Procedure No. 6
lIPMi , Tj 1.
2.
Chromatograph - 4 ca. AKCAS, Model No. 503 SKID and 2 Model No. 905 BK1D with pre-cut and analytical columns and hydrogen flame ionization detec tor.
Programmer - 5 ea. ARCAS, Model No. 1903, Model PMC 2000.
3. Computer - Digital Pqui pmen t Co., POP PM \.:th l.Alh printer.
Operation
1.1 The gas chromatograph and programmer por t ion:, of the Areas Monitoring System must be in operation at all times. Repairs to these two units must be on a call-out priority 1 basis.
1.2 1.3
If the computer pet lien of the Areas Monitoring System is out of service, vinyl chloride leaks, as defined by AOR-9, must be recorded manually and reporter! in the Shift Supervisor log.
Kor automatic operation, following positions:
the prrgram;':n r switches must be in the
T i me r block Sample Inject Calibru te Column Switch Auto Zero Klee trometer St i'earn Select nr Swift hi-:
(kxeept Stiearn 10)
RUN A urn AUTO 01 K AUTO Al'TC FT.KCT ON
D. Iv Maintenance Schedule
2.10
Calibrajjon - Karh gas chromatograph must h* calibrated daily with a
Standard vinyl chlorrUe gas mixture. Tie standard gas mixture may
be different for each area chromatograph,
The standard gas mixture
which must be used for each c hroma t <>g r op! ithe vinyl chloride
concentration defined as a leak for sack area in AOP-9, Vinyl
Chloride I.eak Detection and F,1 imin.it i-m Procedure. Since the
definition of a leak may also change with tine, the current leak
definition for each area can always be 1 emu in Appendix A of AOP-9.
The procedure for calibration is shown in Sect :<>n 7.0 of this procedure.
2.20
Inst rumen t Gas Sunn L y - The hydrogen and helium gas cylinders must be checked daily.
2 TEN0 747
Procedure No. 6
Daily Maintenance Sc. hedn 1 o ( con t'd )
2.21
Record the pressures of the gas cylinders shown on the primary gauge of the regulator.
2.22
If a cylinder is empty (less than 200 psig on primary gauge) have proper gas delivered from warehouse to analyzer,
2.30
Air Supp1y - The air dryer at each analyzer must be checked daily for moisture contamination. Also, check the vototwter for proper air flow as indicated at each analyzer. Adjust air flov; as required.
2.40
St andard Gas Mix tu re - The pressure on the vinyl chloride standard gas uixturn must be checked daily.
2.41 Read the pressure on the primary gauge of the regulator.
2.42
If the cylinder is empty (less than 200 psig on primary gauge) have proper gas mixture for particular area delivered from warehouse .
2.43
The secondary gauge must be set rn higher than 5 psig. If unusual pressure drops are noted fieri day to day, the gas feed lines must be checked for leaks-.
2..30
Ir, s_i i uinenj: hooter Air Supply - The heati r ait supply pressure must be checked daily and maintained at 30 psig, Reach the pressure gauge located at the diaphragm at each analyzer.
2.60
Samp 1e Stream bypass Flow - The vacuum gauge on the sample stream bypass header must be checked daily to assert proper bypass flow. The vacuum should be maintained between 2" and 8" of HaO vacuum.
2.61
If vacuum is low, check for leak and proper operation of sample pump.
2.62
If vacuum is high, check for restriction it1 sample system.
2.70
Samp I e Flow - The sample flow lotomi-tei and sample header pressure must be checked daily on each sample stream of each chromatograph. The rotometer should indincate a minimum ot 17 scfh and the pressure should not exceed 5" It 70- v.icuwi > i street .
2.71
If the vacuum is high- or flow is low, check for restriction at sample line filters, also, check tor proper vacuum pump operation and proper solenoid operation.
2.80
Oven Temperature - The analyzer oven temperature must be checked daily on each chromatograph. The temperature must he within +_ 3 K of the temper iture established for each, instrument.
3 TEN0 748
- I occdure No. 6
' Uailv Main tenance Schedule (cont'd)
2.81
If the temperature is out of l lie 3 F range, check the instrument heater air flow by opening the oven and observing the air flow rate coming out of the heater air nozzle. If a low flow is observed, adjust the air supply pressure. At the same time, check for possible I red line plugagge,
2.82
If the temperature is out of the 3 "K range, and air flow is
normal, try to adjust the temperature with the potentiometer
on the temperature control card.
It still having problems,
check heater elements for continuity.
If this checks out
proper, replace beater control cam1.
1 Column and FID Gas Supply FJow Hate
3.10
Check column and FID gas supply flow rates as required for upset conditions. Upset conditions are indicated by base line drift, erratic base line, and auto zero drift.
3.20
If upset conditions prevail, check tlow changes are insufficient gas aging, flow restriction in the air slide valve not operating properly.
flow rales. Possible causes for pressure at the cylinder, column supply, plugged flame jet, sample i. r s v; i > it lilt in;;, 1 oaks .
Inst rumen t Warm-Up Procedure
4.10 Analyzer Unit
4.11
Turn on heater sir flow. 50 psig.
Fet the air inlet pressure to about
4.12 Turn on the power supply to the analyzer unit.
4.13
With the oven door open, check to :.oe if the heater air is being heated by checking the air at the heater air nozzle.
4.14
If the heater is functioning, close the oven door and allow the oven to Come to the* previously established temperature.
4.15
To adjust ovrn temper a tore al low even to beat up for 30
minutes. The light on the temperature control card should be
blinking. Check temperature ou thermoneter on oven door.
If too low, tern pot on Lemper;,Lure control card clockwise,
wait 15 minutes, and obseivc temperature.
Adjust as
necessary. If temperature is too high, turn counter clockwise
4.16 Turn on high voltage power supply.
4 TEN0 749
Procedure No. 6 Instrument Warm-Up Procedure (cont'd)
4.?0 Control Unit
4.21 Turn on power supply to programmer.
4.22 Put all switches in auto and clock to stop.
4.23 Light flame in KID as instructed in maintenance manual.
4.24 After flame is lit and all flows are set, put clock to run.
Flow and Pressure Settings
5.10 Total Column Flow - Backf lush, and AnnJytieaJ Cpjumn
5.11 Place column switch into the 2 position.
5.12 Close the midpoint pressure regulator valve.
5.13 Adjust the main column pressure regulator to have VCD elute at about 34-40 seconds after injection.
5.20 -Backf lush Flow - Strjuper
5.21
Set backfiush presume as stated : r .,1. ratal.
5.22 This procedure may require being repeated several times.
5.30 FTD Aj_r Flow
5.31
Air flow is monitored by a rotor,rcter just above the Each analyzer is marked for the proper setting. the setting, raise or lower tl' pressure with the just above tire rotomtter.
analyzer. To adjust regulator
5.40 FTD Hydrogen F_low
5.41 Disconnect the capillary Lube from Lie analyzer on the left side of the oven.
5.42
Connect the bubble tube and set the proper flow with the bottle regulator located on th< hydrogen cylinder. .be flow should between 4G-G0 cc/r.ii. .
5 TEN0 750
AOP - Procedure No. 6
6.0 Gate Time Check - Run Mode
6.1 Turn standard gas on by turning on stream 16 on programmer. other streams off. Reset and stop the digital clock.
Turn all
6.2 Turn the electrometer to manual zero and adjust the baseline to somewhere above zero on the chart.
6.3 Put column switch in the 2 position and start the clock. This will allow a one minute purge of standard before injection because it will not inject the first cycle.
6.4 Note the time on the digital clock when the VCM starts to come out and when it is finished. Set the rear digital timer to one second before and the one next to it to one second after the time recorded previously.
6.5 Put the column switch back in auto. Start decreasing the backflush timer till the VCM peak starts to become smaller. Then move the time back 3-4 seconds.
6.6 The auto zero function should be set to finish 2-3 seconds before the peak gates in. This function lasts for 4 seconds so the timer should be set 6-7 seconds earlier than the peak gate in.
6.7 Now turn the electrometer back to elec.; all switches should be in auto except the calibration and it should be off. Turn stream 16 off and turn on all other streams.
7.0 Calibration
7.1 Turn standard on and all other streams off.
7.2 Dial the correct point number into the multiplexer. This answer will read out on the LED display on the front of the multiplexer every time the standard is analyzed.
7.3 Vary digital attenuator to receive the correct standard ppm reading.
7.4 Turn the other streams back on and the standard off and continue with the field results.
7.5 During calibration monitor the recorder to make sure the analyzer is reading and gating correctly.
8.0 Backup Procedures
6 TENO 751
TENNECO POLYMERS DIVISION
AUTHORIZED OPERATING PROCEDURE
PASADENA PLANT
Procedure No.: Date:
8
TITLE:
HNU Photoionization Detector Operation and Maintenance
AUTHORIZED BY: Manufacturing Manager - C. A. Hendricks
Mgr. Envir. Sciences - J. W. Kachtick
Plant Manager - PVC - J. W. Bonnette
Mtce. Manager
- L. Cox, Jr.
Safety Manager
- J. L. Oliver
Rev. Date CC Rev. Pate
Rev. Rev. Dateyr^/" Rev. Date
PURPOSE: The purpose of this procedure is to standardize the operation and maintenance of the HNU Photoionization portable hydrocarbon detector.
EQUIPMENT:
The HNU Photo ionization detector is an instrument designed to measure organic materials in air, with a sensitivity of less than 1 ppm and a range of 2,000 ppm. The detector uses the principle of photionization for detection. The sample gas stream is exposed to a sealed ultraviolet light source which ionizes the hydrocarbons to a collector electrode, where the current measured is proportional to the concentration of hydrocarbon.
The instrument has two basic parts, a hand-held probe and readout box. The probe contains the ultraviolet light source, the ionization and detection chamber, a signal preamplifier, and a pump to draw the sample into the instrument. The readout box contains the battery power detection and ionization electronics, and a visual readout meter.
PROCEDURE:
1. Startup of Instrument
1.1 Check the functionswitch on the control panel of the instrument and make sure that it is in the off position.
1.2 Check the probe to ensure that plastic end cap is properly secured. If not properly secure^, reseat the end cap and secure into place.
1.3 Attach the probe to tbe readout unit via the 12 pin connector. Match the Alignment Key carefully; then twist the connector until a distinct snap and lock is felt.
1.4 Turn the function switch to the battery check position. The needle on the meter should indicate a reading within or beyond the green battery arc on the scale plate. If the indication is in the lower portion of the battery arc, tbe insturment should be recharged prior to making tbe survey.
7
TENO 752
AOP - Proceudie No. 8
I .0
Startup of Instrument (cont'd)
1.5
A brief description of Liu; instrument couliol functions is given below:
Six Posit ion Switch
OKI' - Shuts off all power and removes DC voltages.
ON - In any other function position or measuring mode, the electronics tilt! on#
BATTERY CU1XK - Indicates the com! iLion of the battery. position is below green battery arc, the instrument recharged .
If needle should be
STANDBY - UV lamp is off but electronics are on. This position will conserve power and extend the useful operating time between recharges of the battery. The position is also utilized to adjust the electronic zero.
RANGES - 0-20, 0-200, 0-2,000 direct reading ranges available at minimum gain for benzene. More sensitivity is available by adjusting the span potentiometer.
Zero
pmpter
A ten turn potentiometer is employed to adjust tin zero electronically when the instrument is placed in the sLandby position with the probe attached. This eliminates the need for a hydrocarbon lree zero gas.
Span Potentiometer
A ten turn counting potentiometer is utilized for upscale setting of the
meter on calibration gas.
Counterclockwise rotation increases the
sensitivity ("10 times). This pot can increase the sensitivity to make the
instrument direct reading for nearly any gas which the instrument responds
to.
' 0 Zero Adjustment
2.1 To zero the instni merit, turn the function switch to the standby position and rotate the zero potentiometer until the meter reads zero. Clockwise rotation of the zero potentiometer produces an upscale deflection while counterclockwise rotation yields a downscale deflection. NOTE: No zero gas is needed since this is an electronic zero adjustment.
2.2
Wait 15 or 20 seconds to ensure that the zero reading is stable. not, readjust the ztro.
If
8
TEN0 753
AOP - Procedure No. 8
2.0 Zero Adjustment (cont'd)
2.3 If the span adjustment setting is changed after the zero is set* the zero should be rechecked and adjusted, if necessary.
3.0 Calibration of Instrument
3.1 For normal operation, the span setting should be set at approximately 4.5. This will allow direct readout of vinyl chloride in ppm on all scales. If the span setting is grossly different from 4.5, the instrument should be recalibrated.
3.2 On a routine basis, the instrument should be recalibrated as follows.
3.3 Connect one side of a "T" to a pressurized container of calibration
gas, another side of the MT" to a tedlar or aluminized mylar bag (0.5 or 1 liter capacity) and the third side of the "T" directly to the 8" extension to the photoionization probe.
3.4 Crack the valve of the pressurized container and fill the bag.
3.5 Close the valve and allow the instrument to sample the contents of the plastic bag.
3.6 Adjust the span pot so that the instrument is reading the exact value of the calibration gas. (If the instrument span setting is changed, the instrument should be turned back to the standby position and the electronic zero should be readjusted, if necessary).
3.7 The portable monitor should be zeroed each time it is used. Using a standard gas of 25 ppm of VCM, the portable monitor will be calibrated at least once per month.
3.8 The I & E department is responsible to maintain the portable monitor for proper calibration.
4.0 Battery Charging
To charge the battery, place mini phone plug into jack on left side of bezel prior to plugging charger into 120 VAC. When disconnecting charger, remove from 120 VAC before removing mini phone plug. The battery is completely recharged overnight (ca. 14 hourfe). To ensure that the charger is functioning, turn the function switch to the battery check position, place phone plug into AC outlet. The meter should go upscale if charger is working and is correctly inserted into the jack.
5.0 Troubleshooting
If problems occur while using the photoionization analyzer, recommended that the following troubleshooting guide be followed consulting the factory.
it is before
9 TEN0 754
I'roccdure No. 8
Troubleshoot ink (cont'd)
5.1 General Aid to Fault Determination
Check buttery condition. Recharge if necessary. Turn instrument on. A violet colored glow from the UV light source should be observed in all positions of the mode switch except the standby position. If unstable readings are obtained, a faulty probe cable or electrical connection could be the problem. To check, hold the probe normally and flex the cable firmly. Watch the meter for fluctuations as the cable is stressed. Individual wires in the readout can be checked in a similar way. Check the coaxial connector on the* amplifier board in the probe.
In the more sensitive ranges, a fluctuation in the reading may be noted if a hand or other large object is placed in very close proximity to the probe. This is mutual for the instrument and will not result in an error in the measurement as long as the probe is held stationary while the measurement is being taken.
If the probe is held close to AC power lines or power transformers, an
error may be observed. 11" me as u verier ts r. re to be made in close
proximity to such items, their effect cn measurements can be
determined by Lhe lolloping piociduir.
i u the in;. Li unien L in .in
electrically quiet area in the standby position; then move the
instrument to the questionable aieu involved. If AC pickup is going
to be a problem, the meter (in the standby position) will indicate the
magnitude of the error.
5.2 Disassembly of Instrument
Probe - Turn the function switch to the OFF position and then remove the probe connector from the readout unit. Unsnap the connectors on the side of the probe. Remove the end cap. The ionization chamber which is housed inside the end cap can then be removed. Place a hand over the end of the probe and slightly so that light source slides out into the hand. Then place two fingers inside the probe and tug gently to remove the lamp housing assembly. The amplifier board can be removed from the lamp housing assembly by unsnapping the coaxial connection and then removing the retaining screw.
To reassemble this unit, place lamp housing assembly into probe taking care to align the fan exhaust extension with the vent hole in the probe. Slide assembly ail the way in. Replace Lhe lamp housing or the ion chamber will not go into place. ('ll.is piece will only go on one way). If there is any problem getting it on, make sure that it is correctly aligned. Place end cap on probe assembly, align and snap fasteners into place.
10 TENO 755
AOP - Procedure No. 8
Troubleshooting.
5.2
Disassembly of Instrument (cont'd)
Readout Unit - Turn the function switch to the OFF position and
disconnect the probe from the readout unit before any disassembly is
conducted. To remove the case, loosen the screw on the bottom of the
case and, holding the instrument by the bezel, remove the case. The
power supply board can be removed by removing two screws and two nuts.
The entire panel including the function switch and zero and span pots
is removed in this operation.
No soldering is necessary to
electrically disconnect this nodule since all connections are made
with mo lex connectors.
5.3
Specific Faults
1. No meter response in tiny switch position (including BATT CHK)
A. Broken meter movement
(1) Tip instrument rapidly from side to side. Meter needle should move freely, and return to zero.
B. Electrical connection to metei is broken
(1) Check all wires leading to meter and clean the contacts of quick-disconnecLs.
C. Battery is completely dead
(1) Disconnect battezy and check voltage with a volt-ohm meter.
D. If none of the above solves the problem, consult the f aclory.
2. Meter responds in BATT CNK position, but reads zero or near zero for all others
A. Power supply defective
(1) Check power supply voit ages per Figure 11. If any voltage is out of specification, consult the factory.
B. Input transistor or amplifier has failed
(1) Rotate zero control; meter should deflect up/down as control is turned.
(2) Open probe. Both: transistors should be fully seated in sockets.
11 TENO 756
AOP - Procedure id.. 8
Troubles hooting
5.3
Specific Faults (cont'd)
C. Input signal connection broken in probe or readout
(1) Chock input connector on printed circuit board. Should be firmly pressed duwn.
(2) Check components on back side c*f printed circuit board. All connections should be solid and no wires should touch any oLher object.
(3) Check all wires in readout for solid connections.
3. Instrument responds correctly iri HAVT CllK, and STBY, but not in Measuring mode.
A. Chock to see that light souuc is on. (See General Faults sec tion ) .
(1) Check high voltage power supply (see Figure 11).
(2) Open end oi pm be, ru vove lamp and check high voltage on lamp contact ring.
(3) If high voltage is present at all above points, light source has most likely failed. Consult the factory.
4. Instrument responds correctly in all positions, but signal is lower than expected.
A. Chock span setting for correct value.
B. Clean window of light sou ice.
C. Double check preparation of standards.
D. Check power supply 180 V output. (See Figure 11).
E. Chech for proper fan opeiulHi-. ' Figure 11).
Check fan voltage. (See
5. Instrument responds in all switch positions, but is noisy (erratic meter movement).
A. Open circuit in feedback ciicuit. Consult factory.
E. Open circuit in cable shield or probe shield. Consult factory.
6. Instrument response is slow and or irreproducible.
A. Fun operating improperly. Flu k l.m voltage. hue ligure 11
B. Check calibration and oper.il tun. 12
TENO 757
TKNNECO POLYMERS DIVISION
AUTHORIZED OPERATING PROCEDURES
PASADENA PLANT
Procedure No. Date
9
TITLS:
Vinyl Chloride Leak Detection and Elimination
AUTHORIZED BY
Manufacturing Manager - C
Mgr. Envir. Sciences - J
Plant Manager - PVC - J
Mtce. Manager
-L
Safety Manager
-J
A. Hendricks W. Kachtick W. Bonnette Cox, Jr. L. Oliver
Rev. Da t e C< 'z/
'f
Rev. Date (jktif ahe/e*-
Rev. Date
y/Mf /o f
Rev. Date J7 JS i/?i 'S-'
Rev. Date
PURPOSE:
The purpose of this procedure is to minimize Vinyl Chloride emissions to the environment by detection and elimination of Vinyl Chloride leaks. The National Emission Standard for Vinyl Chloride promulgated by the Environmental Protection Agency requires that a formal leak detection and elimination program be operated. The section of the Emission Standard which defines the requirements for an acceptable program is 61.65(b)(8)(i) to (vi). The procedure which follows makes specific reference by number to each item of the standard.
EQUIPMENT:
1.0 Continuous Sequential Monitoring System 61.65(b)(8)(i)
Vinyl chloride leaks will be detected by six Areas gas chromatographs
monitoring four areas of the plant on a continuous sequential basis. The four
areas of the
plant are: (1) Reactor, (2) Recovery, (3)Dryer, and (4)
Warehouse/VCM Loading. Each area has 15 sample points and a sample frequency of
one sample point per minute. In addition to monitoring, the Areas chromatograph
system will sound an alarm for vinyl chloride concentrations above a limit
defined as a leak. For more information on tbe continuous monitoring system,
refer to Authorized Operating Procedure No. 6, Areas Gas Chromatograph System
Operation and Maintenance Procedure.
2.0 Portable Hydrocarbon Detector 61.65(b)(8)(ii)
A portable hydrocarbon detector will be used routinely to find small leaks and to pinpoint major leaks indicated by the Areas gas chromatograph system. Pr imarily, the portable hydrocarbon detector used is a HNU Systems Photoionization Analyzer, Model PI-101. This device has a sensitivity of at least 10 ppm and is of such design and size that it can be used to measure emissions from localized points. For information on the calibration and maintenance of this device, refer to Authorized Operating Procedure No. 7, Century Organic Vapor Analyzer Operation and Maintenance Procedure, and to Authorized Operating Procedure No. 8, UHU Systems Analyzer Operation and Maintenance Procedures,
13 TENO 758
CP - Procedure No. 9
Calibration and Maintenance Schedule 6J_.65(b_)(S)(jj ij
For the Areas gas chromatograph system, a daily span check will be conducted with a concentration of vinyl chloride equal to the concentration defined as a leak in 61.65(b)(8)(vi) of the Emission Standard in Section 1.0 of this proc edure.
The specific leak concentration tor each area will always be listed in Appendix A of this procedure. A calibration pas cylinder containing the specific leak concentration will be used for the daily span check. The calibration gas cylinder will be supplied by Precision Gas Products, Inc. and will be prepared gravimetrically. The provision of the Emission Standard that the calibration cylinder analysis must be troc able to the National Eureau of Standards cannot be met at this time. (See Appendix C for explanation from Precision Gas Froducts, Inc.)
Calibration and maintenance schedules for the Areas gas chromatograph system and the portable hydrocarbon detectors are detailed in Authorized Operating Procedures 6 and 8.
.0 Loca tion , Number o f Poin ts and Frequency o; Monitoring 61.6j(b)(S)(iv)
Three of the four areas monitored by tl it) Areas gas chromatograph system contain equipment in vinyl chloride service, as defined by 61.64(1).
4.1 Reactor Area - The reactor area contains 10 reactors with reflux condensers operating in vinyl chloride service, with a total of 32 points monitoring the area. The reactor area is approximately 30 ft. x 270 ft. and has five operating levels, three of which are of open non-enclosed construction.
4.2
Recovery Area - The recovery area contains 7 storage tanks, 5 treatment columns, 5 exchangers, 14 pumps, 2 compressors, and 12 filters operating in vinyl chloride st.ivice, with a total of 9 points monitoring Lhe area. The recovery uit-a is approximately 160 ft. x 240 fL., with a 60 ft. diameter gasholder adjacent to the area. The treatment columns, pumps, compressors, and b of the filters are located along a central rip< alley which increases the monitoring efficiency.
4.3
Loading/Unloadiug Area - lhe loadin^/enloading area contains 2 storage
tanks, 4 pumps, 2 compressors ano 2 scrubbers.
The pumps,
compressors, and scrubbers are located in a 40 ft. x 60 ft. area with
the 2 storage tanks on adjacent sidis. A total of 5 points monitors
this area. The loading/unloading rack is i00 ft. long with 3 tank car
stations and is monitored by 3 points.
14 TEN0 759
AOP - Procedure No. 9
PROCEDURE:
1.0 Definition Of Vinyl Chloride Leak 61.65(b)(8)(vi)
A vinyl chloride leak has been defined as an increase above the background concentrations of vinyl chloride in the area. The definition of a leak may vary among the three areas of the plant and may change over time as background concentrations are reduced.
The background concentration of vinyl chloride in all areas is less than 1 ppm. It has been determined that in order for a leak source to be pinpointed with the portable hydrocarbon detector the leak must be a minimum magnitude and duration. This minimum magnitude and duration has been defined as a leak. Since the leak definition for each area may vary over time, the current specific leak definition for each area will always be listed in Appendix A. Appendix A will be revised as required.
2.0 Vinvl Chloride Leaks Detected by Continuous Monitoring System 61.65(b)(8)(v)
2.10 Whenever vinyl chloride concentrations are measured which exceed the area leak definition, an alarm will be sounded in the control room. The Shift Supervisor or his designee will use a portable hydrocarbon detector to attempt to pinpoint the source of the leak. Appropriate respiratory protection for VCH exposure must be used as required while searching for leak sources.
2.20 When the source of the leak has been pinpointed, the leak will be repaired in an expeditious manner to minimize VCH emissions. The actual course of action to be taken for each leak is a matter of judgement and will depend upon the cause and severity of the leak. The severity of a leak will be determined by its relationship to a reading on the portable KC detector of 100 ppm at a distance of 2 feet.
2.21 If a leak can be repaired in operation, such as tightening a flange or packing, this repair should be made. Considerable caution should be exercised when making repairs in operation to prevent over-stressing of equipment which could cause sudden failure.
2.22 A leak which requires scheduling of equipment preparation, downtime, and maintenance crewswill be listed on the VCH Leak Report for scheduling of repairs. See Appendix D for sample copy of VCM Leak Report.
2.30 If a leak alarm is received, and the source cannot be pinpointed, the Shift Supervisor or his designee will initial the leak alarm report. This indicates an attempt was made to locate the leak source.
15
TEN0 760
AOP - Procedure No. 9 PROCEDURE: 2.0 Vinvl Chloride Leaks Detected by Continuous Monitoring System 61.65(b)(8)(v)
(cont'd) 2.40 The procedure used in the event the fixed continuous monitoring system
becomes inoperative is: 2.41 Temporary assignment of a technician to monitor (using a
monitor) the same areas of the plant covered by the fixed system. 2.42 This coverage would be on a three shift/day basis until the
continuous system was returned to operation. 2.43 Routine logging of observed levels would be made. 2.44 Immediate notification to the control room on "high" VCM values
will be accomplished via the plant intercom system ("high" meaning 25 ppm or more).
1 5a TENO 761
AOP - Procedure No. 9
30 Vinyl Chloride Leaks Detected by Portab 1 e Hydrocarbon Detector 61.65(b)(8)(ii)
3.10 A portable hydrocarbon detector will be used on a routing basis to search for small vinyl chloride leaks. The "routine" leak patrol is done on day shift, five days a week. The portable monitor is used on a non-routine basis at other times to trace and locate leaks detected by the fixed monitoring system.
3.11 The primary direction for the search program will be the vinyl chloride concentrations measured by the continuous monitoring gas chromatograph system. These measurements may indicate small increases in the area background concentrations which have not yet reached the leak definition level.
3.12 The search program will also include as a secondary priority a routine check of specified equipment operating in vinyl chloride service. The current list of equipment for the routine check is shown in Appendix B.
3.20 Leaks detected during routine monitoring with the portable hydrocarbon detector that registers 100 ppm or more at a distance of 2 feet will be recorded on the VCM Leak Report form. See Appendix D for sample copy of the VCM Leak Report.
3.30 The VCM Leak Report will be used to schedule equipment preparation, downtime and maintenance crews for leak repairs in an expeditious manner to minimize vinyl chloride emissions.
4.0 Recordkeeping 61.71(a) and (2)
4.10 A record of vinyl chloride leaks as specified below will be kept for a minimum of two years at the Pasadena plant. This record will be made available for inspection by the EPA Administrator upon request.
4.20 It will be the responsibility of the PVC Laboratory Supt. to keep a record of leaks detected by the vinyl chloride monitoring system. The record will include the following information.
4.21 Concentration of vinyl chloride as measured
4.22 Location of measurement
4.23 Date and approximate time of measurement
16 TEN0 762
AOP - Procedure No. 9 4.0 Recordkeeping 61.71(a)(1) and (2) (cont'd)
4.30 It will be the responsibility of the PVC Operations Superintendent to keep a record of the completed copies of VCH Leak Reports. The completed copies of the VCM Leak Report will include leaks detected during routine monitoring with the portable hydrocarbon detector and the following information: 4.31 Location of vinyl chloride leak 4.32 Cause of vinyl chloride leak 4.33 Date and time of vinyl chloride leak 4.34 Action taken to repair vinyl chloride leak
16a
TENO 763
APPENDIX A LEAK DEFINITION
Date:
AREA 1. Reactor 2. Recovery 3. Dryer 4. Warehouse/VCM Loading
LEAK DEFINITION
2 successive samples above 25 ppm for any sample po int
2 successive samples a bo ve 25 ppm for any sample po int
2 successive samples above 25 ppm for any sample po int
2 successive samples above 25 ppm for any sample point
Portable Hydrocarbon Detector
1 sample above 100 ppm taken at a distance of 2 feet
17
TENO 764
APPENDIX i;
Date EQUIPMENT IN VINYL CHLORIDE SERVICE
EOUIPMEHT NO.
DESCRIPTION
C-3C1 C-3C2
C-303 C-304 C-305 C-306 C-307 C-309 C-310 C-316 C-320 C-324 C-328 C-332 C-37 9 C "83 C- j87 C-430 C-434 C-336 C-337 C-338 C-339 C-340 C-342 C-343 C-344 C-345 C-346 C-347 C-348 C-349 C-350 C-351 C-352 C-354 C-355 C-356 C-362 C-367A/B/C C-368 C-369A/B/C C-370A/B/C C-371A/E/C C-372 C-373
Reactor Reactor Reactor Reactor Reactor Reactor Reactor Reactor Reactor Shortstop Tank C301 Shortstop Tank C302 Shortstop Tank C303 Shortstop Tank C304 Shortstop Tank C305 ShortsL6p Tank C-306 Shortstop Tank C-3C7 Shortstop Tank C-3G8 Shortstop Tank C-309 Shortstop Tank C-310 Agitator Seal Oil Tank T-301 Agitator Seal Oil Tank T-302 Agitator Seal Oil Tank T-303 Agitator Seal Oil Tank T-304 Agitator Seal Oil Tank T-305 Pressurized ED Tank VCM Weigh Tank Water Wash Column Water Wash Column Caustic Scrubber Purification Column Discharge Surge Tank Discharge Surge Tank Gasholder Drain Tank Gasholder KO Pot Crude Storage Tank Column Overhead Accumulator Column Bottoms Drain Tank Recovered Storage Tank Flare KO Tank Recovery Compressor KO Pots Recovery Compressor Pulsation Bottle 1st Stage Discharge Pulsation Bottles 1st & 2nd Stage Suction Bottles Recovery Compressor Pulsation Bottles Vacuum Pump Separator Vacuum Pump Separator
18
TENO 765
Equipment In Vinyl Chloride Service (cont'd)
C-375A/B C-376A/B C--37 7 C-391 C-392 C-393 C-394
C-395 C-396 C-397 C-398
C-399 C-4CQ C-401 C-4C2 C-407 C-408 C-409 C-410 C-411 C-412 C-413 C-414 C-416 C-417 C-418 C-419 C-421 C-424A/B C-425 "-428 1,-429 C-438 C-439 C-440 C-441 C-442 C-443 C-444 C-445 C-446 C-447
VCH Absorbers Evacuation Pump Separators Compressor KO Pot Reactor Discharge Surge Tank Reactor Discharge Surge Tank Water Wash Column Vacuum Pump Separator Reactor Wash Water Tank Reactor Wash Water Tank Water Stripper VCH Gasholder Inlet KO Pot VCH Gasholder Outlet KO Pot Sweep N2 KO Pot Toluene Decanter Caustic Stripper Slurry StripperSlurry Stripper Slurry Stripper Slurry Stripper flurry Stripper Flash Tank Slurry Stripper Flash Tank Slurry Stripper Flash Tank Slurry Stripper Flash Tank Stripper Vac. Pump Separator Slurry Stripper Barometric Tank Caustic Stripper Barometric Tank Methyl Chloride Column Waste Solvent Storage Tank Primary Absorber Caustic Tails Tower Blower Knockout Pot Vent Condenser 1st Stg Suction Pulsation Bottle 1st Stg Dischg Pulsation BoLtle 1st Stg Separator 2nd Stg Dischg Pulsation Bottle Reactor Discharge Surge Tank VCM Weigh Tank Reactor Water Wash Tank Slurry Stripper Slurry Stripper Flash Drum T-U/HeOH Separator
TENO 766 19
Equipment In Vinyl Chloride Service (cont'd)
D-301 D-302 D-303 D-3Q4 D-34Q D-342 D-346 D-347 D-364 D-365 D-366 D-36 7 D-374 r-375 D '78 D-384 D-391 D-392
E-3C1 ' E-302 E-303 E-304 E-305 E-306 E-307 E-308 E-309 E-310 E-336 E-337 E-338 E-339 E-340 E-342A-D E-343 E-344 E-343 E-346 E-347 E-348 E-349A/B E-355 E-338 E-359 E-363 E-364 E-36 3
Slurry Tank Slurry Tank Slurry Tank Slurry Tank Ga&ho lder Centrifuge Effluent Tank VCM Gasholder T-U/TCE Surge Tank Slurry Tank Slurry Tank Slurry Tank Slurry Tank Water Stripper Feed TankIncinerator Seal Drum Vent Gas Flash Drum Gasholder K/0 Sump Slurry Tank Slurry Tank
Reflux Condenser C-301 Reflux Condenser C-302 Reflux Condenser C-3G3 Reflux Condenser C-304 Reflux Condenser C-303 Reflux Condenser C-306 Reflux Condenser C-307 Reflux Condenser C-308 Reflux Condenser C-3C9 Reflux Condenser C-310 Regeneration Heater Regeneration Heater Slurry Tank Vent Cooler Regeneration Cas Cooler Circ. Caustic Cooler Compressor Intercooler K-301A Compressor Intercooler K-301B Column Overhead Condenser Column Reboiler Vent Condenser Seal Water Cooler Seal Water Cooler Seal Water Cooler w/K-301A/B Seal Water Cooler Water Stripper Overhead Trim Condenser DMW Heat Exchanger Inert Vent Condenser Circulating Caustic Cooler Sweep N2 Comp. v/Cooler
20
TENO 767
quipment In Vinyl Chloride Service (cont'd)
E-401 E-402 E-403 E-403 E-407 E-409 E-413 E-414 E-415
Caustic Stripper Reboiler Caustic Stripper Cooler Methyl Chloride Col. Condenser Slurry Stripper Condenser Waste Solvent Cooler Slurry Stripper Condenser Stripper Vacuum Tump Feed Cooler Stripper Vacuum Pump Recycle Cooler Evacuation Precondenser
F-301A/B
Inc inerators
G-331A/B G-332A/B G-334A/B G-336A/B G"337A/B G-351 G-332 G-380 G-381 ' G-385A/B G-386A/B G-387A/B C-388A/B G-400A/B G-401A/B C-402 G-403A/B G-404A/B G-405A/B G-406A/B G-409A/B C-413A/B G-416A/B G-417A/B G-418A/B G-419A/B C-420A/B G-421A/B G-423A/E G-429A/B C-431A G-432A G-436A G-441A/B G-442A/B C-451A G-452A G-453A/B G-454 G-471 G-474A/B
Reactor Discharge Pumps Reactor Discharge Pumps Seal Water Pumps Seal Water Pumps Seal Water Pumps Slurry Pump Slurry Pump Water Wash Circulation Pump Water Wash Circulation Pump Crude Feed Pumps Reflux Pumps Recovered Transfer Tumps Charge Pumps Reactor Slurry Discharge Pumps Reactor Slurry Discharge Pumps Water Wash Circulating Pump Seal Water Putaps Centrifuge Feed Pumps Centrifuge Feed Pumps Reactor Slurry Discharge Pumps Caustic Transfer Pumps Reactor Wash Water Transfer Pumps Water Stripper Bottoms Pumps Slurry Stripper Feed Pumps Slurry Stripper Feed Pumps Slurry Stripper Feed Pumps Slurry Stripper Feed Pumps Stripper Quench Circ, Pumps Slurry Stripper Vac. Circ. Pumps Caustic Stripper Feed Pumps Waste Solvent Transfer Pump Waste Solvent Unloading Pump Slurry Stripping Toluene Trans. Pump Gasholder Inlet Line Water Pumpout Carbon Adsorber Condensate Pumps Centrifuge Feed Pump Centrifuge Feed Pump Reactor Wash Water Trans. Pumps Slurry Stripper Feed Tump Slurry Stripper Feed Pump Gasholder Drips
>i
TENO 768
oipment In Vinyl Chloride Service (coat'd)
lA/B
f2
il-303 il-304
K-29 K-301A/B
L-302A-F L-304 L-305 L>06 L- 330 L-354 >355 L-3C4A/B >374 >395 >399
T-306 T-307 >308
2-17-D5 Z-l7-D6 >36-C46 >36-T23 >36-C4 Z-36-T7 Z-36-C47 Z-36-T24 ;'-36-G8 3-36-G9 3-36-G103
Evacuation Tumps Vacuum Tump Vacuum Pump VCM Recovery Vacuum Pump
Compressors A&B Crude VCM Compressors
VCM Charge Tank Filters Crude VCM Strainer Reflux VCM Strainer Recovered VCM Strainer Flare Seal Recovered Water Strainer Water Wash Strainer Water Stripper Feed Filters Slurry Stripper Ovhd Desuperheater Slurry Stripper Steam Filter Sweep N2 Filter
Agitator Seal Oil Tank Agitator Seal Oil Tank Agitator Seal-Oil Tank Agitator Seal Oil Tank Agitator Seal Oil Tank
VCM Removal Unit
Storage Tank Storage Tank Scrubber Filter Scrubber Fi 1 ter Scrubber Filter Pump Pump Pumps A&B
22
TENO 769