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PPG INDUSTRIES INDUSTRIAL CHEMICAL DIVISION LAKE CHARLES, LOUISIANA ORGANICS DISPOSAL PLANT OPERATING MANUAL Judicial District Court Mo, 31-1145 August, 1973 ASSIGNED TO: SL 000758 TABLE OF CONTENTS INTRODUCTION SAFETY I. II. III. IV. V. VI. VII. VIII. IX. X. XI. Introduction General Safety Rules Chemicals in Area Fire Protection Vapor Detector System Fire Extinguishers Control Room Clearing of Process Vessels Emergency Exits Safety Inspections Emergency Horns GENERAL DESCRIPTION DETAILED PROCESS AND EQUIPMENT DESCRIPTION I. II. III. Collection and Storage of Liquid Wastes Vent Gas Collection Incineration of Waste Liquids and Gases STARTUP AND SHUTDOWN I. II. III. IV. General Startup Sequence General Shutdown Sequence Shutdown Systems Detailed Startup Procedures APPENDIX I. II. III. IV. V. VI. VII. VIII. Waste Storage Tank Innage Tables Liquid Waste Flow Rate Vs. Pump Speed Combustion Air Setting for Liquid Waste SRV List RD List Lubrication Schedule Process Flow Sheet Mechanical Flow Sheets IX. Equipment Drawings X. Shutdown System Drawings 5L 000759 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Cour No. 91-1145 2-1 2-1 2-1 2-3 2-28 2-29 2-29 2-29 2-30 2-31 2-31 2-31 3-1 4-1 4-1 4-8 4-14 5-1 5-1 5-2 5-3 5-4 6-1 6-2 6-4 6-5 6-6 6-7 68A-1 68A-1 68A-1 68A-1 68A-1 68A-5 68A-5 68A-5 68A-5 68A-70,020 68A-76-021 1-1 INTRODUCTION The Organics Disposal Plant Manual has been compiled to serve the following purposes: 1. As a training guide for operating personnel. 2. As a reference source for Operations and Maintenance. 3. As a place where current data, information, and procedures are compiled. This manual was written to serve as a basis for startup and initial operation of the incinerators. As experience is gained during startup and during operation of the plant, many or all of the startup and operating procedures will be revised. This manual should be revised and kept current as new procedures are developed. The operators can help keep the manual current by calling attention to new operating techniques which differ from those described in the manual. The information contained in this manual is confidential. This manual is the property of PPG and may be recalled at any time. Subject Of 14th J SAFETY FOR THE ORGANICS DISPOSAL PLANT I. Introduction This section covers the safety rules and precautions which must be followed while working in the Organics Disposal Plant. Safety is a vital part of everyone's job. Working safely is equal in importance to the quantity and quality of work performed. An employee who has a good attitude toward the safety program will continually look for safer ways to do his job. He will be concerned about the safety of his fellow employees and will correct or properly warn all other personnel of a safety problem he observes. Everyone must have a positive attitude toward safety and take part in the safety program. II. General Safety Rules The following list of general safety rules are applicable to Area B and the Organics Disposal Plant. These rules do not replace rules pre sented in the Employees' Manual of Accident Prevention, but are to be used in conjunction with them. Everyone should read and study the Employees' Manual of 'ccident Prevention in addition to the following list. 1. Personnel entering the organics area are required to deposit lighters, matches and other sparking devices at the Area B gate. 2. Smoking is permitted in the control rooms only (labs excluded). Permanent lighters are provided in areas where smoking is allowed. 3. Vehicles are allowed to travel without a permit.only on the roads to the control rooms. A permit signed by the lead operator or an operating supervisor is required before vehicles are allowed in permit areas. SL 000761 CONFIDENTIAL: Subject to = 14th Judicial Disiru-'- v Ho. 91-U45 2-2 4. An equipment permit signed by the operating supervisor is required before the following can be carried into the permit areas: a. Welding machines. b. Cutting torches. c. Electrical equipment (motors, lights, heaters). d. Sparking devices (grinders, chipping devices, gasoline engines. etc.). 5. Only explosion-proof flashlights are permitted in the Organics Area. 6. In case of an emergency warning, all permits are immediately revoked and equipment must be shut off. New permits must be obtained before restarting. Personnel not required for operating plant should evacuate on foot. 7. Anyone not assigned to the area should check with operating personnel before entering. 8. Vessel entry permits signed by the operating supervisor must be obtained before entering a vessel. A safety belt is required for top entering tanks. 9. The use of instrument air for breathing is not permitted. 10. The established plant tagging and locking procedures will apply in Area B. 11. All light circuits outside the control room must be off and tagged before relamping, 12. All steam-out and nitrogen purge equipment must be grounded to prevent sparking caused by discharge of static electricity. 13. Never allow air to enter a vessel containing organic vapors. SL 000762 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 2-3 14. Do not dump flammable organics into trapped sewers where hazardous vapors could be evolved. 15. Do not leave open sample containers of organics sitting around giving off vapors. 16. Use a Full-Face or Scott Air-Pak mask for protection against organic vapors. 17. Clothing that has been wet with organics must be removed immediately and the body thoroughly washed with soap and water. The clothes must be laundered before using again. 18. The laboratory hood fan is to operate continuously. Do not attempt to run flammable samples if the fan is not in service. III. Chemicals in Area Properties and hazards associated with chemicals present in the Organics Disposal Plant are described on the following pages. None of the chlorinated organics described occur in a pure state, but as a mixture either in the liquid waste or vent gas waste. Most compounds, including perchloroethylene and those lighter will be in the vent gases. VC, EC, MC, EDC, and heavies compounds are present in the liquid waste. Some of the terms used to describe the properties of chemicals are defined below: 1. Flash Point: The flash point of a solvent is the lowest temperature at which a vapor is given off in sufficient quantities so that the vapor-air mixture above the surface of the solvent will propagate a flame away from the source of ignition. It is the temperature below which a solvent may be used or stored in open containers without formation of an explosive vapor-air mixture. SL 000763 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 51-1145 2-4 2. Explosive Limits: When combustible vapor is mixed with air in the proper proportions, ignition will produce an explosion. The vaporair mixture which will form this proper proportion is called the explosive range. The explosive range includes all concentrations of a mixture of flammable vapor or gas in air in which a flash will occur or a flame will travel if the mixture is ignited. The lowest percentage at which this occurs is the lower explosive limit and the highest percentage is the upper explosive limit. Explosive limits are expressed in percent by volume of vapor in air. 3* Maximum Allowable Concentration (MAC): The maximum allowable concen tration for a material is the maximum concentration of that material that can be tolerated by personnel for a continuous 8-hour exposure with no ill effects. SL 000764 CONFIDENTIAL1 -r Subject to pr<^tp^^ict Court of 14th audicinl INDEX OF CHEMICALS IN THE ORGANICS DISPOSAL PLANT Name Carbon Tetrachloride Cell Liquor Chloroform Cis 1,2-Dichloroethylene Ethyl Chloride Ethylene Ethylene Dichloride Hexachloroethane Hydrogen Chloride Methane Methyl Chloroform Monochloroacetylene Nitrogen Pentachloroethane Perchloroethylene Phosgene Tetrachloroethane (Sym and Assym) Trichloroethane Trichlor oe thylene Vinyl Chloride Vinylidene Chloride Abbreviation - - - Cis EC C2H4 EDC - HCl cha MC MCA n2 Penta Per Tetra TCE Tri VC VDC 2-5 Page 2-6 2-7 2-8 2-9 2-10 2-11 2^12 2-13 2-14 2-15 2-16 2-17 2-18 2-19 2-20 2-21 2-22 2-24 2-25 2-26 2-27 SL 000765 confidential: lbject to L4th JU-iaI_Dist Court NAME: Carbon Tetrachloride FORMULA: CCI4 OCCURRENCE: Per-Tri Vent Gas MOLECULAR WEIGHT: 154 BOILING POINT: 170.2F FREEZING POINT: -9F VAPOR PRESSURE: 90.9 mm Hg @ 68F VAPOR DENSITY: 5.32 (air = 1.0) LIQUID DENSITY: 98.9 lbs, per Ft @ 77F FLASH POINT: None EXPLOSIVE LIMITS: Nonflammable and non-explosive in air at ordinary temperatures and pressures. MAXIMUM ALLOWABLE CONCENTRATION: 10 ppm for 8 hours DETECTION ODOR CONCENTRATION: Carbon tetrachloride has a distinctive odor but, unfortunately, can be detected only in concentrations exceeding the maximum allowable concentration. HAZARDOUS PROPERTIES: The principal hazard in the industrial use of this chemical is from inhalation of the vapor. The effects of excessive exposure to carbon tetrachloride may be both immediate and delayed. The immediate effects may include headache, symptoms resembling inebriation or drowsiness, and abdominal discomfort. The delayed effects may include severe damage to the heart, liver, and kidneys which may not be evident until 1-10 days after the exposure. TREATMENT: In extensive skin contact the patient should get under the shower immediately, if such is available. Clothing and shoes should be removed under the shower. If liquid carbon tetrachloride has entered the eyes, irrigate immediately with water. This can be done with an eye bath, if available, a gentle stream of water from a hose, or by pouring water from a clean container. The eyelids should be held apart during the irrigation to insure contact of water with all the tissues of the surface of the eye and lids. Subject of 14th J NAME: Chloroform FORMULA: CHCI3 MOLECULAR WEIGHT: 119.5 BOILING POINT: 143<>F FREEZING POINT: -82F VAPOR PRESSURE: 160 mm Hg @ 68F VAPOR DENSITY: 4.13 (air 1.0) LIQUID DENSITY: 93 lbs per Ft3 @ 68F 2-8 OCCURRENCE: Per-Tri Vent Gas FLASH POINT: None EXPLOSIVE LIMITS: Will not burn in air. MAXIMUM ALLOWABLE CONCENTRATION: 50 ppm for 8 hours DETECTION ODOR CONCENTRATION: 200 ppm (NOTE THAT THIS IS HIGHER THAN THE MAXIMUM ALLOWABLE CONCENTRATION) HAZARDOUS PROPERTIES: The most important hazard of chloroform arises from the fact that repeated exposure to low atmospheric concentrations may result in damage to the liver and kidneys. In high concentra tions it has narcotic properties and is an effective surgical anesthetic. Contact with skin and mucus membranes may produce irritation. TREATMENT: If substantial quantities are spilled upon a person, the con taminated clothing should be removed promptly and the affected skin area should be flushed with plenty of water. The contaminated clothing should not be worn until free of the material. If the eyes are contaminated, they should be flushed with plenty of flowing water. Medical attention should be obtained if any irritation persists. If chloroform has been swallowed, vomiting should be induced as soon as possible by tickling the throat with a finger or by giving an emetic, such as two tablespoonfuls of common salt in a glass of warm water. CALL A PHYSICIAN. Anyone showing signs of ill effects from breathing the vapor of chloroform should be removed to fresh air, kept warm and quiet and be made to rest. If breathing stops, artificial resuscitation should be given. Get medical attention promptly. SL 000767 Subjec of 14th TAL: ;ctive Order NAME: Cis 1,2-Dichloroethylene FORMULA: C2H2C12 MOLECULAR WEIGHT: 96.95 BOILING POINT: 140.2F 2-9 OCCURRENCE: OHC Vent Gas Per-Tri Vent Gas VAPOR PRESSURE: 400 mm at 41.0C FREEZING POINT: -80.5C LIQUID DENSITY: 1.2743 at 25 /4C VAPOR DENSITY: 3.34 FLASH POINT: 43F EXPLOSIVE LIMITS: 9.7 to 12.8% by volume MAXIMUM ALLOWABLE CONCENTRATION (OR THRESHOLD LIMIT') : 200 ppm DETECTABLE ODOR CONCENTRATION: Pleasant odor HAZARDOUS PROPERTIES: Dangerous fire hazard. Moderate explosive hazard. Dangerous disaster control. When heated to decomposition, it emits highly toxic fumes of chlorides; can react vigorourly with oxidizing materials. TREATMENT: Skin: Remove contaminated clothing and wash thoroughly with water. Eyes: Flush with water. Swallowing: Report to First Aid immediately. Inhalation: Remove patient from contaminated area. Give artificial respiration and oxygen if necessary. Report to First Aid. Eire: Use water, foam, carbon dioxide, dry chemical, or carbon tetrachloride. Si. 007g8 CONFIDENTIAL: protective Order Of Subject to 14th Judi cial Distri . 91-11-4 ct Court 2-10 NAME: Ethyl Chloride FORMULA: C2H5Cl MOLECULAR WEIGHT: 64.52 OCCURRENCE: Liquid Waste EDC Vent Gas OHC Vent Gas BOILING POINT: 54F (gas under normal conditions) VAPOR PRESSURE @ 75F: 1130 mm FREEZING POINT: -228F LIQUID DENSITY g 68F: 0.893 RELATIVE VAPOR DENSITY (air = 1.0): 2.22 FLASH POINT: Open Cup -45F. Closed Cup -58F AUTOIGNITION: 966F EXPLOSIVE LIMITS: 3.6 - 12.0% SL 000769 MAXIMUM ALLOWABLE CONCENTRATION: 1000 ppm ODOR: Pungent HAZARDOUS PROPERTIES: The liquid is harmful to the eyes, and if spilled on the skin will cause frostbite. The vapor gives some warning of its presence because it is irritating, but it is possible to tolerate exposure to it until one becomes unconscious. EC is the least toxic of all the chlorinated hydrocarbons. It can cause narcosis, but the effects are usually transient. Continued exposures may cause some kidney deterioration. Inhalation of EC vapor in concentrations of 1% (by volume) produces narcotic and anesthetic effects; concen trations of 4% or greater may produce deep or even fatal anesthesia. Although EC is not extremely poisonous, any exposure is very dangerous, because of the extreme flammability of the material. When EC is burned, phosgene and HC1 are formed, so never approach burning EC without a gas mask. Any spill of EC will result in an explosive mixture being formed; and because of the high density of the EC gas, the mixture will tend to stay near the ground. It will take very little to explode EC vapors. Static electricity spark, friction spark or an arcing device are all dangerous when EC is spilled. TREATMENT: Remove the injured person from the contaminated area. If breathing has stopped, perform artificial respiration. In any case make sure the person injured is reported to First Aid immediately. If any liquid enters the eye, wash the eye continuously with a large amount of water for at least 15 minutes. If at the end of 15 minutes eye damage is still apparent, continue washing untilrf^^-^gf$!giftfcsives Dr gives new Instructions. No. 91-1145 NAME: Ethylene FORMULA: C2H4 MOLECULAR WEIGHT: 28.05 2-11 OCCURRENCE; EDC Vent Gas OHC Vent Gas BOILING POINT: -155F FREEZING POINT : -273F RELATIVE VAPOR DENSITY: AUTOIGNITION: 1009F EXPLOSIVE LIMITS: 3-347,, ODOR: Sweet HAZARDOUS PROPERTIES: Ethylene is a flammable gas. It is a very dangerous explosion hazard upon exposure to heat or flame. It can react vigorously with oxidizing materials. Ethylene is moderately toxic, but the slight effects disappear as soon as the patient is removed from the exposure. The main danger with C2H4 is asphyxiation, the ethylene will displace the oxygen of the air, causing the victim to suffocate. (See Methane treatment) TREATMENT: Remove the patient from the area, perform artificial respiration if breathing has stopped. Report to First Aid. SL 000770 Subject Of 14th J -- ilo. 91-1145 NAME: Ethylene Dichloride (EDC) FORMULA: CH2CICH2CI MOLECULAR WEIGHT: 98.97 BOILING POINT: 182.3F VAPOR PRESSURE @ 75F: 75 mm 2-12 OCCURRENCE: EDC Vent Gas OHC Vent Gas . I C ~^ " FREEZING POINT: -31.8F LIQUID DENSITY & 68F: 10.45 #/gal., 1.253 gm/mls FLASH POINT: 65F Open Cup; 55f Closed Cup EXPLOSIVE LIMITS: 6.2 to 15.9% by vol. in air MAXIMUM ALLOWABLE CONC: 75 to 100 ppm DETECTABLE ODOR CONC: Unknown HAZARDOUS PROPERTIES: Ethylene dichloride is a flammable liquid and a dangerous fire hazard. It is toxic by inhalation, by prolonged or repeated contact with the skin or mucous membranes, and by ingestion. Excessive contact gives rise to symptoms such as headache, depression, mental confusion, fatigue, loss of appetite, nausea, vomiting, cough, loss of sense of balance, and visual disturbances. It has an anesthetic effect, and, in high concentrations, is immediately irritating to the eyes, skin, nose, and throat. It can cause dermatitis upon prolonged or repeated contact with the skin. Ethylene dichloride can cause serious eye damage. TREATMENT: Quick removal from exposure is important. Ethylene dichloride should be removed from the patient's person, his respiratory tract, skin, or gastrointestinal tract as quickly as possible. If breathing has ceased, start artificial respiration. If material gets in the eyes, wash promptly with copious quantities of water. If ingested, the patient should be made to vomit. Notify a physician. SL 000771 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 NAME: Hexachloroethane FOBMULA: C2Cl6 BOILING POINT: 367F 2-13 OCCURRENCE: Bottoms Plant Liquid Waste VAPOR PRESSURE: 1 mm at 32.7C FREEZING POINT: 186.6C (sublimes) LIQUID DENSITY: 2.091 VAPOR DENSITY: FLASH POINT: EXPLOSIVE LIMITS: MAXIMUM ALLOWABLE CONCENTRATION: DETECTABLE ODOR CONCENTRATION: Camphor-like odor HAZARDOUS PROPERTIES: Dangerous disaster hazard. Slight explosive hazard by spontaneous chemical reaction with alkalies, metals, etc.. When heated to decomposition, it emits highly toxic fumes of phosgene. TREATMENT: Skin: Remove contaminated clothing. Wash with soap and water. Eyes: Flush with copious quantities of water for at least 15 minutes. Inhalation: Remove patient from contaminated area. Give artificial respiration. Give oxygen if necessary. Keep quiet and warm. Report to First Aid. CONFIDENTIAL: SL 000772 2-14 NAME: Hydrogen Chloride FORMULA: HC1 MOLECULAR WEIGHT: 36.47 OCCURRENCE: EDC Vent Gas Per-Tri Vent Gas Incinerator Scrubber Effluent BOILING POINT: -121F VAPOR PRESSURE (g 75F: 36,000 mm FREEZING POINT: -174F LIQUID DENSITY: Normally a gas RELATIVE VAPOR DENSITY: 1.26 (air = 1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 10 ppm for 8 hour working day DETECTABLE ODOR CONCENTRATION: Unknown HAZARDOUS PROPERTIES: Anhydrous hydrogen chloride is a gas which has a corrosive action upon the skin or mucous membranes. In this form, it will cause rapid and severe burns. It is particularly dangerous to the eyes. It is not flammable; however, the gas is highly soluble in water, forming hydrochloric acid, which attacks most metals with the evolution of explosive hydrogen. TREATMENT: Immediate removal from the toxic area and thorough flushing of the patient's body and/or eyes with large quantities of water is of primary importance. Contaminated clothing should be removed from patient while he is being showered with water. It is essential that all affected body surfaces be washed with copious quantities of water for a sufficient time to remove all hydrochloric acid. No attempt should be made to neutralize the acid with alkaline solutions. Medical assistance should be summoned at the earliest possible moment. CONFIDENTIAL: Subject to o mh SL 000773 2-15 NAME: Methane (marsh gas) (Natural Gas) FORMULA: Cfy MOLECULAR WEIGHT: 16.04 OCCURRENCE: EDC Vent Gas For Auxiliary Fuel BOILING POINT: -258.7F FREEZING POINT: -297.8F VAPOR PRESSURE: <a -115.8F, 34,900 mm Hg LIQUID DENSITY: @ -263.2F, 25.91 lbs per Ft3 RELATIVE VAPOR DENSITY: 0.555 (air = 1.0) FLASH POINT: None EXPLOSIVE LIMITS: 5.3% to 14.0% by volume DETECTABLE ODOR CONCENTRATION: Odorless AUTOIGNITION TEMPERATURE: 1000F HAZARDOUS PROPERTIES: A simple asphyxiant. A dangerous fire and explosion hazard. TREATMENT: Fire should be fought with carbon dioxide or dry chemicals. SL 000774 Subject of 14th J NAME: Methyl Chloroform (MC also known as 1,1,1 Trichloroethane FORMULA: CCI3CH3 2-16 OCCURRENCE: Tri-Ethane Liquid Waste MOLECULAR WEIGHT: 133.42 BOILING POINT: 165F VAPOR PRESSURE @ 77F: 125 mm FREEZING POINT: -22.7F LIQUID DENSITY @ 77F: 11.1 #/gal., 1.3314 gm/ml RELATIVE VAPOR DENSITY: 4.60 (air -1.0) FLASH POINT: None MAXIMUM ALLOWABLE CONCENTRATION: 500 ppm for 8 hour exposure DETECTABLE ODOR CONC: 20-100 ppm HAZARDOUS PROPERTIES: Methyl chloroform is not as toxic as other chlorinated hydrocarbons such as carbon tetrachloride; however, it can still cause damage to the body upon repeated or continuous exposure to large quantities of vapor or liquid. Moderate exposure is unlikely to produce injury. Methyl chloroform is readily absorbed through the lungs. In acute exposure, the most important toxic action is a functional depression of the central nervous system leading ulti mately to respiratory failure. As with most solvents, dermatitis may result from repeated skin contact, but methyl chloroform is only poorly absorbed through the skin. Eye contact may result in pain and discomfort, but no impairment of vision is likely. TREATMENT: As with other materials of this nature, remove the victim to an uncontaminated atmosphere and apply artificial respiration if breathing has stopped. Remove wet clothing and do not allow it to be reworn until it is thoroughly dry. If eyes are contaminated, they should be flushed with large amounts of water. Notify a physician itranediatcly. CONFlDFN'rI7'lL: Subject to Pr of 14th Judiciiaal Dist: No. Q91-1145 SL 000775 NAME; Monochloroacetylene (MCA) FORMULA: C2HC1 2-17 OCCURRENCE: Per-Tri Vent MOLECULAR WEIGHT: 60.483 BOILING POINT: -31C (-23.8F) VAPOR PRESSURE: FREEZING POINT: LIQUID DENSITY: RELATIVE VAPOR DENSITY: EXPLOSIVE LIMITS: Unknown MAXIMUM ALLOWABLE CONCENTRATION: Unknown DETECTABLE ODOR CONCENTRATION: Unknown HAZARDOUS PROPERTIES: MCA is an explosive gas which is spontaneously flammable in air. Monochloroacetylene forms an explosive yellowishred salt with ammonical cuprous solution. Aqueous solutions in contact with air display luminescence. MCA gas is colorless, has a nauseating odor, is irritating to the respiratory tract and is highly toxic. TREATMENT: Remove patient from the area and consult a physician immediately. CONFTnFNTlftI-,! Subject to Pt' of 14th Judicia No. SL 000776 NAME: Nitrogen FORMULA: N2 MOLECULAR WEIGHT: 28.02 2-18 OCCURRENCE: Utility Lines All Vent Gases PHYSICAL APPEARANCE: Colorless, odorless, inert gas SPECIFIC GRAVITY: 1.0 with relation to air. (air is 787. N2) HAZARDOUS PROPERTIES: Even though nitrogen is an inactive gas, it has some inherent dangers since it is used so universally throughout the plant. Its prime use is for padding and sweeping of equipment that has, or has had, flammables in it. The hazard involved is that a vessel may have insufficient oxygen or that nitrogen is used to purge the vessel instead of air, before man-entry. Therefore, every vessel that is entered must not only be first checked for flammability, etc., it must also be checked for sufficient oxygen. Not only that, nitrogen lines, as well as other toxic lines, must be isolated from the vessel before entry and a clean air sweep provided. TREATMENT: Remove person from the oxygen deficient area. Administer artificial respiration if necessary. See Methane for symptoms. CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 SL 000777 NAME: Pentachloroethane (PCE) FORMULA: CC13CHC12 2-19 OCCURRENCE: Liquid Wastes MOLECULAR WEIGHT: 202.31 BOILING POINT: 321F VAPOR PRESSURE g 75F: 4 mm FREEZING POINT: -20F LIQUID DENSITY (3 77C: 14.0 #/gal., 1.681 gm/ml RELATIVE VAPOR DENSITY: 6.98 (air = 1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: Below 121 ppm DETECTABLE ODOR CONCENTRATION: Unknown HAZARDOUS PROPERTIES: Pentachloroethane is a nonflammable and toxic liquid. It has a chloroform-like odor and can cause chronic intoxication. It is considered a stronger narcotic than chloroform and is about as poisonous as tetrachloroethane, which it resembles in its action as a metabolic poison. It has a pronounced irritating effect upon the mucous membranes, causing an inflammation of the nose, throat, and respiratory passages. Chronic poisoning causes fatty degeneration of the liver, inflammation of the kidneys, bronchitis, pronounced hyperemia of the lungs, and purulent pneumonia. TREATMENT: As described under tetrachloroethanes. Notify a physician. Subject. of 14th 3 SL 000778 NAME: Perchloroethylene FORMULA: C2C14 MOLECULAR WEIGHT: 165.85 BOILING POINT: 121.20C VAPOR PRESSURE: 15.8 nan at 22C FREEZING POINT: -23.3C LIQUID DENSITY: 1.6311 at 15/4C VAPOR DENSITY: 5.83 2-20 OCCURRENCE: Per-Tri Vent Gas Liquid Waste FLASH POINT: None EXPLOSIVE LIMITS: Non-explosive MAXIMUM ALLOWABLE CONCENTRATION (OR THRESHOLD LIMIT): 200 ppm DETECTABLE ODOR CONCENTRATION: Chloroform-like odor HAZARDOUS PROPERTIES: Perchloroethylene affects the nervous system, lungs, and mucous membranes. Dangerous disaster hazard. Non-flammable and non-explosive. It will not support combustion. When heated to decomposition, it emits highly toxic fumes of chlorides. TREATMENT: Skin: Remove contaminated clothing and wash with soap and water. Apply lanolin ointment. Eyes: Swallowing: Flush with water for at least 15 minutes. Call a specialist. Report to First Aid. Induce vomiting by drinking soapy or salt water. Induce vomiting three times. Follow with a tablespoon of epsom salt in a glass of water. Call a physician. Report to First Aid. Inhalation: Remove patient from contaminated area. Keep quiet and warm. Give artificial respiration. Give oxygen if necessary. If conscious, give tea or coffee. Call a physician. Report to First Aid. SubjectCOtoNFPIDrEoNteTcIAtiLv: e Order ' ''Aicial District Court SL 000779 NAME: Phosgene 2-21 FORMULA: COCl2 MOLECULAR WEIGHT: 98.92 BOILING POINT: 46F VAPOR PRESSURE: 23.4 psia @ 20C FREEZING POINT: -198F LIQUID DENSITY: 11.39#/gal; 1.37 gm/ml VAPOR DENSITY: FLASH POINT: EXPLOSIVE LIMITS: MAXIMUM ALLOWABLE CONCENTRATION: 1 ppm DETECTABLE ODOR CONCENTRATION: HAZARDOUS PROPERTIES: Poisonous gas. (Present in very dilute concentrations only in main vent stream.) TREATMENT: Skin: Eyes: Remove contaminated clothing. Wash thoroughly with an abundance of water. Flush eyes with copious quantities of water. Breathing: Odor of new mown hay or green corn. Remove patient from contaminated area. Give artificial respiration and oxygen treatment, if necessary. In all cases, report to First Aid. CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 SL 000780 NAME: Symmetrical and Assymmetrical Tetrachloroethane (S.TeCE & A.TeCE) FORMULA: CHC12GHC12 and CCl3CH2Cl 2-22 OCCURRENCE: Per-Tri Vent Gas Liquid Wastes MOLECULAR WEIGHT: 167.86 BOILING POINT: S.TeCE 295F; A.TeCE 267F VAPOR PRESSURE @ 75F: S.TeCE 4mm; A.TeCE 13 mm FREEZING POINT: S.TeCE -47F; A.TeCE -97F LIQUID DENSITY (g 77F: S.TeCE 1.588 gm/ml; A.TeCE 1.533 gm/ml RELATIVE VAPOR DENSITY: 5.78 (air 1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 5 ppm for 8 hour exposure DETECTABLE ODOR CONCENTRATION: Approximately 5 ppm HAZARDOUS PROPERTIES: The tetrachloroethanes are not flammable or explosive but are the most toxic of the chlorinated ethanes that will be handled in the plant. The tetrachloroethanes are toxic by inhalation, by prolonged and repeated contact with skin or mucous membranes or by oral intake. Although toxic, tetrachloroethanes may be handled safely if proper precautions are constantly observed. Prolonged or repeated exposures to the pro duct in any form are hazardous. The signs and symptoms of excessive absorption usually appear gradually and only after repeated exposures. In order of appearance they commonly are unusual fatigue, loss of appetite and weight, sick stomach and vomiting, constipation, abdominal pain, jaundice, drowsiness, going on in severe cases to unconsciousness and death. Some cases show marked involvement of the nervous system with headache, numbness and tingling in fingers and toes, trembling and twitching of muscles and even paralysis of some muscles. The signs and symptoms of tetrachloroethane poisoning given above are due to systematic poisoning characterized by marked damage to the liver, kidneys, heart, blood cells, and nervous system. SL 000781 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 2-23 TREATMENT: Most important in the case of any poisoning is quick removal from exposure. In the case of tetrachloroethane poisoning, this means first removing the patient from the contaminated atmosphere and, insofar as possible, removing the tetrachloroethane from the patient's skin, or gastrointestinal tract, if those areas are involved. The patient should be kept quiet and comfortably warm, but not hot. A physician should be called immediately. He should be told briefly and clearly what has happened and the exact location of the patient. SL 000782 0rder S,, u v^3 ecjtutdoicPial rDoisttricet court of l4th No 91-1143 NAME: 1,1,2-Trichloroethane (TCE) FORMULA: CHCI2CH2CI 2-24 OCCURRENCE: Liquid Wastes MOLECULAR WEIGHT: 133.41 BOILING POINT: 237F VAPOR PRESSURE @ 75F: 22 ran FREEZING POINT: -34F LIQUID DENSITY (? 77F: 11.93 #/gal., 1.4319 gm/ml RELATIVE VAPOR DENSITY: 4.6 (air - 1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 25 to 100 ppm DETECTABLE ODOR CONCENTRATION: Unknown HAZARDOUS PROPERTIES: Trichloroethane can cause bums of the eyes and has a seriously harmful effect upon the liver. It has a local irritating effect upon the mucous membranes, particularly of the eyes and nose. All contact with the eyes and skin should be avoided. This material should generally be handled with caution, because its toxicological properties have not as yet been adequately evaluated. TREATMENT: Remove patient from toxic area. Remove all contaminated clothing and wash all exposed skin surfaces thoroughly with soap and water. Flush eyes with copious quantities of water. Notify a physician. SL 000783 confidential sublet tb of > Order ct Court 2-25 NAME: Trichloroethylene FORMULA: C2HC13 OCCURRENCE: Per-Tri Vent Gas MOLECULAR WEIGHT: 131.4 BOILING POINT: 87C (188.6F) VAPOR PRESSURE: 2.5 psia at 100F FREEZING POINT: -99F LIQUID DENSITY: 11.9 lbs/gal at 100F VAPOR DENSITY: 4.54 (air = 1) FLASH POINT: Practically non-flammable EXPLOSIVE LIMITS: Not flammable or explosive at ordinary room temperatures but moderately flammable at higher temperatures. MAXIMUM ALLOWABLE CONCENTRATION (OR THRESHOLD LIMITS: 200 ppm DETECTABLE ODOR CONCENTRATION: Not known. HAZARDOUS PROPERTIES: Reacts with strong alkalies, such as caustic soda, to form highly flammable and toxic dichloroacetylene. Trichloroethylene may be harmful by inhalation, by prolonged or repeated contact with skin or mucous membranes, or when taken by mouth. TREATMENT: Skin areas affected by a spill should be washed thoroughly with soap and water (except the eyes). A 15-minute eye wash should be used for a spill in the eyes. In general, remove the patient from the contaminated atmosphere and insofar as possible, remove the trichloroethylene from the patient's respiratory tract, skin, or gastrointestinal tract. Vomiting may be induced if taken internally. SL 000784 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 2-26 NAME; Vinyl Chloride (Chloroethylene) FORMULA: C2H3CI OCCURRENCE: Per-Tri Vent Gas Liquid Waste MOLECULAR WEIGHT: 62.50 BOILING POINT: 8F VAPOR PRESSURE @ 75F: 2700 mm (gas under normal conditions) FREEZING POINT: -244F LIQUID DENSITY 0 68F: 0.0908 RELATIVE VAPOR DENSITY: (air = 1.0) 2.15 FLASH POINT: Open Cut -107F. Closed Cup -162F EXPLOSIVE LIMITS: 4-22% MAXIMUM ALLOWABLE CONCENTRATION: 500 ppm for 8 hours ODOR: Faintly sweet (smells like phenol when inhibited) HAZARDOUS PROPERTIES: Vinyl chloride is very much like ethyl chloride. It is not very poisonous, it is extremely flammable and it has a narcotic effect. Continued exposures may cause some kidney de terioration. Inhalation of vapors greater than 500 ppm may produce a slight narcotic effect. At concentrations of 4% or greater, VC vapors may produce a deep or fatal anesthesia. The main danger with VC is the extreme flammability of the vapors. VC when burning will form phosgene and HCl, so never approach a fire without a gas mask. Any spill of VC will result in an explosive mixture being formed and because of the high density of the VC gas, the mixture will tend to stay near the ground. It will take very little to explode the VC vapors-static electricity spark, friction spark or an arcing device are all dangerous when VC is spilled. TREATMENT: Remove the injured person from the contaminated area; if breathing has stopped, perform artificial respiration. In any case, make sure the person injured is reported to First Aid immediately. If any liquid enters the eye, wash the eye continuously with a large amount of water for at least 15 minutes; then get the person to First Aid. SL 000785 CONFIDENTIAL: Subject to Protective of 14th Judicial District Court No. 91-1145 NAME: Vinylidene Chloride (VDC) FORMULA: CC12CH2 2-27 OCCURRENCE: Per-Tri Vent Gas , MOLECULAR WEIGHT: 96.95 BOILING POINT: 89F VAPOR PRESSURE & 75F: 560 mm FREEZING POINT: -187.6F LIQUID DENSITY (g 68F: 10.15 #/gal., 1.218 gm/ml RELATIVE VAPOR DENSITY: 3.35 (air = 1.0) FLASH POINT: 5F Open Cup, 55F Closed Cup EXPLOSIVE LIMITS: 7.3% to 16.0% by volume in air MAXIMUM ALLOWABLE CONCENTRATION: 25 ppm DETECTABLE ODOR CONCENTRATION: 500 to 1,000 ppm HAZARDOUS PROPERTIES: Vinylidene chloride is a flammable and toxic material which is moderately irritating to the eyes and to the skin. The greatest danger from vinylidene chloride is inhalation. A single exposure for a few minutes to a high concentration of vinylidene chloride vapor rapidly produces a "drunkenness" which may progress to unconsciousness if exposure is continued. Even concentrations too l<w to cause an anesthetic effect, may produce organic injury to the liver and kidneys. A secondary danger from vinylidene chloride exists. Unstablized vinylidene chloride in contact with air will form explosive peroxides. These peroxides are evident by the presence of a white solid. TREATMENT: When the skin is contacted by vinylidene chloride it should be thoroughly washed with soap and water and all contaminated clothing removed and washed. If the eyes become contaminated, they should be flushed with water for 15 minutes or more. If a person is affected or overcome from breathing vinylidene chloride vapors, he should be removed to fresh air at once. Medical attention should be obtained immediately. Artificial respiration should be administered if breathing stops. SL 000786 CONFIDENTIAL: Subject to Protective Ordfet of 14th Judicial District CoUtfc No. 91-1145 IV. Fire Protection 2-28 Fire protection equipment for the Organics Disposal Plant consists of: 1. A monitor nozzle to cover tar trailer dump area and waste storage tanks. 2. A sprinkler system to cover the air intakes for the incinerators. 3. An equipment spray system to cover the front of the incinerators. The monitor nozzle was installed to protect the tar trailers during unloading and to provide water for cooling the waste storage tanks in case of fire. The purpose of the sprinkler system is to prevent the incinerator from being an ignition source for a vapor cloud. Assuming a vapor cloud originates in existing plants or storage areas and the wind moves the cloud to the incinerator, the. vapor detectors will trip the sprinkler system. Since chlorinated hydrocarbon vapors are heavier than air, the cloud is more likely to be near the ground. The sprinkler system will create a downdraft around the combustion air intakes and supply fresh air to the incinerators. This will provide some protection against vapor cloud ignition by flashback. The purpose of the equipment spray system is to cool any hot spots on the incinerator which could ignite a vapor cloud. The front section of the incinerator where the primary and secondary combustion chambers join is the most likely area to be hot enough to ignite a vapor cloud. One air-operated ball valve, which fails open, supplies water to both incinerators. This valve supplies water for the sprinklers over the air intakes and for the incinerator spray nozzles. SL 000787 2-29 This valve can be actuated either from the control room or from a switch in front of the incinerators. The valve is also actuated by the vapor detector system. V. Vapor Detector System There are three vapor detectors in the Organics Disposal Plant. They are located along the north side of the east-west road beside the salt pond. They are positioned to monitor explosive vapors originating in the OHC plant, in the EC-VC day tank storage area, or from any location between these two. The vapor detectors alarm when they detect a mixture at 20 percent of the lower explosive limit. They will trip the sprinklers and equipment spray nozzles for both incinerators when a mixture at 40 percent of the lower explosive limit is detected. VI. Fire Extinguishers There are three 30-pound dry chemical and one CO2 fire extinguishers in the Organics Disposal Plant. The dry chemical units are located: 1. At the waste storage tanks. 2. In front of No. 1 incinerator. 3. In front of No. 2 incinerator. The CO2 extinguisher is located at the substation which provides power for the incinerators and auxiliary equipment. This extinguisher is for electrical fires only. VII. Control Room The OHC-Tetra-Incinerator control building is pressurized to prevent accumulation of organic or acidic vapors inside the building. Since the SL 000788 CONFIDENTIAL: Subject to Protective Order of i4th Judicial District Court No. 91-1145 2-30 building is pressurized, non-explosion proof equipment is used and smoking is permitted inside the building. Positive pressure is main tained by a fan which draws its intake air across an activated carbon filter. Should a vapor cloud from a major break engulf the control room, the filter would be unable to remove all the contaminates. To prevent undesirable gases from entering the building when the fan is off, instrument air bleeds should be opened. Care should be taken not to bleed the instrument air system pressure down too low. Should enough vapors get into the building to prevent breathing, an emergency air system is provided. This system can be used to work in the control room and shut the plant down if conditions are not too severe. These masl can also be used for escape if the conditions warrant it. There are also three Scott Air-Paks in the control to be used outside in the plants when breathing air is needed for periods up to 30 minutes. VIII. Clearing of Tanks and Process Vessels The area supervisor and maintenance supervisor will see that all vessels of tanks are cleaned and checked with an explosion meter before declaring them suitable for maintenance. Clearing Procedure: 1. The tank or vessel will be emptied and all valves will be closed and tagged. 2. The vapor contents of the tank will be purged with an inert gas. 3. Blinds will be inserted in all connecting lines. 4. The equipment will be steam-purged where possible to vaporize and remove all flammable materials. If steam cannot be utilized, an inert gas will be used. caWM>"[U Order SL 000789 Subject '^eial'^Hstrict CoUtt o 14th dud _U45 iiO * 2-31 5. Purge the equipment with plenty of air. 6. The equipment will then be checked with an explosion meter before work is begun. If entry into the vessel is required, the vessel must be also checked with an oxygen meter. IX. Emergency Exits The locations of Area B emergency exits are given below: North - West of ethylene metering station. Northwest of VCM Plant. - North of EC Plant. East - Main Area B entrance. Midway between Per-Tri and TCE South of the OHC-Tetra. Northeast of EDC day tanks. West - West of tank car loading rack. West of railroad gate on Parish Road. South - South of organics recovery trap. X. Safety Inspections Once per week an inspection of all safety equipment in each plant shall be made. This includes fire extinguishers, fire protection system, protective masks, safety showers, etc. A form has been provided for use as a check-off list. This has a two-fold purpose: 1. To ascertain that required equipment is in good operating condition; and 2. to familiarize Operations personnel with the location of safety equipment for quick use in an emergency. XI. Emergency Horns There are two distinct emergency horns in each area: the plant or Area B evacuation horn and the local area evacuation siren. The Area B evacuation horn is the regular plant horn blown in short blasts. It may be activated from every Area B control room or the guard house. The sounding of this horn will shut down all non-process equipment in Area B and will cause all non-essential personnel to leave the area. Area B include all the Organics Area--east of Columbia Southern Road and SL 000790 CONFIDENTIAL: Subject, to Protective Order of 14th Judicial District Court No. 91-1145 2-32 south of Parish Road. The Area B evacuation horn should be sounded in case of a major break or if there is some reason to expect a major break. Whenever the evacuation horn is sounded, the guard should be notified of the nature of the emergency if at all possible. If it is desired to evacuate the whole plant, the guards will have to be notified and they will sound the plant evacuation. The guards are the only people able to sound the all-clear signal. The area evacuation siren is used to evacuate all non-essential personnel from the operating area and to have all arcing devices in the operating area shut down. This siren is controlled by a switch on the wall in each control room. The area siren should be used in case of a spill involving release of flammable vapors. SL 000791 CONFIDENTIAL: ~__ a- ^ i-i 4- i \J 0 0 r (5 ^ ^ istrlct Court GENERAL DESCRIPTION The incinerators are designed to oxidize chlorinated organic wastes to carbon dioxide, water, and hydrogen chloride; and to scrub the hydrogen chloride from the combustion gases before the combustion gases are emitted to the atmosphere. The chlorinated organic wastes are oxidized according to the following chemical reactions: (1) C2H5Cl + 302 ------------- 2C02 + HCl + 2H20 Ethyl Chloride (2) C2H3C13 TCE + 202 ---------- 2C02 + 3HCl (3) C2C14 Per + 2H20 + 02 --------- 2C02 (steam) + 4HC1 When light chlorinated compounds are burned as shown in reaction 1, a large amount of heat is released. Heat is consumed when heavier chlorinated compounds are burned as shown in reactions 2 and 3. This heat must be supplied by burning light chlorinated compounds such as ethyl and vinyl chloride, or by burning hydrocarbons such as methane, ethane and ethylene. When chlorinated hydrocarbons which contain fewer hydrogen atoms than chlorine atoms are burned, hydrogen must be supplied from some other source in order for the chlorine to form HCl. Steam is normally used to supply hydrogen for this type reaction, as indicated by reaction 3. Oxygen for the reaction is supplied by air. An excess of oxygen should be maintained at all times. Insufficient oxygen will cause carbon, smoke SL 000792 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 51-1145 3-2 and carbon monoxide to be formed as combustion products. However, too much oxygen causes free chlorine and oxides of nitrogen to be formed. Oxygen in the combustion gases should be maintained between 2 percent and 4 percent to minimize undesirable products of combustion. The temperature at which the above reactions are carried out is also important. If these reactions are attempted below 1800F, the chlorinated organics will not bum completely. It is possible to form phosgene below 1800F when there is no excess oxygen present. Liquid waste from the bottoms plant, the EDC plant, the Tri-Ethane plant, the EC plant and the VCM plant will be collected and incinerated. Liquid waste from the bottoms plant is pumped to one of two waste storage tanks. Bottoms from the VCM quench tower will be hauled in a tar trailer and dumped into the same tank with the bottoms plant waste. Liquid waste from the EDC plants and waste from the MC Dopp kettles will be hauled in separate tar trailers and dumped into a second waste storage tank. The EC tar trailer will be dumped in this same storage tank. Liquid waste which has not been processed with ferric chloride (waste from bottoms plant and VCM quench tower) must be stored separately from waste which may contain active ferric chloride. It is possible that ferric chloride could catalize the decomposition of bottoms plant and VCM quench tower wastes. Liquid waste will be pumped alternately from the storage tanks into either of the incinerators. SL 000793 CONFIDENTIAL: tective Order District Court 3-3 The liquid and gaseous wastes will be burned in the incinerator to form carbon dioxide and hydrogen chloride. Waste chlorinated vent gases are collected from the two liquid phase EDC plants, from the Per-Tri plant, and from the OHC plant for incinera tion. Vent gases are piped from each area to the incinerator area in individual piping. The vent gases are combined in the incinerator area and sent through flame arrestors into either of two incinerators. The liquid and gaseous wastes will be burned in the incinerators to form carbon dioxide, hydrogen chloride, and water vapor as described in reactions 1, 2 and 3. Scrubbers at the end of the combustion chambers will utilize lake water to scrub hydrogen chloride from the combustion gases before they are discharged through the stacks. Lake water is supplied to the scrubbers by pumps located on a platform in Sportsman's Lake. SL 000794 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court Ko. 91-1145 DETAILED PROCESS AND EQUIPMENT DESCRIPTION I. Collection and Storage of Liquid Wastes A. Equipment 1. Nos. 1 and 2 Bottoms Waste Transfer Pumps (68A-55-1783 and 1784) and Incinerator Feed Pumps (68A-55-1785 and 1786). These pumps are Warren Model J-10-X screw pumps. Pumps are designed to deliver 5 GPM at 100 psig discharge pressure, 350F, and a viscosity of 8 cps. The pumps are driven by a Carter Model F-14-5-SFRD constant torque hydrostatic variable speed drive and a Model 5-SFRD parallel shaft speed reducer (68A-52-362, 363). The drive is rated for 4 hp and has an infinitely vari able speed between 25 and 600 rpm. The drive is powered by a Reliance 5 hp, 1730 rpm, 460 volt motor (68A-50-3302, 3303). These pumps are equipped with 1" FEP-Monel-FEP rupture discs which relieve at 100 psig and 350F. 2. Nos. 1 and 2 Bottoms Waste Transfer Pump Suction Screens and Incinerator Feed Pump Suction Screens (68A-92-288, 289, 290 and 291). These screens are Haywood Model 72, 2 inch, 150# flanged cast steel strainers with Monel baskets. 3. EDC and Tri-Ethane Tar Trailers (60A-60-1194 and 61A-60-1195). Both tar trailer tanks are 42" dia. by 84" long. The vessels are designed for 100 psig pressure and full vacuum at 400F with 1/16" corrosion allowance. The bottom of the vessel is equipped with "Dean Panel Coils" 12 on 12 pattern 301, style 3-H. Panel coils are constructed of carbon steel and are de signed for 150 psig at 450F. The trailer is constructed with two 5000# prior coil spring axles. Heavy duty wheels with 15" x 7.50 8 ply tires are used. Tanks are equipped with 8" RD's which rupture at 100 psig and 120F. 4. Nos. 1 and 2 Waste Storage Tanks (68A-1187 and 11881. The waste storage tanks are 17'3" dia. x 17'3" TL to TL and are designed for 29 psig pressure and full vacuum at 350F. Each tank will hold 33,100 gallons. These tanks are equipped with two 24" FEP-Monel-FEP rupture discs each which relieve at 29 psig and 200F. These discs are supplied with vacuum sup ports. The 24" rupture discs are designed to relieve products of a decomposition or polymerization reaction. 6 tO O' The tanks also have one 6" x 8" Farris 26RA10 safety relief valve each set at 24 psig and 200F with 6" FEP-Monel-FEP RD's. 5. Waste Storage Tank Agitators (68A-61-156 and 157). The waste storage tank agitators and gearboxes (68A-52-360 and 361) are Philadelphia Gear Model PTERO, size 12 mixers with Allis- Chalmers 15 hp, Type RGZZ, 460 volt, explosion proof, TEFC induction motors (68A-50-3298 and 3299). The motors are 1740 rpm and the agitators are 25 rpm. CONFIDENTIAL; Subject to Protective Order . of 14th Judicial District Court Ho. 91-1145 B. Operation 4-2 1. Segregation of Liquid Wastes Liquid waste from Area B has been segregated into two types; those wastes which are processed with ferric chloride and those that are processed in the absence of ferric chloride. It has been demonstrated that active ferric chloride can catalize reactions in VC and bottoms plant waste material. Since EC, EDC and MC Dopp kettle wastes contain ferric chloride, a separate storage tank must be provided for these materials. 2. Bottoms Plant Waste Bottoms plant waste is continuously drawn off the side of the small kettle through a 1" line. The waste material then goes through one of two screens. The screens are basket type, designed to remove welding slag, nuts, or other hard material, 1/8" dia. or larger, that could damage the bottoms waste trans fer pumps. The top can be opened easily and the screens will have to be cleaned frequently during operation. Waste from the screens will flow into the suction of the bottoms transfer pumps. These are screw pumps and are classed as positive displacement. However, since definite clearances are established between all internal parts, some slippage does occur when low viscosity fluids are pumped against a high head. These pumps have a rupture disc on the discharge that relieves at 100 psig. The bottoms waste transfer pumps also have cooling water for the oil reservoirs at each end of the pumps. iP a> CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court There is not a flow meter for the bottoms plant waste flow due to the difficulty in metering such a stream. Flow is regulated by the speed of the positive displacement screw pumps. There are handwheel indicators on the variable speed drives which indicate percent of maximum speed for the pumps. This handwheel indicator reading will have to be correlated to flow during startup and must be used instead of a metered flow. Bottoms plant waste is pumped into the No. 1 waste storage tank. This waste could be pumped into the No. 2 waste storage tank by switching a spoolpiece. However, bottoms plant material should not be put in a tank used to store waste containing ferric chloride, or vice versa, unless the tank has been cleaned. VCM Waste and Dumping of Tar Trailer VCM quench tower bottoms are transported to the incinerator area in the tar trailer. The tar trailer will hold about 500 gallons of waste and should be weighed before delivery to the incinerator area. The VCM tar trailer has a SRV set for 90 psig. VCM waste is unloaded into the same tank used for bottoms plant waste, the No. 1 waste storage tank. The tar trailer is connected to the tank with a 2" hammer union and is unloaded through a 2" Teflon-lined hose. The tar trailer is unloaded by pressurizing with nitrogen. The buggy should be pressurized to about 50 psig and then the nitrogen should be blocked off. Then liquid waste lines into the tank should be opened. This proceg^j^i^^jvjpj^j}.be repeated Subject to Protective Order of 14th Judicial District Court No. 91-1145 4-4 one or more times to empty the tar buggy. There is no way to observe the level in the tar trailer, but a rapid decrease of tar trailer pressure and excessive vibration of the unloading hose caused by slugs of liquid and nitrogen are reliable indi cations of an empty tar trailer. The waste storage tanks are vented into the EDC waste gas line to the incinerator. Excessive nitrogen should not be purged into the storage tanks while unloading the tar trailers since this nitrogen will go to the incinerator and could cause an upset in incinerator operation. 4. Tri-Ethane and EDC Wastes The Tri-Ethane and EDC tar trailers also hold about 500 gallons. These trailers have 100 psig rupture discs. The TriEthane and EDC trailers are dumped into the No. 2 waste storage tank. Quick-connect couplings are used to connect the tar trailers to the tanks. Connections for dumping into the tanks are different so that waste containing ferric chloride cannot be dumped into the wrong tank. The same procedure as described for dumping the VCM tar trailer should be used for the TriEthane and EDC trailers. 5. EC Waste The liquid phase from the EC tar trailer is stored in the. No. 2 waste storage tank. The EC tar trailer has the same capacity as the other trailers; however, the design pressure and SRV setting is 75 psig. CP CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 6t0 4-5 Only the liquid phase from the EC trailer is dumped into the tank. This is done as described for the VCM tar trailer. After the liquid phase is dumped, the EC trailer is vented into the vent line provided until most of the volatile compounds have evaporated. A small nitrogen purge will hasten the evaporation process. After the tar trailer has been purged it can be returned to the EC plant; and on Monday, Wednesday, and Friday it should be washed at the dump in the usual manner. 6. Storage of Waste The waste storage tanks will hold about 33,100 gallons. (See Innage Table in Appendix) The tanks are designed for 29 psig pressure and full vacuum at 350F. Each tank has two 24" rupture discs which relieve at 29 psig and 350F. These larger discs are designed to empty the tank very quickly in case a decomposi tion reaction occurs in the tank. Each tank also has one 6" RD and SRV set for 24 psig at 350F. The SRV setting is lower than the rupture pressure for the large rupture disc to prevent unnecessary blowing of the large discs. The waste storage tanks are agitated by 15 horsepower Philadelphia Gear agitators which rotate at 25 rpm. The agitator shaft is 4-inches in diameter and 228 inches lonj>. The impeller is 84 inches in diameter and 62 inches from the bottom of the tank or 1.5 feet above the bottom level indicator nozzle. There is a 4 inch diameter stub shaft from the agitator to a foot bearing about 1 foot above the tank bottom. CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 4-6 The waste storage tanks are also jacketed with Tranter platecoils designed for 145 psig pressure. The platecoils are designed to keep waste material from cooling when cooling would cause solidification. If waste material is fluid at ambient temperatures, then heat input from the platecoils will not be required. Steam is supplied to the platecoils from the dis posal plant steam header which operates at 125 psig. Steam to the coils is regulated by PCV's. N2 Purge DP Cell 1X1 n Inside of Tank Figure 1 The nitrogen injected at the level indicator, HC1 and organic vapors generated by waste decomposition, and nitrogen blown into the tank during tar trailer unloading is vented to the incinerator through the EDC vent gas line. The EDC vent SL 000600 CONFIDENTIAL! 4-7 contain oxygen when the chlorine to the EDC reactors contains air. A positive nitrogen flow through the tank vent line into the EDC header must be maintained at all times to prevent oxygen from backing up into the vapor space of the storage tanks. Nitrogen to the level transmitters provides this flow. Nitrogen flow must be kept above 30 ft /hr to each tank any time the EDC vent header is in service. -An alarm indicates low nitrogen flow to the tanks. When the EDC vent is not being incinerated the storage tanks must still be vented. This is accomplished through a 4-inch line and PCV located in the bottoms plant. This valve will open when pressure in the EDC vent line exceeds 10 psig and will vent material to the bottoms plant scrubber. 7. Incinerator Feed System Liquid waste is drawn off the bottom of the waste storage tanks through 2-inch Strahman valves and 2-inch lines. Liquid waste flows through the pump suction screens into the suction of the incinerator feed pumps. The incinerator feed pumps and the screens are identical to those used in the bottoms plant. The incinerator feed pumps will pump directly to the burner nozzles on each incinerator through two 3/4-inch lines. The incinerator feed lines are not tied together at the discharge of the feed pumps, but they are tied together in the incinerator area. Therefore, either pump can feed either incinerator. The pump suctions are not tied together. The suctions are separated SL 000801 CONFIDENTIAL: Subject to Protective of 14th Judicial District COUtfc No. SI-1145 4-8 so that liquid from one tank cannot be accidentally transferred to the other tank. The suctions could be tied together by installing a spoolpiece; but this should not be done unless blinds have been installed. The incinerator feed pumps have RD's which relieve at 100 psig. The pumps have a high discharge pressure shutdown at 90 psig to shut the pumps down before the rupture discs are blown. The pumps are also shut down anytime liquid feed to the incinerator is blocked. A selector switch at the pump starter pushbutton must be set so that the pump shuts down only when the incinerator it feeds shuts down. Normal waste feed flowrate is about 2.3 gpm. The maximum is 3.0 gpm and the minimum is 1.8 gpm. The waste will not be adequately atomized if the flow is not kept within these limits. The existing atomizers could be replaced and up to 6 gpm of waste burned if necessary. Flowrate to the incinerators will be determined by the handwheel indicators, as described for the bottoms plant waste transfer pumps. (See Correlation Chart in Appendix) II. Vent Gas Collection A. Equipment There is no major equipment involved with the vent gas collection systems. SL 000802 CONFIDENTIAL: Subject to Protective OrdeT of 14th Judicial District CoUft No. 91-1145 B. Operation 4-9 Vent gases from both EDC plants, from Per-Tri, and from OHC will be burned in the incinerators. The vent gases are collected up stream of the plant vent scrubbers and are transported to the incinerators in Chemtite and Haveg pipe. 1. EDC Vent Collection The collection systems for both EDC plants are identical. Vent gas flow is diverted from the plant scrubbers to the incinerators by two automatic valves operated from the EDC con trol room. The valve in the line to the incinerator is an open or closed type valve with no intermediate positions. This is a Teflon-lined butterfly valve with an air operator. This valve will fail closed in case air or power is lost. The second valve is a flow control valve in the line to the plant scrubber. This valve has a controller located on the EDC control panel. This valve fails open when air or power is lost. A FCV was used in the line to the scrubber so the incinerator would not be overloaded when the EDC plant receives slugs of air from the cell building. The FCV in the line to the scrubber does not operate as FCV's normally do. It controls the flow in the line to the incinerator by allowing excessive vent flow to go to the scrubber rather than to the incinerator. During normal operation the setting on the FCV would be higher than the vent flow so the valve to the scrubber would SL 000803 CONFIDENTIALi Subject to Protective Order of 14th Judicial District CtlUIrfc No. 91-1145 4-10 stay closed. Then when the vent flow increases, as with an air slug, the FCV will open and allow part of the vent gas to go to the scrubber. Even though these valves are set up to take an air slug, the vent should never be sent to the incinerator when it is in the explosive range. Anytime there is a possibility of the vent being explosive, or when other problems exist, all of the vent flow can be sent to the scrubber by operating a shutdown switch on the control panel. This switch will close the valve in the line to the incinerator and open the valve in the line to the scrubber. The vent gas can also be directed from the incinerator to the scrubber by a shutdown switch on the incinerator control panel. Vent gas cannot be sent to the incinerator unless both of these switches are in the correct position. EDC plant vent gas will also be diverted from the incinera tor to the scrubber by a high pressure shutdown switch anytime the pressure in the vent gas header exceeds 10 psig. Since this switch is located on the header which is common to both Nos. 1 and 2 plants, the valves in both plants are activated simultaneously. The vent gas collection piping is 4-inch inside the plants. The two 4-inch lines join and the pipe size is 6-inch to the incinerator area. The waste storage tank vents tie into the 6-inch EDC line and the unloading of tar trailers could cause pressure fluctuation in the EDC vent header. There is also a CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 4-11 4-inch PCV on the EDC vent line in the bottoms plant which will open and vent material to the bottoms plant scrubber when the line pressure exceeds 10 psig. Vent gas from EDC can be sent to either incinerator, but there are no controls to split the vent to burn in both incinerators at the same time. The 6-inch line to the incinerator has several risers in the EDC plant, one at the southeast corner of the Per-Tri con trol room,and one where the piperack turns south near the PerTri acid pit. If liquid is present in the vent, or if condensa tion occurs in the vent pipe, it could cause excessive pressure drop or pressure surges in the header which would shut down vent gas flow to the incinerator. 2. Per-Tri Vent Collection Per-Tri vent gases are sent to the incinerator by a valving arrangement similar to that in EDC. The valve to the scrubber is not an FCV since the Per-Tri vent gas flow is not subject to rapid increases as is the case in EDC. However the valve car be manually opened or closed from the control board for startup. The valve in the line to the scrubber fails open on loss of air or power. The valve in the line to the incinerator is an open or closed valve with no intermediate positions. This valve fails closed when air or power is lost. Vent gas flows through this valvq, through a flow meter, and to the incinerator area. SL 000805 CONFIDENTIAL* Subject to Protective Order of 14th jud,.icial nDiissttrrict NO. 91-H45 Court 4-12 These two valves can be operated by a switch on the Per-Tri control board or a switch on the incinerator control board. Both switches must be in the correct position for startup. The vent gas header in Per-Tri has a 10 psig RD. This is to keep pressure in the header from getting high enough to back up into another plant. The vent header also has a high pres sure shutdown switch which diverts the vent gas to the scrubber if the vent gas pressure gets above 7.5 psig. If the Per-Tri vent flow is high, as when there are a lot of dead tubes, one incinerator may not be able to handle all of the Per-Tri vent. There are PCV's at the incinerators to split the Per-Tri vent. Flow to one incinerator would be set and controlled by the FCV. The FCV to the second incinerator should be manually set so that excess flow will go to that incinerator. The Per-Tri vent header will always be under some pressure (2.0-3.5 psig) when the vent is being incinerated. Therefore, the original vent header could not be used to run a reactor at atmospheric rates to perform maintenance. A reactor could not be started up without sending an excessive amount of nitrogen to the incinerator unless the total Per-Tri vent was sent to the scrubbers. Rather than put the total plant vent to the scrubber every time a reactor had to be run at atmospheric rates, or every time a reactor had to be started up or shut down, a SL 000806 CONFIDENTIAL: Subject to Protective Or<*er of 14th Judicial District Court No. 91-1145 4-13 startup header was installed. Any single reactor can be put directly to the scrubber (at atmospheric rates only) without interfering with the other reactor vents. Liquid could collect at the riser in piping near the Per- Tri acid pit; however, a drain line which has a 1/4" orifice will drain pipe continuously. The Per-Tri vent contains oxygen and VDC. There are records of violent explosions of peroxides of VDC. Barberton Research has made VDC peroxides from pure VDC, air, and initiators and has verified its explosive potential. Chemists at Barberton could not make the peroxide without initiators and they could not make the peroxide by a gas phase reaction even with initiators. For this reason, liquid must not be allowed to accumulate in the Per-Tri line to the incinerator. The only low point in the piping to the incinerators is west of the Per-Tri acid pit. A 1-inch line with a 1/4-inch orifice will continually drain the low point to the acid pit. 3. OHC Vent Gas Collection OHC vent gases are diverted from the scrubber and sent to the incinerator in the same manner as Per-Tri vent gases. The valve in the line to the scrubber fails open and the valve in the line to the incinerator fails closed. The valves can be operated by a switch on the incinerator control panel. The valves will divert OHC vent gas to the scrubber if the header pressure exceeds 7.5 psig. SL 000807 CONFIDENTIAL: Subject to Protective Order Of 14th Judicial District Court No. 91-1145 4-14 The valve in the line to the OHC scrubber is below the vent header; therefore, any liquid in the header will collect above the valve. There is a 1/2-inch Kynar line bypassing the valve which will continuously drain liquid from above the valve. OHC vents can be burned in either incinerator but no con trols were provided to split the OHC vent. The OHC vent header has a 10 psig RD to prevent vent gas from reaching sufficient pressure to back up into another plant in case of a valve malfunction. III. Incineration of Waste Liquids and Gases A. Equipment 1. Flame Arrestors (68A-72-286 and 287) . The flame arrestors have 8-inch 125 pound inlet and outlet flanges and are con structed of Hastelloy C with a nickel bank assembly. Design pressure drop is 10 inches of water at a flow rate of 100,000 SCFH. The flame arrestors are designed to stop propagation of a flame without any flow through the bank assembly. 2. Incinerators (68A-58-1 and 2). The incinerators were built by Thermal Research and have LV-48 (48 million BTU per hour) burners with a 48 3/4" long by 48-inch inside diameter cylin drical primary combustion chamber and a 10 foot long by 6'7" ID cylindrical secondary combustion chamber. The incinerator has an external steel shell lined with H.E.S. cement, HW-26 insulating brick and Kroundal XD brick. The incinerator is designed to burn 21.2 TPD of liquid chlorinated waste and 180 TPD of chlorinated vent gases. 3. Scrubbers (68A-67-91 and 92). The scrubbers were built by M. A. Knight and have a 10'8 1/2" high by 10'0" diameter quench section, a 7*6" high by 10'0" diameter packed section, and a 9-inch by 10'0" diameter mist elimination section. The towers are packed with 1 1/2" Berl saddles. The towers have a steel shell lined with pyroflex and acid-proof brick. They are designed to scrub 99.9% of the HC1 fed to the tower using only well water as a scrubbing liquid. Materials of construc tion will allow the use of a weak caustic stream for scrubbing. SL 000808 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 4-15 4. Combustion Air Blowers (68A-57-551 and 552). The combustion air blowers are New York Blower HPE-262 blowers driven by 75 HP, 1770 RPM, 460 volt Type GZ Allis Chambers motors. The fans will deliver 8000 CFM of air at 34.8 inches of water pressure and 70F. The blower rotates at 3100 RPM. 5. Incinerator Lake Pumps (68A-55-1779 and 1780). The lake pumps are Goulds 10 x 14 HMO/256, 2 stage, vertical Centrifugal pumps designed to deliver 2500 GPM of water at 120 feet of head. The pump is cast iron, bronze trim, with a 316 S.S. shaft. They are driven by Westinghouse, 100 H.P., 1775 RPM, 460 volt TEFC motors. B. Operation Both incinerators and the auxiliary equipment are exactly alike. Only one will be described here. 1. Feed Piping Liquid waste is pumped from the storage area through two' 3/4" lines to the incinerator. Liquid waste will flow through a solenoid valve, which is part of the shutdown system, through a flexible Teflon-lined hose, into the burner atomizing gun, and on into the incinerator. The burner nozzle assembly is merely a set of concentric pipes. Liquid waste flows through the central pipe, with atomizing steam, natural gas, and vent gas waste flowing through the outermost pipes. (See drawing 68A-50057 in Appendix) Steam in the second pipe is used to atomize the liquid waste Steam is supplied to the disposal plant area from the 250 pound steam header in the bottoms plant. Steam pressure is reduced to 125 psig at the reducing station near the waste storage tanks The safety relief valve for the steam header is set at 145 psig. SL 000809 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91- 1145 4-16 The liquid waste must be atomized with steam before the waste can be burned. Low steam pressure, plugged steam orifices in the atomizing tip, and high or low liquid waste flow will prevent proper atomization. Liquid waste flow must be kept between 1.8 and 3.0 GPM for adequate atomization. The atomiz ing tip must be adjusted in the horizontal direction to get a good flame pattern inside the primary combustion chamber. This is the reason for the flexible hoses on the atomizing steam and liquid waste lines. The atomizing tip is exposed to an extreme amount of radiant heat. Liquid waste and atomizing steam will keep the tip from overheating during normal operation. Atomizing steam must be kept on the atomizer when the incinerator is running even though no liquid waste is being burned. 10 to 20 psig steam pressure is enough to keep the tip cool. Natural gas is supplied to the disposal plant from the 90 psig header that runs from the VCM to the EDC plant. The pressure is reduced to 1.5 psig at the control station in front of the incinerator. Natural gas flows through the three auto matic double block and bleed valves, through a temperature control valve, and into the incinerator through the burner nozzle assembly. The double block and bleed valves are activated by the shut down system. The temperature control valve controls the amount of natural gas fed to the incinerator so that a temperature of 2600F is maintained. The amount of natural gas will vary depend ing upon which plant vents are being incinerated. The EDC and OHC SL 000810 CONFIDENTIAL: Subject to Protective Otclir of 14th Judicial District Coiitt No. 91-1145 4-17 vents will not normally require natural gas to burn. Per-Tri vent and liquid waste will require some natural gas to burn. Vent gases from the plants are metered after they combine to go to an incinerator. Vent gases like the natural gas, have a double block and bleed arrangement for the shutdown system. How ever, the block valves on the vent line in the plants serve as the first block valve. There are 4-inch vent lines with auto matic valves which fail open and vent the header to the bottoms plant scrubber. The second block valve, located in front of the incinerator, fails closed when the incinerator shuts down. The waste gas also goes through the flame arrestor before going into the burner. The flame arrestor is designed to keep a flame from propagating back into the vent header should an explosive mixture get into the vent headers. If the flame arrestor is to work properly the bank assembly must be kept clean. The bank assembly should be inspected monthly until a fouling frequency is determined. 2. Combustion Air System Combustion air is supplied by a 75 HP blower. It will develop 38 inches of water pressure at the rated capacity. A high speed impeller, which makes an excessive amount of noise, is necessary to develop the required air pressure. Silencers have been installed at the blower inlet to reduce the noise. Combustion air flow is measured by a Taylor pitot venturi flow element. Straightening vanes reduce any turbulence in front of the pitot venturi flow element. Combustion air flow is SL 000811 CONFIDENTIAL: Subject, to Protective Order of 14th Judicial District Court No. 91-1145 4-18 regulated by a butterfly flow control valve. This control valve has a stop which prevents closing. Minimum air flow is 160,000 SCFH. Waste vent gas flew and composition, natural gas flow, and liquid waste flow determine the air requirement for the incinerator. Signals from the waste gas and natural gas flow meters, along with a manually set signal representing waste liquid flow, are added and sent through a ratio controller to the combustion air flow controller. The control system is necessary to provide immediate air adjustments anytime there is a change in natural gas or waste gas flow. But, since a composition for the waste gas had to be assumed to calibrate the instruments, additional corrections will have to be made as the composition varies. The oxygen analyzer will indicate trends toward an oxygen excess or deficiency and adjustments can be made on the ratio controller. Oxygen should be controlled to get 2 to 4 percent O2 in the stack gases. It is important to maintain this oxygen excess since the carbon, smoke, carbon monoxide, nitrogen oxides and chlorine emitted from the top of the stack are directly related to the oxygen excess. Air enters the incinerators at the windboxes, then goes through a set of directional vanes which impart a strong rotational motion or vortex to the air. The vortex goes through a restric tion at the inlet to the primary combustion chamber. The natural gas, waste gas, and liquid waste are introduced at this point SL 000812 IDENT1AL: Protective Order ict Court No. 91-11*5 4-19 into the center of the vortex. After the gases go through the restricted area, they enter the primary combustion chamber where they slow down and burning begins. 3. Combustion Chambers The degree of completion of the combustion reactions is governed by three variables. They are (1) the temperature at which the material bums, (2) the length of time at which the material to be burned is kept at the burning temperature, and (3) the turbulence or the efficiency of mixing the combustible material and the air. The maximum temperature at which wastes can be burned is determined by the type refractories installed in the combustion chambers and is 2600F. Retention time inside the combustion chambers is established by the size of the incinerator and the feed flowrate. The vortex formed by the combustion air is the major factor in creating turbulence inside the combustion chamber. The higher the combustion air flow, the greater the turbulence inside the combustion chamber. The differential pressure gauge at the windbox gives an indication of the drop across the air vanes and therefore is an indication of the turbulence inside the burner. The temperature inside the combustion chamber is measured by two instruments, a radiamatic pyrometer and a thermocouple. The radiamatic provides a signal for the natural gas temperature control valve. The thermocouple provides the signal for the shutdown system. SL 000813 CONFIDENTIAL: Subject to Protective order Of 14th Judicial District Court No. 91-U45 The combustion chamber is constructed of 3/8" carbon steel. The steel shell is lined with 1 inch of Penwalt's H.E.S. acid proof cement. The H.E.S- cement is covered by a course of 2600F Harbison-Walker insulating firebrick. The last course of brick is Harbison-Walker Kroundel-XD firebrick. 4. Scrubbers The Knight scrubbers are designed to remove 99.9 percent (leaving 100 ppm HCl in stack gas) of the HC1 fed to the scrubber using 90F lake water. Although the scrubber can operate without cell liquor, it is desirable to use some in order to control sewer pH. Cell liquor will also reduce the amount of HCl and Cl released from the stack. Cell liquor flow to the scrubber should be limited so that the pH of the water out of the scrubber is always acidic. If too much cell liquor is used, the hot, high pH water will dissolve silica in the acid proof brick and the vitrified clay sewer pipe. Combustion gases are quenched from 2600F to about 200F by the water leaving the packed section. The water also cools the walls of the quench section, the brick arches supporting the packing support, and the graphite packing support. The weak acid solution leaving the packed section is heated to about 160F in the quench section. After the combustion gases are cooled, HCl is scrubbed out in 7 1/2 feet of 1 l/2"Berl saddles. The scrubbed combustion gases go through a 9 inch mist elimination section packed with 1 1/2" Berl Saddles. SL 000814 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 4-21 The scrubber shell is made from 3/8" carbon steel. The steel is lined with 3/8" of pyroflex. Pyroflex is an organic, asphalt like compound which melts above 250F. It is acid-proof and will protect the steel as long as it is not overheated. The pyroflex is protected by a 4 1/2" thick course of acid proof brick. The nozzle faces and the conical section in the top are rubber lined. The brick mortar used is a furan resin. It is resistant to acid and weak caustic solutions up to 212F. The water distri bution parts are made of the same resin. The box beam which supports the water distribution parts and the box beam and packing support for the mist elimination section are FRP with a polyester resin. The stacks on top of the scrubbers are three feet I.D. by 37'2 1/4" long. The top of the stacks are 65 feet above grade. The top of the stacks have a four-foot by seven-foot long expanded section to reduce mist out of the stacks. This mist eliminator also has a one-inch drain back to the scrubber. The stack is FRP with a polyester resin and is designed for 125 MPH winds. 5. Lake Water for Scrubbers Scrubbing water for the incinerator scrubbers is supplied from Sportsman's Lake by either of two 100 HP, 2 stage pumps. Lake water is pumped through a check valve and underground into a 12 inch transite line. The lake water line comes out of the ground west of the scrubbers, goes through a FCV, a flow meter, and into the water distributors in the top of the scrubber. About 1250 GPM of water will be required per scrubber. CONFIDENTIAL: SL 000815 Subject to Protective Qrdet 14th wteHicial District. Court 4-22 The lake level will be maintained by reused well water intially. In 1975, Sportsman's Lake will become a reservoir for Toledo Bend water. A section of the distribution piping for Toledo Bend water is being installed now. This section of piping between Sportsman's Lake and the mercury cell plant will be used to get used well water into the lake. 6, Neutralization of Scrubber Effluent Effluent from the incinerator scrubbers would be about 1.0 percent HC1. This much HC1 would cause low pH in the total plant effluent, so it must be neutralized. Cell liquor will be used to neutralize some of this HCl in the scrubber before it reaches the sewer. Sulphate blowdown from the caustic area is now being sewered to neutralize HCl from Area B. This practice will be continued after incinerator startup. Cell liquor on the scrubbers should be kept between 20 and 40 GPM and can be adjusted within these limits to maintain the plant effluent pH. Cell liquor should never be allowed to go to the incinerator scrubbers unless lake water is also on the scrubber. Cell liquor will dissolve silica in the acid-proof brick and in the vitrified clay sewer if it is above 130F. 7. Oxygen Analyzer The oxygen analyzer will continuously monitor the oxygen content of one of the incinerator stacks. The analyzer can be switched from one stack to the other by a valving arrangement inside the oxygen analyzer cabinet. SL 000816 4-23 The oxygen analyzer is to be used to maintain the oxygen content of the stack gases between 2 and 4 percent oxygen. This will correspond to about 10 to 20 percent excess air. The amount of chlorine, carbon monoxide, nitrogen oxides, smoke, and other unbumed compounds emitted from the stacks is determined in part by the oxygen excess. Smoke, unburned compounds, and carbon monoxide will decrease as excess air is *\ added. Nitrogen oxides and chlorine will increase as excess oxygen is added. Emissions will be minimized if the oxygen excess is kept between 2 and 4 percent. Samples are moved from the stack through the oxygen analyzers by steam ejectors inside the stack. These ejectors must have 70 psig steam to work. The samples are cooled inside the oxygen analyzer cabinets and scrubbed with well water to remove the steam added at the ejector and trace quantities of HCl and chlorine. A sample from each stack can be drawn through individual scrubbers continuously. SL 000817 STARTUP AND SHUTDOWN I. General Startup Sequence The first step in the incinerator startup is starting the combustion air blowers. Combustion air flow into the scrubber will keep scrubber water from splashing into the combustion chamber. The next step is to establish scrubbing water flow. An explosion meter check is made to assure that there is not an explosive mixture inside the combustion chamber before the ignition sequence is started. After the explosion meter check, the pilot and burner are started on natural gas. The combustion chamber can be heated at a rate of 300F per hour once refractory has been cured. This is about as fast as the burner will heat the combustion chamber. Steam must be put on the atomizer before the combustion chamber temperature reaches 1000F. Chlorinated wastes cannot be fed to the incinerator until combustion chamber temperature exceeds 2200F. Steam pressure to atomizers must be above 40 psig before the incinerator feed pumps can be started or before the shutdown valve in the liquid waste line can be opened. Vent lines must be purged with nitrogen and checked with an oxygen meter before attempting to put vent gases to the incinerators. When starting vent gas to an incinerator, the 10-inch shutdown valve in front of the incinerator is opened and the 4-inch vent valve is closed. The valve to the incinerator in the plant whose vent is being put to the incinerator is opened and the valve to the scrubber is slowly closed. Liquid waste and vent gas waste from the plants can be put to the incinerator in any order. However; natural gas flow plus vent gas flow SL 000818 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 5-2 to the incinerator should exceed 250 SCFM at all times. The flame pattern becomes unstable when the burner is fired at rates less than 250 SCFM. II. General Shutdown Sequence Vent gases and liquid wastes can be taken out of the incinerator in any order desired. Vent gas flow should be gradually decreased by slowly opening the vent gas valves to the individual plant scrubbers. When flow from the plant is low, shutdown is completed by closing the valve in the line to the incinerator with the shutdown switch. After all plant vent flows have been sent to the plant scrubbers, the shutdown valve at the incinera tor is closed and the vent valve to the bottoms plant scrubber is opened by pushing the "Fume Waste-Stop" button on the control cabinet at the incinerator. A blind must be installed just upstream of the orifice meter in the waste gas line anytime the incinerator is shut down and not restarted immediately. Liquid waste is shut down by slowly decreasing the flow to zero by reducing pump speed, blocking the pump suction valve, and then blowing liquid waste through the pumps and into the incinerator. The solenoid valve is then closed by pushing the waste liquid flow stop button at the incinerator. After liquid and gaseous wastes to the incinerator have been shut down, the burner switch is turned to "off" to close the natural gas valves The combustion air blowers aye allowed to run until the combustion chamber is cool. SL 000819 Minimum purging time is two hours. CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 5-3 Steam is left on the atomizing tip until the combustion chamber temperature is below 1000F. Steam should not be left on the atomizer until the combustion chamber is cold because the refractory will absorb moisture. If an emergency situation exists, the incinerator can be shutdown using the emergency shutdown button in the control room or using the "burner off" switch at the incinerator. If the incinerators shut down due to loss of scrubbing water, cell liquor and combustion air blowers should be shut down as soon as possible to keep from overheating the pyroflex scrubber lining and fiberglass reinforced plastic parts in the top of the scrubber. Scrubber water flow should be re-established as soon as possible and combustion air flow restarted just prior to starting scrubber water flow. III. Shutdown Systems A. Incinerators The incinerators shut down from any of the following conditions. 1. Low combustion air pressure - 0.75 psig. 2. High or low natural gas pressure - 2.5 and 1.0 psig. 3. Loss of flame. 4. High incinerator temperature - 2750F. 5. High scrubber temperature - 220F. 6. Low scrubber water flow - 300 GPM. B. Liquid Feed System t 1. Shutdown of incinerator. 2. Loss of atomizing steam pressure - 40 psig. 3. Low combustion chamber temperature - 2200F. SL 000820 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 | 5-4 C. Waste Gas Feed System 1. Shutdown of incinerator. 2. Low combustion chamber temperature - 2200F. 3. High pressure in the vent headers. a. Per-Tri - 7.5 psig b. OHC - 7.5 psig c. EDC - 10 psig d. Inc. - 4 psig IV. Detailed Startup Procedures A. Lake Water Pumps 1. If both pumps are down. a. Close pump discharge valve (10 inch). b. Open 4-inch recirculation valve to lake. c. Start pump. d. Open water FCV to one incinerator scrubber. (Combustion air blower to that scrubber must be running.) e. Open 10-inch valve to scrubbers slowly to prevent water hammer in underground transite line. 2. If one pump is running. a. Open 4-inch recirculation valve to lake. b. Ten-inch discharge valve may be opened before or after pump is started. c. Start pump. d. Close 4-inch recirculation valve. SL 000821 CONFIDENTIAL! Subject to Protective Order of 14th Judicial District Court No. 91-1145 5-5 B. Incinerator Startup 1. Start combustion air blowers. 2. Establish at least 1.5 psig natural gas pressure up to the double block and bleed valves. 3. Set natural gas TCV at the startup position. Burner is started with natural valve in the open position. 4. Set the combustion air valve at the startup position (as far closed as possible). 5. Start a lake water pump and establish water flow to the scrubber. 6. Put burner "on-off" switch in "on" position. A two minute purge time delay is started when switch is turned on. Purge complete light will glow when two minutes expires. 7. Remove sight window on south side of incinerator and block off purge air to nozzle. Make an explosion meter check on contents of the incinerator. If contents of the incinerator are not explosive, replace the sight window and turn on purge air. 8. Depress burner start pushbutton and hold button in for 5 to 10 seconds. The solenoid valve in the pilot gas line will open and the ignition transformer is energized. The "pilot on" light also glows. When the pilot lights, the "flame on" light will glow and the "burner start" pushbutton should be released. Ten seconds after the "burner start" button is depressed, power to the ignition transformer and the pilot gas solenoid is lost if a flame has not been established and startup should be resumed at step 6. SL 000822 CONFIDENTIAL: Subject to Protective . o 14th Judicial District Court No. 91-11*5 5-6 9. If the pilot lights, the natural gas double block valves open and the bleed valve closes when the "burner start" button is released. Flame from fuel gas is established. Ten seconds after the "burner start" button is released, the pilot gas solenoid closes. If the fire-eye does not detect a flame, all the gas valves close and startup must be resumed at step 6. 10. Put 10 to 20 psig atomizing steam pressure on the atomizing gun while combustion chamber temperature is between 600F and 1000F. 11. Start up liquid waste or vent gas after combustion chamber tem perature exceeds 2200F. C. Waste Liquid Startup 1. Check valving on liquid waste lines to be sure liquid waste will be fed to correct incinerator. 2. Put 90 psig steam on atomizing nozzle. 3. Push liquid waste flow "start" button to open solenoid in liquid waste line. 4. Set shutdown switch on pump to be used so that correct incinerator shutdown will shut pump down. 5. Open block valves in liquid waste line and set variable speed drive to "zero." 6. Start pump. 7. Increase variable speed drive speed until desired flow is obtained. SL 000823 CONFIDENTIAL: Subject to Protective Qr'dfer of 14th Judicial District Court No. 91-1145 5-7 D. Waste Gas Startup 1. Remove the blind in front of the waste gas flow orifices at the incinerators. 2. Use N2 to purge line from plant whose vent will be put to the incinerator. After 15 minutes purging check the line with an oxygen meter to be sure no oxygen remains in the vent piping. 3. Set 4-way shutdown switch on the incinerator control board so correct vent header or headers will be shut down if an incinerator shuts down. 4. Contact control room whose vent is being started to incinerator and have the plant's shutdown switch put in "on" position. Also have air to the scrubber valve cut off with manual loader so scrubber valve will stay open when the valve to the incinerator is opened. Put plant shutdown switch on the incinerator control board in the "on" position. 5. Push the waste gas flow "start" button at the incinerator to open the 10" waste gas shutdown valve in front of the incinerator and to close the 4-inch vent valve to the bottoms plant scrubber. The start button must be held in until 1.0 psig waste gas pressure is established or the shutdown valves will go to the fail position. 6. Have the plant's control room push the reset button to open t`ie valve from the plant to the incinerator. 7. Have the plant's control room slowly close their valve to the scrubber until it is closed completely. SL 000824 5-8 8. The waste gas flow "start" button can be released when waste gas pressure reaches 1.0 psig at the incinerator. 9. Valves to the bottoms plant scrubber and to the plant's scrubber should be checked to see that they are fully closed. Valves to the incinerator should be fully open. 10. Low point drains in the plant's vent line should be checked to see if liquid is being sent to the incinerator through the gas line. SL 000825 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 Liquid Level Inches 0 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60 63 66 69 72 75 78 81 84 87 90 93 96 WASTE STORAGE TANKS INNAGE TABLE Volume in Gal. 5,169 5,599 6,029 6,458 6,888 7,318 7,748 8,177 8,607 9,037 9,466 9,896 10,326 10,755 11,185 11,615 12,045 12,474 12,904 13,334 13,763 14,193 14,623 15,052 15,482 15,912 16,342 16,771 17,201 17,631 18,060 18,490 18,920 Liquid Level Inches 99 102 105 109 111 114 117 120 123 126 129 132 135 138 141 144 147 150 153 156 159 162 165 168 171 174 177 180 183 186 185 192 195 6-1 Volume in 19,349 19,779 20,209 20,639 21,068 21,498 21,928 22,357 22,787 23,217 23,646 24,076 24,506 24,936 25,365 25,795 26,225 26,654 27,084 27,514 27,943 28,373 28,803 29,233 29,662 30,092 30,522 30,951 31,381 31,811 32,240 32,670 33,100 c, Si- 00082b CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 BOTTOMS WASTE TRANSFER AND INCINERATOR FEED PUMP CURVES 6-2 BOTTOMS WASTE TRANSFER AND INCINERATOR FEED PUMP CURVES 6~3 WASTE LTQUID FLOW VS COMBUSTION AIR VALVE LOADING ! I 6-4 "[ SL 000830 Service No, 1 EDC Plant Vent Headers No. 2 EDC Plant Vent Header Organics Disposal Plant Steam Header Waste Storage Tank No. 1 Waste Storage Tank No. 2 SAFETY RELIEF VALVE LIST Size 3X4 3X4 2X3 6X 8 6X8 Set Press. 30 PS IG 30 PSIG 145 PSIG 24 PSIG 24 PSIG 6-5 Temp. 120F 120F 650F 200F 200F Plant SRV No EDC - 162 EDC - 161 OHC - 324 OHC - 325 OHC - 326 G to *-* c .& Xj rt o- Sr o n C4 rr C z. & rr O H- C *O VI CJ -! I--'I-- o J rt Hrb 01 VT rr M Hn rt- O c tf ft CO O CO C*> Service Bottoms Waste Transfer Pumps and Incinerator Feed Pumps Waste Storage Tanks (Primary) Waste Storage Tanks (Secondary) Tri-Ethane and EDC Tar Trailers Per-Tri Vent Header OHC Vent Header OHC Vent Scrubber O Hi W I- C O' rf u* tr (D a Ct c rf no Q K' 0 2; nh*- M VD $J H C3 ^o W I rr (fl n! r U1 fT Pi (5 O (+ a n. O). 0 e RUPTURE DISC LIST Size 1" 6" 24" 8" 8H 4" 6" Rupture Pressure PSIG 100 24 29 100 10 10 5 6-6 Temperature F 350 200 200 120 120 120 120 Group and Comm. No. 18-699 18-744 18-757 18-755-1 18-658-2 18-643-1 18-651 6-7 LUBRICATION SCHEDULE FOR ORGANICS DISPOSAL PLANT Machine Part to Lubricate 1 & 2 Incinerator Feed Pumps and Bottoms Waste Transfer Pumps Warren Pump Bearings - 2 Vari-Speed Hydraulic System Vari-Speed Gear Coupling Motor Bearings 1 & 2 Incinerator Feed Tank Agitators Phila. Gear Box Gear Bearings Coupling Motor Bearings 1 & 2 F.D. Incinerator Blowers Fan Bearings Motor Bearings 1 & 2 Lake Water Pumps Goulds 0 t-ti to \--' ccr <T <--! Pump Bearings Coupling Motor Bearings Lubricant Method of Application Mobil Compound BB Mobil DTE 26 Bath Bath Mobil Compound DD Mobilux EP-1 Mobilux EP-1 Bath Gun Gun Mobil DTE Oil BB Mobilux EP-1 Mobilux EP-1 Mobilux EP-1 Splash Gun Gun Gun Mobilux EP-1 Mobilux EP-1 Non-Lube Mobilux EP-1 Mobil DTE 797 Gun Gun . Gun Bath Service Frequency 1 Week 1 Week 1 Month 6 Months 6 Months 1 Month 1 Month 6 Months 6 Months 6 Months 6 Months 6 Months 1 Week Change Frequency 6 Months 6 Months 1 Year I Year 1 Year 1 Year 1 Tear 1 Year 1 Year 1 Year 1 Year 6 Months Z & rt Q O K- 0 2* *o 2 VO y ^ S I--1 *-* o Rj 1 ^ HK-n H tn r+ > Srr ^ C i-t H* (t> $-0 o 2*o (5 cn n CO r- CD CD Cb Co AO  *2 Oj CO? ch4 HCl C2H4 C2H4 EC VDC CIS TRANS EDC MC ICE Til m TETIA PENTA HEXA C< HOs ROW WT lbsAi* % 338 23.5 117 8.2 238 14.4 258 18.0 100 7.0 200 14.0 144 10.0 TARS AN DUNK HJO KCI3 OTHB TaOOTWAL 1440LBS/H* 244 SCFM aow WT LE/H* % 437 24.3 158 8.0 237 13.1 404 22.4 108 4.0 204 11.4 .aow WT LE/H* % 862 31.3 617 22.4 458 23.2 8 .3 171 6.2 145 8.0 4 0.1 8 0.3 325 11.8 33 1.3 rot 4.0 1800 LBS/HR 330 SCFM 47 2.4 2750 IIS/HR 411 SCFM aow WT lea* % 3354 21.4 5550 35.7 3104 20.0 588 3.8 600 3.9 754 4.9 492 4.4 17 0.8 150 1.0 aow WT lea* % 2496 23.2 138 (.2 3321 332 1656 532 4 86 294 302 382 308 31.0 s.r (5.5 5.0 0.0 0.7 2.7 2.8 3.5 2.9 344 3.3 58 0.5 92 0.7 aow WT LEA* % 2496 23.2 138 1.2 3321 332 1454 532 4 B6 294 302 382 308 31.0 3.1 15.5 5.0 0.0 0.7 2.7 2.8 3.5 2.9 346 3.3 58 0.5 92 0.7 a'.BoS/wYflt 42 3.4 110 4.1 7 0.4 7.7 142 7.8 40 2.2 208 11.5 472 24.1 545 31.2 4T7 4.0 414 3.0 414 3.8 (5520 L BI/HR 10740 LBS/ttit 10740 LBS/HR 1814 LBS/HR (875 SCFM 1441 SCFM 144}' SCFM 2.6 GPM 3orn&*& W^5rH' N2 02 H? NaOH NoO TFLOOTWAL 0 aow WT aow WT aow wt US/HK % L8S/HR % LJS/lHR % 17,400 75.5 17,400 75.5 5,300 22.7 5,300 22.7 410 (.8 410 i.e ,0 aow wt LBS/HR % acw wr LflS/hR % aow leA* W%T aow WT lea* % 19,850 73.0 2,990 1T.0 4,350 16.0 19,850 73.0 2,990 11.0 4,350 14.0 27,200 LBS/HR 27,200 LBS/HI 46 GPM 44GPM ^2 Oj 4H-O CC2 NoCt HCl Cli NO CO TOTAL aow FLOW WT lea* % aow wr LBS/HR % @ FLOW WT lea* * FLOW WT LEA* % 1 20,100 44.0 20,100 44.0 ; 320 1.0 320 1.0. 2,430 7.8 2,430 7.8 400,300 98.4 400,300 98.4 8,500 27.1 8,500 27.1 8,720 (.4 B,72Q 1.4 3.B 0.0 . 3.8 0.0 1,250 0.2 (,250 0.2 .4 0.0 .4 0.0 7.3 0.0 7.3 0.0 1*8 0.0 1.8 0.0 i 31,400 LBS/HR 7500 CFM 7500 CFM 410,300 LB/HR 010,300 LEA* 1220 GMt 1220 GPM REVISIONS QlGWfrfiS CVG.A/0 P-75/ XXZ&&# t6f '3*3 &JDG**/ '&&cr~2 j 04/C 73?/ u M . CONFIDENTIAL: f ""`fa No. 91-1145 INDUSTRIAL CHEMICAL DIVISION LUCE CHARLES, LOUISIANA n.r. ^S~ mm*. Z"' > wr Hit turn DWgGS^ -- AOOO/ - / M A TC H LIN E - FOR C O N TIN U A TIQ W SEC O V tf. & aA -IO Q O : Vv-iss- I LtLL LIQUOR) Z*-400*PU42 (NATURAE GASl a"-IOO-Pt.>4 fSTtAM) t'V- iOO - PLT9 (NITROGEN) l>t`- 6QO-PLI59 (INST. AIR) y-eOO-fLg (WELL WATER) ; Ifam d'-fest-sx. Od a'- iooo - pl a4 10"- 1007 - PL 107 1004- Pl*A S"-/024`JN.49 i/ *-1 <AfilT*fTORl HA-&I- 1M M> (MOTOR') v&Pi .f*aWun'9RtoO Mk-92-tW U- h**>r /W/4-r !- Vv-iss----^ Q-zfiaoa-M.-* K__________________________________ --------------- n-- >tw** . 1*V?4A ytfi/* W-TO - PL 49 (A`- TO - FC4B X" Jk'l-MA M~- /OIS'^49, . %`asr ) K-t fMOTOlO L/I J2 REVISIONS /\eataM. acksich /** . s-/Z- 72 mr#r*iAt Asm. atv/sjov Sn. ti-3- 74 & iOMWOV b .4* : /-a-ya d-./art-A* a* atm *0-W .j F r-Toi-n-*# (**' tf V-*W 'tMU HOtlU V*24A jtf-M-AM'U Y$0 inn i i>i mut' WASTE STORAGE ** 1 JMM T-t 69A-60-//37 ft *V-wj \ to r $mm hozxu nc*isu moii s-mmXAOoVftt/AAefy/jtoifscton*etwax Si/aay //^a V^'V<|7 TT~T t^TW-fr1 T~T%; <***"- %44 dr-tat-m* '' $PMtE UOZlll 1L. rm*M/ *T ""WeTY SHOWER - ;-w IW-tM i*Vi* nee. *ft. I UA in A? #AS7 ^ STORAGE WSflfcRK MOltkt^ IA.NK ctdrot/AfOso* 73U &VG9Yjreo,o.^ 3S k*' 7---2. 68A-6 IStktfttRkC HOSCO > /tew---SJ! frC*/O*i/rV^iM/AirXO*Mtey>_ * ' l*T Sk-^T t'AAAAr in ict r- VV-MK frf- tTrf TT-ffTfr., UTILITY STATION r r r tee. SL 00083B **v e* snmunuM g_ -J? v*t.vt ^mZ ' < S ri r wo. --y-rsr ry^T-^l Vkrv.sn r-ios -pi4s_ V $1 CONFYft'feNTlAt,? Subject to Protective Order of 14th Judicial District Court No. 91-1145 2?ei/A& *60. $ /T'V/ 1 r* Z*yaR< 49 -~%*-0rt-09 )'-T04.-RtRR s/*V-/f<s -W<g--r--@ @SSH SUCTIOU SCRUM ITM IVv-iw - ^----- >* INCINERATOR FEED RUHR No.M P-5 UA-I9-/W M-5 UA`WJM y-S *3A-33-3*4 %`an-pit M-an-na I MCIMERITOR FEED PWR Mo. a P- M-6 **A'4O*JtS00 ***-32-304 ` VTRAMMMt VAlVt Wnt H* ---------- Pf* r n. 'U&Ma INDUSTRIAL CHEMICAL DIVISION ORGAMCS DISPOSAL PLANT FliW SHT. M^hgyjgr mli ' T-tQ.fj .ru. tm. -f\JL 000838 vurs- Wa t*A. OH ta5THAlOt.E ^'S TlAuCtTKbWcOpJJacBkO. oUTr/T^ *T>p C~ 8.71 Aj7hi5 70" 4 ft 4'^TtS f'T 7 4Vti 7-V 4*6'/*.*^ 31 52 21 12 12 40 S3 43 1 02 [*,4^E 7-4^ t4'L'l tz 4o fQ 2 XjSj K at" 7 * 7C 13 S,4,lt ^-r 9 1 21 72 ,7i i 4-^,4 e'-t- 7<4il?l 21 72 43 U 6,^I4 70" 7*4iS M S2 S3 6,T tX<L*3 sS^. >**4 t.r 7lsL*I ESS ftVL. 3.7 (It 4x4^3 41 2& 71 I f( 56" Wk.`~4 8" 7X4V4. Bt__ 4r EL4^3 45 Z0 76 5Z It ss 61 1,4,IE 411- 70 73 *E 48" 7*7VlKiV 4 Efi 7t EOT 4x7V*',l 14 4i 62 XTCM MO. AT^P ?A SiCA. SC. No -2 AKCN No. 1 ARCH STKA16HT TOTAL MUMBeR REQ'D PER R'NGr BRICK SCHCDULE h * IO i 1 4Vt | 1 1 T JS \ 1 3'4 | s'4 4 NUMBER RINAS H.N *25 H*ui. -2} H.W. -*3 H.W. -20 KORtlHDAL"*-t)" H.W. KOItUMDAL 4y-0" KoltUH6AL*'X-P*1 H.W. -1* KOKUNOAL 4K-D* H.W. -15 H-fe- *K HOKUNDAL "X-0" H.W. -2L KOHUM&AL *X D* HORUHDAL "4-0" HOKUNPAL'X-D" MATERIAL lTft|* fee Rttfo yoo VT. M4 4fi nauc. SPAObNCu. PtHL 3 41 SO LlMlN 6, Wet- sr*.*.. C-1' ^,o t. '^.t-c. jMMi OfL^UKL 'V~5%P.*7-l X.oVfc BY VV, K* KHkftHT T* 66 USTAULfi-p "^(g) r Ml MT* * SI * *tss * 3i.fr * JI3K t EZ * tw * Z3(o Mr It! * * 7JO*1 * a*? HtC 6 3feOI? NTt * flap 1 i i 1 i i nun ho. , t t 3 4- S 4 a * A II a 13 14 rt 16 17 ffi 19 20 Zk NAME BR C"K - HATKRiAL-srccinciruM ,.f u ''4.- ^ ^ SLWSLi H.W. KOWWDAL*X-D,` No. 1 AKftH H.wt rife on csoal Nae arch *4tO h.h< -u on equal* HO. t ARCH 5Api H.W kotiInml *id* 9TKAUUCT 9X4^2^ . H.W KORtfHRM.-V-O" Ho t **L* i1A\* 3. H.YJ. -U OK EQUAL No. I AKU4 9K4i^X 3 -a 1 ON EQUAL ******** 9tt4lfcx 3 BLOCK eCMBKT &LhJL**afcM cbmcut CASTAftLC TH. PMMicZ htdhbcom sl-eiCo Mnu WHLT HIE ACiOMU.T CBMCKtl ACID PROOF CEMET UMINfr HTATtJHEBf ^FrMRLSX HO STAR 1r Sfe riA. HiW. COKALBOND Uul toRAUTT BOMQ c B-'Vb'Al'-T'AEE'-oX* **LL TO 8,vVl OO. VE-rtMginVrfH, Roll To {LUlu H* X SCX-Mr'-'V Foci. To El" I'D, KM & 8-tft.o.4.4W`S'klf 3-l`jt' O.B.RfcS i*Wt M 'j^" O.D.K Vt!4l 46*2 ( IS * l i KLAN&C 25 RCie-yu HIM -2o A 4 Stun.v fcpH SHhfA FOIt CMC. tiHC* C`L-KiWt>rCaXAJt7444. *4 COVER. IS TEE (q> 4 tfcti NED* m a -wab^tctfD, 2 Vv # neoo 4* 24. SI&HT &L433 27 dlutwr za BOLTS 4 HUTS 23 Shell. 1- IO'Oo4-B- s c.t; A4X Sure* Ao& c's Vft-nxiA'L*. C * '/47v*4lt0 A4'^ w IOOD i Se^T Me 15*1 30 C KVTMlLtt H.W. CAT*lA9T 31 TZS. l'/^-*, LckTD H^.KoAOUMt *.<-* A AftN3KAP* St a*ioc. **. HLmN4 **U*iUK, ,9fT*'JTP*T, u rKDNT STAND 6-0Z-tl41-B L ttHtoiss- i^Dia c c Norcs: l- RIFRACTORY NT. 41,800* c STClt WT 1,2 * Total wt. i,oo* sn fMO V FD LOCATION. 6 ALL WILOS TO BK CONTINUOUS ^flUfctlXCC^riWWVl NOTED* *- Paint m aooo<loaho. rw otca. v^,ny.-40iov *L S-RFAAe.TO.RT To Bib ^TAU.V...I.A. Fl.U..t.l....A..?..T..IL- ^O^lM_^_f4OQLLA.Vft 4t.A0o4*%Mu.* WT B M lAvnuLomc-f^3 PMT -TO M KPV'-'S.O AfTtK. uy-46 ^ HT&, (stt, WN6 4-0*-HHr'C>) &6 1 PirrftO TftMTmL., OVKHT*lT\iS SHOWN AIt it P(L IN^lktflLAKTCfl-- OHWT* C-SUAAAC.%. MLtfKtKTiOM TO )HStmvk.|Hta tltM,! it |l\ CONrUkCTolL. "0:rTtWS &K ML-rHSii-k.*1 7- 4 ALL ItVF ItACTOfry /"UvTENtAL* 6Y THtNMAfc- s A At o O'NCCT, >H5TA.LU to BY THEWS Bi V IMS FOKtWN OP MWPUE* UMBK T5 Sft. FWJ.O NtiMAXD RFTSR H-E-L. (riDI ft) IS VmViXEO | CVfftD. ^6 C b*ck 'IO-olase cnM *ock nw< WV6T0-K but trr.q) an-T6AiioH TO ee tur fWE* i.ot*eMSBM* wTwsremjM fFncmtcutm AR<S UKn Iti t>ie.wo TO Mkte. ui j 7 & J. 11. XttwS 23ClhUftTtfct 6 SStHeTtO* NM. khk( FK. tofckNPKoAV***) BY lwjVfLv6.IL., At 8 {%Y Twee.tAACy ^ .v IX- RBi/nOve ALL SUM.P de%v v*jia\tW TTtH '1- iamll, Co^t W c-oj^rl**- kjtffH * & Aa'i " ST" SYMBOL f 3 2 l PkCTUftlS R.T S^^^B5D-Kw-mC.El46lthLTA 0*M*C*.p*E<.e. VDDtD DOT MW 6 LUtK^ 4^45^. <L nti-it. 0UL AttOt QiYt T tl. X\ 4 IT. IDIt* Ms 4< iODV BRtYM. DODfik 13. 46 K*H0 W*T* IX 4Le I'LOl WL I4 4 iSl'TRK, QB IT. SO. EOe.R t". 1 - M.WA^ T-5t. fef`7 C.D. WE3 Co`-S, 70 T Q. UrE X.B.i4ia.S (OS I.WN 41 . **\ tut. WU 16. tRiLK sc MCE ttY.T* Suit AlBO7ECJt jH*tS.ijrleVAeEe*Wd. V. *tt'lUaiw/n: i*wKt,rtrvlooSbEat.iOTys.i.I2M'* .*eSajtftyi.ll.le.'11313f,J4iSfc Ha.' H-Wlt 4t4- mo wn twaifVAt - & ' (f-piE 4*- RCLOO.TCI3 TTt*4 S<l,lBDtrr({9>|<l^i ^NT t > WNH *Lv *N-T6 NofE Y.rhtr wDkEtat r ------ 1 , trrn 31 wAB.iM^viMWEOtStt/TlRisatMw^ Macpi dk mwm. RD.| S-*t7t rfAf AT. ir Mkv UPL<4* KVf.3tr1. A*K,A>D 4t T*t' 4S,*LlC3C Xt,t7. i* _ iSBo' c VttL t*- REVISIONS *r OATT iU. i 4 134 * SCO f-T> f f It# 2. & 34 BACK ETAMO 3S 3W Brick P^C-KIMti 37 bUSKIHC) 36 PlPt 31 shell- 40 fcOLTS 4 UuTS 4* fLLimt 42 Bscrs t HUTS. 4-02-H4AH3 H.YI. KONftL 4X- J NM 4*0*44'4*i ALBEEToZ (WE ^p4. c* t* y^isis*1 C.t. t IM T.O.(. iV^-.LE ' C.t.E, 5.4 *447^ c l-4 it- Rtv h-^; C.t 'L'^OD.mjItRAV^ 1 {Al U O'* mo. (E E*k ~`ir^'4(Sr"^ Z 43 SUKb planct ^'`V-Ko* t.F. a 44 FLM4E ve-t; - 'So* (l*. z 4S- 30 S6JT- 46 47; i,", r.nra- i!;;: .'i-amiintn !' '< PIPE. .t.I. v.ltH 40X , VrELBCC VOIRE FR1L C.%. 12 Cj*. tut CIM'HC, ("q^} WV.A'KWiCiHT* KTA*PL&> J TNERMA1 RESEARCH AND ENG4N0IH0 CDRP. CONSHOHOCKSN. PENNSYLVANIA SO&1 NOT UWORK TO un m STEKL AMD RcrRACTtafV Ditaius AMD* A**"r Xnciweratoa ^5/^** v5*J 7"s V**10' 31*6-02-114* -D FLAT (FOR VtREHCH) ML SIZE AIR PSl PUN V3\% (a) notes (see table) HOLS sa>CS "A-i4)HOLES Elf. smsCD 4S SHOWN STTAUlE s CLAES 2, 20 EX. Fitts UNDERCUT AS REQ'D FOR FACE ID MCE CLOSURE (CENTER ON 1.0 De77?/L Rhst **9 (WOK CCW ROTATION) HOLM JWIES'8 6 (4>HOLES AflMUY ; SFMCZ> OHt's Section'a'-'A' j'sties `S cNir FUME INLET LOCATE AT R0* STEAM INLET LOCATE AT 70* IB0` NAT. OAS INLET LOCATE AT O* NOTES: 1. ALL NACHINCD SURFACES TO HAVE iy FINISH. 2, COAT HACHINED SURFACES OF C.S. FWRTS WITH RUST PPEVENTATIVE. X APPROX. WT 4 . PART Hi S 70 as THREADED SOW ENDS. OHE END STD. PIPE Tup., ONE END POE SPECIFICATION IN DETAIL OF PART NS ? . 5 RWT NS* IAjITj 18 4ft SNOml OUT <FPOSfJICN SEE BHD WEN. A. THI% aim. IS AOJULTHELE tcnvCEH IGT-tA* 7. this Dim. 11 KOJHSTnSLE StTRieEW mini ) e. FLANW (ITEM 1 TO Bt WELDED TO XTO', LG. WITH ECLT HOLES ROTATED 7tfe* CCW OF STRADDLING C_, ohill/ne DsmiE mr tfps n'd/a- fi notes oh J<=.. l_.. SEE note a &|SBL DRILLING Pg-TAtL, Part* *4. I-- (for C.C LO RotMI Ohs) i____________________ t5 ICp 1 , 1 ia(m*t<- ^________ : 14 T' MnWVfMOMATNRS 7ES C* A N'444^Cj^ FUfi*0 :'*`8**l8e(* F.r. F\ AHOB. tUH6} C***- (SO* F.F. CtHTaiHS *AHe& mahnot-c PLAT *SS.a+i(.o,.^ PUT Insert * ? EJECTOR 7\P 5BAUN6 Ri>tt B V8CW.8BX 67 Ut. "1^ DNE IT-OO-OAOtA-A &-RIW yx,% Putt 1-IEL-7TFAT OWE. n-oo-oji-A O'PINS RAH REA -OIN-T7R4S ' ] V- '50* REDUCW& feUSYtVRG aojustihs Pucre |'<t A^ -125* HEX. "''A nV'a** TMROWtD TOC< |e'*' VI3HC *7L CALIBRATION BAR " ^4 DIA-X 7**. HE. NUT V^-AS N.C. BOLT GASKET FLANGE %-// AX HJ48-H- m 1'oJix *HlA,ir */A (a) O'jw-Mtja aw t%ac. ev* 4*-ISo'*F.7LlFlt#r" PIPE PiPG PfPE n CCNTe**** RUtOJFS n CffNTM/N* BUSWMB *'SCH. X *e\ mtm%A- a *+ a tofte" * A1X 19 A> "ATfiM xteVx-tM "4 ROLL R-tHho. II A.A% A 1* out. <7-00- oan-A*4 LS Cs^r> pip* (err,) m.j3 m&S.-L.* HL.TA.-1.7 *- _ I oVfco. 70(^Lt. x H. t(t%WSlLBSHV'4*o a4 14< ' 1* Dins. OF FINISHED `PIECE SL 000840 CONFIDENTIAL? Subject to Protective Order Tol 14th Judicial District Court No. 91-1145 --rUS* Js '-V +***** : W.lN^V- tuts 01**14, Ateto.xr.st i "/a. tMtCf.j mri pp-nitthe ji*m. t UOKB NOTE A. 1 Ut P*.l LRWIltoRU -, REVWOltS >. A M-n-71 r V-Zt-7L 411 BT t lAx S DATE APP. THERMAL RESEARCH AND ENGINEERIN CORE. COHSHOHOCKCN. PENNSYLVANIA J BURNER INJECTOR Fume - Nat. Qas Steam Ato-uzed ] NO. 17 -gfft SMi/raat/A/ cottact Mt &/C/ASCAATDT //-/ ^ TCAAtT 3ATT7YSAS7SAS i /M3TTO>A*AS73 # A/A2/AA3 /A//A4C/A/T4ATOA3 TZAM2 3ATTTY CA3/A/TT3. STT T//TAMAL 4TSTA4CJ* >*<*. *3/-OS- 337 /SAWt/M/TCO&GSTMAVACTCOWA 7MX-C2T TiA/43 SATTTr 3Y37TM ~ \ 1< SA/-/Q 4 AQ8/r/OM,MAWTAMB C&/TACT, 62U2MAL MLkC. S3MSA//TC#. CONTACT OATA/AT/OA/ 4$ /A/ o/catto /a/ cmajst /st/ow. Jf KS=1 [ujl TO* CCk mLa Ol a `OJ Qtfl O n*A_ OA/-3 --iDL-L^-- &*S-A Uirf, A/OTT": SA/-3, 3M-4f3*4-9ATT 2 FOS/T/OM MAtUTAHTO CONTACT 3TCTZXA 3X//TC//43. SU//TCH OP&AT/OA/ COA/TACT fV/nAAOS/TAM a 34 0OX0 X *O X X 0 c O X00 dO X 0 0 0 XX0 4 0 X0 X O - COA/TACT AS S//0MY X - COA/TACT SA//TC//TO /vs. SW-/Q SW/rCH fUMCT/OA/ *t tMC/fi/TTATOT T4/A-M0C-OMC YTA/T TO OCTtASOTT 2 /TC/A/TTATOT 7W/T - TTT- TT/ VTA/T TO 3CTISS&TT */ /MC/A/TTATOT TT/T-FTT-TT/ VTA/T TO 3CTOOOTT *2 dYC/A/TTATOA 7T/T - TOC- OMC VTA/T TO 3C4033TT rt /A/C/A/TSATOT TT/T-TOC- <*0C TTT-TT/ VTA/T TO 6CTi/33/g *2 JZAC/A/TTA70T OOA/A/ wf /HC/A/TTATOT OOiVA/ 2 fMC/A/TTA TOT TT/T - OC> O/VC, A44-T4/ A/T TO SCAt/SOAA T~ LfOLO TOM SWATXCa/ C/J3V. OOASF, err. omc "fIaa0/4tOSAAM//iC/r3oo0M/3MA0s3ArsArAMtA)AtT0047404 ) , AC- 902 (fiTATA? CQ&TAQi ) o* . -4 32-902 -H4- MS-902 -?/* L'2-,AOS. AtOMAA/TAfy COA/TAC7fAy S3AA44i&0 TTTOTAf CJt-9C2 -T'4- *3WZ ** CA- 902 -^0- SzSli. nZMZ ~7^ . /AtSTTVMTA/TS f A//T/A/S XV 0T&AA//CS 0/SA0&AL A4.AA/T COA/TffOA 4AA/4U MY <S#C CQA/TTOA JfOOtM. STT jQA/O'S. OSA-T .* ~r<: .tfAA/.soAf (AAA-74/ 4AA/rt/5V* AOA/2. CAT. S*4aSrTTBAOCMTVSmYT STMV4Atf st.-fsj . (arAT/c awwiM) SMa //TV* 0042, CMT.m9> TOC m2 COA/TTOA \ AAA/41 (COC / A/AA/T SJNfTOOAtN SYSTcA) J/4S& 60MZ. CAT */Q, ABC m2 COA/TAQ2.) 4AJ//TL (TOC "*3 A---t-A----M----T----S---A*iS|Tr)OOi/A/ S VSTA/f) (sUP7Cx`c9o0v0/sm) ) STS. 0~ COMOitt, <s SC-900 -ri4- aos-9oa [JAod s&SSg#8B&!?&,'t.uaa/ CA. 90SA CA.90AA -Hhr CA-9QAA SC- 90/ P-.2&. -&J^6L PC- 90/i (STAJVC COA/TXOt) TSATTOjCOH-O- \U Lt O O- CA-9QOB -H5H- S9Qj -O-S^O-- U-^4- 3U-3 ' 2-^OS., AiA/A/74/4/SO COA/TACT /A/^TAt/A/SA/T3 S MAMAS /A/ TOC T/AA/T ST*r ?AS0'& 0OA -3024 OOA- 7047 amr-SAAS- 2-/*C3.. S44/A/TA/A/AO C&VZ4CT SL 000841 REVISIONS COKFIDE^TIKL? Subject to ?rf*^1i;jet^urt of 14th /A/STAUMTA/rS T A//4/A/0 XV 4ACSCS G f 7 /A/^ />TA-TA/ /T/.AA/T C0A/T40A AOOS4 S >*SG'S O3A-33S0 f 03A-S3S?. G<?A -7C47 OOA 3024 G>3A - 3330 TOC AXAA/T- Ti TC. A43T4. - OAOAA//CS O/STOSA TCAA/T-TOC SAKTWOTSA/3Y37TM M/JT/A/OB/AO&LM fc/iAYCT&OX OTTA/i.3 TOC TCA//T *2 CCVUTAOi TA/VTC A//T/A/T '7/ TTA-7A/ Xt?AySSOA/-/A&TT/S>tT/YrAT&A4 TTA-T4S COA/fTAA/TC TCTCTT/CAi. MAMV.STTJ C3A-333T ` ~3A-33S9 '7/&T4-T4/ CX^AA/ST?//- /A/STjec/SA/rT/JAT/OA/. AT4- r*/ COA/TTO/^ A4A/* T/TCTT/CA/ A//A/A/0, 6//T4. ?/ "CT /A' TAs'.t^.isOV *.\SMTA/TA,,04/ TFT- TT/ ccwneoz /HA&r/ T/T7/e/CAd MX.VAAZ. 3/ZTiZ. gtj&, J6acott & Soviet 0(3-3 , INDUSTRIAL CHEMICAL DIVISION LUCE CHAMES, LOUISIANA ORGANICS DISPOSAL PLANT EQUIPMENT E 0 C. OHC & PER-Tft I S HU TDOWN E LE MENTARY , A/0A/T _DWG. 6~8A-51004.0 CONFIDENTIAL: Subject to Protective Order of 14th Judicial District Court No. 91-1145 Liquid Mutt F1 tnt Gn Fin (Sturt) l"t Sat Fin (Stop) Sut Safety Vain Eat Safety Vain Vent Eat Safety Valve Liquid Matte Shut-Off Val Vent Sat Shut-Off Vain CONFIDENTIAL! Subject to Protective 0*** : 14 th jt-'-.-r/.r of 14 - "trict Court REVISIONS A AOOCO 37- 4 2. TO TCAfiJS. 4/0 T USEO. O L L. J-2T-7j CHG. P 75t GeneraT Hotat ^ 1. All external wiring to be In conduit {weather proof]. 2. Spark plug high voltage lead to be GTO-15. 3. All control wire to be type IN- standard 600 volt, 16 9a. min. 1 4. All external equipment, except, spark plug, theneocouplo leads, rad lunatic pyrometer and flame scanner to be wired thru terminal strip. 1 . S. Jumper all coxmon terminal: of panel mounted equipment. 6. Number all conductors at both 1 nds. 7. Equipment terminal No'S {where shown) appear on equipment. B. Symbol* refer to I.L. 9. For sequence of operation see Sheet Z. 10. Scanner leads to be 600 volts max. wire length Is 50 ft. 11-.Q Indicates terminals In control enclosure and purchaser's panel. 12.<F> Indicates terminals In control enclosure only. 13. Last terminal number used - 65.' 14. last conductor number used 40,84. 15. Terminals not used - 9,10, 45,46,47,40,51,52,56,59,36/37-- 17. All wiring connected to ter minal strip to have Insulated pressure type lugs. 18. ------ Indicates field wiring by purchaser. , 16. Conductors not used - C-3,4,26, 65,66,67,63,71,72,73,74. 1 REFERENCE DWG. I. PANEL LOCATION Z. PANEL LAtOUT 3. CDNTHOL PANEL WIRIN& j^NCF- COnik BOD?) IS o cl- V 00 co o o CO fort, j&acott & Pavfe dammcBoi Cot*m ten le 7^7 a INDUSTRIAL r CHEMICAL DIVISION LUCE CHARLES, LOUISIANA ORGANICS DISPOSAL PLANT ELEC. INSfg Ng I INCINERATOR FIELD C9NTB&WT1COF WIRING 2 DIAGRAM * SHA8BQUC _ PATB 7Z. - HOME _ ni-rm it-21-71. QliMV P-7S1 DWG.68A--76Q2Q. \ ,5/ 32 34 35 36 37 33 39 40 41 42 43 44 45 46 47 C--7778_ SEQUENCE Of OPERATIONS Start-Ue 1. Close switch, SN-1. .2 Depress "Blower" pushbutton (located at blower). Starter Is energized and latched In. "PS-953" will mate. 3. Establish natural gas supply pressure. "PS-992" will mate, energizing "ICFT. 4. Ufth "manual41 of "TIC-947", (HL Item 79), move natural gas control valve to low fire position. "2NSS" will mate. 5. Hove coitustIon air valve to low fire position by "manual on*1 "'FIC-945", (Item 97), "Combustion Air Flow Indicating Controller". "1HSS* will make. 6. Close Burner "Off-On " selector switch, "1SS". a. Establish scrubber water flow, "F5-94B-1H will mate, energizing "6CR" will close. 6CR-1" b. Purge time delay relay, "1T0R41 is energized. t. After pre-purge period "lTOR-V and "1TDR-2" close "TTDR-2" close "TFR" (pfn 3) Is powered. "Purge Complete- indicator leap, "Ul\ will giow. 7. Depress burner start button "IPS". a, I pillion time delay relay ll2TDR" energized, "2TDR-2" (Inst.) closes setting In "2TDA , pilot gas safety shut-off valve "5-1004" opens, Pilot On", light. "2IL" glws, Ignition transformer, "IT" energized. b. Pilot flame Is established, "Flame On", light, "3IL" glows. c. Ten seconds after "1PB" Is depressed, "2T0R-I" opens. If flame Is not established by this time, sequence must be repeated firm Step 6, since "2TOT-1" will open. B. Release "1PB". a. "IT" de-energized, pilot time delay relay "3T0R" energized, gas vent valve "FCV-9S1" closes, gas safety shut-off valves, "FCV-962" and TCV-960" open. b. Plane from fuel gas Is established. Ten seconds after "1PB" Is released 1 "3TDR-2" opens, irS-1004" closes, "21L" is extinguished, 4I3TDR-1" opens, "1IL" Is extinguished, "3IL" stays lighted. If flame is not established by this time, sequence must be repeated from Step 6. c. Fuel control valve moves to "TIC-947" demand position. 9* When Incinerator reaches operating taeperature "TSS-980-1" contacts close, energizing "4CR". end causing "5IL" "incinerator at Temperature", Indicator light to glow. 10. To start Liquid Waste Flow. a. Open atomizing steam manual valves. Stew low pressure switch, "PS-979", will make. b. Establish liquid waste pressure. c. Depress "Liquid Vast* Flow Start41 pushbutton, "4PB". "3CR" Is enarglzad, and latched In by "3CR-1". W3CR-2,V contacts close, energizing "FCY-976" "Liquid Waste Safety Shut-Off Valve". "7IL", "Liquid W<te On" Indicator light will glow. d. By controlling pp output, slowly brfng on Liquid Waste flow. , e. Increase coafeustion air flow during step lOd through "NL-990". fmt11. To start Waste Flow. a. Establish waste fume pressure. "PS-995", waste fme low pressure switch, will not make, until vent valve closes. b. Depress U6PB*. "2CR" will be energized and be latched in by "2CR-1". c. "2CR-2" contacts close, energizing "S-963", waste fume control valve station Instrument air solenoid valve. "61L" "Ftwne On" Indicator light glows. * 12. Slowly Increase waste fume flow. * Note: As Increasing flow Is sensed at "FE-946", the combustion air control valve will automatically modulate to supply co^ustlon air. In a pre-selected ratio to fimm. This ratio may be altered by resetting, "Ratio Relay", "RR-945". j Incinerator Temperature is sensed by the "Radiamatic Pyrometer", 41 RAO", and control led'by "TIC-947" which modulates the "Natural Gas Control Valve". Shut-Down 1. Stop Waste Flows As Follows: a. Slowly decrease flow of liquid waste by decreasing pump output. Note: Steam flow may be decreased but should be allowed to flow to prevent over heating of injector tip. Depress "SP8", Liquid Waste Flow Stop pushbutton causing the liquid waste flow valve to close. b. Slowly decrease flew of wests fume. When flew of fume Is stopped, depress "7PB" dc-ewerglzing "S-963". closing flow valve and opening vent valve. 2. Position burger "Off-On" selector swftch "1SS" at off. T. Emergency Shit-Sown Wmit Step lJ towlcion burner "Off-On- selector switch Hi55' at "Off*._____________ X__________________________________________________ _________,__________ 3. Allow the air blower t3 purge until refractory is cool. When cool, shut-down the air blower by depressing "Stop" pushbutton (located at blower). Minimi* purging time 2 hours. 4. Shut-off steam and water flow. ^ Note: In the event of low or high natural gas pressure, low combustion air pressure (flow), low'Scrubber water flow, high scrubber or incinerator temperature, the burner dill shut-down closing all safety shut-off valves. Combustion air and stejmwill continue to flew. In the event of low steam pressure, the liquid waste flow valve will close. In the eventi of low or high fume pressure, the fine flow control valve will dose, and ijbe vent valve will open. In the event of low Incinerator temperature both the Liquid Waste, and Waste Fuae, flows will be shut-off. All the above mentioned failures are acknowledged by the "Annunciator System". See Operatins Manual For Wore Complete Description Of Operation Of Incinerators. REVISIONS 2CK-3 TiaCry,\ ES,\ 'PJ-- suj r- ` #,'// - / A'- /' IA DELETED A 592-i a-992 H 4 a 9J3 D L l -A - L 5 - 73 CiiC* v i*i :---- 'rtf*n- , F&x--l. ; \ 43 49 2CR-3 ,, 50 OFFsne shutoovm TYPe R rwEHMOCOUPAE spare 3CR-5 fcC-Hi .C-43 51 52 FLAME FAILURE (A 95t) HIGH SCRUBBER: TEMPERATURE (A- 984) HIGH IUC1WE RATOR TE0M-9PE8R0A)T*URE 3CE-3 SCRUBBER WATER FAILURE (A 948') confidential! Subject to Protective Crete* 14th Judicial District No. 91-1145 SL 000843 /cub, S&acoh Si Thtvie * >o< Ic seiz. is INDUSTRIAL CHEMICAL DIVISION LUCE CHARLES, LOUISIANA O F? fiANI C^T-PISP~53 6LPL A N T El~InSBI NO. I INCINERATOR FIELD CONTROL PANEL-WIRING DIAGRAM SHEET 2 OF 2 , F. SMAR&OUO____ OAT1 H-Zl'lt 9CALM _M*TW 7 PWG.66A--76021.2