: 1750 RPM 200hp electric motor Agitator has 4 pitched blades A-305 Agitator for catalyst mix - Lightnin PO# 5012A gear reduction ratio 5.0 output speed 233 RPM Driver: 1150 RPM lhp electric motor Has dual propellers with 3 blades. A-306 A-307 Agitator for catalyst hold tank - Lightnin PO# 5012A gear reduction ratio 20.8 output speed 55.5 RPM Driver: 1170 RPM 2ph electric motor. Agitator has dual impellors with 4 blades. A-311 A-401 402 Agitator for catalyst feed tank - Lightnin PO# 5012A gear reduction ratio 5.0 output speed 350 RPM Driver: 1750 RPM J$hp electric motor Has dual propellers with 3 blades. Agitator for calcium stearate mix - Lightnin PO# 5012A Same as A-306 - A-307. A-411 421 Agitator for calcium stearate feed - Lightnin PO# 5012A gear reduction ratio 5.0 output speed 350 RPM Driver: 1750 RPM lhp electric motor Has dual propellers with three blades A-5I3 A-516 523 526 Agitator for hot melt additives - Lightnin PO# 5012A gear reduction ratio 5.0 output speed 350 RPM Driver: 1750 RPM l/3hp electric motor Has dual propellers with 4 blades ARU 201 202 203 Absorption refrigeration units - Carrier PO# 5510 Model #16JB068 Refrigeration Capacity - 500 tons Absorber section Design pressure - full vacuum Evaporator section Design pressure - full vacuum Condenser section . Design pressure - full vacuum Generator section Design pressure - full vacuum D0 A 057038 confidential > fr501 B-512 A&B 522 A&B BAC-7 BACP 1,2,&12 BACP 3&4 BACP-5 Dowtherm furnace air blower PO# 5004 Type: Direct driven by CFM inlet suction Normal suction pressure - atmosphere Normal discharge pressure - Vacuum pump booster blowers - M. D. Pneumatics ?0if 5055 Type: M-D positive displacement rotary V-Belt driven by 10 hp electric motor CFM inlet suction - 1100 Normal suction pressure - 5 mm Hg absolute Normal discharge pressure - 30 mm Hg absolute Hopper car unloading - M. D. Pneumatics P0J? 5013 Type: positive displacement rotary V-Belt driven by 200 hp electric motor CFM inlet suction - 2260 Normal suction pressure - 11.9 psia Normal discharge pressure - 22.9 psia Check hopper transfer PO# 5013 Type: Centrifugal Hoffman Shaft driven by 100 hp electric motor CFM inlet suction - 1550 Normal suction pressure - atmosphere Normal discharge pressure - 23.7 psia Transfer for blenders - M. D. Pneumatics P0# 5013 Type: positive displacement rotary V-Belt driven by 200 hp electric motor CFM inlet suction - 2550 Normal suction pressure - 14.7 psia Normal discharge pressure - 25.5 psia Transfer for 600,000 lb. storage hoppers (H-l thru H-8) - M. D. Pneumatics P0// 5013 Type: positive displacement rotary V-Belt driven by 200 hp electric motor CFM inlet suction - 2550 Normal suction pressure - 14.7 psia Normal discharge pressure - 25 psia DO A 057039 CONFIDENTIAL BACP-6 BACP 10 & 11 20 & 21 BACV-5 BACV-6 BPA-1,2&3 C-lll 121 Transfer for 1 million lb. hoppers, HS-1 thru HS-6 to hopper loading or hopper bagging - M. D. Pneumatics PO# 5013 Type: positive displacement rotary V-Belt driven by 200 hp electric motor CFM inlet suction - 2550 Normal suction pressure - 1A.7 psia Normal discharge pressure - 25 psia HUH to check hopper transfer P0# 5037 Type: Centrifugal Hoffman Shaft driven by 50 hp electric motor CFM inlet suction - 1538 Normal suction pressure - 14.7 psia Normal discharge pressure - 17.5 psia Transfer from H's - M. D. Pneumatics P0# 5013 Type: positive displacement rotary V-Belt driven by 100 hp electric motor CFM inlet suction - 5170 Normal suction pressure - 11.5 psia Normal discharge pressure - 14.7 psia Transfer for 6,000 lb. hoppers, H-l thru H-8 to hopper loading or hopper bagging - M. D. Pneumatics P0# 5013 Type: positive displacement rotary V-Belt driven by 100 hp electric motor CFM inlet suction - 5170 Normal suction pressure - 11.5 psia Normal discharge pressure - 18.7 psia Hopper purge air P0# 5014 Type: Centrifugal Hoffman Shaft driven by 200 hp electric motor CFM inlet suction - 7000 Normal suction pressure - 14.7 psia Normal discharge pressure - 18.7 psia Ethylene feed compressor P0# 5002 Type: Ingersoll - Rand Direct driven reciprocating compressor, single stage Motor - 350 hp 500 RPM variable speed 575 volts Rated capacity - 30,000 pounds per hour Inlet pressure - 395 pounds Discharge pressure - 671 pounds D0 A 057040 C-711 721 C-902 C-911 CH-1A&B 2A&B CL-511 CT-901 D-lll 121 D-202 Ethylene recycle compressor PO# S5002 Type: Ingersoll-Rand, 3 stage, direct drive, reciprocating compressor Motor: 350 hp, 500 RPM, variable speed Rated capacity: 4500 pounds/hour with 10 psia, first stage Inlet pressure: Discharge pressure: Air compressor PO# 5033 Type: Joy, 3 stage, centrifugal air compressor Motor: 800 hp direct drive Rated capacity: 3000 CFM Freon compressor PO# 5038 Type: Frick Model RWB 40 rotary screw compressor Motor: 125 hp, 575 volts, 3600 RPM Rated capacity: 90 tons Check hoppers PO# S5511 Allied Type: Aluminum 17 ft. 4 in. high, 12 ft. in diameter mounted on weigh cells Rated capacity: 40,000 pounds each Weight empty: 3,365 pounds Rotex classifier P0# 5029 Capacity: 35,000 pounds per hour Motor: 3 hp, 1750 RPM, belt driven Cooling tower PO# 9007 Type: Research - Cottrell, counter Rated capacity: 18,500 gpm Inlet water temperature: 104F Outlet water temperature: 87F Heat load: 157 MMBTU/HR flow, induced-draft Ethylene knock out drum PO# S5515 Size: 3'6" ID., 8' seam to seam Total volume: 576 gallons Weight empty: 5,593 pounds Design pressure: 510 psig at 350F Chill water storage tank PO# S5517 Size: 10* O.D., 10' tall Total volume: 5,875 gallons Weight empty: 7,788 pounds Design pressure: atmospheric at 200F DO A 05704 CONFTDFNTT A D-212 222 D-213 223 A&B D-300 D-301 A.B&C D-302 D-303 D-304 Reactor safety valve knock out drum PO# 5510 Size: 7'6" I.D., 12' seam to seam Total volume: 4,000 gallons Weight empty: 10,300 pounds Design pressure: 102 psig at 500F Reactor mineral oil seal pots PO# S5514 Size: 8-5/8" O.D., 3*6" seam to seam Total volume: 9.1 gallons Weight empty: 239 pounds Design pressure: 1000 psig at 212F HC1 weigh tank PO# Size: Total volume: Weight empty: Design pressure: Magnesium alkyls storage - 3 sections A/B/C PO# S5513 Size: 10* I.D., 34' seam to seam Total volume: 21,164 pounds Weight empty: 35,200 pounds Design pressure: 123 psig at 500 F Triethyl aluminum storage P0# S5513 Size: 10' I.D., 18*seam to seam Total volume: 12,000 gallons Weight empty: Design pressure: 123 psi at 500F Zinc alkyls storage P0# S5513 Size: 10' I.D., 18*seam to seam Total volume: 12,000 gallons Weight empty: Design pressure: 123 psi at 500F Titanate storage PO# S5516 Size: 2' x 5' Total volume: 126 gallons Weight empty: 600 pounds Design pressure: 170 psig D-305 D-306 307 D-308 D-311 321 D-312 322 D-401 402 D-411 421 Catalyst mix drum PO# S5527 Size 6' X 10' Total volume - 2,371 gallons Weight empty - 10,430 pounds Design pressure - 128 PSIG Pre-mix catalyst hold tanks PO0 S5516 Size - 6' X 10' Total volume - 2,371 gallons Weight empty - 4000 pounds Design pressure - 128 PSIG Waste catalyst collection drum PO0 S5516 Size 6' X 10' Total volume - 5,000 gallons Weight empty - 4,000 pounds Design pressure - 128 PSIG Catalyst feed drums P0# S5516 Size 3'6" I.D. 6'6" seam to seam Total volume - 475 gallons Weight empty - 1,900 pounds Design pressure - 131 PSIG ATE feed drums PO# S5514 Size 2' O.D. 9' seam to seam Total volume - 215 gallons Weight empty - 1,353 pounds Design pressure - 170 PSIG Calcium stearate mix tanks PO# 5512 Size 9'6" I.D. 10'3" seam to seam Total volume - 5,435 gallons Weight empty - 10,307 pounds Design pressure 114 PSIG Calcium stearate feed drum PO# S5516 Size 3' I.D. 8'8" seam to seam Total volume - 458 gallons Weight empty - 1,700 pounds Design pressure - 121 PSIG D-500 D-502 D-510 520 D-511 521 D-512 522 D-513 523 D-514 524 Dowtherm flash drum PO# S5512 Size 12' I.D. 22'6" seam to seam Total volume -19,037 gallons Weight empty - 40,400 pounds Design pressure - 102 PSIG and full vacuum Dowtherm make-up drum PO# S5517 Size 16' O.D. 16' tall Total volume - 24,000 gallons Weight empty - 16,607 pounds Design pressure 36" of water at 500F Water heater for hot melt additive PO# S5514 Size 3' I.D. 6' seam to seam Total volume - 317 gallons Weight empty - 1,300 pounds Design pressure - 121 PSI at 450F First devolatilizer PO# S5508 Size 12' X 33' Total volume - 28,000 gallons Weight empty Design pressure - 100 PSI at 650F Second devolatilizer PO# S5525 Size 12' X 24'11 3/4" Total volume - 21,150 Weight empty Design pressure - full vacuum/100 PSI at 650F Hot melt additives PO# S5510 Size 3' O.D. 5'3" seam to seam Total volume - 285 gallons Weight empty Design pressure - 139 PSI at 500F Solvent knock out drum vacuum system PO# S5515 Size 2' O.D. 5'seam to seam Total volume - 118 gallons Weight empty - 900 pounds Design pressure - full vacuum/180 PSI at 400F CD^?D^Sr7.44 'TAL ( D-515 525 D-516 526 D-517 527 D-518 528 ( D-519 529 D-611 621 D-711 721 e. Vacuum pump discharge knock out drum PO# S5515 Size 4' I.D. 8' seam to seam Total volume - 877 gallons Weight empty - 2693 pounds Design pressure - 115 PSI at 350F Hot melt additives PO// S5510 Size 2' I.D. 3' seam to seam Total volume - 75 gallons Weight empty Design pressure - 209 PSI at 500F Hot melt additives high flow PO// S5519 Size 6" Sch80 pipe 15*9" tall Total volume - 23 gallons Weight empty Design pressure - Schl20 pipe at 650F Hot melt additives low flow PO// S5519 Size 3" Sch80 pipe 13' tall Total volume - 4.8 gallons Weight empty Design pressure - Schl20 pipe at 650F Dowtherm knock out on E-511 PO// S5515 Size 4' I.D. 6' seam to seam Total volume - 689 gallons Weight empty - 3,258 pounds Design pressure - full vacuum/115 PSI at 650F Solvent recovery drum PO/f S5512 Size - 8'6" I.D. 15' seam to seam Total volume - 6,368 gallons Weight empty - 15,220 pounds Design pressure - 127 PSI at 500F Ethylene recovery drum PO// S5514 Size 3' I.D. 5' seam to seam Total volume - 264 gallons Weight empty - 1,100 pounds Design pressure - 121 PSI at 450F DO A 057045 CONFIDENTIAL D-712 722 D-713 723 D-801 D-802 D-803 D-804 D-809 C-711 2nd stage suction PO# S5002 Size - 16" O.D., 60" high Total volume - 52 gallons Weight empty - 450 pounds Design pressure - 140 psig at 350F C-711 3rd stage suction PO# S5002 Size - 12-3/4" O.D., 42" high Total volume - 23 gallons Weight empty - 300 pounds Design pressure - 325 psi at 350F Solvent storage P0# S5517 Size - 16' X 16' Total volume - 24,000 gallons Weight empty - 16,314 pounds Design pressure - 36" water and (2oz.vac) Octene storage PO# S9006 Size - 28' X 28' Total volume - 129,000 gallons Weight empty - 47,000 pounds Design pressure - 36" water and (2oz.vac) Octene Storage tanks P0# S9006 Size - 28' diameter 28' height Total volume - 129,000 gallons Weight empty - 47,600 pounds Design pressure - 36" water and 2 oz. vac Design temperature - 400F Solvent swing tank PO# S5517 16' diameter 16'height Total volume - 24,000 gallons Weight empty - 16,315 pounds Design pressure - 36' water Design temperature - 400F Waste solvent tank PO# S5517 Size - 16' diameter 16' height Total Volume - 24,000 gallons Weight empty - 16,225 pounds Design pressure - 36" water Design temperature - 400F DO A 057046 CONFIDENTIAL D-811 821 D-901A D-901B D-904 D-905 Solvent/Octene storage tank - Train One PO# S5517 Size - 16' diameter 16' height Total volume - 24,000 gallons Weight empty - 15,500 pounds Design pressure - 36" water Design temperature - 400F Cooling tower inhibitor tank PO# S5040 Size 11' length 4' diameter Total volume - 1000 gallons Weight empty - 280 pounds Design pressure - ambient Design temperature - ambient Cooling tower dispersant tank PO# S5040 Size - 11* length Total volume - 1000 gallons Weight empty - 280 pounds Design pressure - ambient Design temperature - ambient Flare knock out drum PO# S5512A Size - 10'6" seam to seam 8' Total volume - 4000 gallons Weight empty Design pressure - 113 PSI Design temperature - 500F diameter Mineral oil storage drum PO# S5517 Size - 10' diameter 13' height Total volume - 5900 gallons Weight empty - 8152 pounds Design pressure - 36" water Design temperature - 400F DO A 057047 CONFrOETNTTAl D-907 D-908 D-911 921 DPW-500 DPW-501 E-lll 121 Condensate flash drum PO0 S5514 Size - 8' seam to seam 30 7/8" diameter Total volume - 476 gallons Weight empty - 2280 pounds Design pressure - 121 PSI Design temperature - 450F Condensate storage tank POff S5517 Size - 10' seam to seam 10' diameter Total volume - 5,880 gallons Weight empty - 7,714 pounds Design pressure - 36" water Design temperature - 220F Oil separator from freon compressor (C-911) P0I S5038 Description - a horizontal three stage separator with oil carry over not to exceed 2 PPM by weight of oil circulated also with replaceable coalescence type oil filters as the final stage. The unit also has oil level sight glasses, dual safety valves and an oil heater that can be replaced with unit in service. Primary pellet water tank P0# S5520 Size 10' X 10' X 8' Total volume - 5,964 gallons Weight empty Design pressure and temperature - atmospheric at 200F Pellet basket P0if S5520 Size - 10'6" total height X 4' square Total volume - N/A (168ft3/l,257 gallons) Weight empty Design pressure and temperature - atmospheric at 150F C-lll discharge cooler PO0 S5008 Size - 8' X 6'7" Weight empty - 11,714 pounds Design pressure and temperature tube side - 750 psi @ 300F (Ethylene) Number of tubes: 135 - A-179 - Tube O.D. 1", 14 gage, 8' long Total flow tube side - 30,000 pounds/hour FAN - Westinghouse 7.5 hp 575V "V" belt driven DO A 057048 CONFIDFNTTAL E-210 220 E-211A/B 221A/B E-500/501 E-502 E-511 521 E-512 522 Feed cooler (cooling tower water) PO# S5502 Size - 28' long by 4'5" in diameter Weight empty - 18,100 pounds Design press/temp tube side - 750 PSI @ 250F (process) Design press/temp shell side - 150 PSI @ 200F (water) Number of tubes: 498 - 90-10 CuNi - 3/4" O.D., 14 BWG Total flow tube side - 166,667 pounds/hour Feed chillers (chill water) PO# S5502 Size - approx. 20' long X 30" in diameter Weight empty - 15,300 pounds Design press/temp tube side - 750 PSI @ 250F (process) Design press/temp shell side - 150 PSI @ 200F (water) Number of tubes: 648 - 90-10 CuNi - 3/4" O.D., 14 BWG Total flow tube side - 166,667 pounds/hour Seal fluid heat exchanger P0# S5036 Size - 64 1/8" long 6" diameter Weight empty Design press/temp tube side - 125 PSI @ 375F (water) Design press/temp shell side - 125 PSI @ 600F (Dovtherm) Number of tubes: 24 - 90-10 CuNi - 3/4" O.D., 5' long Total flow tube side/shell side - 20,000/3625 pounds/hour Dowtherm storage condensor P0# S5008 Size - approx. 8' X 6'8" Weight empty - 5,199 pounds Design press/temp tube side - 10 PSI @ 650F (Dowtherm) Total flow tube side - 40,000 pounds/hour Number of tubes: 80 (Data) A-179 Tube O.D. IV' 8' long Fan- Westinghouse 10 hp/575 volt "V" belt driven Devolatilizer preheater P0# S5504 Size - 32' flange to flange X 50" diameter Weight empty - 72,300 pounds Design press/temp tube side - 750 PSI @ 650F (process) Design press/temp shell side - 100 PSI @ 650F (Dowtherm) Number of tubes: 3714 (Data) 5A-179 O.D. V' 32' long Total flow tube side/shell side - 147,020/113,626 pounds/hour Expansion joint - Inconel 600 (2 per unit) Plate heater exchanger PO# S5506 Size - Approximately 14' long by 5' in diameter Weight empty - 31,000 pounds Design press/temp process - 1000 psig at 650F Number of plates - 26,000 Total flow - 30,000 pounds per hour (process) Design press/temp Dowtherm - 100 psig at 650F Number of tubes: 408 - 304 SS - O.D. 5/8", 9'4" long D0 A 05704c CONFrDFNTIAL E-513A 523A E-513B 523B E-514 524 E-515 525 E-516 526 E-517 527 Vacuum cooler (cooling tower water) PO# S5503 Size - 7' long 42" diameter Weight empty - 14,100 pounds Design press/temp tube side - 100 PSIG @ 550F (process) Design press/temp shell side - 150 PSIG @ 350F (water) Number of tubes - 1485 90-10 CuNi 3/4" O.D. 7' long Total flow tube side/shell side - 4070/78,146 pounds/hour Vacuum cooler (chill water) PO// S5503 Size - 7' long 42" diameter Weight empty - 12,800 pounds Design press/temp tube side 100 PSIG @ 550F (process) Design press/temp shell side 100 PSIG @ 350F (water) Number of tubes - 1485 90-10 CuNi 3/4" O.D. 7' long Total flow tube side/shell side - 4,070/16,449 pounds/hour Vacuum condenser (freon) PO# S5503 Size - approx. 4' long 47" diameter Weight empty - 6,700 pounds Design press/temp tube side - 100 PSIG @ 550F (process) Design press/temp shell side - 100 PSIG @ 200F (freon) Number of tubes - 1031 A-179 3/4" O.D. 4' long Total flow tube side - 4070 pounds/hour Seal liquid cooler (chill water) PO# S5518 Size - 36-3/4" x 35-3/4" Weight empty - 485 pounds Design press/temp cold side - 150 PSIG @ 200F (water) Design press/tenp hot side - 100 PSIG @ 250F (solvent) Number of plates - 58 (Monel) Total flow cold side/hot side - 40,000/16,867 pounds/hour Seal liquid chiller (freon) PO# S5524 Size - 11' long 19' I.D. Weight empty - 5000 pounds Design press/temp tube side - 100 psig at 250F (Solvent) Design press/temp shell side - 150 psig at 250F (Freon) Number of tubes - 104 Tube O.D. .750 in. gage 14 8' long Pellet water cooler P0// S5502 29'2" long 29" diameter Weight empty - 15,800 pounds Design press/temp tube side - 100 PSIG @ 350F (pellet water) Design press/temp shell side - 150 PSIG @ 350F (cooling tower) Number of tubes - 384 (Data) 90-10 CuNi 1" O.D. 24' long Total flow tube side/shell side - 440,000/1,186,243 pounds/hour D0 A 057050 confidential E-611 621 E-612 622 E-617 627 E-711 721 E-712 722 E-906 Steam generator POd S5502 Size - 24*6" long 70" diameter Weight empty - 29,000 pounds Design press/temp tube side - 100 PSIG @ 550F (solvent) Design press/temp shell side - 150 PSIG @ 450F (steam) Number of tubes - 484 U-tubes (Data) A-179 1" O.D. 40* U long Total flow tube side/shell side - 151,046/8061 pounds/hour Solvent cooler POd S5008 Size - approx. 34' long X 19' wide Weight empty - 126,830 pounds Design press/temp tube side - 100 PSIG @ 550F (solvent) Number of tubes - 528 (Data) A-214 1" O.D. 34' long Total flow tube side - 151,046 pounds/hour Fan - Westinghouse 30 hp 575 volt "V" belt driven Recycle solvent cooler POd S5502 Size - approx. 20' 8V' long 24" diameter Weight empty - "72oO Ur. Design press/temp tube side - /3ooF (solvent) Design press/temp shell side - /<50pSl- / (cooling tower) Number of tubes - I >*vck iqJSo-jO C.-NK Total flow tube side/shell side - 300,000 UrjUr- f 24/S000 VlrjUr 1st stage cooler (C-711) POd S5002 Size - 12' long 8-5/8" diameter Weight empty - 450 pounds Design press/temp tube side - 150 psi at 300F Design press/temp shell side - 150 psi at 150F Number of tubes -- 61 90-10 CuNi 5/8" O.D. 12' long Total flow tube side/shell side - 4635 lbs/hr, water 32 gpm 2nd stage cooler (C-711) POd S5002 Size - 12' long, 8-5/8" diameter Weight empty - 450 pounds Design press/temp tube side - 300 psi at 250F Design press/temp shell side - 150 psi at 150F Number of tubes - 16 U Steel 3/8" O.D. 10' long Total flow tube side/shell side - ethylene 4635 lbs/hr, water 22 gpm Potable water heater (safety shower system) POd S5064 Design - The shell is made of steel rated at 150 psig, coil of cupro nickel. Potable water on shell side is heated with 15 pounds of steam in coil. Temperature control of water is adjustable from -110F to 185F. D0 A 057051 CONFIOFNITM' E-908 E-911 921 Condensate storage tank condenser PO# S5008 Size - approx. 10' long 8'2" wide Weight empty - 5199 pounds Design press/temp tube side - 50 PSIG @ 250F (steam) Number of tubes - 148 (Data) SA-214 1" O.D. 10' long Total flow tube side - 3885 pounds/hour Fan - Westinghouse, 575 volt, 10 hp "V" belt driven Condenser for C-911 PO# S5038 Size Weight empty Description - (Freon) EJ-211 221 EJ-212 222 F-501 Inline mixer for R-211 PO# S5032 Size Weight empty - PROPERTIES OF MATERIALS TO BE MIXED SOLVENT ETHYLENE Flow lb/hr 150,000 Press PSI 600 Temp C 40 30,000 550 40 Inline mixer for R-212 PO# S5034 Size Weight Empty - PROPERTIES OF MATERIALS TO BE MIXED SOLVENT ETHYLENE Flow lb/hr 100,000 Press PSI 600 Temp C 40 15,000 550 40 Dowtherm Furnace - PO# L5004 Model No. 6VI-33-6HE-12-42-B Size - 13' X 45' tall Description - vaporizer with self-supporting stack with air preheater and forced draft fan. Maximum capacity - 32,000,000 BTU/hr. Operating condition: outlet press, 20 psig; vapor temp 572F inlet liquid temp 566 F; liquid outlet temp 650F (next page) DO A 057052 CONFIDENTIAL F-501 FL-502 FL-510 520 FL-611 A/B 621 FL-614 A/B 624 (cont'd) minimum liquid temperature 550 F; maximum differential pressure 3 psi. Dowtherm Filter PO# L5066 Model No. - 26798-SFG-7-3-2-2F Process basis flow - 50 gpm Particle size - 5 microns Maximum operating pressure - 60 psig Maximum operating temperature - 575F, allowable press, 10 psi Description - fiberglass disposable cage unit element Filter shell - design press 150 psig design temp 650F drop Pellet Water Filter PO# L5006 Model No. - FS-1300-8 Process basis flow - 1000 gpm Particle size retain - 200 micron minimum Maximum operating press - 80 psig Maximum operating temp - 150*F Filter shell - design press - 150 psig design temp - Recycle Solvent Filters POtf L5009 Model No. - 914945/L59M5368FD-C150 Process basis flow - 300,000 lb/hr Particle size - 5 microns Maximum operating press - 85 psig Maximum operating temp - 120F allowable press drop 5 psi Description - 30" length cotton disposable cage unit elements Filter Shell - design press - 150 psig Design temp - 350F T-611 Bottoms Filter PO# L5009 Model No. - 914947/015LH20-1F-C150 Filter basis flow - 10 gpm Particle size - 5 microns Maximum operating press - 60 psig Maximum operating temp - 347F, allowable press drop 5 psi. Description - 20" length fiberglass elements Filter Shell - design press - 150 psig design temp - 450F DO DO NF t 5753 rfrNTrA( FL-901 FN-901 A/B K-511 521 SC-511 521 P-113 A/B P-202 A/B Cooling Tower Filter PO0 L5063 Model No. - HD841 multi-media Filter basis flow - 770 gpm Maximum operating press - 70 psig Maximum operating temp - amb. allowable press drop 30 psig Description - sand filter Filter Shell - design press. - 125 psig design temp - 100F Fan for C.T. 901 P0# L9007 Model No. - XT Motor size - 125 hp, 2 speed single winding 1800/900 RPM Enclosure - explosion proof Description - 8 blades with vibration safety switch Pelletizer P0# L5048 Werner - Pfleiderer Drive Motor size - 100 hp, variable speed A.C. Output capacity - 35,000 lbs/hr Die Plate Description - approx. 900 holes 0.125" diameter die plate design for Dowtherm (Flow) Die Face - 1/8" thick Cutter Description - retractable knife shaft and cutter head, maximum 12 cutter knives. Rotor Speed - 800 RPM's maximum Screen Changer - Werner - Pfleiderer Type - Swz 1900 Description - oval self-supporting actuation with 27 screen elements 2700 sq. cm. of total screen area. Hydraulic system press - 2300 psig maximum Propylene Pump PO0 L5067 Manufacturer - Union Pump Co. Model No. - TX-10 IX 1-5/8 Capacity normal 600 gph, maximum 1200 gph, minimum 100 gph Suction press - 200 pgis, discharge press - 700 psig, min. suction press - 60 psig Motor - 10 hp, 1780 RPM's, Frame - 215T, Enclosure - exp. proof. Make - Seimans - Allis Chilled Water Pumps POtf L5016 Manufacturer - Goulds Pumps, Inc. Model No. - 3196XLT 6X8-15 Capacity - 2280 gpm, max at 50F pumping temp. Suction press 14.7 psia, discharge press - 77.5 psia, Diff erential press 628 psi Motor - 100 hp, 1750 RPM, frame - 405T, enclosure - TEFC Make - Reliance 570m DO * C,0^1 P-211 A/B/C P-221 P-308 P-311 A/B/C P-321 Solvent Pumps PO# L5023 Manufacturer - Sundstrond (Sundyne) Model No. - LMV-311 Capacity - 230 gpm each Suction press - 15 psla, discharge - 665 psia Differential press - 650 psi Motor - 200 hp, 3550 RPM, frame -- 445 hp, enclosure - TEFC Make - Reliance D-308 Pump (Catalyst waste) P0# L5016 Manufacturer - Goulds Pumps, Inc. Model No. - 3996MT 3X4-10 Capacity - 170 gpm Suction psia - 14.7, discharge press - 34.2 psia, Differential press - 19.5 psi Motor 5 hp, 1750 RPM, frame - 184 TC, enclosure - TEFC Make - Reliance Premix Catalyst Pumps PO# L5025 Manufacturer - Milton Roy Model No. - 0MR2-71-140T milroyal Capacity - 0 to 64 gph Discharge press - 750 psi maximum Motor - 1 hp P-312 A/B/C P-321 A/B/C P-322 A/B/C P-401 P-402 Sidestream Pumps (ATE) PO# L5025 Manufacturer - Milton Roy Model No. - DMR2-62-142T milroyal Capacity - Normal 12.8 gph, maximum 25.5, minimum 0 Discharge press - normal 550, maximum 750, minimum 500 psig Motor - hp, 50-1750 RPM maximum, frame - 56C, enclosure - Exp proof Make - T. B. Woods D-401/402 Circulation pumps PO# L5016 Manufacturer - Gould Pumps, Inc. Model No. - 3996 ST lh x 2/8 Capacity - 40 gpm Suction press - 74.7 psia, discharge - 91.7 psia Differential press - 17.0 psia Motor - 2 hp, 1750 RPM, frame - 145TC, enclosure - TEFC Make - Reliance DO A 057055 CONFIDENTIAL. P-411 421 P-500 A/B/C P-501 A/B/C P-502 A/B P-510 P-520 Calcium Stearate Feed Pumps PO# 5025 Manufacturer - Milton Roy Model No. DMR2-91-140T Milroyal Capacity - Normal - 45 gpm, maximum - 90 gpm, minimum - 0 Suction press - , discharge press - normal 500 psig, maximum - 750, minimum - 500 psig Motor - 3hp, 50-1750 RPM, maximum, frame - 215 foot mount, enclosure - Ex proof Dowtherm Circulation Pumps PO# L5016 Manufacturer - Union Model No. - UNILIGN 6X6-18VL Capacity - 1000 gpm Suction press - 34.5 psia, discharge press - 113.43 psia differential press - 78.93 psi Motor - 100 hp, 1750 RPM, Frame - 405LP, Enclosure - TEFC Make - Reliance F-501 Feed Pumps PO# L5016 Manufacturer - Union Model No. - UNILIGN 6X8 13VL Capacity - 1250 gpm Suction press - 34.0 psia, discharge - 86.5 psia, differ ential press - 52.5 psi Motor - 75hp, 1750 RPM, frame - 365LP, enclosure - TEFC Make - Reliance Dowtherm Make-up Pump PO# L5016 Manufacturer - Goulds Pumps, Inc. Model No. - 3996 ST 14X2-8 Capacity - 100 gpm Suction press - 14.7 psia, discharge press - 94.7 psia, differential press - 80 psi Motor - 15 hp, 3550 RPM, Frame - 254TC, Enclosure - TEFC, Make - Westinghouse D-510 circulation pumps (Hot H*0) PO# L5016 Manufacturer - Union Pump Co. Model No. - UNICHEM 14X2X7 VCM Capacity - 40 gpm Suction press - 52.4 psia, discharge press - 122.1 psia, differential press - 69.7 psi Motor - 74 hp, 3500 RPM, Frame - 213LP, Enclosure - TEFC Make - Reliance Do A 0570 CONFIDENT! P-511 512 521 522 P-514 A/B 524 P-515 A/B 525 P-519 A/B 529 P-611 A/B 621 D-511 & D-512 Gear Pumps PO# L-5001 Manufacturer: Scbewaing Tool 6 Eng. Co. Type: 34" high press gear Capacity: 40,000 lb/hr Discharge press: 4015 psia Differential press: 4000 psi Speed: 20 RPM max , 2 RPM min. Motor: 500 hp, 1800 variable speed A.C. Make: Fuji (Dow designed) D-514 Bottoms Pump PO# Manufacturer: Viking Pump Model No.: K4123R Capacity: 55 gpm Suction: 5 mmHg Discharge press: Differential press: 60 psi Motor: 7.5 hp, 1800 RPM Frame: 213T Make: U.S. Motors, TYPE TCE 60 psia Enclosure: TEFC D-515 Bottoms Pump PO# L-5016 Manufacturer: Goulds Pumps, Inc. Model No.: 3996 MT 1*5X2-10 Capacity: 100 gpm Suction press: 14.8 psia Discharge press: 109.4 psia Differential press: 94.6 psi Motor: 20 hp, 3500 RPM Frame: 256TC Enclosure: TEFC Make: Dowtherm Return Pumps PO# L-5016 Manufacturer: Union Model: Unilign 3X4-8*sVL Capacity: 340 gpm Suction press: 34.5 psia Discharge press: 104.5 psia Differential press: 70.0 psi Motor: 25 hp, 3550 RPM Frame: 284LP Enclosure: TEFC Make: Reliance T-611 Reflux Pump P0# 5016 Manufacturer: Goulds Pumps, Inc. Model: SggbMTl^-lO Capacity: 100 gpm Suction press: 24.7 psia Discharge press: 131.7 psia Differential press: 107 psi Motor: 20 hp, 3500 RPM Frame: 256CT Enclosure: TEFC Make: Westinghouse A 057QS7 P-612 A/B 622 P-613 A/B 623 P-614 A/B 624 P-711 721 P-801 Solvent Recycle Pumps Manufacturer: Union Model: 4X6-11VCM Capacity: 875 gpm Suction press: 24.7 psia Discharge press: 113.8 psia Differential press: 89.1 psi Motor: 75 hp, 3550 RPM Frame: Enclosure TEFC Make: T-611 Recirculation Pump Manufacturer: Goulds Pumps, Inc. Model: 3996MT4X6-13 Capacity: 770 gpm Suction press: 18 psia Discharge press: 58 psia Differential press: 40 psi Motor: 40 hp, 1780 RPM Frame: Enclosure: TEFC Make: T-611 Bottoms Pump P0# L-5058 Manufacturer: Union Model: 15sX2X7 VCM Unichem Capacity: 15 gpm Suction press: 58 psia Discharge press: Differential press: Motor: 3 hp, 3500 RPM Frame: 183LP Enclosure: TEFC Make: S.A. D-711 Bottoms Pump PO# L-5058 Manufacturer: Union Model: l*sX2X7 VCM Unichem Capacity: 10 gpm Suction press: 24.7 psia Motor 3 hp, 3500 RPM Frame: Make: S.A. 182LP Enclosure: TEFC D-801 Circulation Pump PO0 L-5016 Manufacturer: Goulds Pumps, Inc. Model: 3996 ST 2X3-6 Capacity: 250 gpm Suction press: 14.7 psia Discharge press: 46.5 psia Differential press: 31.8 psi Motor: 10 hp, 3500 RPM Frame: 215TC Enclosure: TEFC Make: Westinghouse DO A 057058 CONFIDENTIAL P-802 A/B P-803 A/B P-804 A/B P-806 A/B P-809 D-802 Pumps PO# L-5016 Manufacturer: Goulds Pumps, Inc. Model: 3996 ST 2X3-6 Capacity: 250 gpm Suction press: 14.7 psia Discharge press: 52.5 psia Differential press: 37.8 psi Motor: 10 hp, 3500 RPM Frame: 215TC Enclosure: TEFC Make: Westinghouse D-803 Pumps PO# L-5016 Manufacturer: Goulds Pumps, Inc. Model: 3996 MT 1*5X2-10 Capacity: 45 gpm Suction press: 14.7 psia Discharge press: 105.7 psia Differential press: 91.0 psi Motor: 15 hp, 3600 RPM Frame: 254TC Enclosure: TEFC Make: Westinghouse Swing Solvent Tank Pumps PO# L-5016 Manufacturer: Goulds Pumps, Inc. Model: 3996 MT 2X3-10 Capacity: 250 gpm Suction press: 14.7 psia Discharge press: 66 psia Differential press: 51.3 psi Motor: 15 hp, 3500 RPM Frame: 254TC Enclosure: TEFC Make: Westinghouse Tank Car Unloading Pump PO# L-5016 Manufacturer: Goulds Pumps, Inc. Model: 3996 MT 3X4-10 Capacity: 200 gpm Suction press: 14.7 psia Discharge press: 36.5 psia Differential press: 21.8 psi Motor: 5 hp, 1750 RPM Frame: 184TC Enclosure: TEFC Make: Reliance Waste Solvent Pump PO# L-5016 Manufacturer: Goulds Pumps, Inc. Model: 3996 MT 3X4-10 Capacity: 250 gpm Suction press: 14.7 psia Discharge press: 34.4 psia Differential press: 19.7 psi Motor: 7.5 hp, 1750 RPM Frame: 21BTC Enclosure: TEFC Make: Reliance C>0 Comp P-811 A/B 821 P-900 A/B P-901 A/B/C P-904 P-906 A/B P-907 A/B Solvent/Monomer Pumps PO// L-5016 Manufacturer: Goulds Pumps, Inc. Model: 3996 MT 2X3-10 Capacity: 250 gpm Suction press: 14.7 psia Discharge press: 66.0 psia Differential press: 51.3 psi Motor: 15 hp, 3500 RPM Frame: 254TC Enclosure: TEFC Make: Westinghouse Water Treatment Chemicals PO# L-5040 Manufacturer: Betz Model: A111-95B Capacity: Normal: 12 gpd Maximum: 24 gpd Minimum: Suction press: atmos. Discharge press: 5 psig Motor: 1 amp full load current 1.0 gpd Cooling Water Pumps PO# L-5016 Model: 3415M 16X18-22G Capacity: 9250 gpm Suction press: 14.7 psia Discharge press: 79.9 psia Differential press: 65.2 psi Motor: 500 hp, 1180 RPM Frame: Enclosure: WP-1 Make: Toshiba D-904 Pump PO// L-5016 Manufacturer: Goulds Pumps, Inc. Capacity: 50 gpm Suction press: 14.7 psia Discharge press: 58.7 psia Differential press: 44 psi Motor: 7.5 hp, 3500 RPM Frame: 213TC Make: Reliance Enclosure: TEFC Potable Water Pumps PO// L-5016 Manufacturer: Goulds Pumps, Inc. Model: 3996 ST l*sX2-6 Capacity: 50 gpm Suction press: 45 Discharge press: Motor: 5hp, 3500 RPM Frame: 184TC Make: Westinghouse 80 Enclosure:TEFC Mineral oil pumps for Seal Pots PO# L-5027 Manufacturer: Graco, Inc. Model: 205-626 Capacity: 30 gph Air actuated pump; required air flow - 36 CFM Discharge press: 650 psig. Liquid inlet size: IV' MNPT, liquid outlet size:3/4" MNPT, Air inlet size: 3/8" FNPT DO A 057060 CONFIDENTIAL R-211 212 221 222 RE-611 621 SD-511 521 T-611 621 XS-511 521 Reactor PO# L-5505 Manufacturer: Raleigh Beard Model: Size: 10'0" ID Vessel - 10'9" jacket Total volume: 3915 gal Wt Empty: Wt. Full: Operating press shell: 500 psig Operating press jacket: 255 psig Operating temp shell: 428F/220C Operating temp jacket: 401F/205C Design press shell 750 psig jacket 275 psig Design temp shell: 650F jacket: 650F T-611 Reboilers PO# L-5503 Size: Shell ID 27.0 in. 367 tubes 8 ft length Total flow: shell side 2130 lb/hr steam tube side 172760 lb/hr process Tube Data A-179 Max operating temp: Shell side-382F Tube side-351F Max operating press: Shell side - 185 psig Design temp: Shell side-500F Tube side-650F Design press: Shell side-300 psig Tube side-100 psig Centrifugal Pellet Dryer PO# L-5031 Manufacturer: Gala Industries Capacity: 35,000 lb/hr Inlet water rate: 880 gpm Motor: 15 hp Dewax Column Flow rate: liquid - 200 gpm Vapor - 180,000 lb/hr. Bottom section: Liquid - 500 gpm Vapor - 180,000 lb/hr Operating press: 17 psig Operating temp - 350F Design press: 100 psig Design temp - 650F Packing one 10* section 3V Monel pall rings one 10' section 2" Monel pall rings Additive Extruder PO# L-5003 Manufacturer: NRM Corporation Model: Special Pacemaker III Capacity: 25 lb/hr min. to 375 lb/hr max. Discharge press: 400 psig Motor: 75 hp, 1750 RPM Enclosure: TEFC D0 A 057061 CONFIDENTIAL Y-- 111 A/B Y-121 A/B Y-112 A/B Y-122 A/B Y-113 A/B Y-211 A/B Y-221 A/B Y-611 A/B Y-621 A/B Y-801 Y-802 Ethyl Regenerate Beds (silica gel) PO# S-5521 Size: 17' seam to seam Wt. Empty: 19,231 lbs. Wt. Full: Design pressure/temp: 535 psig @ 650F Total volume: 2742 gallons 42,097 lbs. Ethylene Regenerate Beds (molecular selves) PO# S-5521 Size: 17' seam to seam Wt. Empty: 19,231 lbs. Wt. Full: 42.097 lbs. Design press/temp: 535 psig @ 650F Total volume: 2742 gallons Propylene regenerate beds (silica gel & molecular sieves) PO# S-5526 Size: 10' seam to seam 2' inside diameter Wt. Empty: Wt. Full: Design press/temp: 402 psig @ 650F Total volume: Solvent regenerate beds (molecular seives) POff S-5521 Size: 12'6" seam to seam Wt. Empty: 7,765 lbs. Wt. Full: 29,010 lbs. Design press/temp: 167 psig @ 500F Total volume: 2547 gallons Solvent regenerate beds (silica gel) PO# S-5521 Size: 12'6" seam to seam Wt. Empty: 7765 lbs. Wt. Full: Design press/temp: 167 psig @ 500F Total volume: 2547 gallons 29,010 lbs. Solvent storage regenerate beds (silica gel) PO# S-5521 Size: 10' seam to seam 3' inside diameter Wt. Empty: 2927 lbs. Wt. Full: 7,703 lbs. Design press/temp: 153 psig @ 500F Total volume: 581 gallons Octene regenerate beds (silica gel) PO# S-5521 Size: 10' seam to seam 3' inside diameter Wt. Empty: 2,927 lbs. Wt. Full: 7,703 lbs. Design press/temp: 153 psig @ 500F Total volume: 581 gallons DO A 05706? CONFIDENTIAL Y-902 A/B YB-111 121 YB-112 122 YB-211 221 YB-611 621 YB-801 Air Dryers (active alumina) PO# S-5047 Size: approx. 7' x 4* x 9.5' Weight empty: 1050 pounds Design press/temp: 150 psig at 450F Volume: 3000 scfm Nitrogen blower for Y-lll A/B PO# S-5005 Model: G5050-HMOD 60 hp motor 3600 RPM Inlet SCFM - 1379 at 50 psia 100F Outlet 5 psid or 65 psia Nitrogen blower for Y-112 P0# S-5005 Model: G5050-HMOD 60 hp motor 3600 RPM Inlet SCFM - 1379 at 60 psia 100F Outlet 5 psid or 65 psia Nitrogen blower for Y-113 PO# S-5005 Model: G5050-HM0D 60 hp motor 3600 RPM Inlet SCFM 1379 at 60 psia Outlet 5 psid or 65 psia 100F Nitrogen blower for Y-611 PO# S-5005 Model: G5050-HMOD 60 hp motor 3600 RPM Inlet SCFM 1379 at 60 psia Outlet 5 psid or 65 psia 100F Nitrogen blower for Y-801 P0# S-5005 Model: H5015-HMOD 15 hp motor 3600 RPM Inlet SCFM 345 at 60 psia Outlet 5 psid or 65 psia 100F YH111/121 YH112/122 YH113 YH211/221 YH611/621 YH801 Heater Ylll Y112 Y113 Y211 Y611 Y801 & Y802 P0# S-5041 DO A 057063 CONFIDENTIAL YH111 112 113 211 611 801 Inlet Temp 350 350 350 350 350 350 Outlet Temp 550 550 550 550 550 550 Opr Press 50 50 50 50 50 50 Nj Flow 1250 1250 90 920 1325 301 Input kw 94 94 6 65 94 22 DO A 05706* CONFTDFNTIAl EA's Air conveying coolers for System 3, 4, 5, 6 and 7 PO# S-5056 Manufacturer: Exchanger, Inc. Model: C-225-81M12 Inlet size: 12" Outlet size: 12" Description: Removable Fin Tube Bundle Coil connection inlet: 2-1/8" O.D. outlet: 2-1/8" O.D. Housing; fabricated aluminum Normal air operated pressure: 25.5 psig Inlet temperature: EA's 3 & 4, 260F outlet temp 140F maximum EA's 5 & 6, 256F outlet temp 140F maximum EA 7, 281.5F outlet temp 140F maximum G-511/512 521/522 Gearboxes (P-511, 512, 521 and 522) PO# L-5072 Manufacturer: Horsburgh & Scott Co Gear ratio: 90/1 Single Helica Gears Service factor: 1.75 AGMA ratings: 500 ph at 1800 RPM input Torque at maximum continuous speed: 131,300 lb. ft. Lubrication system: 2 oil pumps and 2 filter system Oil pump motors: Westinghouse 2 hp, 1200 RPM, 3 phase, 575 volts Frame - 184TC Heat Exchanger: BASCO #06024-54; Water flow rate of 20 gpm at 90F Oil Heaters (2): 2 kw each with maximum watt density of 5 watts per square inch. 575 volts A.C., 3 phase MX-212 222 Static Mixers PO# S-5045 Manufacturer: Koch Size: 30'4Js" long - 18" diameter Process design pressure: 750 psig Design temperature: 450F Maximum pressure drop: 30 psi Number of elements: 20 Jacket design pressure: 300 psig Design temperature: 65 F Diameter: 20" 00 A 057065 CONFIDENTIAL MX-512 522 YD111/121 112/121 211/611 YE111/121 A/B/C 112/122 YE111/121 D/E/F 112/122 YE- 211/221 A/B/C Static mixer PO# S-5045 Manufacturer: Koch Eng. Size: 22 ft. Process design pressure: 4000 psia Process design temperature: 550F Number of elements: 11 Maximum pressure drop: 1000 psi Jacket design pressure: 235 pound steam service K.0. Drum P0# S-5523 Design pressure: 144 psig Design temperature: 550F Weight empty: 744 pounds Size seam to seam: 5 ft. Diameter: 2 ft. Regeneration coolers P0# S-5059 Type: Fintube (24) Design temperature Design pressure Total flow Process - Shell Side 650F 100 psig 5535 lbs/hr Nitrogen Tube Side 550F 150 psig 62900 lbs/hr Cooling tower water Steam regeneration heaters POit S-5059 Type: Fintube (36) Shell Side Design temperature - 650F Design pressure - 100 psig Total flow - 5535 lbs/hr Process - Nitrogen Tube Side 550F 300 psig 375 lbs/hr Steam Regeneration coolers PO# S-5059 Type - Fintube (24) Design temperature Design pressure Total flow Process - Shell Side 650F 100 psig 4073 lbs/hr Nitrogen Tube Side 550F 100 psig 46300 lbs/hr Water cooling tower 00 A 057066 CONFIDENTIAL YE211/221 D/E YE611/621 A/B/C/D YE611/621 E/F/G YE-801A YE-801B Steam regeneration heaters POif S-5059 Type: Fintube (36) Shell Side Design temperature - 650F Design pressure - 100 psig Total flow - 4073 lbs/hr Process - Nitrogen Regeneration coolers PO// S-5059 Type: Fintube (24) Design temperature Design pressure Total flow Process - Shell Side 650F 100 psig 5867 lbs/hr Nitrogen Steam regeneration heaters PO// S-5059 Type: Fintube (36) Shell Side Design temperature - 650F Design pressure - 100 psig Total flow - 5867 lbs/hr Process - Nitrogen Regeneration cooler PO// S-5059 Type: Fintube (24) Design temperature Design pressure Total flow Process - Shell Side 650F 100 psig 1333 lbs/hr Nitrogen Steam regeneration heater PO# S-5059 Type: Fintube (36) Shell Side Design temperature - 650F Design pressure - 100 psig Total flow - 1333 lbs/hr Process - Nitrogen Tube Side 550F 300 psig 285 lbs/hr Steam Tube Side 550F 150 psig 66700 lbs/hr Cooling tower water Tube Side 550F 300 psig 398 lbs/hr Steam Tube Side 550F 150 psig 15150 lbs/hr Cooling tower water Tube Side 550F 300 psig 91 lbs/hr Steam 00 A 057067 CONFTDFNTTAL ( YE-113A Regeneration cooler PO# S-5059 Type: Fintube (24) Shell Side Design temperature - 650F Design pressure - 100 psig Total flow - 421 lbs/hr Process - Nitrogen YE-113B Steam regeneration heater PO# S-5059 Type: Fintube (36) Shell Side Design temperature - 650F Design pressure - 100 psig Total flow - 421 lbs/hr Process - Nitrogen \/P' P.0* ( Tube Side 550F 150 psig 3329 lbs/hr Cooling tower water Tube Side 550F 300 psig 29 lbs/hr Steam DO A 05706-8 CONFIDENTIAL i YE-113A Regeneration cooler PO# S-5059 Type: Fintube (24) Design temperature Design pressure Total flow Process - Shell Side 650F 100 psig 421 lbs/hr Nitrogen YE-113B Steam regeneration heater PO# S-5059 Type: Fintube (36) Shell Side Design temperature - 650F Design pressure - 100 psig Total flow - 421 lbs/hr Process - Nitrogen 9.0* Tube Side 550F 150 psig 3329 lbs/hr Cooling tower water Tube Side 550F 300 psig 29 lbs/hr Steam ! I DO A 057069 CONFIDENTIAL