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CHEMICALS GROUP
STANDARDS INSTRUCTIONS specifications
SCOPE OF WORK BREftTfflHtTMK System
CC-1333 GEF 0468
This project will Install equipment to compress, purify, store and
continuously monitor the air supplied to the breathing air stations In the PVOH and Emulsion Plants. Air from this system will be suitable for
human respiration and will conform to the standards for 6rade-D of the Compressed Gas Association Commodity Specification G-7.1, 1966. In ad dition the air supplied by this system will meet OSKA Standards (para.
1910.134 on Respiratory Protection).
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The compressors, . desiccant air dryers and monitoring equipment will be installed in the Emulsion Plant truck alley. Design provisions have been made to Incorporate carbon filtration equipment should it prove ^necessary. The breathing air storage receiver will be located outside, 'adjacent to the Emulsion Plant chemical storage area. Air processed from
these units will be distributed to the seventeen (17) MSA respirator $ stations in the Emulsion Plant, twelve (12) MSA respirator stations in
the PVOH Plant and to one(l) station In the PVOH control roan.
The major components and design features of this system Include:
1. Two (2) 40 Hp air compressors each capable of supplying 100 CFN of water flushed air at 50 psig.
2. Dual desiccant air dryers with a capacity for conditioning 225 CFM of 50 PSIG air to 6 -10F dew point.
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3. Instrumentation to monitor and sound an alarm In event of a compressor failure and/or low system pressure.
4. A process gas chromatograph to monitor the system's air 7 continuously for vliypp chloride and othejr* hydrocarbons.
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A 125 cubic foot air receiver to provide for storage of
quality air in event of total compressor failure. This -quantity of air is sufficient to provide five (*5) - -
'minutes of maximum usage to thirty (30) percent"of the Installed stations.
6. A two (2) Inch distribution header with one(1) tie-in to
the Emulsion Plant stations, three(3) tie-ins to the PVOH Plant stations and a final tie-in and system purge at the PVOH control room.
7. Air Intake for the compressors will be piped from a point twelve (12) feet above grade and approximately
sixty (60) feet from the east wall of the Emulsion Plant.
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AP00031699
FOHM -APC-174
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CHEMICALS GROUP
STANDARDS INSTRUCTIONS
specifications
CC-1333 GEF 0468
8. Approximately two hundred (200) feet of the air header
leading to the PVOH building will be electric traced and insulated to condition the air.
9. Present respirators will be replaced with new low pressure
breathing masks.
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Additional design features and the basis for design:
Respirator Stations
Number - 17 Emulsion and 13 PVOH, Total - 30 Type - Constant Flow/min. air flow 4.0 SCFM Hose Size - 3/8" max. 50` length 7 $Min. Pressure l? Respirator Valve - 20 psig ^ (_Max. Pressure G Respirator Valve - 40 psig Design for 6.7 SCFM/Respirator @ 20 psig min.
Max. Usage - 80% or 24 stations at anytime. Requiring a total of 161 SCFM.
Compressor Requirements
Volume - Assume simultaneous usage max. of 80% utilization Max. Usage for 24 Stations - 161 SCFM Estimate System Losses Less Than 20 CFM Design Contingency for Future Additions - 10% Total Air Requirements - 200 CFM
System Pressure/Air Storage
Pressure @ Stations - 20 psig Header Pressure Drop - 5 psig (workable design) Allowable Drop Thru Dryer'- 5 psig (workable design) Allowable Drop Thru Carbon Bed - 5 psig Min. Air Pressure at Receiver - 25 psig Provide for 5 minute supply for 10 stations in event of compressor failure.
Design Features
The compressor package consists of 2-40 HP units. One compressor will carry a base load with the other compressor available to handle the system requirements at rated design. A transfer switch periodically alternates compressor positions and during periods of extended non-use both compres sors will shutdown.
The desiccant air dryers are sized to handle 10% additional capacity _ .and will, condition the air to a -IQOf dew point.
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STANDARDS INSTRUCTIONS SPECIFICATIONS
CC-1333 GEF 0468
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A pressure je1 ease valve operated intermittently through a timer will
remove enough air from the system to insure compressor operation and
to keep a fresh supply of air in the system.
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The distribution piping is sized to keep the normal operating drop through the system below 5 pslg. The larger pipe also provides for additional air storage without a significant effect on the total cost.
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Provisions have been made to add a carbon qflsorption unit to the system. This unit, if needed will reduce the total hydrocarbon and vinyl chloride
levels to conform to established standards.
A separate process gas chromatograph is included in the design. The
twenty(20) minutes between sampling using the existing Emulsion Area VCM chromatograph is too infrequent to assure that the air is suitable for
human respiration. However the new unit could be made available for other uses whenever the breathing air compressors are not in use.
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PROJECT TITLE ESTIMATOR ^A. 1 QUOTED_ '&%
AIR PRODUCTS AND CHEMICALS, INC.
Section 4.07 A
CALVERT CITY PROJECT ENGINEERING DEPARTMENT
ESTIMATE SUMMARY
Ge* o^/:-r *4/# .SVig7Tg** fstWM/r&tfvc) PROJECT NUMBER CC. S333
CHECKED BY
CLASS OF ESTIMATE ^3^/W7Vl/~tf-
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LABOR MANHOUR i $
MATERIAL $
SUBCONTRACT S\
TOTAL
EQUIPMENT
Pressure Vessels
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Towers rt*? &0V&Z
/ >51
Heat ,Ey.ohanqey/^ rr. jJ___
Pumo - Compressors AfA&SS
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XfiKtrAC. C4A+JC A Total EcruiDment
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3 3 o\$ 3_ 2
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I OTHER B Pipinq C Instruments
D Electrical E Structural F Concrete & Site <3 Insulation H Paintinq I Buildinos J HVAC
K Spare Parts L Fxeiqht
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Total Others 1 1 Total Direct Cost
1 FIELD COST
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Supervision
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y Equipment Rental |
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Temporary Facilities
7%
Small Tools-Coneuiiable si 4 %
~3|TTesting, Housekeediiig i| 2 %
Overhead 5 Profit I
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Total Field Cost I j 9| 8 _%
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DESIGN COST
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Misc. Overhead
Estimate Cost Total Design Cost
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SUBTOTAL
Contingency, 7% of Subtotal i
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R Escalation, 10% of Subtotal 1
_Y__ Proc. Engr. Start-Dp Costs i o_ 21 E
S Tax, 5% of Mat'l. Total
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U1 T Bldr`s Risk, 0.35% of Subtot
0-- Interest, 0.917%/month
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TOTAL
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AP00031705
AIR PRODUCTS AND CHEMICALS, INC* Calvert City Project Engineering Dept.
EXPENDITURE A CONSTRUCTION SCHEDULE
PROJECT TITLE:
PROJECT NO.: DATE: CHECKED BY:
MONTHS ELAPSED 0 1 1-1/2 3 4 5 6 7 8-1/2
Breathing Air System (Emulsion & PVOH)
GEF-0468
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July 8, I960
APPROVED BY: /
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REMARKS
Project Approval
Design Underway
Purchase Major Equipment
Prepare & Transmit Installation Package
Award Installation Contract Receive Equipment
Begin Construction/ / 0r
Finish Construction, System Ofrarational Final Invoices
CUMULATIVE EXPENDITURES
5,000 5,500 7,500 10,000 12,500 15,000 17,000 77,000 261,000
AP00031706