Document nmwVoE0KNOM895E7MVQqzaBNm

ABD00286663 Appendix I ABD00286664 APPENDIX I ITEM NO. 1-2 1-3 1-4 1-5 1-6 1-7 1-8 1-9 1-10 1-11 1-12 1-13 1-14 TABLE OF CONTENTS DESCRIPTION Operating Manual for the Old Module. This manual was prepared by the vinyl operations engineer in early 1982, but was not dated at that time. This manual is an update of one Issued March 16, 1979. Operating Manual for 745 Reactor dated October 1981. Operating Procedure for the Refrigeration System on the RVCM Receivers dated August 1, 1976 Incinerator Training Manual dated June 21, 1978 Operating Procedure for the Deltech Instrument Air Dryer dated March 17, 1980 Operating Manual for the Batch Water Stripper dated June 19, 1981 Operating Manual for the AMS Emergency Kill System dated September 1, 1981 Operating Manual for the VCM Tank Farm dated June 3, 1983 Operating Procedures for the Initiator Injection Pot Replacement dated March 21, 1983 Vinyl Winterization and Operations Program, 1983-84 Operating Manual for Emergency Cooling to the Reactors dated February 23, 1984 BME Addition System Operating Manual dated May 15, 1984 Revised Operating Procedure for the Emission Recovery System dated July 25, 1984 A ABD00286665 APPENDIX B (Continued) ITEM NO. DESCRIPTION 1-15 1-16 1-17 1-18 1-19 1-20 1-21 1-22 1-23 1-24 1-25 1-26 1-27 Operating Manual for the Pall Instrument Air Dryer dated October 18, 1984 Power Failure Procedure dated April 30, 1985 Checklist for Boiler Interlock & Instrument Test Log Checklist for Emergency AMS Kill System Checklist for Incinerator Interlock & Instrument Test Log Checklist for Reactor Calibration Standard Operating Procedure for Safety Disc Change and Testing dated August 20, 1983 Standard Operating Procedure for Propane Vaporizer Start-Up dated March 30, 1981 A-Operator Questions-Reactors, Rotary Dryers & Fluid Bed Dryer Lead Operator-Questions Vinyl A Operator Training Guide Batch Water Stripping-Operator Training Quiz Records of Training Sessions ABD00286666 ABD00286667 TABLE OF CONTENTS OPERATING MANUAL OLD UNIT PVC REACTORS ABERDEEN, MISSISSIPPI I. INTRODUCTION A. Operator Responsibilities B. Process Information ---------1. Evacuation 2. Charge 3. Initiator 4. Polymerization 5. Recovery and Steam Stripping 6. Dumping II. GENERAL PROCESS DESCRIPTION A. Evacuation ------------------------------------B. Charge --------------------------------------------1. Precharge Preparations 2. Reactor Charge C. Polymerization ----------------------------D. Recovery and Steam Stripping 1. Recovery 2. Steam Stripping 3. Hydroquinone Injection 4. Recovery of Blowdown Tank E. Reactor Dump and Rinse -----------F. Chem Wash --------------------------------------G. Water Swirl ----------------------------------H. Batch Water Stripping System III. OPERATING PROCEDURES A. Reactor Evacuation B. Reactor Precharge A 1-2 Page No. 1 3 5 5 8 10 14 15 16 17 22 ABD00286668 1-2 TABLE OF CONTENTS (CONT.) III. OPERATING PROCEDURES (CONT.) C. Reactor Charge ------------------------------------------------------------------------ D. Polymerization ------------------------------------------------------------------------ E. Recovery and Steam Stripping---------------------------------------------- F. Reactor Dump and Rinse -------------------------------------------------------- G. Chem Wash and Rinse -------------------------------------------------------------- H. Full and Partial Swirl -------------------------------------------------------- 1. Full Swirl 2. Partial Swirl I. Colloid Solution Make-Up------------------------------------------------------ J. Hydroquinone Solution Make-Up ------------------------------------------ K. Used Chem Wash Solution Disposal ------------------------------------ L. Initiator Handling and Storage ---------------------------------------- 1. Safety Precautions in Handling Initiator 2. Physical Characterics 3. Initiator Storage Freezers 4. Design and Operational Functions 5. Daily Operational Checks 6. Emergency Procedure for Initiator Freezer 7. Circle Chart Responsibility and Change Schedule M. Reactor Pressure Check -------------------------------------------------------- N. Reactor Cleaning and Entry ------------------------------------------------ 1. Reactor Manhead Opening Procedures 2. Reactor Cleaning and Entry O. Filters----------------------------------------------------------------------------------------- 1. Dura-Seal Oil Filters 2. Reactor Gearbox Oil Recirculation Filters 3. Charge Water Filters 4. Seal Water Filters 5. Vinyl Chloride Charge Filters 6. Recovered VCM Filters Housekeeping Page No. 24 28 36 44 46 50 51 55 57 58 67 68 72 76 ABD00286669 TABLE OF CONTENTS (CONT.) IV. BATCH WATER STRIPPING SYSTEM OPERATIONS MANUAL V. INCINERATOR VI. APPENDIX A. Equipment List B. Instrument List C. P & I Diagram i Operating Manual Old Unit PVC Reactors Page 3 ABD00286670 A 1-2 I. INTRODUCTION (CONTINUED) B. Process Information Several types of resins are produced. Resin type is determined by a set of physical properties such as particle size and viscosity. Each type of resin produced requires that a certain set of operating conditions be closely followed so that the desired resin properties are obtained. Minor changes in formulas or operating conditions can cause major differences in the physical properties of the resin. Some factors in determining resin properties are reaction temperature, which helps determine viscosity, colloid, which influences particle size, and the amount of recovered VCM charged, which also effects particle size, amount of short-stop which effects stability and amount of calcium stearate which effects drying and customer processing. The phases of reactor operation and a brief description of each follows: 1. Evacuation This step removes all air possible by steam ejectors. Too much air left in a reactor will alter particle size. Evacuation should require about five minutes. 2. Charge Water, Colloid and VCM are charged to .the reactor simultaneously through a timed sequence system. The temperature of the reactor contents at the end of charging is determined by the charge water temperature. The reactor will be below run temperature at the end of the charge and jacket steam will be used to raise ABD00286671 1-2 Operating Manual Old Unit PVC Reactors Page 4 I. INTRODUCTION (Cont.) B. Process Information (Cont.) 2. Charge (Cont.) the temperature to the desired level. Charge should take about nine minutes for D-300, D-400, D-500, and D-600. D-700 will require about fifteen minutes. 3. Initiator The initiator is manually loaded into the initiator injection pot and charged into the reactor after reactor charge is complete. 4. Polymerization This is the time from the initiator addition until most of the VCM has been converted to resin. The reaction generates heat continu ously as liquid VCM becomes PVC resin. Heat that is generated is removed by cooling water on the reactor jacket and condenser. Reaction times varies, but generally requires five to six hours for D-300, D-400, D-500, and D-600. D-700 will require 4 1/2 to 5 hours. 5. Recovery and Steam Stripping Recovery and steam stripping removes most of the un-reacted VCM from the eractor via a compressor-vacuum pump system. Steam is added to the bottom of the reactor and rises through the PVC and water slurry to help remove unreacted VCM. Recovery and steam stripping takes about 60 minutes for D-300, D-400, D-500, and D-600 and 90 minutes for D-700. 6. Dumping The PVC resin, after reaction is complete, is in a slurry form. The slurry is dumped to a strainer and dump tank and is pumped to blend tanks in the Dryer Room for drying. Dump requires about 25 minutes for D-300, D-400, D-500, and D-600 and 35 minutes for D-700. A ABD00286672 1-2 Operating Manual Old Unit PVC Reactors Page 5 n. GENERAL PROCESS DESCRIPTION A. Evacuation Before charging, the inerts present in the polymerization reactor are removed by evacuation. The interlock selector switch is placed on "evacuation" position. *The main condenser valve is opened; the reactor evacuation valve is opened, and the evacuation header valve and the steam supply valves to the ejector system to be used are opened. The emergency cooling water supply valve to the reactor is then opened. When the reactor reaches 28.5 inches of mercury vacuum, as indicated by the pressure indicator in the control room and at the reactor, evacuation is complete. This portion of the cycle requires about 10 minutes. B. Charge 1. Precharge Preparations After evacuation, the reactor is ready to be charged. In pre paration for charge, adequate quantities of VCM, hot water, col loid solution, and initiator are made ready for the charge sequence. Prior to charge, fresh VCM is transferred from the VCM storage sphere to the fresh VCM storage tank. This transfer of VCM begins automatically when the VCM liquid level falls below a certain level. When the high liquid level is regained, the transfer process shuts down automatically. Two 150 gpm VCM transfer pumps are used to transfer the VCM from the VCM storage sphere. ABD00286673 1-2 Operating Manual Old Unit PVC Reactors Page 6 GENERAL PROCESS DESCRIPTION (Continued) 1. Precharge Preparation (Cont.) Process water is automatically supplied to the hot water tank when the water level drops below a certain point. The water is filtered by the process water filter, and is heated in the hot water pre heater, enroute to the hot water tank. The colloid solution, pre viously made up, is pumped from the make-up tank to the charge tank before every charge. When the make-up tank becomes empty, a new batch of colloid will be made up. After a new batch is made, a sam ple is taken to the laboratory for analysis. The colloid percenttotal solids must be 1.40-1.60. The colloid is then pumped from the make-up tank to the colloid charge tank. Immediately before the re actor is to be charged, the initiator injection system is made ready for the charge in the following manner. First the initiator injec tion pot at the reactor to be charged is drained to the sewer. One gallon of water is manually added as indicated by the local flow totalizer. The initiator is then manually added to the initiator injection pot. The pot is then blocked in and pressurized with high pressure service water to at least 180 psig. The initiator injec tion system is now ready for the reactor when the charge is com plete. Caution: The initiator should never be left in the charge pot if the charge is aborted. It is to be dumped to the sewer and the pot flushed with water. After evacuation is completed, the interlock selector switch is moved to the "charge" position. If the following precharge contions are met, the charge sequence is ready to begin: .v Operating Manual Old Unit PVC Reactors Page 7 ABD00286674 1-2 A II. GENERAL PROCESS DESCRIPTION (Cont.) Charge (Cont.) 2. Reactor Charge (Cont.) b. There is sufficient pressure in the initiator injection pot and in the high pressure service water header. c. The charge meters are reset to the charge quantities. Steam is usually applied to the reactor jacket at the start of charge by manually opening the steam valve from the Control Room. This aids in heating the reaction mass to the desired temperature during and immediately following charge. The automatic charge sequence begins with the hot water charge. The hot water is pumped from the hot water tank, to the reactor by the hot water charge pump. After a predetermined quantity of hot water has been charged, the colloid charge pumps and the second hot water charge pump start. The next step in the charge sequence begins with the fresh and recovered VCM charges. The fresh VCM is pumped to the reactor from the fresh VCM storage tank, by one of the two VCM charge pumps. The recovered VCM is pumped from one of two recoverd VCM storage tans by the recovered VCM charge pump into the suction of the VCM charge pump. The recoverd VCM is filtered in the recovered VCM filter and the total VCM charge is filtered enroute to the reactor by the VCM charge filter. Shortly after the beginning of the VCM charge, one of the hot water charge pumps shuts down until the VCM charge is completed and then restarts. This insures that there will be an adequate amount of water charge remaining to flush out the charge line except on D-700 where the VC line is separate. Both hot water charge pumps continue to run until charge is completed. Operating Manual Old Unit PVC Reactors Page 8 ABD00286675 1-2 II. GENERAL PROCESS DESCRIPTION (CONTINUED) B. Charge (Continued) *When the VCM, water and colloid charge is complete, the initiator is charged by opening the initiator charge valve from the reactor by nA" operator. Loading the initiator and preparation of the initiator charge pot was discussed in the precharge preparation section. C. Polymerization After charge is completed, the reactor interlock selector switch is placed in the "polymerization" position, and the reactor temperature controller is placed on automatic. When the reaction mass reaches the desired temperature the steam is turned off. The reaction mass temperature is automatically controlled by varying the amount of cooling water that is passed through the top-mounted knockback condenser and the reactor jacket. The reaction mass is continually mixed and kept in suspension by the bottom-mounted single speed agitator. The agitator mechanical seals are lubricated and cooled by seal oil from a seal oil pressure unit. During polymerization, mechanical seal purge water is injected into the reactor through the reactor cleaning nozzle and through the agitator mechanical seal. The water is added to keep the reactor cleaning nozzle and agitator mechanical seals clean. The purge water flow for each service is indicated with a rotameter and manually adjusted. Operating Manual Old Unit PVC Reactors Page 9 ABD00286676 1-2 II. GENERAL PROCESS DESCRIPTION (Cont.) C. Polymerization (Cont.) The inerts present in the reactor during polymerization accumulate in the reactor condenser head space. These inerts are vented to the recovery system to prevent inert blanketing. When the desired degree of polymerization is reached and the reactor pressure has dropped to the desired pressure, the reaction is stopped by manually adding a mixture of AMS and Naugard (the short stop solution) to the reactor. High pressure service water is used to pressure the short stop solution from the initiator injection charge pot into the reactor through the same piping as the initiator charge. The charge pot is then blocked in and refilled with the short stop solution which will be used at the middle of steam stripping. An emergency AMS kill pot, located at grade, is provided to pressure AMS into the reactor to kill the reaction in the event of a power failure or upon loss of agitation. The AMS will be injected into the reactor through nozzles in the reactor head, using push buttons on the control panel or by manually operated valves in the field. The pots for D-300, D-400, D-500 and D-600 will contain 15 - 20 gallons of AMS. The pot for D-700 will contain 40 gallons of AMS. The material will be pressuirzed into the reactors using nitrogen, supplied by a nitrogen bottle located beside the pot. Operating Manual Old Unit PVC Reactors Page 10 ABD00286677 1-2 II. GENERAL PROCESS DESCRIPTION (Cont.) C. Polymerization (Cont.) A nitric oxide (NO) short stop addition system is provided to inject NO into the reactors in the event of power failure, major VCM releases, fires, or other emergencies. The system is activated locally. NO is supplied from emergency NO short stop bottles and is injected into the reactor through the same piping as the agitatcr mechanical seal purge water. Recovery and Steam Stripping 1. Recovery When the reaction is completed, the interlock selector switch is moved to the "recovery and steam stripping" position. The following sequence then occurs. The recovery compressor seal water systems, the water recirculation systems for the recovery knockout drums and two of the three recovery compressors are manually started from the board. Cooling water to the recovered VCM condenser and the water recirculation cooler starts automatically with the compressors, and the hydroquinone injection system starts with the compressor seal water systems. ABD00286678 1-2 Operating Manual Old Unit PVC Reactors Page 11 II. GENERAL PROCESS DESCRIPTION (Cont.) D. Recovery and Steam Stripping (Cont.) The vapor from the reactor flows through a pressure control valve to two resin knockout drums in series which remove carryover resin. The pressure control valve prevents excessive carryover of resin from the reactor by limiting the pressure to the recovery system to about 35 psig Each of the knockout drums have an internal water spray system and a recirculation pump. Both knockout drums have an on-off level control system which, on high liquid level, diverts the discharge of the water recirculation pumps to the blowdown tank. A water recirculation cooler, (the function of which is explained in the steam stripping portion of the recovery system process description), is provided and can be used in the water recirculation loop of either scrubbing stage. The VCM vapors from the knockout drums are compressed by the recovery compressors. The recovery compressors are constant volume liquid ring compressors with a water seal. The discharge streams from the compressors flow to two parallel seal water recirculation systems which operate as fol lows. Seal water is separated from the VCM vapors in the seal water separators, filtered by the seal water filters, cooled by the seal water coolers, and pumped back to the compressors by the seal water pumps. The flow of seal water to each compressor is controlled at 50 gpm. The seal water temperature is controlled just above the VCM conden sation temperature (95-105F). Automatic draining of the seal water ABD00286679 1-2 Operating Manual Old Unit PVC Reactors Page 12 II. GENERAL PROCESS DESCRIPTION (Cont.) D. Recovery and Steam Stripping (Cont.) 1. Recovery (Cont.) separators to the water stripper is provided to maintain the correct water level. The VCM vapors from the seal water system are condensed in two recovered VCM condensers. The condensed VCM is collected in the recovered VCM collect tank which is on automatic on-off level control. VCM is transferred to the recovered VCM storage tanks by the recovered VCM transfer pump when there is high liquid level in the VCM collect tank. Inerts are bled from the collect tank to the incinerator. When the reactor pressure drops to 3' psig, the two recovery vacuum pumps automatically start. The VCM flow from the recovery knockout drums and the seal water flow are both diverted to the vacuum pumps which discharge into the suction of the compressors. 2. Steam Stripping In order to reduce residual VCM in the slurry, the slurry in the reactor is heated and stripped with steam. At the start of a normal recovery, steam addition to the reactor is manually started from the control room and the slurry mass is heated. When the temper ature of the reactor has risen to the desired temperature, the steam stripping operation is completed. As recovery proceeds, less and less VCM is recovered from the reactor To supply sufficient VCM vapor to the recovery vacuum pumps and com pressors, a VCM backpressure system is used. This is done to prevent ABD00286680 1-2 Operating Manual Old Unit PVC Reactors Page 13 II. GENERAL PROCESS DESCRIPTION (Cont.) D. Recovery and Steam Stripping (Cont.) 2. Steam Stripping (Cont.) cavitation and overheating of the vacuum pumps and compressors. Before entering the recovery knockout drums, the steam and VCM from the reactor are combined with a bleed stream of VCM from the recovered VCM storage tanks. The amount of VCM bled into the recovery system is adjusted by the backpressure control valve such that a set supply pressure to the vacuum pumps is maintained. The majority of the steam is condensed in the first knockout drum described in the normal recovery process description. The first stage of the scrubbing system consists of a recovery knockout drum with an internal water spray system, a water recirculation pump and the water recirculation cooler. The water cooler reduces the water . temperature sufficiently to allow the internal spray system in the knockout drum to cool the VCM and condense much of the steam in the vapor stream. After leaving the first stage of the water scrubbing system, the VCM vapor flows to the second stage of the scrubbing system and then to the rest of the recovery system in the same manner as during normal recovery. 3. Hydroquinone Injection The VCM removed from the reactor during recovery still contains a small amount of initiator. As a result, the VCM will continue to polymerize, resulting in plugged lines, charge lines, and recovered VCM storage tanks. Polyermization is significantly reduced by Operating Manual Old Unit PVC Reactors Page 14 ABD00286681 1-2 II. GENERAL PROCESS DESCRIPTION (CONTINUED) D. Recovery and Steam Stripping (Continued) 3. Hydroquinone Injection (Continued) the addition of an inhibitor such as hydroquinone to the VCM stream as it is being recovered. A 4.6 percent solution of hydroquinone in water is prepared in the hydroquinone storage tank. The hydroquinone solution is pumped by the hydroquinone injection pump into the suction of the recovery seal water pumps. The injection pump starts and stops automatically with the seal water pumps. The metering pump has a variable stroke which can be adjusted manually to maintain the preset hydroquinone injection rate. 4. Recovery of Water Stripper The water stripper is to collect the various steam and water streams containing VCM from the four-reactor module. The emission recovery system is used to recover VCM vapor. When the temperature of the tank rises to the desired temperature, re covery of the tank is stopped. E. Reactor Dump and Rinse After the reactor is recovered and steam stripped, the reactor interlock selector switch is moved to the "dump" position. The appropriate dump valves are opened from the control room and the Operating Manual Old Unit PVC Reactors Page 15 ABD00286682 1-2 IX. GENERAL PROCESS DESCRIPTION (CONTINUED) E. Reactor Dump and Rinse (Continued) slurry flows by gravity to the dump system. The slurry passes through an enclosed vibrating slurry strainer where the PVC culls are collected until dump is completed. The slurry then flows to the slurry dump tank. The slurry transfer pumps transfer the slurry to the blend tanks. The dump tank level is automatically controlled. Near the end of dump, the reactor condenser is flushed with water by turning on the condenser rinse system from the board. Hot water is pumped from the hot water tank by the hot water charge pumps through the cleaning nozzle in the reactor condenser. The rinse water mixes with any remaining slurry and is pumped with the slurry to the blend tanks flushing out the slurry transfer lines. F. Chem Wash and Rinse If it has been determined that the reactor needs cleaning, the reactor interlock selector switch is moved to the "clean and rinse" position after the dump and rinse is completed. The chem wash solution is a caustic solution. The cleaning solution pump pumps the solution at 500 GPM from the cleaning solution tank through the cleaning solution heater to the reactor condenser spray nozzle. Steam to cleaning solution heater is automatically adjusted to provide an exit solution temperature of 190^F. When the chem wash solution tank is empty, recirculation is started with the chem wash solution being pumped from the reactor and back to the reactor through the reactor cleaning nozzle. ABD00286683 1-2 Operating Manual Old Unit PVC Reactors Page 16 II. GENERAL PROCESS DESCRIPTION (CONTINUED) F. Chem Wash and Rinse (Continued) When chem wash has ended, the solution is pumped back to the clean ing solution tank by the cleaning solution pump. The process for D-300, D-400, D-500, and D-600 requires ten minutes to fill the re actor through the condenser, five minutes to wash the reactor, and ten minutes to empty the reactor, for a total of twenty-five minutes. D-700 requires a total time of forty-one minutes -- twenty one minutes to wash through the condenser, ten minutes to wash the reactor, and ten minutes to empty the reactor. After the chem wash is completed, the reactor is rinsed with hot water from the hot water tank. The hot water is pumped by the hot water charge pumps to the reactor. The water first enters through the condenser cleaning nozzle and then the reactor cleaning nozzle. The chem wash and rinse system in manually controlled from the con trol room. The operator monitors the bullseye at the sewer drain to be sure the reactor is empty. When the reactor amps have dropped to the no load amps indicated on the ammeter, the lead operator opens the rinse valve for a short period of time. By observing the water flowing from the bullseye, he can determine that the reactor is empty. G. Water Swirl If the resin formula calls for a water swirl, the reactor interlock selector switch is placed in the "swirl" position after the chem ABD00286684 1-2 A Operating Manual Old Unit PVC Reactors Page 16a wash rinse is completed. Cold or hot water enters the suction of the hot water charge pumps, and is pumped through the reactor charge line into the reactor. When the water charge reaches a preset amount, the water charge system is automatically shut down. Operating Manual Old Unit PVC Reactors Page 17 ABD00286685 I IX. GENERAL PROCESS DESCRIPTION (CONTINUED) G. Water Swirl (Continued) The reactor agitator is then used to swirl the water for approximately 25 minutes. The lead operator then drains the water to the sewer. This completes one reaction cycle; the reactor is now ready for evacuation. H. Water Collection System Various waste water streams from the process must be collected and treated before discharge to the plant sewer system. The batch water stripping system serves as a central collection point for all the contaminated streams, which include water drains from the V-ll receivers, water from the emission recovery system, water from the new module, and water from miscellaneous flushes and seal waters. A separate operating guide is included in Section IV of this manual. The various streams are routed to one of two parallel stripping tanks. Each new tank is used as both a storage tank and a stripper. While one tank serves as a collection vessel, the other one is being stripped with steam. The water collected in each tank is stripped to 170F and recovered to a vacuum using the emission recovery system. Once the stripping operation is finished, the operator opens the outlet valve on the tank and drains the tank to the sewer. When the liquid level falls below 12% in the tank, the outlet valve is automatically closed, completing the cycle. Operating Manual Old Unit PVC Reactors Page 18 ABD00286686 1-2 III. OPERATING PROCEDURES A. Reactor Evacuation Evacuation of the reactor is required prior to charging in order to remove as much of the air as possible. Air is introduced into the reactor during previous phases of the reactor batch cycle since dump, rinse, and chem wash require that the reactor be vented to the atmosphere. Air in the reactor during reaction causes poor temperature control during the polymerization and may alter the particle size of the resin. Evacuation is accomplished using one of the two available twostage steam jet ejector systems. Evacuation is controlled by the lead operator from the board. The "A" operator must confirm that all process equipment is operating correctly during evacuation. Procedure 1. If the reactor has been opened, follow procedure given in the "Reactor Cleaning and Entry" section on how to close the reactor manhead. 2. The lead operator puts the interlock mode selector on "evacuation." 3. The lead operator checks to see that all valves are closed. 4. The lead operator opens the condenser recovery valve and the evacuation reactor valve. Then the lead operator opens the steam supply valves and the evacuation valve to the steam ejector systems as follows: Operating Manual Old Unit PVC Reactors Page 19 ABD00286687 1-2 A III. OPERATING PROCEDURES (CONTINUED) A, Reactor Evacuation (Continued) a. For D-300, D-400, D-500 and D-600, the operator will open vAlves CV-151 and CV-152. This starts the ejector system located in the V-ll building. b. For D-700 the operator will open valves CV-133 and CV-131. This starts the ejector system located on the D-700 reactor structure. He then opens the emergency cooling water valve, which supplies cooling water to the reactor condenser. Note: In the following steps, 5-10, the operators prepare the initiator for charge while evacuation is in progress. 5. The "A" operator will go to the initiator freezer and bring the specified amount of initiator to the initiator charge pot. Extreme caution must be exercised by the "An operator to be sure that no VCM is allowed to get back into the initi ator injection pot. When a small amount of VCM is mixed with a large amount of initiator, an extremely fast reaction takes place giving off heat and pressure. To guard against this situation, the operator must know that he has an adequate water supply and pressure. The reactor initiator injection valve must never be opened unless the bomb is fully pressurized with the inlet water valve open. Note: The following precautions must be taken when handling initiator. ABD00286688 1-2 Operating Manual Old Unit PVC Reactors Page 20 III. OPERATING PROCEDURES (Cont.) A. Reactor Evacuation (Cont.) a. Plastic gloves must be worn while handling initiator. b. If any initiator is spilled on skin or clothing, immediately flush with water. c. Should any initiator remain in the containers, return it to storage. d. Take all empty containers to trash and split side of all containers. e. Never put the caps back on the empty bottle. Dispose of the caps seperately. f. Do not allow the initiator to stand in the bomb for more than 10 minutes. Drain it to the sewer, and flush with water. 6. The "A" operator must check the initiator charge pot to be sure that it is empty. Close the drain valve. Open the initiator addition valve. 7. The "A" operator will now add the initiator to the injection pot and pressure the pot to 180 pounds. 8. The lead operator will stop evacuation when a vacuum 28.5 inches Hg is attained. The reactor vacuum is double checked by the "An operator on top of the reactor with a mercury manometer. The lead operator stops evacuation by closing the condenser recovery valve, evacuation header valve, and the steam supply valve to the ejector. This will shut off the evacuation steam jets. He then closes the emergency cooling water valves. 9. Evacuation is now complete. A Operating Manual Old Unit PVC Reactors Page 21 ABD00286689 1-2 III. OPERATING PROCEDURES (Cont.) A. Reactor Precharge The reactor precharge procedure includes a series of precharge checks and precautions that must be carried out by the lead and "A" operators. If the necessary precharge conditions are not met, the Modicon (a small computer which controls the automatic charge sequence) will not allow the automatic charge sequence to begin. It is the responsibility of the lead operator to see that all precharge checks and precautions are carried out. He should also read the log book at the start of the shift, covering the period since he was last on the job. This will alert him to any changes in formula, mechanical, or operational procedures that may have been passed on verbally. 1. Lead Operator Duties a. Check level in fresh VCM receiver to see that it is adequate for charge. 80% reading on the level gauge at the panel. b. Drain water in the recovered VCM receiver to the water stripper. Valves from the recovered receiver are manually opened from the board until pressure rise in the blowdown tank indicates all the water is out and VCM is being transferred. Valves are then manually shut from the board. c. Fill out the reactor charge sheet. d. Check the hot water tank level and temperature. Tank level should be 85% and the tank temperature 150p e. Check to see that all valves on the reactor are closed. Operating Manual Old Unit PVC Reactors Page 22 ABD00286690 1-2 A III. OPERATING PROCEDURES (CONTINUED) B. Reactor Precharge (Continued) 1. Lead Operator Duties (Continued) f. Have the "A" operator make a precharge check and reading on the following: (1) Dura-Seal* oil level and pressure. (2) Mechanical seal purge water pressure and rate to the reactor agitator seal. (3) Colloid charge tank level and temperature. g. Record the readings on the charge sheet as they are trans mitted by the "A" operator. 2. MAM Operator Duties a. Check Dura-Seal* level and pressure. There are five DuraSeal* units. Each individual unit supplies seal oil pressure to individual reactors. If the units fail, an emergency supply of seal oil is provided by the emergency seal oil drum that is nitrogen pressurized. Valves must be opened manually at the unit if the emergency seal oil system is used. Note: When the primary and spare Dura-Seal* oil units are down and the emergency system is in operation, reactors are not to be charged until at least one of the Dura-Seal* oil units is operating. The emergency system is designed to be a backup system that should be used short term only. *Registered Trademark Operating Manual Old Unit PVC Reactors Page 23 ABD00286691 1-2 III. OPERATING PROCEDURES (CONTINUED) B. Reactor Precharge (Continued) 2. "A" Operator Duties (Continued) When one of the Dura-Seal* oil units is not in operating condition, inform the lead operator so that repairs can be made. The seal oil level should be checked in both units. The discharge pressure should be checked and be in the range of 205-250 psig. Report the seal oil pressure to the lead operator. b. Check the mechanical seal purge water pressure and rate of flow to the agitator mechanical seal. Pressure should be 180-220 psig. Adjust the water flow rate to that given in the formula. Report the seal water pressure and flow rate to the lead operator. c. Check the colloid charge tank level to be certain enough is in the tank to complete a charge. Notify the lead operator of the present level. d. Inform the lead operator when checks are completed and the reactor is ready for charge. *Registered Trademark ABD00286692 Operating Manual Old Unit PVC Reactors Page 24 1-2 III. OPERATING PROCEDURES (CONTINUED) C. Reactor Charge This section includes vacuum break and reactor charge. The reactor charge is one of the most critical operations in terms of product quality. Care must be taken to assure that all the raw materials are added in the proper order and amount. Procedure 1. When evacuation and precharge checks are complete, the lead operator can move the interlock mode selector to "charge". 2. The lead operator should take the following steps and see that the following conditions are met before charge: a. VCM transfer should be in auto. b. Recovered VCM charge should be in auto. c. Fresh VCM charge should be in auto with either the primary or spare pump selected for charge. d. Hot water charge should be in auto. e. Colloid charge should be in auto with either the primary or spare pump selected for charge. f. Select recipe to be charged by dialing recipe number on the recipe selector on the board. g. Push meter reset button, which resets all charge meters. Operating Manual Old Unit PVC Reactors Page 25 ABD00286693 1-2 III. OPERATING PROCEDURES (CONTINUED) C. Reactor Charge (Continued) 2. h. The charge light will now come on if all the following conditions are met: (1) The fresh VCM storage tank, hot water tank, and colloid charge tank all have a level adequate for one complete charge. (2) One reactor is in charge mode. (3) The reactor being charged has at least 28.5 inches Hg vacuum. 3. When a charge light is obtained on the panel, the lead operator will inform the "A" operator to stand by for breaking vacuum. The lead operator will break vacuum by: a. Manually opening the reactor VCM charge valve from the board. b. Manually opening the reactor charge valve from the board. c. Turbine meters will start counting as VCM flows into the reactor. d. As soon as a positive pressure is indicated in the reactor, close the VCM charge valve. Operating Manual Old Unit PVC Reactors Page 26 ABD00286694 1-2 III. OPERATING PROCEDURES (Continued) C. Reactor Charge (Continued 4. The "A" operator will then watch the pressure gauge at the top of the reactor. When the pressure rises above zero, start checking the following: a. Inspect manhead visually and listen for escaping vapor. b. Check safety disc gauges for pressure. Any pressure indicates a leaking or ruptured disc. c. Turn flush water (injection water) on sprayhead. The purpose is to keep spray heads free of resin. Set rate according to recipe. d. If all checks okay, notify lead operator. If not, notify lead to hold on charge until problem can be corrected. 5. The lead operator can now push the charge button. In rapid sequence, the following occurs: a. Reactor water charge valve opens. b. "A" hot water pump starts, valves open, and water starts into the reactor. c. The valves from the fresh VCM receiver to the VCM charge pump and discharge valve open. Operating Manual Old Unit PVC Reactors Page 27 ABD00286695 1-2 III. OPERATING PROCEDURES (CONTINUED) C. Reactor Charge (Continued) 5. d. At set point No. 1 on water meters: (1) "B" hot water pump starts and discharge valve opens. (2) The colloid charge pump discharge valve will open and pump will start. The preset amount of colloid will be pumped into the reactor. When the colloid meter set point is reached, the colloid charge pump will cut off and the discharge valve and reactor colloid charge valve will close. Note: The lead operator will turn on reactor jacket steam during colloid and water charge to assist reactor heatup. e. At set point No. 2 on water meter, the reactor VCM charge valve opens and the VCM and recovered VCM charge pump start. f. At set point No. 3 on the water meter, "B" hot water pump stops and discharge valve closes. This allows time for all VCM to be charged to the reactor before the water charge is completed. Operating Manual Old Unit PVC Reactors .Page 28 ABD00286696 1-2 III. OPERATING PROCEDURES (CONTINUED) C. Reactor Charge (continued) 5. g. When VCM meters reach the set point (two meters running in tandem, first to reach the set point cuts pump off and closes valve), the VCM pump, and reactor VCM valve close. This action also starts "B" hot H^O pump and opens discharge valve. h. At set point No. 4 on the water meters, hot water pump stops and the valves ilose. i. At set point No. 5 on the water meters "A" hot water pump stops and the valves close. At this time the main dump valve also closes. 6. When the automatic charge sequence has been completed, it is safe to charge the initiator. 7. The reactor "A" operator charges the initiator by flushing the initiator charge pot into the reactor with 50 counts of high pressure service water. 8. The lead operator will now record the final reactor temperature. Adjust reactor temperature set point to setting called for in the formula and put temperature controller in "auto" position. D. Polymerization Polymerization is the phase of the reactor cycle in which liquid VCM is converted into solid PVC. This portion of the reactor cycle is mainly accomplished by accurate instrumentation. The primary area of responsibility for the A Operating Manual Old Unit PVC Reactors Page 29 ABD00286697 1-2 III. OPERATING PROCEDURES (CONTINUED) D. Polymerization (Continued) lead operator is coordination of the activities of the "A" operator. The "A" operator is required to kill the reaction when polymerization has progressed to the point that product quality is satisfactory. < 1. Lead Operator Duties a. Change the interlock mode selector to "polymerization". Monitor the temperature and pressure closely until the reactor reaches the desired set point and lines out. b. Cut off steam valve to jacket at two to four degrees below set point, depending on the rate of temperature rise. c. Have the "A" operator sample the reactor .1 hour after reaching heat up. A fresh air mask must be worn and personnel f cleared of the general area before sample is taken. d. Examine the resin. At this stage of the reaction, the resin should be formed into individual, separate particles. Notify the shift supervisor if you notice the following: (1) Stringers-- Resin particles are stringy and stuck together. (2) Hard Particles--Gritty resin particles which are harder and larger than most. Operating Manual Old PVC Reactors Page 30 ABD00286698 1-2 A III. OPERATING PROCEDURES (Cont.) d. (continued) If either of the above conditions are observed, have the "A" operator take samples every fifteen minutes until the shift supervisor makes the decision as to what corrective action should be taken. It may become necessary to remove the inerts. Inerts in the condenser will cause the reactor pressure to rise as the blanket condenser and do not allow VCM vapor to be condensed. Under these conditions, less heat can be removed even though the con denser water flow will be full open. Vent the inerts through the main condenser valve to the recovery system. Start the compressor and put the pressure controller in manual and close the control valve. Open the reactor condenser valve and recovery valve. Set the controller on 35 PSIG and put it back in automatic. Operating Manual Old Unit PVC Reactors Page 31 ABD00286699 1-2 III. OPERATING PROCEDURES (CONTINUED) D. Polymerization (Continued) f. Irregularities during polymerization; (1) Slow Heatup--May be caused by weak or no initiator. Slow heatup can also be caused by no steam on reactor jacket or the cooling water valves may be open. Contact the shift supervisor if this condition persists. (2) Long Reaction Time --Caused by low initiator level, weak initiator, long heat up, low reactor temperature setting or chem wash . solution in the batch. If there is only slow reaction and the resin checks okay, the shift supervisor will give word on what to do. If caustic is in the reactor, the batch will turn slightly yellow and coarsen. If this is found to be true, kill immediately with the amount of short stop solution specified in the formula. (3) Simultaneous Temperature and Pressure Rise--Check cooling water temperature and valves. The reactor is producing more heat than the cooling water can remove. Also could be an overcharge of initiator. Notify shift supervisor for instructions. A Operating Manual Old Unit PVC Reactors Page 32 ABD00286700 I III. OPERATING PROCEDURES (CONTINUED) D. Polymerization (Continued) 1. Lead Operator Duties (Continued) (4) Simultaneous Temperature and Pressure Drop-- The cooling water valves are probably wide open. This happens more often in freezing weather when relays freeze up. Throttle manual valves until malfunction is found and corrected. (5) Agitator Kicks Out or Power Failure-- Most power failures are of short duration (seconds to two minutes), and the reactor pressure does not have time to build to a dangerous level. If outage is prolonged, the pressure will build. If this situation occurs, follow the procedure in Section III.C.3, which outlines action to be taken during emergency shutdown (such as during a power failure). 2. "A" Operator Duties a. When charge is complete, recheck water injection rates through the cleaning nozzle and seal flush. b. On instruction from the lead operator, resin samples will be taken from the reactor. This normally occurs 1 hour after heat up. If the first sample shows formation of undesirable resin particles, additional samples may be called for every fifteen minutes until a decision is made about what to be done * with the batch. ABD00286701 Operating Manual Old Unit PVC Reactors Page 33 III. OPERATING PROCEDURES (Cont.) D. Polymerization (Cont.) 2. "A" Operator Duties When taking a sample from the reactor a fresh air mask must be worn and personnel cleared of the general area. c. When the lead operator instructs the "A" operaor to do so, the batch is killed by adding short stop solution to the reactor. The amount of short stop solution and the procedure for adding it depends on the product. The kill procedure is as follows: ' 5305 (Normal) - lh gallons AMS 5305 (CTA) - 3^5 gal. AMS/3^ gal. Naugard 5425 - gal. AMS/2^ Naugard initially and again at 170F 1-2 5465 - 2h gal. AMS/3^ gal. Naugard initially and again at 170^F. 5385 - gal. AMS/3*s gal. Naugard. It is very important that the proper amount of short stop solution be added since it effects the quality of the resin. High pressure service water is used to pressure the short stop solution from the initiator pot into the reactor. 3. Emergency Shutdown The following parameters are to be maximum limits on a runaway reaction. The reaction should be killed with AMS if either one of these parameters are exceeded. ABD00286702 1-2 Operating Manual Old Unit PVC Reactors Page 34 III. OPERATING PROCEDURES (Cont.) D. Polymerization (Cont.) 3. Emergency Shutdown (Cont.) Resin 5385, 5425, 5465 5305 (CTA) Maximum Temperature 142F 155F Maximum Pressure 145 PSIG 155 PSIG 5305 (Normal) 162F 165 PSIG A runaway reaction immediately after charge and heat-up indicates that the reactor condenser may be plugged, and that the reaction myst be killed. If AMS will not kill the reaction, use the nitric oxide (N.O.) short stop system. CAUTION: N.O. is a highly poisonous orangecolored gas. A Scott Air Pack must be worn while killing a reactor with NO short stop system. The runaway reaction myst be killed immediately if either one of the pressure or temperature limits listed above exceeded. If the reaction is allowed to exceed these limits, it may not be controllable and result in a relief valve or rupture disc discharge to the atmosphere. The following steps are to be taken during emergency shutdown: (a) (I) Use the emergency AMS kill system to kill each reactor. Each reactor has a pot located at grade, containing AMS. The AMS is injected into the head space of the reactor with nitrogen by opening the appropriate control valve from the control room. The handswitch for the control valves for each reactor is located next to the reactor agitator start-stop handswitch on each reactors control station. A ABD00286703 Operating Manual Old Unit PVC Reactors Page 35 1-2 IU. OPERATING PROCEDURES (Cont.) D. Polymerization (Cont.) 3. Emergency Shutdown (Cont.) (a) (2) Use the nitric oxide (NO) system short stop if the AMS does not kill the reaction. There are six cylinders of NO that can be released for D-300, D-400 D-500 & D-600. D-700 has 12 cylinders of NO which can be released. The NO system can be activated at the reactors by manually opening the correct valves. (b) Use nitrogen to pressurize the Dura-Seal* unit emergency seal water drums with their respective systems must be opened manually. (c) There will be sufficient air in the air system surge tank to operate valves for approximately fifteen minutes. It will be necessary to use the nitrogen backup system to operate valves after fifteen minutes. The surge tank should be valves off before the backup nitrogen system is activated. (d) Monitor each reactor for pressure rise. If the pressure continued to rise, the following steps are to be taken: (1) Equalize the reactor with any other empty or killed reactor of the same type product. (2) If the pressure still continues to rise, vent through the main condenser valve to the recovery system and the recovered VCM receiver. (3) If this will not releive the pressure buildup, then equalize the reactor with a reactor of different type resin. * Registered Trademark Operating Manual Old Unit PVC Reactors Page 36 ABD00286704 1-2 III. OPERATING PROCEDURES (CONTINUED) D. Polymerization (Continued) 3. Emergency Shutdown (Continued) (d) (4) If steps 1, 2, and 3 above fail to relieve the reactor pressure, the relief valve vent system will allow the reactor to vent off and on thru* the relief valves to control the pressure. Note: Step (4) is to be the last resort. Under the new EPA law, any venting must be reported and could result in a fine. E. Recovery and Steam Stripping The reactor is ready for recovery when certain conditions are reached in the reaction process. The conditions under which recovery will start are: Pressure Drop--There is not enough unreacted VCM left in the reactor maintain run pressure. A pressure drop is accompanied by a drop in the cooling water flow to the reactor jacket and condenser. Runaway--Reaction has increased to the point that it has outrun the capabilities of the cooling water to control. Temperature and pressure will both rise when this occurs. Follow instructions on each product formula as to the exact conditions at which the reaction is killed. Operating Manual Old Unit PVC Reactors Page 37 ABD00286705 I III. OPERATING PROCEDURES (CONTINUED) E. Recovery and Steam Stripping Temperature Rise--Pressure Prop--This is the ideal recovery situation and indicated proper initiator loading. The reaction will peak and slightly out run the capabilities of the cooling water. This situation gives the best recovery conditions since there is less VCM to be recovered and more converted to resin. Quick Kill--A reactor is sometimes killed on specific products to meet certain customer specifications--lower dry time (higher plasticizer absorbtion). The reactor is killed with a specified amount of the short stop solution at a specified set of conditions. The short stop solution mixture stops the reaction chain. On a quick-kill batch, it is very important to guard against resin carryover to the recovery system. An injection of defoamer will help to control foaming. A fast recovery is also important and will affect the dry time. 1, "A" Operator Duties When notified by the lead operator that the recovery conditions specified in the formula are met, the "A" operator will take the following steps: a. Check the hydroquinone injection system to make sure that the proper valves are open and hydroquinone level is adequate. Operating Manual Old Unit PVC Reactors Page 38 ABD00286706 1-2 III. OPERATING PROCEDURES (CONTINUED) Recovery and Steam Stripping (Continued) 1. "A11 Operator Duties (Continued) b. Check the blowdown tank level and pressure. Level and pressure roust be low to allow the automatic drain on the water circulation pump to operate. c. Check the water levels in the seal water separators and knockout drums. These levels are controlled automatically but should be checked before startup. Knockout drum level should be at or below the mid-point of the inlet to the vessel. The seal water separator level should be at or below the raid-point of the inlet to the vessel. d. Check the backflow pressure controller. It should be set at ten inches Hg vacuum. e. Check to see that the flush to the knockout drum and seal water separator level are on. f. Notify the lead operator that the recovery system is ready to start up. g. Steam header pressure should be greater than 100 psig. h. Reactor steam line should be checked and reactor steam valves should be checked to make sure that they are opening correctly. i. Fill out once per shift the recovery system checklist. A Operating Manual Old Unit PVC Reactors Page 39 ABD00286707 1-2 A III. OPERATING PROCEDURES (CONTINUED) E. Recovery and Steam Stripping (Continued) 2. Lead Operator Duties a. When the "A" operator has checked the recovery system, the lead operator can change reactor interlock mode to "recovery". b. Start the water recirculation pumps, 72-031 and 72-431. c. Start the seal water pumps, 72-033 and 72-032. This automatically starts the hydroquinone injection pump. d. Start two recovery compressors, 72-711, 72-712 or 72-792. This also opens the valves associated with compressor startup. e. The vacuum pumps wdLLlautomatically come on when the suction pressure of the compressor is 10 psig. The necessary valve changes are also automatically made. f. This unit will produce 5385 product only. The stripping procedure is: (1) Put reactor temperature controller on 200F. (2) Set new steam flow controller at 20,000 lbs./hr. (3) When the reactor is at 200F and vacuum pumps are on, move the temperature controller to 230F. Do not move the temperature controller until both conditions are met. Operating Manual Old Unit PVC Reactors Page 40 ABD00286708 1-2 III. OPERATING PROCEDURES (CONTINUED) E. Recovery and Steam Stripping (Continued) 2. Lead Operator Duties (Continued) f. (4) When the reactor is at 215F, open the emergency cooling water to the condenser. (5) Hold the reactor at this stage for 25 minutes. (6) The reactor must be recovered to a vacuum. Extend the hold time if necessary. (7) Record the inches of mercury vacuum reached on the batch sheet. (8) If a vacuum pump kicks out and will not restart, shut off the corresponding compressor to prevent VCM from backing up into the other vacuum pump. (9) Do not recover the blowdown tank at the same time as recovering a reactor. g. Watch the temperature of the reactor condenser. h. When stripping conditions specified in step "f" are met, steam stripping is complete. i. When steam stripping and recovery is complete, the recovery system is shut down as follows: (1) Push stop buttons for the recovery compressors 72-711, 72-712, or 72-792. This also stops the vacuum pumps. (2) Push stop buttons for seal water pumps 72-033 and 72-032. This also stops hydroquinone injection pump. Operating Manual Old Unit PVC Reactors Page 41 ABD00286709 1-2 in. OPERATING PROCEDURES (Cont.) E. Recovery and Steam Stripping (Cont.) 2. Lead Operator Duties (Cont.) i. (3) Push stop buttons for the water recirculation pumps, 72-031 and 72-431. 3. Recovery System Troubleshooting a. High Compressor Outlet Temperature Probable cause is poor or no water recirculation in the recovery knockout drum, 45-027. Check K. 0. pump discharge pressure. Check VCM feedback controller setting. Controller setting should be at 25 inches Hg. b. High Compressor Discharge Pressure High pressure can be caused by: (1) Plugged Condenser-- Have lead operator report problem to the shift supervisor. (2) Plug in the Line from the Condenser to the VCM Collect Tank-- Line will have to be pulled and cleaned. (3) High Level in the VCM Collect Tank (a) Switch transfer pump to manual. (b) Check level of the recovered VCM receiver-- east or west. (4) High RVCM Receiver Pressure (a) Switch receiver (b) Check line pressure to the RVCM receiver to be sure line is not plugged. (5) No Cooling Water to Condenser--Check inlet and outlet water valves. (6) High Seal Water Temperature--This temperature should be 110 + 10. Check seal water pump for flow and pressure and check filter pack. Operating Manual Old Unit PVC Reactors Page 42 ABD00286710 1-2 A III. OPERATING PROCEDURES (CONTINUED) E. Recovery and Steam Stripping (Continued) 3. Recovery System Troubleshooting (Continued) c. If the compressor is not compressing the VCM vapor and does not have a 50 to 70 psi discharge pressure: (1) Check seal water flow. (2) Check seal water separator water level and adjust as necessary. (3) Check seal water temperature--below 80F water will condense the VCM vapor and cause displacement of the water seal around the compressor cone. d. Recirculation water pump 72-031 goes out (mechanical-electrical). (1) Under normal operation, recirculation water pump 72-031 circulates water through the water recirculation cooler and into recovery knockout drum 45-027. Crossover piping is provided so that, if recirculation water pump 72-031 fails, recirculation water pump 72-431 will be valved to circulate throught the recirculation water cooler and into recovery knockout drum 45-027. Operating Manual Old Unit PVC Reactors Page 43 ABD00286711 1-2 III. OPERATING PROCEDURES (CONTINUED) E. Recovery and Steam Stripping (Continued) 3. Recovery System Troubleshooting (Continued) Note: Normal operating temperatures for the recovery system during stripping are: (a) Reactor Condenser- 215-225F (Peak Temperature) (b) 45-027 Knockout Drum Outlet-122-128F (c) 45-017 Knockout Drum Outlet -90-115F (d) Compressor Outlet- 130-140F The lead operator must monitor these temperatures on the multipoint recorder and have the "A" operator check out and correct deviations. e. Reactor Foaming (carryover)--When foaming is detected, the "A" operator will: (1) Inject defoamer into the reactor to reduce slurry surface tension and lower the reactor slurry level. It may become necessary for the lead operator to shut down one compressor to slow the recovery. If excessive foaming occurs, shut down recovery and thoroughly flush the entire system with water until clear. All flushing must be done to the water stripper tanks. Operating Manual Old Unit PVC Reactors Page 44 ABD00286712 1-2 III. OPERATING PROCEDURES (CONTINUED) F. Reactor Dump and Rinse When the recovery of the reactor has been completed, the slurry is ready to be dumped to the slurry blend tank(s) that has been designated by the shift supervisor. I. "A" Operator Duties a. Check the selected blend tank or tanks to make sure it will hold the batch. b. Check to see that the blend tank sewer valve is closed and Air Sparger* aeration air is on. c. Check the slurry transfer pump valving to make sure the flow will be going to the correct line. d. Place the coarse overflow collector into position. Inform the lead operator that the dump can begin. e. Monitor the dump tank level until the flow to the pump and discharge from the reactor have leveled out to a steady rate. f. Add the formula amount of calcium stearate to the dump tank. *Registered Trademark Operating Manual Old Unit PVC Reactors Page 45 ABD00286713 1-2 III. OPERATING PROCEDURES (CONTINUED) F. Reactor Dump and Rinse (Continued) 2. Lead Operator Duties a. Select the blend tank to be used by opening the appropriate control valves in the slurry transfer lines. The valves will be operated by pushbuttons located on the recovery control panel under the "Slurry Dump" section as follows: CV-1517 To T-501 CV-1518 To T-407 CV-1520 To T-747 CV-1502 To T-502 CV-1519 To Small blend tank manifold b. Check the sewer valve on the reactor to be sure it is closed. c. Turn on Sweco* screener d. Check the Sweco* exhauster to be sure it is running. It should be running continuously. e. Turn the interlock mode selector switch to the "dump" position. f. After the "A" operator informs lead operator that dump can begin, place the slurry transfer pumps, 72-496 and/or 72-497, in the "run" position. The level in slurry dump tank 89-007 is automatically controlled. *Registered Trademark Operating Manual Old Unit PVC Reactors Page 46 ABD00286714 1-2 III. OPERATING PROCEDURES (CONTINUED) F. Reactor Dump and Rinse (Continued) 2. Lead Operator Duties (Continued) g. Five minutes after the start of dump, open the reactor vent to the atmosphere. h. When there is no slurry flow through the sight glass, the reactor is rinsed according to formula instructions. Reactor is empty when agitator shows no load amps and sewer bullseye shows no flow. i. When dump and rinse are complete, place the slurry transfer pumps in the stop position. This shuts down the pumps, 72-496 and/or 72-497. G. Chem Wash and Rinse Chem wash and rinse is not done as a matter of routine on all reactors; however, if it is has been determined that chem wash is needed the formula states what the lead operator is to do. After the reactor has been rinsed during the dump cycle, it is ready to be chem washed. The chem wash cycle is necessary to remove polymer buildup from the reactor condenser, walls, baffles, and agitator. If polymer buildup is allowed to remain in the reactor, it continues to grow with each successive charge. Buildups will contribute to high gel, low quality resin, and will make reactor dumping very difficult if they get large enough to break off and plug dump valves and lines. *Registered Trademark ABD00286715 Operating Manual Old Unit PVC Reactors Page 47 1-2 III. OPERATING PROCEDURES (CONTINUED) Chem Wash and Rinse (Continued) Operators must exercise caution during chem wash due to the caustic in the solution. If any solution should get on an operator, flush immediately with water. Caustic feels slick to the touch and will start burning the skin just a few seconds after contact. If the solution spray over the body, immediately get under a safety shower and remove your clothing. If any should get in the eyes, flush eyes for at least fifteen minutes but until all the burning stops and report to your supervisor. Procedure 1. The lead operator will check and make sure the reactor sewer valve is closed. 2. The lead operator will then place the interlock mode selector switch to "clean and rinse." 3. The lead operator then checks to see that cleaning solution tank 45- is at leat 85% full. 4. The lead operator then opens the valves from the cleaning solution pumps, 72-961 or 72-962, to the reactor condenser cleaning nozzle. The atmospheric vent on the reactor should be closed. All other reactor valves are closed. 5. The lead operator then opens the suction valve, CV-122 for the cleaning solution pumps, 72-961 or 72-962. Note: The cleaning solution pumps will start only if one of the suction valves, CV-122 or CV-125, is opened. A Operating Manual Old Unit PVC Reactors Page 48 ABD00286716 1-2 III. OPERATING PROCEDURES (CONTINUED) G. Chem Wash and Rinse (Continued) Procedure (Continued) 6. The Reactor"A" operator willcheck to see that the cleaning solution heater temperature controller is set at 190F. 7. The lead operator will then turn on one cleaning solution pump 72-961 or 72-962. 8. When the chem wash has been flushed through the reactor condenser, the lead operator will: CAUTION: The atmospheric vent valve must remain closed. a. Shut off cleaning solution pump. Close pump suction valve CV-122 from the cleaning solution tank. b. . Open chem wash return valve on reaactor. c. Open cleaning solution pump suction valve CV-125 from the reactor. d. Close valves to the condenser cleaning nozzle, e. Open valves to the reactor cleaning nozzle. f. Restart the cleaning solution pump. The chem wash solution should now be circulating from the bottom of the reactor back to the reactor cleaning nozzle. g. The reactor agitator remains on. ABD00286717 Operating Manual Old Unit PVC Reactors Page 49 1-2 III. OPERATING PROCEDURES (CONTINUED) G. Chem Wash and Rinse (Continued) Procedure (Continued) 9. The lead operator will recirculate the chem wash solution through the reactor for five minutes and will them pump the chem wash solution back to the cleaning solution tank by: a. Opening CV-124 b. Closing CV-123. This sends the cleaning solution pump discharge to the cleaning solution tank. 10. The "A" operator should monitor the cleaning solution pump and notify the lead operator when it loses suction (check pressure gauge on pump discharge). 11. The lead operator will not shut off the cleaning solution pump. 12. The lead operator will then check the cleaning solution tank level indicator to see if all the chem wash solution has returned. If any solution is lost or accidently dumped to the sewer, notify the utilities operator. The spilled solution must be neutralized to avoid upsetting the chemical balance in the lagoons. 13. The lead operator will now close the reactor cleaning valves and open the condenser cleaning valve and the reactor sewer valve. 14. The lead operator will cut on both hot water charge pumps and flush through the condenser to the sewer for ten minutes. Operating Manual Old Unit PVC Reactors Page 50 ABD00286718 1-2 III. OPERATING PROCEDURES (CONTINUED) G. Chem Wash and Rinse (Continued) Procedure (Continued) 15. The lead operator will then close the condenser cleaning valve, open the reactor cleaning valve, and flush the reactor to the sewer for ten minutes. Reactor is empty when agitator shows no load amps and sewer bullseye is empty. 16. The lead operator will now close the reactor sewer valve. 17. Because of water dilution and resin accumulation, chem wash mast be disposed of and fresh caustic pumped to the cleaning solution tank once per week. Follow the procedure outlined under "Used Chem Wash Solution Disposal". H. Full and Partial Swirl To assist in the production of quality resin, particularly low gel, it has been found that, by filling the reactor with water and agitating, the gel count is markedly lower. Swirl is performed when specified in the formula. 1. Full Swirl In this swirl, the reactor is almost completely filled with water. Lead Operator Duties a. Turn the interlock mode selector switch to the ''swirl" position. b. Opens the reactor main charge valve and water charge valve. c. Starts both hot water charge pumps. ABD00286719 Operating Manual Old Unit PVC Reactors Page 51 1-2 III. OPERATING PROCEDURE (CONTINUED) H. Full and Partial Swirl Lead Operator Duties d. (1) Adds 1400 counts of water to D-300, D-400, D-500 and D-600 reactors. (14000 gallons) (2) Adds 2000 counts of water to D-700 reactor (20000 gallons) e. Cuts off pumps and closes valves. f. Agitates for ten minutes g. Opens sewer valve and dumps 2. Partial Swirl This swirl procedure is the same as the full swirl except for the amount of water used. Charge 700 counts, (7000 gallons) for D-300, D-400, D-500 and D-600. Charge 1000 counts (10,000 gallons) for D-700. Then follow the same procedure as the full swirl. I. Colloid Solution Makeup The properties of polyvinyl chlordie (PVC) are strongly dependent upon the type and quality of the colloid solution used. The colloid solution must be very accurate and consistent every time it is prepared. The colloid solution is a one and one-half (lh) percent solution of Dow F-50 Methocel* powder in water. *Registered Trademark Operating Manual Old Unit PVC Reactors Page 52 ABD00286720 1-2 III. OPERATING PROCEDURES (CONTINUED) I. Colloid Solution Makeup 1. Lead Operator Duties As soon as the lead operator is notified by the "A" operator that the colloid storage tank level is below the stright wall, he will schedule the "A" operator to make up colloid solution as follows: a. When the "A" operator indicates that the makeup tank is empty, schedule the "A" operator to make up a new batch of colloid solution as soon as possible. b. During the first part of the colloid makeup procedure when notified by the lead operator, the "A" operator will open the hot water charge valve to the makeup tank and the lead operator will start one hot water charge pump and the discharge valve associated with the charge pump to transfer hot water to the colloid makeup tank. When the water reaches the desired amount, the "A" operator will notify the lead operator to stop the hot water addition. 2. "A" Operator Duties The "A" operator aids in colloid solution transfer by notifying the lead operator when the colloid charge tank needs to be refilled. Operating Manual Old Unit PVC Reactors Page 53 ABD00286721 1-2 III. OPERATING PROCEDURES (CONTINUED) I. Colloid Solution Makeup (Continued) 2. "A" Operator Duties The "A" operator aids in colloid solution transfer by notifying the lead operator when the make-up tank is empty. When notified by the lead operator, the "A" operator makes up a new batch of colloid solution by the following procedure: a. Bring 3 bags of Dow F-50 Methocel* powder (50 pounds per bag) to the top of the colloid makeup tank. b. Rinse the colloid makeup tank with water to the sewer until it is clean. c. Open the hot water charge valve into the colloid makeup tank. Notify the lead operator to start the hot water charge pump to put in the tank. When the makeup tank is about h full, notify lead operator to shut off pumps (this is approximately 72 counts). d. Start the colloid tank heater and the tank agitator. Heat the water in the tank to 180F. *Registered Trademark Operating Manual Old Unit PVC Reactors Page 54 ABD00286722 1-2 III. OPERATING PROCEDURES (CONTINUED) I. Colloid Solution Makeup (Continued) 2. "An Operator Duties (Continued) e. When the heater is off, add the raethocel powder very slowly with the agitator still on. Each bag should take about one minute to add. If the powder is added too quickly, it will form lumps and not dissolve properly. Carry the empty bags to a trash container. f. Allow about thirty minutes to let the agitator thoroughly mix the powder into the hot water. Check the mixture for lumps and continue to mix if lumps are present. g. When the mixture contains no lumps, add cold water to the tank until the outage is 3 inches from the top of the tank. h. Start the colloid tank cooler. Close the cooling jacket valve when the colloid solution reaches 85F. i. Check the temperature after four hours of cooling. If the temperature is 85F, close the cooling jacket valves and turn off the agitator. If the tank is still cooling, leave the agitator on until the tank has reached 85F. It is very important to cool the colloid solution completely each time to produce a good quality colloid solution, j. Caution: Spills of colloid solution are slick and present a dangerous slipping hazard. ABD00286723 1-2 Operating Manual Old Unit PVC Reactors Page 55 III. OPERATING PROCEDURES (CONTINUED) J. Hydroquinone Solution Makeup Hydroquinone is injected into the recovery system to short stop the chain reaction and polymerization of vinyl chloride. If the hot VCM gases are allowed to flow through the recovery lines with out any inhibitor, they continue the reaction that was started in the reactor and rapidly fill and plug the recovery lines. Plugged lines in the recovery system are very time consuming to pull and clean and cause considerable amounts of downtime. Adequate and accurate injection of hydroquinone eliminates this problem. Hydroquinone (commercial name Tecquinol*) comes in a powder form and must be put into a solution with water for our use. When the hydroquinone solution level is low, a new batch is to be made. Each batch should last approximately one month. 1. Lead Operator Duties As soon as it is determined that the hydroquinone storage tank is low, the lead operator should schedule hydroquinone makeup between reactor recoveries. 2. "A" Operator Duties When notified by the lead operator to make up a new batch of hydroquinone solution, the "A" operator does the following: a. Weight up twenty pounds of hydroquinone powder. * Registered Trademark ABD00286724 1-2 Operating Manual Old Unit PVC Reactors Page 56 n. OPERATING PROCEDURES (CONTINUED) J. Hydroquinone Solution Makeup (Continued) 2. "A" Operator Duties (Continued) b. Turn off hydroquinone metering pump suction valve and, with the nitrogen turned on and the vent closed, drain the remaining heel to the sewer and rinse with water to the sewer. c. Add water to the mixing drum until it is within 2-3 inches from the top. d. Turn the agitator on and add the hydroquinone powder. Mix thoroughly. e. Transfer the hydroquinone mixture to the charge tank using the drum pump. f. Close the vent and open the nitrogen to the charge tank. Maintain 1-2 PSIG on the charge tank. g. Make sure the valves are lined up to the hydroquinone metering pump. 3. Safety Precautions Rubber gloves and full face shield must be worn while handling and transferring hydroquinone dust and liquid. Hydroquinone dust can irritate and seriously damage the eyes. First Aid -- In case of contact, immediately flush eyes with water for fifteen (15) minutes. Notify the plant nurse. Flush skin with water and wash clothing before reuse. ABD00286725 Operating Manual Old Unit PVC Reactors Page 57 III. OPERATING PROCEDURES (CONTINUED) K. Used Chetn Mash Solution Disposal Procedure 1. The shift supervisor must have given instructions to dump the used chem wash solution and make up a fresh batch. 2. The lead operator will instruct the "A" operator to open the tank drain valve, CV-137. The "A" operator will open the valve using a locally mounted handswitch mounted on the south side of the tank. 3. As soon as the tank is empty of solution, the "A" operator will open the three-inch process water valve to the cleaning solution tank to flush out the tank to sewer. Then the operator will close the process water valve and the tank's drain valve. 4. Make up a new batch of cleaning solution. Notify the P-l operator to transfer new caustic to the tank. Note: Notify the utility operator that the cleaning solution has been dumped to the sewer. ABD00286726 1-2 Operating Manual Old Unit PVC Reactors Page 58 n. OPERATING PROCEDURES (CONTINUED) L. Initiator Handling and Storage In the conversion of vinyl chloride monomer to polyvinyl chloride resin, an initiator is needed to start and help sustain the reaction process. The Aberdeen plant uses peroxide-type initiators. The physical properties of the type resin needed to determines the type of initiator to be used. All of these products must be kept in cold storage because of rapid dangerous decomposition rates at room temperatures. The initiator is a skin and eye irritant and must be handled accordingly. Safety precautions for all types of initiators are basically the same, with some differences in hadling temperatures and explosive limits. 1. Safety Precautions in Handling Initiator a. Always wear impervious gloves. b. Avoid contact with skin or clothing (will bleach out clothes). c. Do not leave initiator unattended when not under refrigeration. d. If initiator is spilled, soak up with absorbent material. e. Dispose of empty containers immediately. Leave cap off and split the side of this container.and store away from the unit in an open area. f. Bring only what is necessary to the production area. Do not allow the amount in the reactor area freezers to exceed one day's comsumption. ABD00286727 1-2 Operating Manual Old Unit PVC Reactors Page 59 III. OPERATING PROCEDURES (Cont.) L. Initiator Handling and Storage (Cont.) g. If a partial or full jug of initiator is found sitting out, it may be water, but always handle and dispose just as if it were initiator. h. If spill on skin area, wash with large amounts of water. If splashed in the eyes, flush with water fifteen (15 minutes) and notify your supervisor. Do not use oils or salve on eyes. i. Should any initiator catch on fire, use water to cool the surround area. However, if the fire is spreading and likely to ignite other initiator set the portable fire monitor and get out of the area since an explosion is very likely. 2. Physical Characteristics These, Lucidol 223M75, Trigonox EHP-C75 and Witco 939M75, must be stored at a safe temperature below 20F to prevent rapid decom position of the material which occurs at approximately 50F. Lupersol L-ll catalyst must be stored at a temperature not below 15F because it freezes if stored below 15F for extended periods of time. These types of catalyst are not self ignited because they contain 75% product and 25% OMS, odorless mineral spirits. Operating Manual Old Unit PVC Reactors Page 60 ABD00286728 1-2 III. OPERATING PROCEDURES (CONTINUED) L. Initiator Handling and Storage (Continued) 3. Initiator Storage Freezers The walk-in freezers and one chest freezer have been installed for initiator storage at temperatures down to -30F. Each freezer has two independent refrigeration compressors with one to be held in reserve. This is to insure continuous operation at the temperature set point. High temperature in any freezer will activate the air horn and beacon flasher alarms. An automatic defrost system controlled by time clocks will provide frost-free operation. a. Operating Conditions (1) Temperature The temperatures are adjustable. They can be set from -30F to +30F. (2) Alarms The chest and the walk-in freezers on high temperature setting will activate the red beacon light and air horn. This is the same for all freezers in the plant. The alarm's present setpoint is 17F (+_ 2). Operating Manual Old Unit PVC Reactors Page 61 ABD00286729 1-2 ^ III. OPERATING PROCEDURES (CONTINUED) L. Initiator Handling and Storage (Continued) a. Operating Conditions (3) Compressors The compressors for the freezers are located in two interconnected sheds 50 feet north of the freezers. The compressors for the chest freezer and the west and middle walk-in freezers are located in the west shed. The compressors for the east walk-in freezer is in the east shed. The compressors in the west shed are numbered 1 thru 6. (a) No. 1 and No. 2 compressors serve the middle walk-in freezer. (b) No. 3 and No. 4 compressors serve the west walk-in freezer. (c) No. 5 and No. 6 compressors serve the chest freezer on the west end. The compressors in the east shed are numbered 7 and 8. They serve the east walk-in freezer. (4) Compressor Shutdown Conditions (Automatic) (a) Freezer Temperature (b) Compressor low oil level (c) High or low compressor pressure Operating Manual Old Unit PVC Reactors Page 62 ABD00286730 1-2 A III. OPERATING MANUAL (CONTINUED) L. Initiator Handling and Storage (Continued) a. Operating Conditions (5) Circuit Breakers (a) West compressor shed--located on north wall (1) Compressor panel-- the compressor circuit breakers are numbered in sequence 1 thru 6. (2) Fan panel-- the fans are numbered 2, 3, 5, and 6. (3) Auxiliary Panel--contains lights, defrost controls, alarms, fans and defrost time clocks. (b) East Compressor Shed- located on north wall (1) Compressor panel--the compressor circuit breakers are numbered 1 and 2. The fans are numbered 7 and 8. (2) Auxiliary Panel--contains lights, defrost controls, alarms, and defrost time clocks. (6) Defrost Cycles - Adjustable In the walk-in freezers, each compressor switches to hot gas bypass every six hours to provide a defrost cycle. This is controlled by a time clock. (7) Freezer Capacity (a) East walk-in freezer - 600 gallons (b) Middle and West walk-in freezers - 550 gallons (c) Chest freezer - 100 gallons Operating Manual Old Unit PVC Reactors Page 63 ABD00286731 1-2 A III. OPERATING MANUAL L. Initiator Handling and Storage (Continued) 4. Design and Operational Functions Each freezer is provided with two refrigeration units each which are capable of maintaining the desired freezer temperature. Both units can be run simultaneously to allow a check on compressor operation. The temperature element in each freezer is connected to a mercury switch which starts and stops the compressor. These are adjustable and can be set for different temperatures. Each compressor has a timer which activates a solenoid valve in the hot gas line to send hot gas directly to the evaporator to allow for the defrost cycle. The fan normally runs with the compressor but is off during the defrost cycle. The east middle and west walk-in freezers defrost every six hours, and the chest freezer defrosts every eight hours. The water-cooled condensers on each compressor in the west compressor shed have water bypass to allow continuous flow and prevent freezeup during cold weather. The condensers also have inlet and outlet valves to allow for acid cleaning. Condenser cooling water is normally supplied by and returned to the cooling tower. During shutdowns and power outages, a bypass valve from the well/city water can be opened to supply Operating Manual Old Unit PVC Reactors Page 64 ABD00286732 A 1-2 III. OPERATING MANUAL (CONTINUED) L. Initiator Handling and Storage (Continued) 4. Design and Operational Functions (Continued) water pressure. If the condensers are put on the well water, open the block valve in the manhole at the west end of the cooling tower to divert the water to the sewer. The condensers on the east walk-in freezer are air cooled and are not tied in to the cooling water system. 5. Daily Operational Checks a. Each compressor oil level by maintenance b. Temperature recorders by Chief Operator. c. Frost buildup on freezer coils by Chief Operator. NOTE: Manual defrost instructions are on the inside front of each time clock. NOTE: Due to the explosive nature of this initiator, formal approval must be obtained from the operations superintendent and the mechanical superintendent before any changes are made to this operation. Operating Manual Old Unit PVC Reactors Page 65 ABD00286733 1-2 III. OPERATING PROCEDURES (Cont.) L. Initiator Handling and Storage (Cont.) 6. Emergency Procedure for Initiator Freezers If the power should go off, do not open the freezers but do the following: a. Notify the shift supervisor to find out the reason for the power failure. (1) If trouble is inside the plant, the supervisor will survey the situation and estimate how long thecoutage will be. Freezers should hold temperature from 3-4 hours, depending on what is in them, the outside temperature, and how many times the door is opened. (2) If trouble is determined to be outside the plant, the shift supervisor will notify the proper people on the call list. (a) The duration of the outage will be determined. (b) If outage is expected to be over three (3) hours Joan Pope will arrange for purchase of dry ice. b. If a compressor should fail and it is not an electrical problem, get in touch with maintenance as soon as possible. Operating Manual Old Unit PVC Reactors Page 66 ABD00286734 til. OPERATING MANUAL (CONTINUED) L. Initiator Handling and Storage (Continued) 6. Emergency Procedure for Initiator Freezers (Continued) b. (1) If the problem cannot be fixed, try to move all initiator to other freezers. If not possible get dry ice. 1-2 n NOTE: If compressors should go out on a freezer, make sure the fans are turned off to that freezer. Middle freezer I and 2 fans, west freezer 3 and 4 fans, and chest freezer 5 and 6 fans. The east freezers have two fans, nos. 7 and 8, whose switches are located in the new panel located on the north wall of the east shed. c. Notify the following if an emergency should arise with the initiator freezers: Jim Barton - 369-4755 Pete Markey- 369- 6019 7. Circle Chart Responsibility and Change Schedule a. The Chief operator on each shift will check the charts to be sure they have ink and are rotating. b. The Chief operator on the 7pm-7am shift will place new charts in the recorder and trun in the previous day's chart to the shift supervisor. Operating Manual Old Unit PVC Reactors Page 67 ABD00286735 I III. OPERATING PROCEDURES (CONTINUED) M. Reactor Pressure Check Prior to the startup of a reactor after an extended outage or following a maintenance outage such as replacing a main dump valve or rodding out the condenser tubes, the reactor must be hydrostically pressure checked. This is to insure that no leakage occurs at the reactor, either inward or outward. Procedure 1. The lead operator sets up the pressure check as follows: a. Place the reactor mode in "emergency" to gain use of both the charge water valve and the rinse valves. b. Open both hot water charge pump discharge valves. c. Open the reactor charge water valve. d. Open the main charge dump valve. e. Open the emergency vent valve. 2. The lead operator then turns on both hot water charge pumps and fills the reactor. 3. The "A" operator stands by to notify the lead operator when the water comes out the atmospheric vent, showing that the reactor is full. 4. The lead operator then shuts down the hot water charge pumps and closes all valves. This must be done immediately to avoid overpressuring the reactor and blowing the rupture discs. 5. The "A" operator then increases the reactor pressure by charging water into the reactor through the initiator injection system. ABD00286736 1-2 Operating Manual Old Unit PVC Reactors Page 68 II. OPERATING PROCEDURES (CONTINUED) M. Reactor Pressure Check (Continued) Procedure (Continued) 6. The lead operator monitors the reactor pressure from the control room and instructs the "A" operator to shut off water addition when the pressure reaches 130 psig. 7. The "A" operator then checks the reactor for leaks at the reactor bottom and top side. If an flange or gasket has been changed, check these very closely. 8. The lead operator then monitors the reactor pressure. If the reactor holds 130 psig for ten minutes, the pressure check is terminated. If the reactor loses pressure, instruct the "A" operator to bring the pressure back up to 130 psig with the high pressure service water and reinspect the reactor for leaks. NOTE: Do not charge a reactor that will not hold pressure. 9. When the pressure check is completed, the lead operator dumps the water in the reactor to the sewer. The reactor is now ready to start evacuation procedure. N. Reactor Cleaning and Entry 1. Reactor Manhead Opening Procedures One of the most critical parts of the operator's job is the opening of the reactor Lenape* manhead. Following is a list of procedures that must be followed by the "A" operator or anyone else when opening a reactoT manhead. ABD00286737 1-2 Operating Manual Old Unit PVC Reactors Page 69 III. OPERATING PROCEDURES (CONTINUED) N. Reactor Cleaning and Entry Procedure a. Check the pressure gauge and/or bleed valve for pressure or vacuum. b. Unlatch Lenape* lock on Lenape manhead roll-bar and drop down. NOTE: If the reactor has pressure when the roll-bar arm is lifted, the pressure will start escaping. If this should happen notify the lead operator. c. Slowly raise manhead four to six inches and hold in that position. d. Call lead operator and have him cut on the reactor evacuation ejector to pull air inward through the manhead. e. Finish raising the manhead. f. Change "0" ring on manhead. g. Look at the bottom of rupture discs to determine if they are plugged with resin. h. If the bottom manhead is to be opened, inspect the bottom of the reactor through the open manhead. The reactor should contain no liquids. i. Go to the bottom of the reactor and make sure that the safety chain and jacking bolts are in proper position on the bottom manhead. *Registered Trademark Operating Manual Old Unit PVC Reactors Page 70 ABD00286738 1-2 III. OPERATING PROCEDURES (CONTINUED) N. Reactor Cleaning and Entry (Continued) Procedure (Continued) j. Maintenance will remove the bolts and open the manhead. 2. Reactor Cleaningr.and Entry This section willcover precautions taken prior to entry and during entry and cleaning of the reactor'. The following is a check list stating conditions which must be met by anyone entering the reactor. The equipment entry sheet is to be filled out and placed at the reactor. Procedure a. The reactor must be empty, steam stripped, recovered and flushed with water. b. The 02 content must be greater than 20 percent. c. The VCM content must be less than 10 ppm. d. The top and bottom manways must be open. e. The nitric oxide (NO) piping must be disconnected at the bottles. f. The following lines must be blanked or disconnected. (1) Main eight inch dump line. (2) Four inch steam stripping lines -- D-700 has two four inch steam stripping lines to be blanked or disconnected. (3) Six inch condenser lines. (4) Four inch chem wash and rinse line to condenser.* (5) Four inch chem wash and rinse line to reactor.* *When preparing to blank or remove blank in chem wash line, lock out cleaning solution pump, open chem wash line to reactor, and bleed line at discharge of pump before breaking chem wash flange. Operating Manual Old Unit PVC Reactors Page 71 ABD00286739 1-2 III. OPERATING PROCEDURES (CONTINUED) N. Reactor Cleaning and Entry (Continued) Procedure (Continued) f. (6) One inch initiator injection line. (7) Six inch VCM charge line--only on D-700 reactor. g. Lock out and tag agitator breaker. h. Test agitator switch. i. Special precautions and safety equipment that may be needed are: (1) Impervious suit (2) Plastic mats on the bottom disk to prevent slipping. (3) Continuous flow fresh air mask. (4) Rubber gloves. (5) Scaffolding for work above bottom level. (6) Two-way radio communication plus manway watch. (7) Safety harness (8) 12 volt explosion proof light. j. While cleaning the buildups from the baffles and blade, take extreme care not to scratch the reactor walls. These walls have been polished to eliminate giving the resin being formed during reaction a place to create a buildup. NEVER SCRAPE THE WALLS. K. Around the shaft at the bottom of each reactor is a carbon throttle bushing. The purpose of the throttle bushing is to protect the reactor seal from resin. The seal water flush will not be effective if the throttle bushing or A Operating Manual Old Unit PVC Reactors Page 72 ABD00286740 1-2 III. OPERATING PROCEDURES (CONTINUED) N. Reactor Cleaning and Entry (Continued) Procedure (Continued) k. holder is damaged. If there is any buildup in this area, it is the Maintenance Department's responsibility to remove it. Operators are NOT to clean the throttle bushing. Damage to the throttle bushing may cause seal failure. l. If hammer and chisel are required to clean the reactor, be careful of chisel placement to avoid it kicking back out of the buildup and causing personal injury. m. While in the reactor, check the safety discs for buildups, nozzles for plugs, and the bottom of the condenser for plugging. n. When internal job is completed, remove scaffolding from the reactor and store nearby. Remove any loose buildup on the reactor bottom and close the bottom manhead. o. Clean up any debris, rags, etc. The job is never complete until the area is clean. O. Filters There are numerous filter packs in the Old Unit PVC Reactors. The purpose of any filter is to remove any foreign matter from the flow stream. In doing so, these filters gradually become clogged and dirty which causes a restricted flow and poor filteration. Except in cases of high contamination, these Operating Manual Old Unit PVC Reactors Page 73 ABD00286741 1-2 III. OPERATING PROCEDURES (CONTINUED) 0. Filters filters must be changed out on a regular basis to prevent equipment damage and product contamination. This procedure will list the filters to be changed, the type filter element to be used and any safety precautions and methods to be used. 1. Dura Seal Oil Filters Type: Micro-Kleen II, 75 micron, 10 inch Change: Performed by maintenance NOTE: Each Dura-Seal unit and reactor has a spare filter. If it is necessary for operations to switch from a fouled unit to the clean one, follow up to make sure the filter element is changed out. 2. Reactor Gear Box Oil Recirculation Filters Type: Micro-Kleen II, 75 micron, 10 inch Change: Performed by maintenance NOTE: Filters can be changed out only when agitator is turned off. 3. Charge Mater Filters Type: Diamond Filter Tube, 10 micron, 30-inch Change: Performed by operations Operating Manual Old Unit PVC Reactors Page 74 ABD00286742 1-2 III. OPERATING PROCEDURES (CONTINUED) 0. Filters 4. Seal Water Filters Type: Diamond Filter Tube 10 micron, 30 inch Change: Performed by operations. NOTE: A large amount of resin carry over into the knockout tank will force an early charge. Filters must be changed out immediately after any resin carry over to prevent resin settling out in the filter pack. If neglected, the entire filter pack will have to be removed and drilled out. NOTE: A continuous flow fresh air mask must be worn when opening a vessel or line that may contain VCM. 3. Vinyl Chloride Charge Filters Type: Diamond Filter Tube, 10 micron, 40 inch Change: Performed by operations NOTE: Extreme caution must be exercised when changing these filters since the filter pack and filter elements are full of VCM and under pressure. Steps to be taken are: a. Close inlet and outlet valves of filter pack to be changed. Operating Manual Old Unit PVC Reactors Page 75 ABD00286743 1-2 III. OPERATING PROCEDURES (CONTINUED) 0. Filters (Continued) 5. b. Have lead operator pull a vacuum on the blowdown tank using the recovery system. c. Open the valve on the 2 inch line to the blowdown tank. d. Open the valve on the blowdown tank. e. The top of the filter pack will get cold if there is flow to the blowdown tank. If VCM is not going to the blowdown tank check the valves to make sure they are open. f. After it has been determined that flow is going to the blowdown tank, open the 1 inch steam valve on the bottom of the pack. g* Recover the filter pack until all cold spots disappear and the pack is hot on all surfaces. h. Close steam valve and valve to blowdown tank. Put on fresh air mask and remove filter pack manhead. i. Remove the old filters and install clean filters. Be sure and install a complete set of filters. Any filters left out will permit a flow of unfiltered VCM to the reactor. j * Replace the filter pack o-ring before replacing the manhead. Tighten manhead evenly to insure no leakage. Open vapor to pack. Check for leaks. If none, open inlet and outlet valves. ABD00286744 1-2 Operating Manual Old Unit PVC Reactors Page 76 HI, OPERATING PROCEDURES (CONTINUED) O. Filters (Continued) 6. Recovered VCM Filters Type: Diamond Filter Tube, 10 micron, 30 inch Change: Performed by operations. Note: Take the same precautions and use same procedure as stated in //5 Vinyl Chloride Charge Filters. Note: The VCM recovered filters may become plugged and require frequent changing. P. Housekeeping Good housekeeping is a major portion of any task to be under taken, and no task can be called complete until the work area has been cleaned. Return all tools and materials used to their proper place and do not leave lying around to create a safety hazard. The housekeeping of the reactor area is the responsibility of all people working there. Operating Manual D-700 PVC Reactors Page 77 ABD00286745 1-2 A IV. EQUIPMENT INDEX A. Reactors I. Polymerization Reactors 45-755 a. Purpose Vessel used to react VCM to PVC in a water suspension. b. Description Vertical-mounted, bottom-agitated vessel, 13-foot diameter by 28 foot straight wall height (37 feet overall height), jacketed, and with top-mounted condenser. The reactor is stainless steel, and the cooling water and steam jacket is carbon steel. Approximate capacity is 29,000 gallons. c. Normal Operating Conditions The reactor produces various resin types, operating in a pressure range of 28.5 inches Hg vacuum to 155 psig and a temperature range of 80-225F. d. Design Conditions Temperature, F Pressure, psig Shell Jacket 250 200 200(and full 45 vacuum) B. Heat Exchangers 1. Reactor Condensers 55-356 a. Purpose To remove the heat of reaction from the polymerization reactor by condensing VCM vapor. Operating Manual D-700 PVC Reactors Page 78 ABD00286746 1-2 IV. EQUIPMENT INDEX (CONTINUED) B. Heat Exchangers (Continued) b. Description Each of the reactor condensers are vertical, mounted on top of the polymerization reactors. Cooling water (shell side is used to condenser VCM (tube side). Each condenser has 2700 tubes which are ten feet long by one-inch diameter. Materials of construction are stainless steel clad for all surfaces in contact with VCM. c. Normal Operating Conditions Condensers operate in a temperature range of 80-225F and pressure range of 28.5 inches Hg vacuum to 155 psig during the reactor cycle. d. Design Conditions Temperature, F Pressure, psig Shell 250 120 Tubes 250 200 (and full vacuum) 2. Cleaning Solution Heater 55-557 a. Purpose To heat and maintain chem wash solution temperature during chem wash of the reactors. b. Description Horizonal-mounted shell and tube type heat exchanger. Steam is on the shell side, and chem wash solution (caustic) is on the tube side. Surface area of 214 square feet is Operating Manual D-700 PVC Reactors Page 79 ABD00286747 1-2 IV. EQUIPMENT INDEX (CONTINUED) B. Heat Exchangers (Continued) 2. Cleaning Solution Heater 55-357 (Continued) b. Description provided by 79 tubes 14 feet long by 3/4-inch diameter. The tubes are stainless stell, and the shell is carbon steel. c. Normal Operating Conditions Steam temperature and pressure on the shell side will vary. Cleaning solution on the tube side is estimated to enter at 17SF and leave at 190F with a pressure of 125 psig. d. Design Conditions Temperature, F Pressure, psig C. Tanks and Vessels 1. Initiator Injection Pot 45-778 Shell 175 400 Tube 200 400 a. Purpose To inject initiator into the reactor D-700 during charge. b. Description Vertical-mounted, two-foot straight wall height with one and one half feet diameter, approximate capacity 15 gallons, stainless steel construction. c. Normal Operating Conditions Temperature near 70F and 180-260 psig. d. Design Conditions 300F and 450 psig. ABD00286748 1-2 A Operating Manual D-700 PVC Reactors Page 80 IV. EQUIPMENT INDEX (CONTINUED) C. Tanks and Vessels (Continued) 2. AMS Emergency Kill Charge Pots 45-780 a. Purpose To provide a means for injecting short stop solution into D-700 reactor to stop the reaction in the event of a power failure or loss of agitation. b. Description Vertical mounted three foot straight wall height, two feet diameter, capactiy approximately 60 gallons, stainless steel construction. c. Normal Operating Conditions 150 and 400 psig. 3. Cleaning Solution Tank 45-776 a. Purpose To provide an adequate amount of chem wash solution during reactor chem wash. b. Description Vertical-mounted, flat top, cone bottom, eleven foot straight wall height, eleven foot diameter, approximate capacity 8800 gallons, carbon steel construction. c. Normal Operating Conditions Atmoshperic pressure and 60-190F ABD00286749 1-2 Operating Manual D-700 RVC Reactors Page 81 IV. EQUIPMENT INDEX (CONTINUED) C. Tanks and Vessels (Continued) 3. Cleaning Solution Tank 45-776 d. Design Conditions 250F and + five-inch water pressure. 4. Reactor Evacuation Ejector Cyclone Separator 45-768 a. Purpose To remove any condensate present in the motive steam to the reactor evacuation steam ejector. b. Description High efficiency horizontal separator, Anderson LS-6-175 fourteen inch outside diameter, 34 inches long, carbon steel construction with stainless steel internal baffles. c. Normal Operating Conditions Steam in is 125 psig and 353F. d. Design Conditions 650 and 175 psig. D. Filters 1. Agitator Seal Water Outlet Filters 64-763, 64-764 a. Purpose To remove dirt and scale from agitator seal water. b. Description Filterite model LM010S-3/4HP, cartridge type, stainless steel element, cotton filter. Operating Manual D-70G PVC Reactors Page 82 ABD00286750 1-2 IV. EQUIPMENT INDEX (CONTINUED) D. Filters 1. Agitator Seal Water Outlet Filters 64-763, 64-764 c. Normal Operating Conditions 7,5F and 230 psig d. Design Conditions 105F, 3S0 psig, 3 GPM, particle size retention size 10 microns. 2. Mechanical Seal Purge Water Inlet Filters 64-757, 64-762 a. Purpose To remove dirt and scale from mechanical seal purge water. b. Description Filterite model 12 UM0525-2-2UM, cartridge type, stainless steel element, cotton filter- no. C10AK120A. 3. Cleaning Solution Strainer 64-756 a. Purpose To remove PVC particles from the cleaning solution. b. Description Ten-inch Winston line strainer, carbon steel construction- stress relieved. c. Normal Operating Conditions 2 psig and 180F. d. Design Conditions 200F, 20 psig, 500 gpm, particle retention on four-mesh screen. Operating Manual D-700 PVC Reactors Page 83 ABD00286751 1-2 IV. EQUIPMENT INDEX (CONTINUED) E. Pumps 1. Mechanical Seal Purge Water Pumps 72-953, 72-954 a. Purpose To supply high pressure water to the reactor agitator seals and the reactor cleaning nozzle flush. b. Description Centrifugal type, Sundyne P2AFH, 15-HP, 3,500 rpm. The casing and the impeller are stainless steel. c. Normal Operating Conditions Rated for 30 GPM at 540 feet of head. 2. Cleaning Solution Pumps 72-951 and 72-952 a. Purpose To supply chem wash solution to the reactors during chem wash. b. Description Centrifugal type, Durco Model Mark II, Group II, 4X3-10/75. 50-HP, 3,550 rpm, stainless steel casing and impeller. c. Normal Operating Conditions Rated for 500 gpm at 185 feet of differential head. F. Agitators 1. Reactor Agitators 51-109 a. Purpose To keep the colloid, VCM and water in the reactor well mixed. A Operating Manual D-700 PVC Reactors Page 84 ABD00286752 1-2 IV. EQUIPMENT INDEX (CONTINUED) 1. Reactor Agitators 51-109 b. Description Bottom entering, single speed, four blades at 45 angle, 350 HP, 125 rpm, stainless steel construction. c. Normal Operating Conditions 25,000 gallons of liquid or slurry in vertical vessel, 28-foot straight wall by 13-foot diameter, at about 120F and 130 psig. A ABD00286753 1-2 A Operating Manual Old Unit PVC Reactors Page 85 V. INSTRUMENT INDEX A. Flow Controllers Item No. Service Type Set Point FIRC-101 Reactor Cooling Water Flow Controllers Meter run with orifice plate, board-mounted indicators and recorders. Cascade control; the temperature controller of each reactor sets the set point. NOTE: FIRC-101 controls the cooling water to reactor 45-741. FIC-302 Reactor Steam Stripping Flow controllers Flow nozzle with D/P cell, board mounted indicator 20,000 lbs/hour FCI-108 Reactor Agitator Mechanical Seal Oil Supply Flow Regulators Kates Model MFA1-1 Flow Regulator 1.0 gpm NOTE: FCi-108 controls the seal water flow to reactor 45-741 double mechanical seal. B. Flow Totalizers Item No. Service Type FQI-103 Initiator Injection Pot Service Water Flow Totalizer Neptune Rotating Disc Meter, Local Local Readout Set Point None, totalize's only C. Level Indicator LI-101 Chem Wash Tank Level Indicator D/P Transmitter, Rosemount, board mounted indicator None, indication only D. Pressure Controllers PIC-325 Recovery System Absolute D/P Transmitter Rosemount with Foxboro board mounted controller 35- psig Operating Manual Old Unit PVC Reactors Page ye ABD00286754 1-2 V. INSTRUMENT INDEX (CONTINUED) D. Pressure Controllers (Continued) Item No. PCV-100 Service IXE Set Point AMS Emergency Kill System Nitrogen Supply Pressure Regulator Self-Contained 275 psig Pressure Regulator PIC-102 Evacuation Ejector EE-100 Steam Supply Pressure Controller Local, Fisher 4160 100 psig FR Controller PCV-113 Reactor Agitator 51Seal Oil Pressure Controller Self-Contained 230 psig Pressure Regulator PCV-119 Steam Tracing Header Pressure Regulator Self-contained Pressure Regulator 15 psig E. Temperature Controllers Item No. Service Type Set Point TIRC-101 Reactor Polymerization Temperature Controllers Resistance Bulb with Foxboro Controller Determined by Specific Batch Recipe NOTE: TIRC-101 controls reactor 45-101 polymerization temperature. TIRC-102 Reactor Stream Stripping Temperature Controller Resistance Bulb with boardmounted Foxboro Controller 225F NOTE: TIRC-102 controls reactor 45-101 steam stripping temperature. TIC-104 0 Cleaning Solution Heater Filled System with 190 F Outlet Local Foxboro Temperature Controller Controller Operating Manual Old Unit PVC Reactors Page 87 ABD00286755 1-2 VI. ALARMS AND SAFETY EQUIPMENT A. Continuous Flow Fresh Air System In order to provide personnel protection, a continuous flow fresh air system has been installed. This system consists of personnel fresh air masks and a constant flow breathing air supply. The supply lines are piped to all affected areas of the plant. The individual hookup stations consist of quick connect/disconnecttype fittings. The individual lines to the designated areas are designed to allow a minimum flow of 6 SCFM to each mask at approximately 10-15 psig. An air pressure regulator, shutoff valve, and an air filter are provided at the piping header to each individual area. The air supply system utilizes two Nash compressors supplying 100 SCFM each at a maximum pressure of 80 psig. Each compressor will supply about fifteen masks with air at one time. The com pressors normally are both in operation at the same time, except in cases of mechanical failure. The system is equipped with both visable and audible low pressure alarms which are activated at 50 psig. The revolving beacon light is mounted on a pole to give wider visibility, and the horn is mounted at the compressor. An on-off switch is provided at each compressor. ABD00286756 Operating Manual Old Unit PVC Reactors Page 88 VI. ALARMS AND SAFETY EQUIPMENT (CONTINUED) A. Continuous Flow Fresh Air System (Continued) The following job operations will REQUIRE the wearing of a continuous flow fresh air mask supplied through the fresh air lines or a Scott Air Pak: 1. Venting or changing filters in any VCM vessel. NOTE: No vessel or line should be vented unless there is no alternative, such as using pipe or hose to transfer VCM into the recovery system or blowdown tank. 2. Entering any vessel that normally contains VCM, such as reactors, blowdown tanks, knockout drums, receivers, etc. (except for scaf folding construction). 3. Opening large reactor manhead (wear mask until the manway is partially open and the evacuation jet is moving air through the manway). 4. Opening any line that may possibly contain VCM vapors. 5. At ANY location where the VCM concentration is above the current allowable limit. Anytime VCM is detected by sight or smell, the concentration is well above the limits and precaution is mandatory. Operating Manual Old Unit PVC Reactors Page 90 ABD00286757 1-2 VI. ALARMS AND SAFETY EQUIPMENT (CONTINUED) B. Alarms and Switches (Continued) 4. Temperature Alarms and Switches Item No. Service Type Set Point TAH-101 A&B High Temperature in the Reactors Board-Mounted Alarm 160F NOTE: TAH-101 A&B indicates high temperature in reactor. Firewater System The firewater system consists of a deluge system, combustible hydrocarbon analyzer, and fire monitors with hose connections. 1. Fire Monitors The fire monitors are normally supplied from the city water system. A tie-in with the firewater system allows the fire monitors to operate off either water system. There are four fire monitors located around the perimeter of the reactor area. 2. Hydrocarbon Analyzer A continuous combustible hydrocarbon analyzer is used to detect major VCM leaks. When the VCM level at any sample point reaches the set point, the deluge system is activated automatically. 3. Deluge System The deluge system is normally supplied from the firewater system. It can be operated on process water. The deluge system is a sprinkler system which will cover the reactors, dump system, fresh and recovered VCM storage tanks, and both floors of the Operating Manual Old Unit PVC Reactors Page 91 ABD00286758 1-2 VI. ALARMS AND SAFETY EQUIPMENT (CONTINUED) C. Firewater System (Continued) 3. Deluge System (Continued) recovery building with ^ water spray. The deluge system is designed to lower VCM concentrations in the reactor and recovery building area in the event of a VCM leak and as a sprinkler system to help put out fires. The deluge system can be acti vated manually, by the combustible hydrocarbon analyzer, or by thermal sensors. The revised firewater system contains three new post indicator valves (PIV) and one PIV was relocated. These are valves which have indicators on them to show whether the valve is open or closed. These valves are used to direct water to either the D-700 reactor area of the V-ll area. The valves are located at: 1. The southwest corner of the new cooling water tower. 2. East wall of the V-ll building. 3. Two are located at the northwest corner of the intersec tion of the entrance road and second street. D. Fixed Point VCM Monitor A fixed point VCM monitor is used to detect VCM and record the VCM concentration at various locatinos in the reactor and recovery building. ABD00286759 1-2 APPENDIX A EQUIPMENT LIST Reactors 45-755 Heat Exchangers 55-356 55-357 Educators and Ediectors EE-101 A, B, & C EE-100 Tanks and Vessels 45-778 45-780 45-776 Filters 64-757 64-762 64-763 64-764 Service Polymerization Reactor Reactor 45-755 Condenser Cleaning Solution Heater Reactor 45-755 Jacket Educator Reactor Evacuation Ejector Initator Injection Pot for Reactor 45-755 AMS Emergency Kill Pot for Reactor 45-755 Cleaning Solution Tank Mechanical Seal Purge Water Filter Mechanical Seal Purge Water Filter Seal Water Filter for Reactor Agitator 51-109 Seal Water Filter for Reactor Agitator 51-109 Pumps 72-951 72-952 72-953 72-954 Agitator 51-109 Motors 70-951 70-952 70-953 70-954 70-970 Service Cleaning Solution Pump Cleaning Solution Pump Mechanical Seal Purge Water Pump Mechanical Seal Purge Water Pump Reactor 45-755 Agitator Package Units PA-200 PA-201 Service Emergency NO Short Stop Bottle Nitrogen Supply Bottle for AMS Emergency Kill Pot ABD00286760 A 1-2 Item No. Amperage Instruments 11-100 IR-100 IAH-100 IAL-100 Control Valves CV-100 CV-101 CV-102 CV-103 CV-104 CV-105 CV-106 CV-107 CV-108 CV-109 CV-110 CV-111 CV-113 CV-114 CV-115 CV-116 CV-117 CV-118 CV-119 CV-120 CV-121 CV-122 CV-123 CV-124 CV-125 CV-126 CV-127 CV-128 CV-129 CV-131 CV-132 CV-134 CV-136 CV-137 CV-144 CV-145 APPENDIX B INSTRUMENT LIST Service Reactor Agitator 51-109 Motor Amperage Indicator Reactor Agitator 51-109 Motor Amperage Recorder Reactor Agitator 51-109 Motor High Amperatue Alarm Reactor Agitator 51-109 Motor Low Amperage Alarm Reactor 45-755 Main Charge Valve Reactor 45-755 VCM Charge Valve Reactor 45-755 Slurry Dump Valve Reactor 45-755 Chem Wash Return Valve Reactor 45-755 Hot Water Charge Valve Reactor 45-755 Sewer Drain Valve Reactor 45-755 Steam Stripping Valve Reactor 45-755 Steam Stripping Valve Reactor 45-755 Colloid Vharge Valve Reactor 45-755 Initiator Charge Valve Reactor 45-755 Reactor Sampling Valve Reactor Jacket Educator EE-101 A, B, & C Steam Valve Reactor 45-755 Chem Wash Supply Valve Reactor 45-755 Rinse Supply Valve Reactor Condenser 55-356 Cleaning and Rinse Valve Reactor 45-755 Cleaning and Rinse Valve Reactor 45-755 Evacuation Valve Reactor 45-755 Recovery Valve Reactor 45-755 Evacuation and Recovery Valve Reactor Condenser 55-356 Inert Vent Valve Reactor 45-755 Vent Valve Chem Wash Pumps 72-951 and 72-952 Suction Valve Chem Wash Heater 55-357 Inlet Valve Chem Wash Tank 45-776 Top Inlet Valve Reactor Chem Wash Return Valve to Chem Wash Tank 45-776 Reactor 45-755 Chem Wash Return Valve Reactor 45-755 Chem Wash Return Valve Reactor 45-755 Chem Wash Return Valve Reactor 45-755 Chem Wash Return Valve Evacuation Ejector EE-100 First Stage Steam Valve Evacuation Ejector EE-100 Second Stage Steam Valve Reactor 45-755 VCM Charge Valve Chem Wash Recirculation Valve Chem Wash Tank 45-776 Drain Valve Reactor 45-755 AMS Emergency Kill System Supply Valve Reactor 45-755 AMS Emergency Kill System Supply Valve ABD00286761 1-2 Item No. Flow Instruments FQI-103 FRC-101 FI-100 FI-102 FI-105 FCV-108 FI-109 OF-106 RO-107 FIC-302 Pressure Gauges PS-105 PAH-106 A&B PR-106 PT-106 PI-114 PS-116 PAL-116 Rupture Discs RD-100 RD-101 RD-102 RD-103 RD-104 RD-106 RD-107 RD-108 RD-109 APPENDIX B INSTRUMENT LIST (CONTINUED) Service Initiator Injection Pot 45-778 Service Water Flow Totalizer Reactor 45-755 Cooling Water Flow Controller Reactor Agitator 51-109 Lip Seal Flush Rotameter Reactor 45-755 Spray Nozzle Flush Rotameter Reactor Agitator 51-109 Mechanical Seal Water Inlet Flow Indicator Reactor Agitator 51-109 Mechanical Seal Water Flow Controller Reactor Agitator 51-109 Mechanical Seal Water Outlet Flow Indicator Reactor Condenser 55-356 Cooling Water Orifice Reactor 45-755, Inlet Vent Restriction Orifice Reactor Steam Stripping Flow Controller Reactor 45-755 Pressure Switch (Prevents dump before recovery) Reactor 45-755 High Pressure Alarm Reactor 45-755 Pressure Recorder Reactor 45-755 Pressure Transmitter Reactor 45-755 Pressure Indicator (Manometer) Initiator Injection Pot 45-778 Pressure Switch AMS Emergency Kill Pot 45-780 Low Pressure Alarm Reactor 45-755 Rupture Disc Reactor Condenser 55-356 Rupture Disc Reactor 45-755 Rupture Disc Reactor 45-755 Rupture Disc Initiator Charge Pot 45-778 Rupture Disc Reactor 45-755 Rupture Disc Reactor 45-755 Rupture Disc AMS Emergency Kill Pot 45-780 Rupture Disc Reactor Condenser 55-356 Rupture Disc ABD00286762 A 1-2 APPENDIX B INSTRUMENT LIST (CONTINUED) Item No. Safetv-Relief Valves PSV-100 PSV-101 PSV-102 PSV-103 PSV-105 PSV-106 PSV-108 PSV-109 PSV-110 PSV-111 PSV-112 PSV-113 PSV-114 PSV-116 PSV-117 PSV-118 Temperature Gauges TG-101 TG-102 Temperature Instruments TRC-101 TAH-101 A&B TRC-102 TR-103 TW-110 Service Reactor 45-755 Relief Valve Reactor Condenser 55-356 Relief Valve AMS Emergency Kill Pot Relief Valve VCM Charge Header Relief Valve Chem Wash Heater 55-357 Relief Valve Chem Wash Strainer 64-756 Relief Valve Chem Wash Return Header Relief Valve Reactor 45-755 Relief Valve Reactor 45-755 Relief Valve Reactor 45-755 Relief Valve Reactor 45-755 Relief Valve Mechanical Seal Purge Water Filter 64-757 Relief Valve Mechanical Seal Purge Water Filter 64-762 Relief Valve Reactor Condenser 55-356 Shell Relief Valve Reactor 45-755 Jacket Relief Valve Reactor Condenser 55-356 Relief Valve Reactor 45-755 Jacket Cooling Water Return Temperature Reactor 55-358 Cooling Water Return Temperature Reactor 45-755 Temperature Controller Reactor 45-755 High Temperature Alarms Reactor 45-755 Steam Stripping Temperature Controller Reactor Condenser 55-356 Temperature Recorder Reactor 45-755 Cooling Water Return Temperature ABD00286763 i 1-3 y \ i V. ABD00286764 1-3 A OPERATING MANUAL D - 1^5 P V C REACTORS ABERDEEN, MISSISSIPPI OCTOBER, 1981 Vernon L. Thornhill Senior Process Engineer / J. E. Barton Vinyl Expansion Coordinator ABD00286765 TABLE OF CONTENTS OPERATING MANUAL d-7^5 pvc reactors ABERDEEN. MISSISSIPPI I. INTRODUCTION A. Operator Responsibilities . . . B. Process Information ........................ 1. Evacuation 2. Charge 3. Initiator 4. Polymerization 5. Recovery and Steam Stripping 6. Dumping II. GENERAL PROCESS DESCRIPTION A. Evacuation ........................................... B. Charge ..................................................... 1. Precharge Preparations 2. Reactor Charge C. Polymerization .................................. D. Recovery and Steam Stripping . 1. Recovery 2. Steam Stripping 3. Hydroqulnone Injection 4. Recovery of Blowdown Tank E. Reactor Dump and Rinse .... F. Chem Wash and Rinse ........................ G. Water Swirl ........................................... H. Water Collection System . . III. OPERATING PROCEDURES A. Reactor Evacuation ........................ B. Reactor Precharge ............................. 1. Lead Operator Duties 2. "A" Operator Duties A 1-3 Page No. 1 3 5 5 9 12 16 17 19 19 20 24 ABD00286766 t Table of Contents Operating Manual 0--T^5 PVC Reactors Page 2 III. OPERATING PROCEDURES (CONTINUED) C. Reactor Charge D. Polymerization 1. Lead Operator Duties 2. "A" Operator Duties 3. Emergency Shutdown Page No. 28 33 E. Recovery and Steam Stripping.................................................................. 1. "A" Operator Duties 2. Lead Operator Duties 3. Recovery System Troubleshooting 39 F. Reactor Dump and Rinse................................................................................ 1. "A" Operator Duties 2. Lead Operator Duties 46 G. Chem Wash and Rinse........................................................................... 48 H. Full and Partial Swirl................................................................................ 1. Full Swirl 2. Partial Swirl 52 I. Colloid Solution Makeup . 1. Lead Operator Duties 2. "A" Operator Duties 53 J. Hydroquinone Solution Makeup .................................................................. 1. Lead Operator Duties 2. "A" Operator Duties 3. Safety Precautions 58 K. Used Chem Wash Solution Disposal......................................................... 60 L. Initiator Handling and Storage .............................................................. 1. Safety Precautions in Handling 2. Physical Characteristics 3. Initiator Storage Freezers 4. Design and Operational Functions 5. Daily Operational Checks 6. Emergency Procedure for Catalyst Freezers 7. Circle Chart Responsibility and Change Schedule 61 ABD00286767 Table of Contents Operating Manual D-7U5 PVC Reactors Page 3 III. OPERATING PROCEDURES (CONTINUED) M. Reactor Pressure Check ................................. N. Reactor Cleaning and Entry ........................ 1. Reactor Manhead Opening Procedures 2. Reactor Cleaning and Entry O. Housekeeping Guidelines ............................. IV. EQUIPMENT INDEX ............................................................ V. INSTRUMENT INDEX...................................... ....................... VI.ALARMS AND SAFETY EQUIPMENT A. Continuous Flow Fresh Air System B. Alarms and Switches ........................ C. Firewater System ................................. 1. Fire Monitors 2. Hydrocarbon Analyzers 3. Deluge System D. Fixed Point Monitors ........................ VII. EQUIPMENT OPENING PROCEDURES . . . . VIII. APPENDIX A. Equipment List B. Instrument List C. P & I Diagrams 1-3 A Page No. 70 72 77 78 114 120 123 131 132 133 ABD00286768 1-3 A OPERATING MANUAL p-7^5 pvc reactors ABERDEEN. MISSISSIPPI I. INTRODUCTION A. Operator Responsibilities The purpose of this plant Is to safely and economically convert vinyl chloride monomer (VCM) into a useable form of poly vinyl chloride (PVC). This is accomplished by a batch process in vhich VCM, water, initiator and colloid solution are charged into the reactor and under carefully controlled conditions, PVC with the desired physical properties is produced. This chemical reaction, which changes VCM to PVC, is called polymerization. The operator helps fulfill the plant's purpose by making sure that quality production is obtained from his equipment without endangering his fellow workers or his equipment. The operator is able to attain his goals in safety. Job performance and efficient operation through a training period and on the Job experience and passing a written exam. The operator fulfills his responsibilities by: 1. Demonstrating understanding of how his equipment functions. 2. Being able to explain what role each piece of equipment plays in the process. 3. Keeping a close and regular check on equipment. 4. Being able to demonstrate trouble shooting and corrective measures. 5. Keeping his area of responsibility safe and clean. .6 Keeping complete and accurate records. ABD00286769 1-3 A Operating Manual D-745 PVC Reactors Page 2 I. INTRODUCTION (CONTINUED) A. Operator Responsibilities (Continued) The operating Manual will cover the normal responsibilities and duties of the Lead Operator and the Reactor "A" Operator. Each phase In the production method will be covered. In addition to normal operating methods. It will also discuss operations under abnormal and emergency conditions. The operator must be prepared to meet these situations with temporary measures until the abnormal condition is corrected or the emergency crisis ceases to exist. The safety of the plant personnel and equipment is to be care fully considered before any job is started. The Conoco safety slogan, "our work is never so urgent or important that we can not take time to do it safely", is an idea that can help make the work area safer for everyone when it is put into practice. Good housekeeping is also an important responsibility of the operators. It requires careful attention for safety reasons and to maintain good working conditions. Cleaning up after job completion is the responsibility of the person doing the job. A job should not be considered complete until all materials are picked up and properly stored. ABD00286770 1-3 Operating Manual D-745 PVC Reactors Page 3 I. INTRODUCTION (Cont.) B. Process Information Several types of resins are produced. Resin type is determined by a set of physical properties such as particle size and viscosity Each type of resin produced requires that a certain set of operating conditions be closely followed so that the desired resin properties are obtained. Minor changes in formulas or operating conditions can cause major differences in the physical properties of the resin. Some factors in determining resin properties are reaction temperature, which helps determine viscosity, colloid, which influences particle size, and the amount of recovered VCM charged, which also effects particle size, amount of short-stop which effects stability and amount of calcium stearate which effects drying and customer processing. The phases of reactor operation and a brief description of each follows: 1. Evacuation This step removed all air possible by steam ejectors. Too much air left in a reactor will alter particle size. Evacuation should re quire about five minutes. 2. Charge Water, Colloid and VCM are charged to the reactor simultaneously through a timed sequence system. The temperature of the reactor contents at the end of charging is determined by the charge water temperature. The reactor will be below run temperature at the end of the charge and jacket steam will be used to raise the temperature to the desired level. Charge should take about nine minutes for D-741, D-742, D-743, and D-744. D-745 will require about fifteen minutes to charge. ABD00286771 Operating Manual pvc Reactors Page 4 J. INTRODUCTION (Cont.) B. Process Information (Cont.) 3. Initiator The initiator is manually loaded into the initiator injection pot and charged into the reactor after reactor charge is complete. 4. Polymerization This is the time from the initiator addition until most of the VCM has been converted to resin. The reaction generates heat continu ously as liquid VCM becomes PVC resin. Heat that is generated is removed by cooling water on the reactor jacket and condenser. Reaction time varies, but generally requires five to six hours for D-741, D-742, D-743, and D-744. D-745 will require about 4h to five hours. 5. Recovery and Steam Stripping Recovery and steam stripping removes most of the unreacted VCM from the reactor via a compressor-vacuum pump system. Steam is added to the bottom of the reactor and rises through the PVC and water slurry to help remove unreacted VCM. Recovery and steam stripping takes about 60 minutes for D-741, D-742, D-743, and D-744 with D-745 taking about 90 minutes to recover and strip. 6. Dumping The PVC resin, after reaction is complete, is in a slurry form. The slurry is dumped to a sweco and dump tank and is pumped to blend tanks in the Dryer Room for drying. Dump requires about 25 minutes for D-741, D-742, D-743, and D-744 and 35 minutes for D-745. ABD00286772 1-3 Operating Manual D-745 PVC Reactors Page 2 I. INTRODUCTION (CONTINUED) A. Operator Responsibilities (Continued) The operating Manual will cover the normal responsibilities and duties of the Lead Operator and the Reactor "A" Operator. Each phase in the production method will be covered. In addition to normal operating methods, it will also discuss operations under abnormal and emergency conditions. The operator must be prepared to meet these situations with temporary measures until the abnormal condition is corrected or the emergency crisis ceases to exist. The safety of the plant personnel and equipment is to be care fully considered before any job is started. The Conoco safety slogan, "our work is never so urgent or important that we can not take time to do it safely", is an idea that can help make the work area safer for everyone when it is put into practice. Good housekeeping is also an Important responsibility of the operators. It requires careful attention for safety reasons and to maintain good working conditions. Cleaning up after job completion is the responsibility of the person doing the job. A Job should not be considered complete until all materials are picked up and properly stored. ABD00286773 1-3 Operating Manual D-7^5 PVC Reactors Page 5 II. GENERAL PROCESS DESCRIPTION A. Evacuation Before charging, the inerts present in the polymerization reactor are removed by evacuation. The interlock selector switch is placed on "evacuation" position. The main condenser valve is opened, the reactor evacuation valve is opened, the evacuation header valve, and the steam supply valves to the ejector system to be used are opened. Any condensate in the steam to the ejector is removed by a cyclone separator. The emergency cooling water supply valve to the reactor is then opened. When the reactor reaches 28.5 inches of mercury vacuum, as indicated by the pressure indicator in the control room and a manometer at the reactor, evacuation is complete. This portion of the cycle requires about five minutes. B. Charge 1. Precharge Preparation After evacuation, the reactor is ready to be charged. In pre paration for charge, adequate quantities of VCM, hot water, colliod solution, and initiator are made ready for the charge sequence. Prior to charge, fresh VCM is transferred from the VCM storage sphere to the fresh VCM storage tank. This transfer of VCM begins automatically when the VCM liquid level falls below a certain level. Whenthe high liquid level is regained, the transfer process shuts down automatically. Two 150 gpm VCM transfer pumps are used to transfer the VCM from the VCM storage sphere. ABD00286774 A 1-3 Operating Manual D-7^5 PVC Reactors Page 6 II. GENERAL PROCESS DESCRIPTION (CONTINUED) B. Charge (Continued) Process water is automatically supplied to the hot water tank when the water level drops below a certain point. The water is filtered by the process water filter, and is heated in the hot water preheater, enroute to the hot water tank. The hot water tank temperature is maintained by the external steam coils on the hot water tank. The colloid solution, previously madeup, remains in the makeup tank until tested and approved. The colloid percent total solids must be 1.40 - 1.60. The colloid is then pumped from the makeup tank to the colloid charge tank. After each reactor charge, colloid is transferred at 50 gpm from the storage tank to the colloid charge tank by the colloid circulation pump. When the makeup tank contains less than one charge, the full charge tank will contain sufficient colloid to charge seven reactors. The colloid charge tank can be emptied to less than one charge while the new colloid solution is being made up and analyzed. Immediately before the reactor is to be charged, the initiator injection system is made ready for charge in the following manner. First, the initiator injection pot, at the reactor to be charged, is drained to the sdwer. One gallon of water is manually added as indicated by the local flow totalizer. ABD00286775 Operating Manual D-7^5 PVC Reactors Page 7 II. GENERAL PROCESS DESCRIPTION (Cont.) B. Charge (Cont.) 1. Precharge Preparations (Cont.) The initiator is then manually added to the initiator injection pot. The pot is then blocked in and pressurized with high pressure service water to at least 180 psig. The initiator injection system is now ready for the reactor charge. When the charge is complete. CAUTION: The initiator should never be left in the charge pot if the charge is aborted. It is to be dumped to the sewer and the pot flushed with water. 2. Reactor Charge After evacuation is completed, the interlock selector switch is moved to the "charge" position. If the following precharge con ditions are met, the charge sequence is ready to begin: a. Levels in the fresh VCM storage tank, the hot water tank, and the colloid charge tank are adequate for a complete reactor charge. b. There is sufficient pressure in the initiator injection pot and in the high pressure service water header. c. The charge meters are reset to the charge quantities. Steam is usually applied to the reactor jacket at the start of charge by manually opening the steam valve from the Control Room. ABD00286776 f Operating Manual D-7^5PVC Reactors Page 8 IX. GENERAL PROCESS DESCRIPTION (CONTINUED) B, Charge (Continued) 2. Reactor Charge (Continued) This aids in heating the reaction mass to the desired temperature during and immediately following charge. The automatic charge sequence begins with the hot water charge. The hot water is pumped from the hot water tank, to the reactor by the hot water charge pump. After a predetermined quantity of hot water has been charged, the colloid charge pumps and the second hot water charge pump start. The next step in the charge sequence begins with the fresh and recovered VCM charges. The fresh VCM is pumped to the reactor from the fresh VCM storage tank, by one of the two VCM charge pumps. The recover ed VCM is lumped from one of two recovered VCM storage tanks by the recovered VCM charge pump into the suction of the VCM charge pump. The recovered VCM is filtered in the recovered VCM filter and the total VCM charge is filtered enroute to the reactor by the VCM charge filter. Shortly after the beginning of the VCM charge, one of the hot water charge pumps shuts down until the VCM charge is com pleted and then restarts. This insures that there will be an adequate amount of water charge remaining to flush out the charge line except on D-745 where the VC line is separate. Both hot water charge pumps continue to run until charge is completed. ABD00286777 A 1-3 Operating Manual D--T**5 PVC Reactors Page 9 H. GENERAL PROCESS DESCRIPTION (Cont.) B. Charge (Cont.) 2. Reactor Charge (Cont.) When the VCM, water and colloid charge is complete, the initiator is charged by opening the initiator charge valve from the reactor by the '`A" operator. Loading the initiator and preparation of the initiator charge pot was discussed in the precharge preparation section. C. Polymerization After charge is completed, the reactor interlock selector switch is placed in the "polymerization" position, and the reactor temperature controller is placed on automatic. When the reaction mass reaches 3 below desired set point temperature the steam is turned off. The reaction mass temperature is automatically controlled by varying the amount of cooling water that is passed through the top-mounted knockback condenser and the reactor jacket. The reaction mass is continually mixed and kept in suspension by the bottom-mounted single speed agitator. The agitator mechanical seals are lubricated and cooled by seal oil from anoil pressure unit. During polymerization, mechanical seal purge water is injected into the reactor through the reactor cleaning nozzle and through the agitator mechanical seal. The water is added to keep the reactor Operating Manual D-7U5 PVC Reactors Page 10 ABD00286778 A 1-3 IX. GENERAL PROCESS DESCRIPTION (CONTINUED) C. Polymerization (Continued) cleaning nozzle and agitator mechanical seals clean. The purge water flow for each service is indicated with a rotameter and manually adjusted. The inerts present in the reactor during polymerization from initiator decomposition, suspending agent and water accumulate in the reactor condenser head space. These inerts are vented to the recovery system to prevent inert blanketing. When the desired degree of polymerization is reached and the reactor pressure has dropped to the desired pressure, the reaction is stopped by manually adding a mixture of AMS and Naugard (the short stop solution) to the reactor. High pressure service water is used to pressure the short stop solution from the initiator injection charge pot into the reactor through the same piping as the initiator charge piping. The charge pot is then blocked in and refilled with the short stop solution which will be used at the middle of steam stripping. An emergency AMS kill pot, located at grade, is provided to pressure AMS into the reactor to kill the reaction in the event of a power failure or upon loss of agitation. The AMS will be injected into the reactor through nozzles in the reactor head, using pushbuttons on the control panel or by manually operated valves in the field. Operating Manual 0-7*45 PVC Reactors Page 11 ABD00286779 1-3 II. GENERAL PROCESS DESCRIPTION (CONTINUED) C. Polymerization (Continued) The pots for D-741, D-742, D-743 and D-744 will contain 15-20 gallons of AMS. The material will be pressurized into the reactors using nitrogen. A nitric oxide (NO) short stop addition system is provided to inject NO into the reactors in the event of power failure, major VCM releases, fires, or other emergencies. The system is activated locally. NO is supplied from the emergency NO short stop bottles and is injected into the reactor through the same piping as the agitator mechanical seal purge water. ABD00286780 1-3 Operating Manual D-7^5 pvc Reactors Page 12 11 * GENERAL PROCESS DESCRIPTION (Cont.) , D. Recovery and Steam Stripping 1. Recovery When reaction is completed, the interlock selector switch is moved to the ''recovery and steam stripping" position. The following sequence then occurs. The recovery compresssor seal water systems, the water recirculation systems for the recovery knockout drums, and two of the three recovery compressors are manually started from the board. Cooling water to the recovered VCM condenser and the water recirculation cooler starts automati cally with the compressors, and the hydroquinone injection system starts with the compressor seal water systems. The vapor from the reactor flows through a pressure control valve to two resin knockout drums in series which cool the vapor and remove carryover resin. The pressure control valve prevents excessive carry over of resin from the reactor by limiting the pressure to the recovery system to about 35 psig. Each of the knockout drums have an . internal water spray system and a recirculation pump. Both knock out drums have on-off level control system which, on high liquid level, divert- the discharge of the water recurculation pumps to the water stripper. A water recirculation-cooler, (the function of which is explained in the steam stripping portion of the recovery system process description). ABD00286781 Operating Manual D-7^5 PVC Reactors Page 13 II. GENERAL PROCESS DESCRIPTION (Cont.) D. Recovery and Steam Stripping (Cont.) is provided and can be used in the water recirculation loop of either scrubbing stage. The VCM vapors from the knockout drums are compressed by the recovery compressors. The recovery compressors are constant volume liquid ring compressors with a water seal. The discharge streams from the compressors flow to two parallel seal water recirculation systems which operate as follows. Seal water is separated from the VCM vapors in the seal water separators, filtered by the seal water filters, cooled by the seal water coolers, and pumped back to the compressors by the seal water pumps. The flow of seal water to each compressor is controlled at 50 gpm. The seal water temperature is controlled just above the VCM condensation temp erature (95-105F). Automatic draining of the seal water separators to the water stripper is provided to maintain the correct water level. "Hie VCM vapors from the seal water system are condensed in two recovered VCM condensers. The condensed VCM is collected in the re covered VCM collect tank which is on automatic on-off level control. VCM is transferred to the recovered VCM storage tanks by the recovered VCM transfer pump when there is high liquid level in the VCM collect tank. Inerts are bled from the collect tank to the incinerator, ABD00286782 A 1-3 Operating Manual D-745 PVC Reactors Page 14 II. GENERAL PROCESS DESCRIPTION (CONTINUED) D. Recovery and Steam Stripping (Continued) 1. Recovery (Continued) When the reactor pressure drops to 8 psig, the two recovery vacuum pumps automatically start. The VCM flow from the recovery knockout drums and the seal water flow are both diverted to the vacuum pumps which discharge into the suction of the compressors. 2. Steam Stripping In order to reduce residual VCM in the slurry, the slurry in the reactor is heated and stripped with steam. At the start of a normal recovery, steam addition to the reactor is manually started from the control room and the slurry mass is heated. When the temperature of the reactor has risen to the desired temperature, the steam stripping operation is completed. As recovery proceeds, less and less VCM is recovered from the reactor. To supply sufficient VCM vapor to the recovery vacuum pumps and compressors, a VCM backpressure system is used. This is done to prevent cavitation and overheating of the vacuum pumps and compressors. Before entering the recovery knockout drums, the steam and VCM from the reactor are combined with a bleed stream of VCM from the recovered VCM storage tanks. The amount of VCM bled into the recovery system is adjusted by the backpressure control valve such that a set supply pressure to the vacuum pumps is maintained. ABD00286783 A 1-3 Operating Manual D-7^5PVC Reactors Page 15 II. GENERAL PROCESS DESCRIPTION (CONTINUED) D. Recovery and Steam Stripping (Continued) 2. Steam Stripping (Continued) The majority of the steam is condensed in the first knockout drum described in the normal recovery process description. The first stage of the scrubbing system consists of a recovery knockout drum with an Internal water spray system, a water recirculation pump and the water recirculation cooler. The / water cooler reduces the water temperature sufficiently to allow the internal spray system in the knockout drum to cool the VCM and condense much of the steam in the vapor stream. e After leaving the first stage of the water scrubbing system, the VCM vapor flows to the second stage of the scrubbing system and then to the rest of the recovery system in the same manner as during normal recovery. 3. Hydroquinone Injection The VCM removed from the reactor during recovery still contains a small amount of initiator. As a result, the VCM will continue to polymerize, resulting in plugged recovery lines, charge lines, and recovered VCM storage tanks. Polymerization is significantly reduced by the addition of an inhibitor such as hydroquinone to the VCM stream as it is being recovered. A 4.6 percent solution of hydroquinone in water is prepared in the hydroquinone storage tank. L ABD00286784 1-3 Operating Manual D-7U5 PVC Reactors Page 16 11 GENERAL PROCESS DESCRIPTION (Cont.) D. Recovery and Steam Stripping (Cont.) 3. Hydroquinone Injection (Cont.) The hydroquinone solution is pumped by the hydroquinone injection pump into the suction of the recovery seal water pumps. The in jection pump starts and stops automatically with the seal water pumps. The metering pump has a variable stroke which can be adjusted manually to maintain the preset hydroquinone injection rate. 4. Recovery of Water Stripper The water stripper is to collect the various steam and water streams containing VCM from the four-reactor module. The emission recovery system is used to recover VCM vapor. The water is transferred to the V-ll: water strippers and recovered by the emission recovery system. E. Reactor Dump and Rinse After the reactor is recovered and steam stripped, the reactor inter lock selector switch is moved to the "dump'' position. The appropriate dump valves are opened from the control room and the slurry flows by gravity to the dump system. The slurry passes through an enclosed vibrating slurry strainer where the PVC culls are collected until dump is completed. The slurry then flows to the slurry dump tank. The slurry transfer pumps transfer the slurry to the blend tanks. The dump tank level is automatically controlled. ABD00286785 A 1-3 Operating Manual D-745pvC Reactors Page 17 II. GENERAL PROCESS DESCRIPTION (CONTINUED) E. Reactor Dump and Rinse (Continued) Neat the end of dump, the reactor condenser is flushed with water by turning on the condenser rinse system from the board. Hot water is pumped from the hot water tank by the hot water charge pumps through the cleaning nozzle in the reactor condenser. The rinse water mixes with any remaining slurry and is pumped with the slurry to the blend tanks flushing out the slurry transfer lines. The slurry strainer and the slurry dump tank are equipped with a water wash system to remove resin from the equipment between production of different types of resin. F. Chera Wash and Rinse If it has been determined that the reactor needs cleaning, the reactor interlock selector switch is moved to the "clean and rinse" position after the dump and rinse is completed. The chera wash solution is a caustic solution. The cleaning solution pump or spare pumps the solution at 500 gpm from the cleaning solu tion tank through the cleaning solution heater to the reactor condenser spray nozzle. The reactor atmospheric vent must remain closed.to prevent splashing out of the reactor. Steam to the clean ing solution heater is automatically adjusted such that the exit temperature of the chem wash solution is 190F. When the level in the reactor is above the agitator blades (approximately 5,000 gallons) as determined by the level change in the cleaning solution tank* no more solution is added to system. Recirculation is then started with ABD00286786 1-3 Operating Manual D-7^5PVC Reactors Page 18 11 GENERAL PROCESS DESCRIPTION (Cont.) F. Chem Wash and Rinse (Cont.) the cleaning solution being pumped from the reactor at approximately 250 gpm and back to the reactor through the reactor cleaning nozzle. Large PVC particles picked up in the reactor cleaning process are removed from the cleaning solution in the cleaning solution strainer before entering the suction of the cleaning solution pump. When the Chem Wash has ended, the solution is pumped back to the cleaning solution tank at 500 gpm by the cleaning solution pump. For D-741, 742, 743, and 744, the process required ten minutes to fill the reactor through the condenser, five minutes to wash the reactor, and ten minutes to empty the reactor, for a total of twenty-five minutes. For D-745, the process requires a total time of forty-one minutes--twenty-one minutes to wash through the condenser, ten minutes to wash the reactor and ten minutes to empty the reactor. After the Chem Wash is completed, the reactor is rinsed with hot water from the hot water tank. The hot water is pumped by the hot water charge pumps to the reactor. The water first enters through the condenser clean ing nozzle and then the reactor cleaning nozzle. The Chem Wash and rinse system is manually controlled from the control room. The operator monitors the bullseye at the sewer drain to be sure the reactor is empty. When the reactor amps have dropped to the no load amps indicated on the ammeter. The lead operator opens the rinse valve for a short period of time. By observing the water flowing from the bullseye he can determine that the reactor is empty. ABD00286787 1-3 Operating Manual IJ-7^5 PVC Reactors Page 19 II. GENERAL PROCESS DESCRIPTION (Cont.) C- Water Swirl If the resin formula calls for a water swirl, the reactor interlock selector switch is place in the "swirl" position after the Chem wash rinse is completed. Cold or hot water enters the suction of the hot water charge pumps, and is pumped through the reactor charge line into the reactor. When the water charge reaches a preset amount, the water charge system is automatically shut down. The reactor agitator is then used to swirl the water for approximately 2S minutes. The lead operator then drains the water to the sewer. This completes one reaction cycle; the reactor is now ready for evacuation. H. Water Collection System Various waste water streams from the process must be collected in an enclosed system for treatment. Water streams containing PVC and VCM from the recovery system, the VCM storage tanks, line and vessel purges, and miscellaneous flush and seal waters are intermittently sent to the blowdown tank. When the liquid in the blowdown tank reaches a level 22 inches from the top of the tank, a high level alarm sounds in the control room. The "A" operator also checks the level gauge on the tank twice per shift to be sure the level doesn't go above 22 inches from the top of the tank. The operator will then start the tank's transfer pump and send the waste water to the batchwater stripping tanks in the V-ll module. The waste water is then stripped with steam and vapors are recovered with , the emission recovery system. Once stripping has been completed, the wastewater is drained to the sewer. ABD00286788 1-3 Operating Manual D-7^5 PVC Reactors Page 20 III. OPERATING PROCEDURES A. Reactor Evacuation Evacuation of the reactor is required prior to charging in order to remove as much of the air as possible. Air is introduced into the reactor during previous phases of the reactor batch cycle since dump, rinse, and chem wash require that the reactor be vented to the atmosphere. Air in the reactor during reaction causes poor temperature control during polymerization and may alter the particle size of the resin. Evacuation is accomplished using one of the two-stage steam jet ejector systems. Evacuation is controlled by the lead operator from the board. The "A" operator must confirm that all process equipment is operating correctly during evacuation. Procedure 1. If the reactor has been opened, follow procedure given in the "Reactor Cleaning and Entry" section on how to close the reactor manhead. 2. The lead operator puts the interlock mode selector on "evacuation 3. The lead operator checks to see that all valves are closed. 4. The lead operator opens the condenser recovery valve and the reactor evacuation valve. Then the lead operator opens the steam supply valve and the evacuation header valve to the steam ejector system to be used as follows. ABD00286789 1-3 Operating Manual D-7U5F'/C Reactors Page 2.1 III. OPERATING PROCEDURES (Cont.) A. Reactor Evacuation (Cont.) Procedures (Cont.) 4. Continued (a) For D-741, 742, 743, and 744, the operator will open valves CV-230 and CV-226. THis starts the ejector system located between D-742 and D-743. (b) For D-745 the operator will open valves CV-222 and CV-224. This will start the ejector system located between D-743 and D-744 reactor structure. The operator then opens the emergency cooling water valve, which supplies cooling water to the reactor condenser. NOTE: In the following steps, 5-10, the operators prepare the initiator for charge while evacuation is in progress. 5. The "A" operator will go to the initiator freezer and bring the specificed amount of initiator to the initiator injection pot. Extreme caution must be exercised by the "A" operator to be sure that no VCM is allowed to get back into the initiator injection pot. When a small amount of VCM is mixed with a large amount of initiator, an extremely fast reaction takes place giving off heat and pressure. To guard against this situation, the operator must know that he has an adequate water supply and pressure. The reactor initiator injection valve must never be opened unless the bomb is fully pressurized with the inlet water valve open. NOTE: The following precautions must be taken initiator. when handling ABD00286790 Operating Manual D-7^5 PVC Reactors Page 22 III. OPERATING PROCEDURES (Cont.) A. Reactor Evacuation (Cont.) Procedures (Cont.) 5. Continued (a) Plastic gloves must be worn while handling initiator. (b) If any initiator is spilled on skin or clothings, immediately flush with water. (c) Should any initiator remain in the containers, return it to storage. (d) Take all empty containers to trash and split side of of all containers. (e) Never put the cap back on the empty bottle. Dispose of the cap separately. (f) Do not allow the initiator to stand in the bomb for more than 10 minutes. Drain it to the sewer and flush with water. 6. The "A" operator must check the injection bomb to be sure that it is empty. Close the drain valve. Open the initiator addition valve. 7. The "A" operator will manually open the HPSW inlet valve, until the initiator water totalizer shows that 15 counts of water are in the initiator to the inejction pot. 8. The "A" operator will now add the initiator to the injection pot. 9. The "A" operator will now close the initiator addition valve and inform the lead operator that the initiator loading is complete and the bomb is ready to be pressurized. Operating Manual D-7^5 PVC Reactors Page 23 ABD00286791 X-3 III. OPERATING PROCEDURES (Cont.) A. Reactor Evacuation (Cont.) Procedures (Cont.) 10. The "A" operator will now open the 1" valve which supplies high pressure service water to the initiator injection pot and pressure the pot to 180 pounds. 11. The lead operator will stop evacuation when a vacuum of 28.5 inches Hg is attained. The reactor vacuum is double checked by the "AM operator on top the reactor with a mercury manometer. The lead operator stops evacuation by closing the condenser recovery valve, the reactor evacuation valve, the evacuation header valve and steam supply valve to the ejectors. This shuts off the evacuation steam jets. He then closes the emergency cooling water valves. .12 Evacuation is now complete. ABD00286792 1-3 A opor.it inn Manual D-7^5 PVC Reactors Page 24 m. OPCRATING PROCEDURES (CONTINUED) B. Reactor Precharge The reactor precharge procedure includes a series of precharge checks and precautions that must be carried out by the lead and "A" operators. If the necessary precharge conditions are not met, the Modicon (a small computer which controls the automatic charge sequence) will not allow the automatic charge sequence to begin. It is the responsibility of the lead operator to see that all pre charge checks and precautions are carried out. He should also read the log book at the start of the shift, covering the period since he was last on the job. This will alert him to any changes in formula, mechanical, or operational procedures that may not have been passed on verbally. 1. Lead Operator Duties a. Check level in fresh VCM receiver to see tl\3t it is ade quate for charge. 80% reading on the level gauge at the panel. b. Drain water in the recovered VCM receiver to the water strip- per Valves from the recovered receiver are manually opened from the board until pressure rise in the blowdown ' tank indicates all the water is out and VCM is being trans ferred. Valves are then manually shut from the board. c. Fill out the reactor charge sheet. d. Check the hot water tank level and temperature. Tank level should be 85% and the tank temperature 160F. ABD00286793 T-3 Operating Manual D-lh1} pvc Ren ctora Page 25 HX. OPERATING PROCEDURES (CONTINUED) ' B. Reactor Precharge (Continued) 1. Lead Operator Duties (Continued) e. Check to see that all valves on the reactor are closed. f. Have the "A" operator make a precharge check and reading of the following: (1) Dura-Seal* oil level and pressure. (2) Mechanical seal purge water pressure and rate to the reactor agitator seal. (3) Colloid charge tank level and temperature. g. Record the readings on the charge sheet as they are trans mitted by the "A" operator. 2. "A" Operator Duties V a Check Dura-Seal* level and pressure. There are two Dura- Seal* units. One supplies seal oil pressure to all five reactor agitator mechanical seals and the other is a spare and starts automatically when the operating unit has low seal oil level or discharge pressure. If both units fail, an emergency supply of seal oil is provided by the emergency seal oil drum that is nitrogen pressurized. Valves must be opened manually at the unit if the emergency seal oil system is used. A *Registered Trademark ABD00286794 1-3 A Operating Manual D-7^5 PVC Reactors Page 2b III. OPERATING PROCEDURES (CONTINUED) B. Reactor Precharge (Continued) 2. "A11 Operator Duties (Continued) NOTE: When the primary and spare Dura-Seal* oil units are down and the emergency system is in operation, reactors are not to be charged until at least one of the DuraSeal* oil units is operating. The emergency system is designed to be a backup system that should be used short term only. When ot.e of the Dura-Seal* oil units is not in operating condition, inform the lead operator so that repairs can be made. The seal oil level should be checked in both units. The discharge pressure should be checked and be in the range of 205-250 psig. If the pressure falls below 205 psig, the spare unit will automatically start up and the primary unit shut down. The spare unit will also automatically start up and the primary unit shut down when a low seal oil level is detected in the primary unit. Report the seal oil pressure to the lead operator. *Registered Trademark ABD00286795 1-3 Operating Manual D-7U5 PVC Reactors Page -7 III. OPERATING PROCEDURES (CONTINUED) B. Reactor Precharge (Continued) 2. "A*1 Operator Duties (Continued) b. Check the mechanical seal purge water pressure and rate of flow to the agitator mechanical seal. Pressure should be 180-220 psig. Adjust the water flow rate to that given in the formula. Report the seal water pressure and flow rate to the lead operator. c. Check the colloid charge tank level to be certain enough is in the tank to complete a charge. Notify the lerd operator of the level present. A level of at least 26 inches should be shown on the sight glass before charge is started. d. Inform the lead operator when checks are completed and the reactor is ready for charge. ABD00286796 1-3 Operating Manual D-7^5 PVC Reactors Page 28 III. OPERATING PROCEDURES (Cont.) C. Reactor Charge This section includes vacuum break and reactor charge. The reactor charge is one of the most critical operations in terms of product quality. Care must be taken to assure that all the raw materials arc added in the proper order and amount. Procedure 1. When evacuation and precharge checks are complete, the lead operator can move the interlock mode selector to "charge." 2. The lead operator should take the following steps and see that the following conditions arc met before charge: a. VCM transfer should be in auto. b. Recovered VCM charge should be in auto with either the primary or spare pump selected for charge. c. Fresh VCM charge should be in auto with either the primary or spare pump selected for charge. d. Hot water charge should be in auto. e. Colloid charge should be in auto with either the primary or spare pump selected for charge. f. Select recipe to be charged by dialing recipe number on the recipe selector on on the board. g. Push the meter reset button, which resets all charge meters. ABD00286797 f c Operating Manual D-7^5PVC Reacco rs Page 29 III. OPERATING PROCEDURES (CONTINUED) C. Reactor Charge (Continued) Procedure (Continued) h- The charge light will now come on if all the following conditions are met: (1) The fresh VOl storage tank, hot water tank, and colloid charge tank all have a level adequate for one complete charge. (2) One reactor is in charge mode. (3) The high pressure service water header is at least 150 psig. (4) The reactor being charged has at least 28.5 inches Hg vacuum. (5) The initiator injection pot is at least 180 psig. 3. When a charge light is obtained on the panel, the lead operator will inform the "A" operator to stand by for breaking vacuum. The lead operator will break vacuum by: a. Manually opening the reactor VCM charge valve from the board.. b. Manually opening the reactor charge valve from the board. c. Turbine meters will start counting as VCM flows into the reactor. d. As soon as a positive pressure is indicated in the reactor, close the VCM charge valve. Operating Manual D-7^5 PVC Reactors Page 30 ABD00286798 1-3 III. OPERATING PROCEDURES (Continued) Reactor Charge (Continued 4. The "A" operator will then watch the pressure gauge at the top of the reactor. When the pressure rises above zero, start checking the following: a. Inspect manhead visually and listen for escaping vapor. b. Check safety disc gauges for pressure. Any pressure indicates a leaking or ruptured disc. c. Turn flush water (injection water) on sprayhead. The purpose is to keep spray heads free of resin. Set rate according to recipe. d. If all checks okay, notify lead operator. If not, notify lead to hold on charge until problem can be corrected. 5. The lead operator can now push the charge button. In rapid sequence, the following occurs: a. Reactor water charge valve opens. b. "A" hot water pump starts, valves open, and water starts into the reactor. c. The valves from the fresh VCM receiver to the VCM charge pump and discharge valve open. d. At set point No. 1 on water meters: ^Registered Trademark ABD00286799 1-3 Operating Manual D-745pvC Reactors Page 31 III. OPERATING PROCEDURES (CONTINUED) C. Reactor Charge (Continued) Procedure (Continued) (1) "B" hot water pump starts and discharge valve opens. (2) The colloid charge pump discharge valve will open and pump will start. The preset amount of colloid will be pumped into the reactor. When the colloid meter set point is reached, the colloid charge pump will cut off and the discharge valve and reactor colloid charge valve will close. NOTE: The lead operator will turn on reactor jacket steam during colloid and water charge to assist reactor heatup. e. At set point No. 2 on water meter, the reactor VCM charge valve opens and the VCM and recovered VCM charge pumps start. f. At set point No. 3 on the water meter, "B" hot water pump stops and discharge valve closes. This allows time for all VCM to be charged to the reactor before the water charge is completed. NOTE: A partially plugged filter pack can cause slow VCM flow, and it may be necessary to cut off "A" hot water pump also. If this should happen, be sure to have a minimum of 50 counts left on water charge meter. This is enough to clean lines and manifold of VCM. When the VCM is within ten counts of being complete, put "A1' and "B" hot water pumps back on automatic and complete the charge. A Operating Manual D-745 PVC Reactors Page 32 ABD00286800 1-3 III. OPERATING PROCEDURES (Coat.) C. Reactor Charge (Continued) NOTE: When a filter is known to be fouled, isolate and switch to the spare unit. If you continue to try to force VCM through fouled filters, the high pressure will cause the filter elements to collapse and greatly increase the time taken to change them out. Collapsed filters also will cause a gel problem affecting the quality of the resin. g. When VCM meters reach the set point (two meters running in tandem, first to reach the set point cuts pump off and closes valve), the VCM pump, outlet valve, inlet and discharge valve to VCM charge pump, and reactor VCM valve close. This action also starts "B" hot t^O pump and opens discharge valve. h. At set point No. 4 on the water meters, nBM hot water pumps stop, and the valves close. i. At set No. 5 in the water meters "A" hot water pump stops and the valves close. At this time the main dump valve also closes. 6. When the automatic charge sequence has been completed, it is safe to charge the initiator. 7. The "A" operator charges the initiator by opening the initiator reactor charge valve and flushing the initiator into the reactor with 50 counts of high pressure service water. 8. The lead operator will now record the final recator temperature. Adjust reactor temperature set point to setting called for in the formula and put temperature controller in "auto" position. ABD00286801 1-3 A Operating Manual D-745 PVC Reactors Page 33 III. OPERATING PROCEDURES (CONTINUED) D. Polymerization Polymerization is the phase of the reactor cycle in which liquid VCM is converted into solid PVC. This portion of the reactor cycle is mainly accomplished by accurate instrumentation. The primary area of responsibility for the lead operator is coordination of the activities of the "A" operator. The "A" operator is required to kill the reaction when polymerization has progressed to the point that product quality is satisfactory. 1. Lead Operator Duties a. Change the interlock mode selector to "polymerization." Monitor the temperature and pressure closely until the reactor reaches the desired set point and lines out. b. Cut off steam valve to Jacket at two to four degrees below set point, depending on the rate of temperature rise. c. Have the "A" operator sample the reactor 1 hour after reading heat up. a fresh-air mask must be worn and personnel cleared of the general area before sample is taken. d. Examine the resin. At this stage the resin should be formed into individual separate particles. Notify the shift super visor if you notice the following: (1) Stringers - Resin particles are stringy and stuck together. (2) Hard Particles - Gritty resin particles which are harder ahd larger than most. ABD00286802 1-3 Operating Manual D-745 PVC Reactors Page 34 III. OPERATING PROCEDURES (CONTINUED) D. Polymerization (Continued) 1. Lead Operator Duties (Continued) If either of the above conditions are observed, have the "A" operator take samples every fifteen minutes until the shift supervisor makes the decision as to what c , corrective action should be taken. e. It may become necessary to remove the inerts. Inerts in the condenser will cause the reactor pressure to rise as they blanket the condenser and do not allow VCM vapor to be condensed. Under these conditions, less heat can be removed even though the condenser water flow will be full open. Vent the inerts through the main condenser valve to the recovery system. Start the compressors and put the pressure controller in manual and close the control valve. Open the reactor condenser valve and recovery valve. Set the controller on 35 psig and put it back in automatic. f. Irregularities during polymerization: (1) Slow Heatup--May be caused by weak or no initiator. Slow heatup can also be caused by no steam on reactor jacket or the cooling water valves may be open. Contact Che shift supervisor if this condition persists. ABD00286803 1-3 A :ing Manual PVC Reactors Page 35 III. OPERATING PROCEDURES (CONTINUED) D. Polymerization (Continued) 1. Lead Operator Duties (Continued) (2) Long Reaction Time--Caused by low initiator level, weak initiator, long heat up, low reactor temperatures or chem wash solution setting or chem wash solution in the batch. If there is only slow reaction and the resin checks okay, the shift supervisor will give word on what to do. If caustic is in the reactor, the batch will turn slightly yellow and coarsen. If this is found to be true, kill immediately with the amount of short stop solution speci fied in the formula. (3) Simultaneous Temperature and Pressure Rise--Check cooling j;ater temperature and valves. The reactor is producing more heat than the cooling water can remove. Also could be an overcharge of initiator. Notify shift supervisor for instructions. (4) Simultaneous Temperature and Pressure Drop--The cooling water valves are probably wide open. This happens more often in freezing weather when relays freeze up. Throttle manual valves until malfunction is found and corrected. (5) Agitator Kicks Out or Power Failure--Most power failures are of short duration (seconds to two minutes), and the reactor pressure does not have time to build to a dangerous level. If outage is prolonged, the pressure will build. Operating Manual D-745 pvc Reactors Page 36 ABD00286804 T-3 III. OPERATING PROCEDURES (CONTINUED) D. Polymerization (Continued) l. Lead Operator Duties (Continued) If this situation occurs, follow the procedure in Section III.D.3 which outlines action to be taken during emergency shutdowns (such as during a power failure). 2. A" Operator Duties a. When charge is complete, recheck water injection rates through the cleaning nozzle and seal flush. b. On instruction from the lead operator, resin samples will be taken from the reactor. This normally occurs 1 hour after heat up. If the first sample shows formation of undesirable resin particles, additional samples may be called for every fifteen minutes until a decision is made about what should be done with the batch. When taking a sample from the reactor a fresh air mask must be worn and personnel cleared of the general area. c. When the lead operator instructs the "A" operator to do so, the batch is killed by adding short stop solution to the reactor. The amount of short stop solution and Che procedure for adding it depends on the product. The kill procedure is as follows: 5305 (normal) 14 gallons AMS 5305 (CTA) 34 gallons AMS/34 gal. Naugard 5425 14 gal. AMS/24 gal* Naugard initially and again at 170F. 5465 24 gal. AMS/34 gal. Naugard initially and again at 170F. 5385 14 gal. AMS/34 gal* Naugard Operating Manual -D-745pyC Reactors Page 37 ABD00286805 1-3 III. OPERATING PROCEDURES (CONTINUED) D. Polymerization (Cont.) It is very important that the proper amount of short stop solution be added since it effects the quality of the resin. High pressure service water is used to pressure the short stop solution from the initiator put into Che reactor. 3. Emergency Shutdown The following steps are to be taken during emergency shutdown: a. 1. . Use the AMS emergency kill system for killing each reactor. Each reactor has a pot located at grade beside each reactor, containing AMS. The AMS is injected into the head space of the reactor with nirtogen by opening the appropriate control valves, from the control room. The hand switch for the control valves for each reactor is located next to the agitator start-stop handswitch on each reactors control station. Refer to the operating manual for the AMS Emergency Kill System. 2. If the AMS does not stop the reaction, use the nitric oxide (NO) short stop system for killing each reactor. There are six cylinders of NO that can be released for each reactor D-741, M2, 743 and 744. D-745 has twelve cylinders of NO which can be released. The NO system can be activated at the reactors by manually opening the correct valves. ABD00286806 1-3 Operating Manual D-745 PVC Reactors Page 38 III. OPERATING PROCEDURES (Cont.) D. Polymerization (Cont.) 3. Emergency Shutdown (Cont.) b. Use nitrogen to pressurize the Dura-Seal* unit emergency seal oil drum and the mechanical seal purge water surge drum. The valves connecting the emergency seal oil and seal water drums with their respective systems must be opened manually. c. There will be sufficeint air in the air system surge tank to operate valves for approximately fifteen minutes. It will be necessary to use the nitrogen backup system to operate valves after fifteen minutes. The surge tank should be valved off before the backup nitrogen system is activated. d. Monitor each reactor for pressure rise. If the pressure con tinues to rise, the following steps are to be taken: (1) Equalize the reactor with any other empty or killed reactor of the same type product. (2) If the pressure still continues to rise, vent through the main condenser valve to the recovery system and the re covery system to the recovered VCM receiver. (3) If this wil1 not relieve the pressure buildup, then equal ize the reactor with a reactor of different type resin. * Registered Trademark ABD00286807 J-3 Operating Manual D-7'45 PVC Reactors Page 39 III. OPERATING PROCEDURES (CONTINUED) D. Polymerization (Cont.) 3. Emergency Shutdown (Cont.) d. (4) When 1, 2, and 3 alone fail to relieve the reactor pressure, the relief valve vent system will allow the reactor to vent off and on thru the relief valves to control the pressure. NOTE: Step (4) is to be the last resort. Under the new EPA law, any venting must be reported and could result in a fine. The foilwing guidelines, when followed, will control a runaway reactor and prevent a VCM release. The NO system is to be activated if either one of the parameters is exceeded. Resin Type Maximum Temperature Maximum Pressure 5385, 5425, 5465 5305 (CTA) 5305 (Normal) 142F 152F 162F 145 psig 155 psig 165 psig NO is high poisonous orange-brown colored gas. A Scott Air Pak must be worn while killing a reactor with the NO short stop system. E. Recovery and Steam Stripping The reactor is ready for recovery when certain conditions are reached in the reaction process. The conditions under which recovery will start are Pressure Drop -- There is not enough unreacted VCM left in the reactor to maintain run pressure. A pressure drop is accompanied by a drop in the cooling water flow to the reactor jacket and condenser. Runaway --Reaction has increase to the point that it has outrun the capabilities of the cooling water to control.Temperature and pressure will Operating Manual D^7A5pvc Reactors Page 40 ABD00286808 T-3 III. OPERATING PROCEDURES (CONTINUED) E. Recovery and Steam Stripping (Cont.) Runaway (Cont.) both rise when this occurs. Follow instructions on each product formula aa to the exact conditions at which the reaction is killed. Temperature Rise-Pressure Drop-- This is the ideal recovery situation and indicated proper initiator loading. The reaction will peak and slightly out. run the capabilities of the cooling water. This situation gives the best recovery conditions since there is less VCM to be recovered and more converted to resin. Quick-Kill-- A reactor is sometimes killed on specific products to meet certain customer specifications--lower dry time (higher plasticizer absorbtion ). The reactor is killed with a specified amount of the short stop solution at a specified set of conditions. The short stop solution mixture stops the reaction chain. On a quick-kill batch, it is very important to guard against resin carryover to the recovery system. An injection of defoamer will help to control foaming. A fast recovery is also important and will affect the dry time. I. "A" Operator Duties When notified by the lead operator that the recovery conditions specified in the formula are met, the "A" operator will take the following steps: a. Check the hydroquinone injection sytem to make sure that the proper valves are open and hydroquinone level is adequate. b. Check the blowdown tank level and pressure. Level and pressure must be low to allow the automatic drain on the water recirculation Dumo to onerate. ABD00286809 1-3 Operating Manual D-745 PVC Reactors Page 41 III. OPERATING PROCEDURES (Cont.) E. Recovery and Steam Stripping (Cont.) 1. "A" Operator Duties (Cont.) c. Check the water levels in the seal water separators and knockout drums. These levels are controlled automatically but should be checked before startup. Knockout drum level should be at or below the mid-point of the inlet to the vessel. The seal water separator level should be at or below the mid-point of the inlet of the vessel. d. Check the backflow pressure controller. It should be set at twenty-five inches Hg vacuum. e. Check to see that the flush to the knockout drum and seal water separator level gauges are on set at 1 gpm. These are FI-726, FI-727, FI-741, and FI-742. f. Notify the lead operator that the recovery system is ready to startup. g. Steam header pressure should be greater than 100 psig. h. Reactor steam line should be checked and reactor steam valves should be checked to make sure they are opening correctly. 2. Lead Operator Duties a. When the "A" operator has checked the recovery system, the lead operator can change reactor interlock mode to "recovery." b. Start the water recirculation pump, 72-889 and 72-890. ABD00286810 1-3 Operating Manual D-745 PVC Reactors Page 42 III. OPERATING PROCEDURES (Cont.) E. Recovery and Steam Stripping (Cont.) 2. Lead Operator Duties (Cont.) c. Start the seal water pumps, 72-891 and 72-892. This auto matically starts hydroquinone injection pump 72-895. d. Two recovery compressors, 72-903, 72-904, or 72-905, are started from handswitches located on the recovery control panel. This starts two compressors and opens' the valves associated with compressor startup. e. The vacuum pumps will atuomatically come on when the suction pressure of the compressor is 7 psig. The necessary valve changes are also automatically made. f. When the reactor reaches the pressure specified in the product formula, the lead operator will move the reactor temperature set point to the specified stripping temperature, set the steam stripping flow controller on 23,000 lbs/hour, and begin steam stripping. g. Watch the temperature of the reactor condenser. h. When stripping conditions specified in the formula are met, steam stripping is complete. i. When steam stripping and recovery is complete, the recovery system is shut down as follows: ABD00286811 1-3 Operating Manual .D-745 PVC Reactors Page 45 III. OPERATING PROCEDURES (Cont.) E. Recovery and Steam Stripping (Cont.) 2. Lead Operator Duties (Cont.) i. (1) Push stop buttons for the recovery compressor 72-903, 72-904, 72-905. This also stops the vacuum pumps. (2) Push stop buttons for seal water pumps 72-891 and 72-892. This also stops hydroquinone injection pump. (3) Push stop buttons for the water recirculation pumps, 72-889-72-890. 3. Recovery System Troubleshooting a. High Compressor Outlet Temperature Probable cause is poor or no water recirculation in the recovery knockout drum, 45-760. Check VCM feedback controller setting. Controller setting should be at 25 inches Hg. b. High Compressor Discharge Pressure High pressure can be caused by: (1) Plugged Condenser-- Have -lead operator report problem to the shift supervisor. (2) Plug in the Line from the Condenser to the VCM Collect Tank--Line will have to be pulled and cleaned. (3) High Level in the VCM Collect Tank (a) Switch transfer pump to manual. (b) Check level of the recovered VCM receiver--east or west. (4) High RVCM Receiver Pressure (a) Switch receivers (b) Check line pressure to V-ll RVCM receivers to be sure line is not plugged. ABD00286812 1-3 Operating Manual D-745 pvc Reactors Page 44 III. OPERATING PROCEDURES (Cont.) E. Recovery and Compressor Stripping (Cont.) b. High Compressor Discharge Pressure (Cont.) (5) No Cooling Water to Condenser--Check inlet and outlet water valves. (6) High Seal Water Temperature--This temperature should be 110 _+ 10. Check seal water pump for flow and pressure and check filter pack. c. If the compressor is not compressing the VCM vapor and does not have a 50 to 70 psi discharge pressure: (1) Check seal water flow. (2) Check seal water separator water level and adjust as neces sary. (3) Check seal water temperature--below 80F water will condense the VCM vapor and cause displacement of the water seal around the compressor cone. d. Recirculation water pump 72-889 goes out (mechanical-electrical). (1) Under normal operation, recirculation water pump 72-889 circu lates water through the water recirculation cooler and into recovery knockout drum 45-760. Crossover piping is provided so that, if recirculation water pump 72-889 fails, recircu lation water cooler and into recovery knockout drum 45-761. NOTE: Normal operating temperatures for the recovery system during stripping are: ABD00286813 1-3 Operating Manual D-745 PVC Reactors Page 45 111 OPERATING PROCEDURES (Cont.) E. Recovery and Steam Stripping (Cont.) 3. Recovery Troubleshooting (Cont.) d. (1) Continued (a) Reactor Condenser - 215-225F (Peak Temperature) (b) 45-760 Knockout Drum Outlet - 122-128F (c) 45-761 Knockout Drum Outlet - 90-115F (d) Compressor Outlet - 130-140F The lead operator must monitor these temperatures on the multipoint recorder and have the "A" operator check out and correct deviations. e. Reactor Foaming (carryover)--When foaming is detected, the "A" operator will: (1) Inject defoamer into the reactor to reduce slurry surface tension and lower the reactor slurry level. It may become necessary for the lead operator to shut down one compressor to slow the recovery. If excessive foaming occurs, shut down recovery and thoroughly flush the entire system with water until clear. All flushing must be done to the blowdown tank. ABD00286814 1-3 A Operating Manual D-745 PVC Reactors Page 46 HI. OPERATING PROCEDURES (CONTINUED) F. Reactor Dump and Rinse When the recovery of the reactor has been completed, the slurry is ready to be dumped to the slurry blend tank(s) that has been designated by the shift supervisor. I. "A" Operator Duties a. Check the selected blend tank or tanks to make sure it will hold the batch. b. If transferring to small blend tank, set up piping to go to appropriate tank. Check to see that the blend tank sewer valve is closed and the aeration is flowing in the tank. c. Check the slurry transfer pump valving to make sure the flow will be going to the correct line. d. Place the coarse overflow collector into position. Inform the lead operator that the dump can begin. e. Monitor the dump tank level until the flow to the pump and discharge from the reactor have leveled out to a steady rate. f. Add the formula amount arf calcium stearate to the dump tank as directed by the shift supervisor. *Registered Trademark ABD00286815 1-3 Operating Manual D-745 PVC Reactors Page 47 III. OPERATING PROCEDURES (Cont.) F. Reactor Dump and Rinse (Cont.) 2. Lead Operator Duties a. Select the blend tank to be used by opening the appropriate control valves in the slurry transfer lines. The valves are operated by handswitches located on the recovery section of the control panel, as follows: CV-1521 CV-1522 CV-1506 CV-1523 CV-1524 To T-501 To T-407 To T-747 To T-502 To small blend tank manifold b. Check the sewer valve on the reactor to be sure it is closed. c. Turn on the Sweco* strainer. d. Check the Sweco* exhauster to be sure it is running. It should be running continuously. e. Turn the interlock mode selector switch to the "dump" position. f. After the "AM operator informs lead operator that dump can begin, place the slurry transfer pumps, 72-896 and/or 72-897, in the "run" position. This opens the slurry transfer pumps' seal water supply valves, CV-864 and/or CV-866, before the pumps start. The level in slurry dump tank 45-766 is auto matically controlled. g. Five minutes after the start of dump, open the reactor vent to go the atmosphere. Registered Trademark ABD00286816 I Operating Manual D-745 PVC Reactors Page 48 III. OPERATING PROCEDURES (CONT.) F. Reactor Dump and Rinse (Cont.) 2. Lead Operator Duties (Cont.) h. When there is no slurry flow through FI-747, the reactor is rinsed according to formula instructions. Reactor is empty when agitator shows no load amps and sewer bullseye shows no flow. i. When dump and rinse are complete, place the slurry transfer pumps in the 3top position. This shuts down the pumps, 72-896 and/or 72-897, and closes the slurry transfer pump seal flush water valve, CV-864 and/or CV-866. G. Chem Wash and Rinse Chem wash and rinse is not done as a matter of routine on all reactors however, if it has been determined that chem wash is needed, the formula states what the lead operator is to do. After the reactor has been rinsed during the dump cycle, it is ready to be chem washed. The chem wash cycle is necessary to remove polymer buildup from the reactor condenser, walls, baffles, and agitator. If polymer buildup is allowed to remain in the reactor, it continues to grow with each successive charge. Buildups will contribute to high gel, low quality resin, and will make reactor dumping very difficult if they get large enough to break off and plug dump valves and lines. Operators must exercise caution during chem wash due to the caustic in the solution. If any solution gets on a operator, flush immediately with water. Caustic feels slick to the touch and will start burning the skin just a few seoonds after contact. If the solution should spray over ABD00286817 1-3 A Operating Manual D-745 PVC Reactor rage 49 III. OPERATING PROCEDURES (Cont.) G. Chem Wash and Rinse (Cont.) the body, immediately get under a safety shower and remove your clothing. If any should get in the eyes, flush eyes for at least' fifteen minutes until all burning stops and report to your supervisor. Procedure 1. The lead operator will check and make sure the reactor sewer valve is closed. 2. The lead operator will then place the interlock mode selector switch to "clean and rinse." 3. The lead operator then checks to see that the cleaning solution tank, 45-767, is at least 85 percent full. 4. The lead operator then opens the valves from:the cleaning solution pumps, 72-989 or 72-899, to the reactor condenser cleaning nozzle. The atmospheric vent on the reactor should be closed. All other reactor valves are closed. 5. The lead operator then opens the suction valves, CV-873, for the cleaning solution pumps, 72-898 or 72-899. 6. The lead operator will then turn on one cleaning solution heater temperature controller is set at 190F. 7. The lead operator will then turn on one cleaning solution pump 72-898 or 72-899. ABD00286818 1-3 Operating Manual D-745 pvc Reactor Page 50 III. OPERATING PROCEDURES (Cont.) G. Chem Wash and Rinse (Cont.) Procedure 8. When the chem wash solution has been flushed through the reactor condenser, the lead operator will: CAUTION: The atmospheric vent valve must remain closed. a. Stop the cleaning solution pump. b. Close pump suction valve CV-873 from the cleaning solution tank. c. Open chem wash return valve on reactor. d. Open cleaning solution pump suction valve CV-874 from the reactor. e. Close valves to the reactor cleaning nozzle. f. Open valves to the reactor cleaning nozzle. g. Restart the cleaning solution pump. The chem wash solution should now be circulating from the bottom of the reactor back to the reactor cleaning nozzle. h. The reactor agitator remains on. 9. The lead operator will recirculate the chem wash solution through the reactor for five minutes and will then pump the chem wash solution back to the cleaning solution tank by: a. Opening CV-872 b. Closing CV-871. This sends the cleaning solution pump dis charge to the cleaning solution tank. ABD00286819 1-3 Operating Manual D-745 PVC Reactor Page 51 m. OPERATING PROCEDURES (Cont.) G. Chem Wash and Rinse (Cont.) Procedure (Cont.) 10. The "A" operator should monitor the cleaning solution pump and notify the lead operator when it loses suction (check pressure gauge on pump discharge). 11. The lead operator will now shut off the cleaning solution pump. 12. The lead operator will then check the cleaning solution tank level indicator to see if all the chem wash solution has returned. If any solution is lost or accidentally dumped to the sewer, notify the utilities operator. The spilled solution must be neutral ized to avoid upsetting the chemical balance in the lagoons. 13. The lead operator will now close the reactor cleaning valves and open the condenser cleaning valve and the reactor sewer valve. 14. The lead operator will cut on both hot water charge pumps and flush through the condenser to the sewer for ten minutes. 15. The lead operator will then close the condenser cleaning valve, open the reactor cleaning valve, and flush the reactor to the sewer for ten minutes. Reactor is empty when agitator shows no load amps and sewer bullseye is empty. 16. Tne lead operator will now close the reactor sewer valve and open the atmospheric vent. 17. Because of the water dilution and resin accumulation, chem wash solution must be disposed of and fresh caustic pumped to the cleaning solution tank once per week. Follow the procedure out lined under "Used Chem Wash Solution Disposal'*. ABD00286820 1-3 Opeating Manual D-745 PVC Reactors Page 52 III. OPERATING PROCEDURES (Cont.) H. Full and Partial Swirl To assist in the production of quality resin, particularly low gel, it has been found that, by filling the reactor with water and agitating, the gel count is markedly lower. 1. Full Swirl In this swirl, the reactor is almost completely filled with water. Lead Operator Duties a. Turn the interlock mode selector switch to the "swirl" position. b. Opens the reactor main charge valve and water charge valve. c. Starts both hot water charge pumps. d. (1) D-741, 742, 743, and 744--Adds 1500 counts of water to reactor (15,000 gallons). (2) D-745--Adds 2000 counts of water to reactor (20,000 gal Ions). e. Cuts off pumps and closes valves. Agitates for ten minutes. g. Opens sewer valve and dumps. 2. Partial Swirl This swirl procedure is the same as the full swirl except for the amount of water used. Charge 750 counts (7500 gallons) for D-741, D-742, D-743, and D-744 and 1000 counts (10000 gallons) for D-745. Then follow the same procedure as the full swirl. ABD00286821 1-3 Operating Manual D-745 PVC Reactors Page 53 m. OPERATING PROCEDURES (Cont.) I. Colloid Solution Makeup A-Operator The properties of polyvinyl chloride (PVC) are strongly dependent upon the type and quality of the colloid solution used, the colloid solution must be made very accurately and consistently every time it is prepared. The colloid solution is a percent solution of Dow F-50 Methocel* powder in water. There is a local instrument panel located near the colloid makeup tank on the second floor of the recovery building. These instruments are to aid the operator in making the colloid solution in a consis tent manner. 1. Lead Operator Duties As soon as the lead operator is notified by the "A" operator that the colloid storage tank level is below the straight wall, he will schedule the "A" operator to make up colloid solution as follows: a. With the "A" operator at the colloid tanks, open the makeup tank outlet valve (CV-857) and start the colloid transfer pump to the transfer the colloid solution to the storage tank. b. To mix any remaining heel in the storage tank with the new colloid solution, open the storage tank inlet valve (CV-858). Registered Trademark ABD00286822 1-3 Operating Manual D-745 PVC Reactors I'age 54 III. OPERATING PROCEDURES (CONTINUED) I. Colloid Solution Makeup (Continued) 1. Lead Operator Duties (Continued) and circulation pump inlet valve (CV-859) and start the colloid circulation pump. The charge tank inlet valve (CV-861) must be closed. c. When the "A" operator indicates that the makeup tank is empty, close the makeup tank outlet valve (CV-857) and turn off the transfer pump. d. With the circulation pump still running, notify the "A" operator to catch a colloid solution sample and take it to the laboratory for analysis. e. Close the storage tank inlet valve (CV-858) and circulation pump inlet valve (CV-859) and turn off the circulation pump. f. Schedule the "A" operator to makeup a new batch of colloid solution as soon as possible. g. During the first part of the colloid makeup procedure when notified by the "A" operator, the lead operator will open the hot water charge valve (CV-706) and will start one hot water charge pump and the discharge valve associated with the charge pump to transfer hot water to the colloid makeup tank. The colloid makeup tank water meter will close the valves and shut down the hot water pump automatically when it reaches its set point. ABD00286823 A 1-3 Operating Manual ( D-745 PVC Reactors Page 55 in. OPERATING PROCEDURES (CONTINUED) I. Colloid Solution Makeup (Continued) 2. "A*1 Operator Duties The "A" operator aids in colloid solution transfer by notifying the lead operator when the colloid storage tank needs to be refilled. After transfer, the "A" operator notifies the lead operator that the makeup tank is empty. laboratory. When notified by the lead operator, the "A" operator makes up a new batch of colloid solution by the following procedure: C a. Bring eight bags of Dow F-50 Methocel* powder (50 pounds per bag) to the top of the colloid makeup tank. b. Rinse the colloid makeup tank with water to the sewer until it is clean. c. Reset the colloid makeup water meter to 538 gallons, open the colloid tank inlet valve (CV-856), and notify the lead operator to open the hot water charge valve (CV-706), start a hot water charge pump, and open the discharge valve associ ated with the pump selected. The water meter will stop the pump and close the actuated valves that were opened when the set point is reached. Check to see that the agitator blades are covered. L ^Registered Trademark ABD00286824 1-3 Operating Manual D-745PVC Reactors Page 56 III. OPERATING PROCEDURES (CONTINUED) I. Colloid Solution Makeup (Continued) 2. "A" Operator Duties (Continued) d. Start the colloid tank heater and the tank agitator. The temperature controller will close the steam valve when the water in the tank reaches 200F. e. When the heater is off, add the methocel powder very slowly with the agitator still on. Each bag should take about one minute to add. If the powder is added too quickly, it will form lumps and not dissolve properly. Carry the empty bags to a trash container. f. Allow about thirty minutes to let the agitator thoroughly mix the powder into the hot water. Check the mixture for lumps and continue to mix if lumps are present. g. When the mixture contains no lumps, reset the colloid makeup water meter to 2,623 gallons and open the colloid tank inlet valve (CV-856) and the colloid tank water valve (CV-828) to add cold water. The water meter will close the actuated valves that were opened when the set point is reached. Measure the outage on the colloid makeup tank to check the accuracy of the water meter. The straight wall por tion of the tank contains 14.8 gallons per inch. 9 ABD00286825 Operating Manual D-745 PVC Reactors Page 57 III. OPERATING PROCEDURES (CONTINUED) I. Colloid Solution Makeup (Continued) 2. mAm Operator Duties (Continued) h. Start the colloid tank cooler. The temperature controller will close the cooling jacket valve when the colloid solu tion reaches 85dF. Check the cooling water temperature. If it is 80*F or above, the solution will cool very slowly; so close the manual cooling water valves and open the process water valves to the jacket. i. Check the temperature after four hours of cooling. If the temperature is 85F and the temperature controller has closed the cooling jacket valve, turn off the agitator. If the tank is still cooling, leave the agitator on until the tank has reached 85F. It is very important to cool the colloid solution completely each time to produce a good quality colloid solution. j. Caution: Spills of colloid solution are slick and present a dangerous slipping hazard. ABD00286826 1-3 Operating Manual D-745 PVC Reactors Page 58 III. OPERATING PROCEDURES (CONTINUED) J. Hydroquinone Solution Makeup Hydroquinone is injected into the recovery system to short stop the chain reaction and polymerization of vinyl chloride. If the hot VCM gases are allowed to flow through the recovery lines with out any inhibitor, they continue the reaction that was started in the reactor and rapidly fill and plug the recovery lines. Plugged lines in the recovery system are very time consuming to pull and clean and cause considerable amounts of downtime. Adequate and accurate injection of hydroquinone eliminates this problem. Hydroquinone (commercial name Tecquinol*) comes in a powder form and must be put into a solution with water for our use. When the hydroquinoni solution level is low, as determined by the low level alarm LA-733 in the control room and/or by the hydro quinone storage tank sight glass, a new batch is to be made Each batch should last approximately one month. 1. Lead Operator Duties As soon as it is determined that the hydroquinone storage tank is low, the lead operator should schedule hydro quinone makeup between reactor recoveries. *Registered Trademark ABD00286827 A 1-3 Operating Manual D-7A5 pvc Reactors Page 5 9 III. OPERATING PROCEDURES (CONTINUED) J. Hydroquinone Solution Makeup (Continued) 2. "A" Operator Duties When notified by the lead operator to make up a now batch of hydroquinone solution, the "A" operator does the following: a. Weight up twenty pounds of hydroquinone powder. b. Turn off hydroquinone metering pump suction valve and, with the nitrogen turned on and the vent closed, drain the remaining heel to the sewer and rinse with water to the sewer. c. Open the vent and add water until the tank is about half full. d. Turn off the nitrogen temporarily and add the hydroquinone powder through the funrel. e. Turn on the agitator and open the nitrogen line. f. Fill with water to the full mark on the sight glass (fifty gallons). g. Close the vent and mix until the powder is dissolved. h. Make sure the valves are lined up to the hydroquinone metering pump. 3. Safety Precautions Rubber gloves and full face shield must be worn while handling and transferring hydroquinone dust and liquid. Hydroquinone dust can irritate and seriously damage the eyes. ABD00286828 A 1-3 V, Operating Manual D-745PVC Reactors Page 60 III. OPERATING PROCEDURES (CONTINUED) J Hydroquinone Solution Makeup (Continued) 3. Safety Precautions (Continued) First Aid--In case of contact, immediately flush eyes with water for fifteen (15) minutes. Notify the plant nurse. Flush skin with water and wash clothing before reuse. K. Used Chem Wash Solution Disposal Procedure 1. The shift supervisor must have given instructions to dump the used chem wash solution and make up a fresh batch. 2. The lead operator wil 1 instruct the "A" operator to open the tank's drain valve. The valve is opening using the gear operator on the valve. 3. As soon as the tank is empty of solution as indicated by the level indicator in the control room, the "A" operator will open the.three inch process water valve to the tank to flush out the tank. Then the "A" operator will close the process water valve and the drain valve. 4. Make up a new batch of cleaning solution. Notify the P-1 operator to transfer new caustic to the tank. NOTE: Notify the utility operator that the cleaning soution has been dumped to the sewer. ABD00286829 A 1-3 Operating Manual D-745 PVC Reactors Page 61 III. OPERATING PROCEDURES (CONTINUED) L. Initiator Handling and Storage In the conversion of vinyl chloride monomer to polyvinyl chloride resin, an initiator is needed to start and help sustain the reac tion process. The Aberdeen plant uses peroxide-type initiators. The physical properties of the type resin needed determines the type of initiator to be used. All of these products must be kept in cold storage because of rapid dangerous decompos i t i.on rates at room temperatures. The initiator is a skin and eye irritant and must be handled accordingly. Safety precautions for all types of initiator are basically the same, with some differences in handling temperatures and explosive limits. 1. Safety Precautions in Handling Initiator a. Wear full face shield when handling an open container, tj. Avoid contact with skin or clothing (will bleach out clothes). c . Do not leave initiator unattended when not under refriger ation. d. If initiator is spilled, soak up with absorbent material, such as vermiculite, and spread thinly in an isolated area. e, Dispose of empty containers Immediately. Leave cap off and split the side of this container and store away from the unit in an open area. ABD00286830 Operating Manual D-745 pvc Reactors Page 62 III. OPERATING PROCEDURES (CONTINUED) Initiator Handling and Storage (Continued) 1. Safety Precautions in Handling Initiator (Continued) f. Bring only what is necessary to the production area. Do not allow the amount in the reactor area freezers to exceed one shift's comsumption. g. If a partial or full jug of initiator is found sitting out, it may be water, but always handle and dispose of just as if it were initiator. h. If spilled on skin area, wash with large amounts of water. i. If splashed in the eyes, flush with water for fifteen (15) minutes and notify your supervisor. Do not use oils or salves on the eyes. j. Should any initiator catch on fire, use water to cool the surrounding area. However, if the fire is spread ing and likely to ignite other initiator set the portable fire monitor and get out of the area, since an explosion is very likely. 2. Physical Characteristics These Lucidol 223M75 Trigonox EHP-C75 and Witco 939M75 must be stores at a safe temperature below 20F to prevent rapid decomo position of the material which occurs at approximately 50 F, Operating Manual D-745 PVC Reactors Page 63 ABD00286831 1-3 III. OPERATING PROCEDURES (CONTINUED) L. Initiator Handling and Storage (Continued) 2. Physical Characteristics (Continued) Lupersol L-ll catalyst must be stored at a temperature not below 15F because it freezes if stored below 15F for extended periods of time. These types of catalyst are not self ignitied because they contain 75% product and 25% OMS, odorless mineral spirits. 3. Initiator Storage Freezers Three walk-in freezers and one chest freezer have been installed o for initiator storage at temperatures down to -30 F. Each freezer has two independent refrigeration compressors with one to be held in reserve. This is to insure continuous operation at the temperature set point. High temperature in any freezer will activate the air horn and a beacon flasher alarms. An automatic defrost system controlled by time clocks will provide frost-free operation, a. Operating Conditions (1) Temperature The temperatures are adjustable. They can be set from -30F to +30F. (2) Alarms The chest and the walk-in freezers on high temperature ABD00286832 1-3 Operating Manual D-745 PVC Reactors Page 64 III. OPERATING PROCEDURES (Cont.) L. Initiator Handling and Storage (Cont.) 3. Initiator Storage Freezers (Cont.) a. Operating Conditions (Cont.) (2) Alarms (Cont.) setting with actuate the red beacon light and air freezer. This is the same for all freezers in the plant. The alarm's present setpoint is 17F (+2). (3) Compressors The compressors for the freezers are located in two inter connected sheds 50 feet north of the freezers. The com pressors for the chest freezer and the west and middle walk-in freezers are located in the west shed. The compressors for the east walk-in freezer is in the east shed. The compressors in the west shed are numbered 1 thru 6. (a) No. 1 and NO. 2 compressors serve the middle walkin freezer. (b) No.3 and No. 4 compressors serve the west walk-in freezer. (c) No.5 and No. 6 compressor serve the chest freezer on the west end. The compressors in the east shed are numbered 7 and 8. They serve the east walk-in freezer. ABD00286833 1-3 Operating Manual D-745 PVC Reactors Page 65 III. OPERATING PROCEDURES (Cont.) L. Initiator Handling and Storage (Cont.) a. Operating Conditions (Cont.) (4) Compressor Shutdown Conditions (Automatic) (a) Freezer temperature (b) Compressor low oil level (c) High or low compressor pressure (5) Circuit Breakers (a) West Compressor Shed - Located on north wall. (1) Compressor Panel--The compressor circuit breakers are numbered in sequence 1 thru 6. (2) Fan Panel - The fans are numbered 2, 3, 5, and 6. (3) Auxiliary Panel - Contains lights, defrost controls, alarms, fans, and defrost time clocks. (b) East Compressor Shed - Located on north wall. (1) Compressor Panel - The compressor circuit breakers are numbered 1 and 2. The fans are numbered 7 and 8, (2) Auxiliary Panel - Contains lights, defrost controls, alarms, and defrost time clocks. (6) Defrost Cycles - Adjustable In the walk-in freezers, each compressor switches to hot gas bypass every six hours to provide a defrost cycle. This is controlled by a time clock. (7) Freezer Capacity (a) East walk-in freezer - 600 gallons (b) Middle and West walk-in freezers - 550 gallons (c) Chest freezer - 100 gallons ABD00286834 1-3 Operating Manual D-745 PVC Reactors Page 66 III. OPERATING PROCEDURES (Cont.) L. Initiator Handling and Storage (Cont.) 4. Design and Operational Functions Each freezer is provided with two refrigeration units each which are capable of maintaining the desired freezer temperature. Both units can be run simultaneously to allow a check on com pressor operation. The temperature element in each freezer is connected to a mer cury switch which starts and stops the compressor. These are adjustable and can be set for different temperatures. Each compressor has a timer which activates a solenoid valve in the hot gas line to send hot gas directly to the evaporator to allow for the defrost cycle. The fan normally runs with the compressor but is off during the defrost cycle. The east, middle, and west walk-in freezers defrost every six hours, and the chest freezer defrosts every eight hours. The water-cooled condensers on each compressor in the west compressor shed have water bypass to allow continuous flow and prevent freezeup during cold weather. The condensers also have inlet and outlet valves to allow for acid cleaning. Condenser cooling water is normally supplied by and returned to the cooling tower. During shutdowns and power outages, a bypass valve from the well to city water can be opened to supply water pressure. If the condensers are put on the well water, open the block valve in the manhole at the west end of the cooling tower to divert the water to the sewer. ABD00286835 A 1-3 Operating Manual D-745 PVC Reactors Rage 6-7 III. OPERATING PROCEDURES (Cont.) L. Initiator Handling and Storage (Cont.) 4. Design and Operational Functions (Cont.) The condensers for the east walk-in freezers are air-cooled and are not tied into the cooling water system. 5. Daily Operational Checks a. Each compressor oil level by maintenance. b. Temperature recorders by Chief Operator. c. Frost buildup on freezer coils by Chief Operator. NOTE: Manual defrost instructions are on the inside front of each time clock. NOTE: Due to the explosive nature of this initiator, formal approval must be obtained from the operations super intendent and the mechanical superintendent before any changes are made to this operation. ABD00286836 Operating Manual D-745 PVC Reactors Page 68 III. OPERATING PROCEDURES (CONTINUED) L. Initiator Handling and Storage (Continued) 6. Emergency Procedure for Initiator Freezers If the power should go off, do not open the freezers but do the following: a. Notify the shift supervisor to find out the reason for the power failure. (1) If trouble is inside the plant, the supervisor will survey the situation and estimate how long the outage will be. Freezers should hold temperature from 3-4 hours, depending on what is in them, the outside temperature, and how may times the door is opened. (2) If trouble is dtermined to be outside the plant, the shift supervisor will notify the proper people on the call list. (a) The duration of the outages will be determined. (b) If outage is expected to be over three (3) hours, Joan Pope will arrange for purchase of dry ice. b. If a compressor should : fail and it is not an electrical problem, get in touch with maintenance as soon as possible. 1-3 ABD00286837 A 1-3 Operating Manual D-745 PVC Reactors Page 69 III. OPERATING PROCEDURES (Cont.) L. Initiator Handling and Storage (Cont.) 6. Emergency Procedure for Initiator Freezers (Cont.) (2) If the problem cannot be fixed, try to move all initiator to other freezer. If not possible, get dry ice. NOTE: If compressors should go out on a freezer, make sure fans are turned off to that freezer. Middle walk-in freezer 1 and 2 fans, west walk-in freezer 3 and 4 fans, and chest freezer 5 and 6 fans in the west compressor shed. The east walk-in freezer 7 and 8 fans located in the east compressor shed. c. Notify the following if an emergency should arise with the initiator freezers: Jim Barton - 369-4755 Pete Markey - 369- 6019 7. Circle Chart Responsibility and Change Schedule a. The Chief Operator on each shift will check the charts to be sure they have ink and are rotating. b. The Chief Operator on the 7 P.M. - 7 A.M. shift will place new charts in the recorder and turn in the previous day's chart to the shift supervisor. ABD00286838 A 1-3 V2* Operating Manual D-745 PVC Reactors Page 70 III. OPERATING PROCEDURES (CONTINUED) M. Reactor Pressure Check Prior to the startup of a reactor after an extended outage or following a maintenance outage such as replacing a main dump valve or rodding out the condenser tubes, the reactor must be hydrostatically pressure checked. This is to insure that no leakage occurs at the reactor, either inward or outward. Procedure 1. The lead operator sets up the pressure check as follows: a. Place the' reactor mode in "emergency" to gain use of both the charge water valve and the rinse valves. b. Open both hot water charge pump discharge valves CV-849 and CV-829. c. Ojen the reactor charge water valve. d. Open the main dump valve. e. Open the emergency vent valve. 2. The lead operator then turns on both hot water charge pumps and fills the reactor. 3. The "A" operator stands by to notify the lead operator when water comes out the atmospheric vent, showing that the reactor is full. 4. The lead operator then shuts down the hot water charge pumps and closes all valves. This must be done immediately to avoid overpressuring the reactor and blowing the rupture discs. ABD00286839 1-3 Operating Manual t- D-745 pvc Reactors Page 71 III. OPERATING PROCEDURES (CONTINUED) M. Reactor Pressure Check (Continued) Procedure (Continued) 5. The "A" operator then increases the reactor pressure by charging water into the reactor through the initiator injec tion system. 6. The lead operator monitors the reactor pressure from the control room and instructs the "A" operator to shut off water addition when the pressure reaches 130 psig. 7. The MA" operator then checks the reactor for leaks at the reactor bottom and top side. If a flange or gasket has been changed, check these very closely. 8. The lead operator then monitors the reactor pressure. If the reactor holds 130 psig for ten minutes, the pressure check is terminated. If the reactor loses pressure, instruct the "A" operator to bring the pressure back up to 130 psig with the high pressure service water and reinspect the reactor for leaks. NOTE: Do not charge a reactor that will not hold pressure. 9. When the pressure check is completed, the lead operator dumps the water in the reactor to the sewer. The reactor is now ready to start evacuation procedure. k. ABD00286840 1-3 Ope rat ing Manua1 D-745 PVC Reactors Page. 7 2 III. OPERATING PROCEDURES (CONTINUED) N. Reactor Cleaning and Entry 1. Reactor Manhead Opening Procedures One of the most critical parts of the operator's job is the opening of the reactor Lenape* manhead. Following is a list of procedures that must be followed by the "A" operator or anyone else when opening a reactor manhead. Procedure a. Check the pressure gauge and/or bleed valve for pressure or vacuum. b. Put on continuous flow fresh air mask. c. Unlatch Lenape* lock on Lenape* manhead roll-bar and drop down. NOTE: If the reactor has pressure when the roll-bar arm is lifted, the pressure will start escaping. If this should happen, notify the lead operator. d. Slowly raise manhead four to six Inches and hold in that position. e. Call lead operator and have him cut on the reactor evacu ation ejector to pull air inward through the manhead. f. Finish raising the manhead. g. The continuous flow fresh air mash may be removed at this time. h. Change "0" ring on manhead. *Registered Trademark Operating Manual D-745 PVC Reactors Page 73 ABD00286841 III. OPERATING PROCEDURES (CONTINUED) N. Reactor Cleaning and Entry (Continued) 1. Reactor Manhead Opening Procedures (Continued) i. If the bottom manhead is to be opened, inspect the bottom of the reactor through the open manhead. The reactor should contain no liquids. j. Go to the bottom of the reactor and make sure that the safety chain and jacking bolts are in proper position on the bottom manhead. k. Maintenance will remove the bolts and open the manhead. 2. Reactor Cleaning and Entry This section will cover precaustions taken prior to entry and during entry and cleaning of the reactor. The following is a check list stating conditions which must be met by anyone entering the reactor. The equipment entry sheet is to be filled out and placed at the reactor. Procedure a. The reactor must be empty/steam stripped, recovered and flushed with water. b. The 0^ content must be greater than 20 percent. c. The VCM content myst be less than 10 ppm. d. The top and bottom manways myst be open. e. The nitric oxide (NO) piping myst be disconnected at the bottles. Operating Manual D-745 PVC Reactors Page 74 ABD00286842 III. OPERATING PROCEDURES (CONTINUED) N. Reactor Cleaning and Entry (Continued) 2. Reactor Cleaning and Entry (Continued) Procedure (Continued) f. The following lines must be blanked or disconnected. (1) Main eight-inch dump line. (2) Four-inch steam stripping lines. (3) Six-inch condenser lines. (4) Four-inch chem wash and rinse line to condenser* (5) Four-inch chem wash and rinse line to reactor* (6) One-inch initiator injection line. (7) One-inch inerts vent. (8) Three-inch colloid charge line. (9) One-inch sample line. (10) Six-inch VCM charge line - D-745 only. g. Lock out and tag agitator breaker. h. Test agiator switch i. Special precautions and safety equipment that may be needed are: (1) Impervious suit (2) Plastic mats on the bottom dish to prevent slipping. (3) Continuous flow fresh air mask *When preparing to blank or remove blank in chem wash line, lock out cleaning solution pump, open chem wash line to reactor, and bleed line at discharge of pump before breaking chem wash flange. ABD00286843 Operating Manual D-745 pvc Reactors Page 75 III. OPERATING PROCEDURES (CONTINUED) 2. Reactor Cleaning and Entry (Continued) Procedure (Continued) (4) Rubber gloves (5) Scaffolding for work above bottom level. (6) Two-way radio communication plus manway watch. (7) Safety harness and rope. (8) 12 volt explosion proof lights. ABD00286844 Operating Manual D-745 PVC Reactors Page 76 III. OPERATING PROCEDURES (CONTINUED) N. Reactor Cleaning and Entry (Continued) 2. Reactor Cleaning and Entry (Continued) j. While cleaning the buildups from the baffles and blade, take extreme care not to scratch the reactor walls. These walls have been polished to eliminate giving the resin being formed during reaction a place to create a buildup. NEVER SCRAPE THE WALLS. k. Around the shaft at the bottom of each reactor is a carbon throttle bushing. The purpose of the throttle bushing is to protect the reactor seal from resin. The seal water flush will not be effective if the throttle bushing or holder is damaged. If there is any buildup in this area, it is the Maintenance Department's responsibility to remove it. Operators are NOT to clean the throttle bushing. Damage to the throttle bushing may cause seal failure. l. If hammer and chisel are required to clean the reactor, be careful of chisel placement to avoid it kicking back out of the buildup and causing personal injury. m. While in the reactor, check the safety discs for buildups, nozzles for plugs, and the bottom of the condenser for plugging. n. When internal job is completed, remove scaffolding from the reactor and store neatly. Remove any loose buildup on the reactor bottom and close the bottom manhood. o. Clean up any debris, rags, etc. The job is never complete until the area is clean. Operating Manual D-745 PVC Reactor Page 77 ABD00286845 1-3 III. OPERATING PROCEDURES (CONTINUED) 0. Housekeeping Guidelines Good housekeeping is a major portion of any task to be under taken, and no task can be called complete until the work area has been cleaned. Return all tools and materials used to their proper place and do not leave lying around to create a safety hazard. The housekeeping of the reactor area is the responsibility of all people working there. ABD00286846 A 1-3 Operating Manual. D-745 PVC Reactors Page 78 IV. EQUIPMENT INDEX A. Reactors 1. Polymerization Reactors 45-741, 45-742, 45-743, and 45-744 a. Purpose Vessel used to react VCM to PVC in a water suspension. b. Description Vertical-mounted, bottom-agitated vessel, 12-foot diameter by 22-foot straight wall height (28 feet overall height), jacketed, and with top-mounted condenser. The reactor is stainless steel, and the cooling water and steam jacket is carbon steel. Approximate capacity is 22,500 gallons. c. Normal Operating Conditions The reactor produces various resin types, operating in a pressure range of 28.5 inches Hg vacuum to 150 psig and a temperature range of 80-225F. d. Design Conditions Shell Temperature, F Pressure, psig 250 200 (and full vacuum) 2. Polyaerization Reactors 45-781 Jacket 200 30 a. Purpose Vessel used to react VCM to PVC in water suspension. b. Description Vertical-mounted, bottom-agitated vessel, diameter by 28-foot straight wall height (35 feet overall height), jacketed and ABD00286847 1-3 Operating Manual D-745 PVC Reactors Page IV. EQUIPMENT INDEX (Cont.) A. Reactors (Cont.) 2. Polymerization Reactors 45-781 (Cont.) b. Description (Cont.) with top-mounted condenser. The reactor is stainless steel, and the cooling water and steam jacket is carbon steel Approximate capacity is 30,000 gallons. c. Normal Operating Conditions The reactor produces various resin types, operating in a pres sure range of 28.5 inches Hg vacuum to 150 psig and a temper ature range of 80 - 225F. d. Design Conditions Shell Jacket Temperature, F Pressure, psig 250 FV-225 200 45 B. Heat Exchangers 1. Reactor Condensers 55-328, 55-329, 55-330, and 55-331 a. Purpose To remove the heat of reaction from the polymerization reac tor by condensing VCM vapor. b. Description Each of the reactor condensers are vertical, mounted on top of the polymerization reactors. Cooling water (shell side) is used to condenser VCM (tube side). Each condenser has 2,100 square foot surface area provided by 999 tubes which are eight feet long by one-inch diameter. Materials of construction ABD00286848 I Operating Manual D-7A5 pvc Reactors Page 80 IV. EQUIPMENT INDEX (Cont.) B. Heat Exchangers (Cont.) b. Description (Cont.) are stainless steel or stainless steel clad for all surfaces in contact with VCM. c Normal Operating Conditions Condensers operate in a temperature range of 80-225F and pres sure range of 28.5 inches Hg vacuum to 150 psig during the reactor cycle, d. Design Conditions Shell Tubes Temperature, F Pressure, psig 200 250 120 200 (and full vacuum) 2. Reactor Condenser 55-358 a. Purpose To remove the heat of reaction from the polymerization by condensing VCM vapor. b. Description Condenser is vertical, mounted on top of the polymerization reactors. Cooling water (shell side) is used to condense VCM (tube side). Each condenser is provided with 2700 tubes which are ten feet long by one-inch diameter. Materials of con struction are stainless steel and stainless steel clad for all surfaces in contact with VCM. ABD00286849 1-3 A Operating Manual D-745 pyc Reactors Page SI IV. EQUIPMENT INDEX (Cont.) B. Heat Exchangers (Cont.) 2. Reactor Condenser 55-558 (Cont.) c. Normal Operating Conditions Condensers operate in a temperature range of 80-225F and a pressure range of 28. 5 inches Hg vacuum to 150 psig during the reactor cycle. Design Conditions Shel 1 Tubes Temperature, F Pressure, psig 3. Hot Water Preheater 55-332 250 250 120 FV-225 a. Purpose To heat process water to 145F before it enters the hot water tank, 45-748. b. Description Horizontal shell and tube type exchanger with steam on the shell side and water on the tube side. Surface area of 331 square feet is provided by 64 tubes 20 feet long by one-inch diameter. The tubes are stainless steel, and the shell is carbon steel. c. Normal Operating Conditions Steam temperature and pressure on the shell side will vary. Water on the tube side will be around 50 psig and will enter near 60F and exit at 145F. ABD00286850 I Operating Manual D-745 PVC Reactors Page 8 2 1V. EQUIPMENT INDEX (Cont.J B. Heat Exchangers (Cont.) 3. Hot Water Preheater 55-'332 (Cont.) Design Conditions Shcl 1 Tube Temperature, F Pressure, psig 400 400 175 200 4. Hot Water Tank Heater 55-333 a. Purpose To maintain water temperature in hot water tank 45-748. b. Description External plate coil type heat exchanger that will be clamped outside the hot water tank; stainless steel construction. c. Normal operating Conditions Steam in the coil should be around 341F and 150 psig. Water in the hot water tank should be near 160P. d. Design Conditions 400F and 175 psig. 5. Water Recirculation Cooler 55-334 a. Purpose To cool the recirculation water in recovery knockout drum 45-760. b. Description Horizontal mounted, shell and tube type heat exchanger. Cooling water is on the shell side and recirculating water is on the tube side. Surface area of 1,441 square feet is pro vided by 466 tubes, 16 feet long by 3/4-inch diameter. The tubes are stainless steel and the shell is carbon steel. ABD00286851 I Operating Manual D-745 PVC Reactors Page S3 IV. EQUIPMENT INDEX (Cont.) B. Heat Exchangers (Cont.) 4. Water Recirculation Cooler 55-334 (Cont.) c. Normal Operating Conditions d. Design Conditions Shell Tube Temperature, l: Pressure, psig 450 400 150 150 5. Seal Water Coolers 55-335 and 55-336 a. Purpose To cool the circulating vacuum pump and compressor seal water. b. Description Horizontal-mounted shell and tube type heat exchanger. Cooling water is on the shell side and recirculating seal water is on the tube side. Surface area of 339 square feet is provided by 182 tubes 10 feet long by 3/4-inch diameter. The tubes are stainless steel and theshell is carbon steel. c. Normal Operating Conditions d. Design Conditions Shell Tube Temperature, F Pressure, psig 200 380 150 150 6. Recovered VCM Condensers 55-337 and 55-338 a. Purpose To condense VCM vapor during recovery as it is removed from the polymerization reactors. r Operating ManuaL \_ D-745 PVC Reactors Page S4 ABD00286852 A 1-3 IV. EQUIPMENT INDEX (CONTINUED) B. Heat Exchangers (Continued) c. Normal Operating Conditions Steam temperature and pressure on the shell side will vary. Cleaning solution on the tube side is estimated to enter at 175F and leave at IPO0!' with a pressure of 125 psig. d. Design Conditions Teraperatue, F Pressure, psig Shell 175 400 Tube 200 400 C. Tanks and Vessels 1. Instrument Air Capacity Tank 45-301 a. Purpose To provide adequate instrument air during periods of high demand and temporarily supply air during instrument air failure. b. Description Vertical-mounted, five-foot nine-inch straight wall height, four-foot diameter, carbon steel construction. c. Normal Operating Conditions 100 psig and 80F d. Design Conditions ABD00286853 A I-.3 Operating Manual D-745 PVC Reactors Page S3 IV. EQUIPMENT INDEX (CONTINUED) C. Tanks and Vessels (Continued) 2. Recovered VCM Storage Tanks 45-317 and 89-520 a. Purpose Storage of recovered VCM and charge tank for recovered VCM. b. Description Vertical-mounted, 18-foot straight wall height, 22-foot overall height, eight-foot diameter with an approximate capacity of 7,200' gallons, carbon steel construction c. Normal Operating Conditions Ambient temperature and 20-70 psig. 3. Water Stripyrer 45-319 a. Purpose To provide for collection and recovery of various VCM con taining vapor vents and waste waters. b. Description Horizontal-mounted, 26-foot straight wall length, six-foot diameter, approximate capacity 5,500 gallons, carbon steel construction. c. Normal Operating Conditions Ambient temperature to 150F and pressure from 10 inches Hg vacuum to 10 psig. d. Design Conditions 350F and full vacuum to 150 psig. ABD00286854 A 1-3 Operating Manual D-745 PVC Reactors Page #6 IV. EQUIPMENT INDEX (CONTINUED) C. Tanks and Vessels (Continued) 4. Fresh VCM Storage Tank 45-745 a. Purpose VCM storage tank which holds fresh VCM used in reactor charge. b. Description Vertical-mounted, 22-foot straight wall height, 26-foot overall height, eight-foot diameter with an approximate capacity of 8,700 gallons, carbon steel construction. c. Normal Operating Conditions Ambient temperature and 20-70 psig. d. Design Conditions 150F and full vacuum to 150 psig. 5. Hot Water Tank 45-748 a. Purpose To supply a large volume of hot water for reactor charge and rinse. b. Description Vertical, cone roof, 42-foot straight wall height, 12-foot diameter with an approximate capacity of 35,000 gallons, aluminum construction. c. Normal Operating Conditions Atmospheric pressure and 160F. d. Design Conditions 212F and 1.5 inches of water. ABD00286855 1-3 Operating Manual b-745 PVC Reactors Page 87 IV. EQUIPMENT INDEX (Cont.) C. Tanks and Vessels (Cont.) 6. 1. Initiator Injection Pot 45-750 a. Purpose To inject initiator into the reactor during charge. b. Description Vertical-mounted, two-foot straight wall height with onefoot diameter, approximate capacity 12 gallons, stainless steel construction. c. Normal Operating Conditions Temperature near 70F and 180-260 psig. d. Design Conditions 150F and 300 psig. 2. Initiator Injection Pot 45-784 a. Purpose To inject initiator into the reactor during charge. b. Description Vertical-mounted, two foot straight wall height with one and one-half foot diameter, approximate capacity 30 gallons, stainless steel construction. c. Normal Operating Conditions Temperature near 70F and 180-260 psig. d. Design Conditions 300 0 F and 450 psig ABD00286856 Operating Manual D-745 PVC Reactors Page 88 IV. EQUIPMENT INDEX (Cont.) C. Tanks and Vessels (Cont.) 7. Colloid Makeup Tank 45-751 a. Purpose To provide for consistent colloid solution makeup. b. Descript ion Top agitated, vertical-mounted, flat top, 11 1/2-foot straight wall height, seven-foot diameter, approximate capacity 3,300 gallons, bottom jacket for heating, side jacket for cooling, stainless steel construction. c. Normal Operating Conditions Atmospheric pressure and 70-200F. d. Design Conditions 400 F and 0 psig ABD00286857 1-3 Operating Manual D-7A5 PVC Reactors Page 89 IV. EQUIPMENT INDEX (CONTINUED) C. Tanks and Vessels (Continued) 8. Colloid Storage Tank 45-752 a. Purpose To provide colloid solution storage. b. Description Vertical-mounted, flat top, cone bottom, 12-foot straight wall height, seven-foot diameter, approximate capacity 3,400 gallons, stainless steel construction. c. Normal Operating Conditions Atmospheric pressure and 70-85F. d. Design Conditions 150F and 0 psig 9. Colloid Charge Tank 45-753 a. Purpose To provide a sufficient quantity of quality colloid solution for charge. b. Description Vertical-mounted, flat top, cone bottom, 14-foot straight wall height, 5 1/2-foot diameter, capacity approximately 2,400 gallons, stainless steel construction. c. Normal Operating Conditions Atmospheric pressure and 70-85*F. d. Design Conditions 150F and 0 psig ABD00286858 1-3 Operating Manual D-745pvC Reactors Page 90 IV. EQUIPMENT INDEX (CONTINUED) C. Tanks and Vessels (Continued) 10. Seal Oil Storage Drum 45-754 a. Purpose To provide seal oil storage. b. Description Horizontal-mounted, five-foot straight wall length by three-foot diameter, carbon steel construction, approxi mate capacity 270 gallons. c. Normal Operating Conditions Atmospheric pressure, ambient temperature. d. Design Conditions 150F and 0 psig 11. AMS Short Stop Charge Pots 45-7>5, 45-756, 45-757, and 45-758 a. Purpose To provide a means for injecting short stop solution into any or all of the reactors to stop the reaction. b. Description Vertical-mounted, two-foot straight wall height, six-inch diameter, capacity approximately three gallons, stainless steel construction. c. Normal Operating Conditions Approximately 70F and 180-260 psig. d. Design Conditions 150F and 300 psig ABD00286859 1-3 Operating Manual D-745pVC Reactors Page 91 IV. EQUIPMENT INDEX (CONTINUED) C. Tanks and Vessels (Continued) 12. Mechanical Seal Purge Mater Surge Drum 45-759 a. Purpose To provide seal purge water in the event of electrical power failure. b. Description Vertical-mounted, seven-foot straight wall height, 3 1/2-foot diameter, capacity approximately 500 gallons, stainless steel construction. c. Normal Operating Conditions Approximately 70F and 200 psig. d. Design Conditions 150F and 300 psig 13. Recovery Knockout Drums 45-760 and 45-761 a. Purpose To prevent liquid and solids carryover to the recovery vacuum pumps and compressors during reactor recovery. b. Description Vertical-mounted; bottom section has five-foot straight wall height; five-foot diameter; top section has ten-foot straight wall height; three-foot diameter; top section has water spray to help remove carryover; carbon steel construc tion. A ABD00286860 1-3 Operating Manual D-745 PVC Reactors Page 92 IV. EQUIPMENT INDEX (CONTINUED) C. Tanks and Vessels (Continued) c. Normal Operating Conditions 100-200F and 0-35 peig d. Design Conditions 300F and full vacuum to 150 psig 14. Seal Water Separators 45-762 and 45-763 a. Purpose To separate the circulating vacuum pump and compressor seal water from the recovered VCM vapor. b. Description Vertical-mounted, seven-foot straight wall height, fourfoot diameter, approximate capacity 650 gallons, carbon steel construction. c. Normal Operating Conditions 100-150F and 40-80 psig d. Design Conditions 300F and full vacuum to 150 psig 15. Recovered VCM Collect Tank 45-764 a. Purpose To collect recovered VCM and provide liquid head for VCM transfer pump to allow pumping of recovered VCM to recovered VCM storage tank. ABD00286861 1-3 Operacing Manual D-745 PVC Reactors Page 93 IV. EQUIPMENT INDEX (CONTINUED) C. Tanks and Vessels (Continued) b. Description Horizontal-mounted, ten-foot straight wall length, three- foot diameter, approximate capacity 520 gallons, carbon steel construction. c. Normal Operating Conditions 70-100F and 35-75 psig d. Design Conditions 160F and full vacuum to 150 psig 16. Hydroquinone Storage Tank 45-765 a. Purpose Provide for hydroquinone storage and makeup. b. Description Top-agitated, vertical-mounted, 2*6" straight wall height, two-foot diameter, approximate capacity 60 gallons, carbon steel construction. c. Normal Operating Conditions Temperature near ambient; pressure about 1 psig. d. Design Conditions 150F and 16 psig ABD00286862 A 1-3 Operating Manual D-745 pvc Reactors Page ^4 IV. EQUIPMENT INDEX (CONTINUED) C. Tanks and Vessels (Continued) 17. Slurry Dump Tank 45-766 a. Purpose To provide sufficient head for the slurry transfer pumps to operate correctly. b. Description Vertical-mounted, flat top, cone bottom, three-foot straight wall height, five-foot diameter, approximate capacity 440 gallons, stainless steel construction. c. Normal Operating Conditions One-inch water vacuum and 150-200F. d. Design Conditions 250F and two-inch water pressure. 18.` Cleaning Solution Tank 45-767 a. Purpose To provide an adequate amount of chem wash solution during reactor chera wash. b. Description Vertical-mounted, flat top, cone bottom, ten-foot straight wall height, ten-foot diameter, approximate capacity 5,800 gallons, carbon steel construction. c. Normal Operating Conditions Atmospheric pressure and 60-190F d. Design Conditions 250F and + five~lnch water pressure. ABD00286863 Operating Manual 0-745 pvc Reactors Page 95 IV. EQUIPMENT INDEX (CONTINUED) C. Tanks and Vessels (Continued) 19. Reactor Evacuation Ejector Cyclone Separator 45-768 a. Purpose To remove any condensate present in the motive steam to the reactor evacuation steam ejector. b. Description High efficiency horizontal separator, Anderson type L5-4-175, 10 3/4-inch outside diameter, 26 inches long, carbon steel construction with stainless steel internal baffles. c. Normal Operating Conditions Steam in is 125 psig and 353F. d. design Conditions 400F and 175 psig 20. Reactor Sampling Bomb 45-770 a. Purpose To safely obtain a resin sample from the reactor. b. Description 3/4-inch stainless steel pipe, three inches long. One end is capped, and the other is fitted with a coupling. A basket strainer fits inside the sampler for <;jsy resin removal. c. Normal Operating Conditions Slight vacuum to 60 psig and 70-140F. 1-3 ABD00286864 Operating Manual D-745 PVC Reactors Page 36 IV. EQUIPMENT INDEX (Cont.) C. Tanks and Vessels (Cont.) 21. AMS Emergency Kill Pots 45-786 a. Purpose To inject AMS into the reactor during power failure or upon loss of agitation. b. Description Vertical-mounted, three-foot straight wall height, two feet in diameter, capacity approximately 60 gallons, car bon steel construction. c. Normal Operating Conditions Approximately 70F and 300 psig. d. Design Conditions 150F and 400 psig. ABD00286865 Operating Manual D-745PVC Reactors Page 97 IV. EQUIPMENT INDEX (CONTINUED) D. Filters 1. Process Water Charge Filter 64-716 a. Purpose To remove dirt and scale from the charge water. b. Description Filterlte Model 88MS04-316-4FD-C300, cartridge type, stainless steel. c. Normal Operating Conditions 40 psig and 70F d. Design Conditions 300 psig and 200F. Particle retention size is ten microns. 2. VCM Charge F'.ltera 64-718 and 64-742 a. Purpose To remove any PVC particles from the VOl charge to the reactor. b. Description , Filterite model 906415-001, cartridge type, stainless steel filter with polypropylene filtering element. c. Normal Operating Conditions 150-200 psig and ambient temperature. d. Design Conditions 150F, 300 psig, 1,000 gpm, particle retention size is ten microns. ABD00286866 A 1-3 Operating Manual D-745PVC Reactors Page 98 IV. EQUIPMENT INDEX (CONTINUED) D. Filters (Continued) 3. Recovered VCM Filter 64-719 a. Purpose To remove PVC particles from the recovered VCM charge to the reactor. b. Description Filterite Model 909596, cartridge type, stainLess steel filter with polypropylene filtering element. c. Normal Operating Conditions 40-130 psig and ambient temperature. d. Design Conditions 150F, 190 psig, 250 gpra, particle retention size ten microns. 4. Process Water Filter 64-720 a. Purpose To remove dirt and scale from process water to the hot water tank. b. Description Dollinger Model LL-122-280, cartridge type, carbon steel filter with polypropylene filtering element. c. Normal Operating Conditions 40 psig and 70F d. Design Conditions 100F, 100 psig, 200 gpm, particle retention size ten microns. ABD00286867 A 1-3 Operating Manual D-745 PVC Reactors Page 99 IV. EQUIPMENT INDEX (CONTINUED) D. Filters (Continued) 5. Colloid Makeup Water Filter 64-721 a. Purpose To remove dirt and scale from water used in colloid makeup, b ' Description Dollinger Model LL-222-180, Series 150, cartridge type, stainless steel filter, cotton filtering element. c. Normal Operating Conditions 40 psig and 70F d. Design Conditions 250F, 250 psig, 125 gpm, particle retention size ten microns. 6. Service Water Filter 64-724 a. Purpose To remove dirt and scale from service water. b. Description Dollinger Model LL-222-280, cartridge type, stainless steel filter with cotton filtering element. c. Normal Operating Conditions 40 psig and 70F d. Design Conditions c lOO^F, 100 psig, 190 gpm, particle retention size ten microns. ABD00286868 1-3 & Operating Manual D-745 pvc Reactors Page 100 IV. EQUIPMENT INDEX (CONTINUED) D. Filters (Continued) 7. Seal Oil Supply Filters 64-723 and 64-726 a. Purpose Removes dirt and scale from seal oil. b. 'Description Dollinger Model U.-222-39, Series 150, cartridge type, stainless steel filter with cotton filtering element. c. Normal Operating Conditions 245 psig and 100F d. Design Conditions 150F, 275 psig, 4 gpm, particle retention size one micron. 8. Seal Oil Return Filters 64-727 and 64-728 a. Purpose Removes dirt and scale from seaKoil. b Description Dollinger Model LL-222-39, Series 150, cartridge type, stainless steel filter with cotton filtering elements. c* Normal Operating Conditions 220 psig and 100F d Design Conditions 150F, 275 psig, 4 gpm, particle retention size one micron ABD00286869 A 1-3 Operating Manual D-745 PVC Reactors Page 10i IV. EQUIPMENT INDEX (CONTINUED) \w. D. Filters (Continued) 9. Seal Water Filters 64-731 and 66-732 a. Purpose To remove PVC resin from the circulating seal water for the recovery vacuum pumps and compressors. b. Description Dollinger Model LL-122-140, cartridge type, carbon steel filter with polypropylene filtering element. c. Normal Operating Conditions . 90-130 psig and 100-150? d. Design Conditions . 300F, 150 psig, 160 gpm, particle retention size 100 microns. 10. Slurry Strainer 64-733 a. Purpose To remove large resin particles from'the slurry. b. Description Sweco Model LS605 1210, vibrating screen, stainless steel filter and filtering element. c. Normal Operating Conditions One-inch water vacuum and 150-200F d. Design Conditions 250F, two-inch water pressure, 1,000 gpm, particle reten tion on four-mesh screen. ABD00286870 & 1-3 Operating Manual D-74 5 PVC Reactors Page 102 IV. EQUIPMENT INDEX (CONTINUED) D. Filters (Continued) 11, Cleaning Solution Strainer 64-734 a. Purpose To remove PVC particles from the cleaning solution. b. Description Ten-inch Elco line strainer, carbon steel construction. c. Normal Operating Conditions 2 psig and 180F d. Design Conditions 200F, 20 psig, 500 gpm, particle retention on four-mesh screen. 12. Breathing Air Filters 64-735, 64-736, 64-737, 64-738, 64-739, 64-740; ________ ________________ a. Purpose To remove dirt and scale from the breathing air. b. Description Dollinger Model GP-246-15, cartridge type, stainless steel filter. Nylon 147 filtering element. c. Normal Operating Conditions 70-90 psig and 60-70F d. Design Conditions 100F, 125 psig, 6,000 standard cubic feet per hour (SCFH), particle retention size five microns. ABD00286871 1-3 Operating Manual D-745 PVC Reactors Page 103 IV. EQUIPMENT INDEX (Cont.) D. Filters (Cont.) 13. Blowdown Tank Drain Strainer 64-741 a. Purpose To remove PVC particles in water dumped to the sewer from the blowdown tank. b. Description Andale type 105 simplex strainer, basket strainer, cast iron with stainless steel filtering element. c. Normal Operating Conditions 8-9 psig and 100 150F d. Design Conditions 200F, 125 psig, 200 gpm, particle retention size 3/8 inch. ABD00286872 A 1-3 Operating Manual D-74.5pvC Reactors Page 104 IV. EQUIPMENT INDEX (CONTINUED) E. Pumps 1. VCM Charge Pumps 72-875 and 72-876 a. Purpose To supply reactors with VCM during charge. b. Description Centrifugal type, Goulds Model 3736, 3X6-13DV, Group L, 150-HP, 3,560 RPM. The casing is carbon steel and the impeller is cast iron. c. Normal Operating Conditions Rated for 800 gpm at 450 feet of differential head. 2. Recovered VQi Charge Pumps 72-877 and 72-878 a. Purpose To supplv recovered VCM to the suction of the VCM charge pumps during charge. b. Description Centrifugal type, Goulds Model 3196 MT, 2X3-13, 25 hp 1,750 rpm. The casing is stainless steel and the impeller is cast iron. c. Normal Operating Conditions Rated for 450 gpm at 82 feet of differential head. ABD00286873 1-3 A Operating Manual D-745 PVC Reactors Page 10S IV. EQUIPMENT INDEX (CONTINUED) E. Pumps (Continued) 3. Hot Water Charge Pumps 72-879 and 72-880 a. Purpose To supply the reactor with hot water during charge. b. Description Centrifugal type, Goulds Model 3196 LTC, 2X3-13, 100-HP, 3,550 rpra. The casing is stainless steel and the impeller is cast iron. c. Normal Operating Conditions Rated for 450 gpm at 410 feet of differential head. 4. Colloid Batch Transfer Pump 72-881 and Colloid Circulation Pump 72-882______________________________________________________ _ a. Purpose The batch transfer pump is used primarily to transfer colloid from the colloid makeup tank to the colloid storage tank. The colloid circulation pump is used primarily to circulate colloid in the storage tank and to transfer col loid from the storage tank to the colloid charge tank. These pumps are piped so they can be used to spare each other. b. Description Centrifugal type, Goulds Model 3196 MT, 1X2-10, 3-HP, 1,750 rpm. The casing and impeller arc stainless steel. c. Normal Operating Conditions Rated for 50 gpm at 69 feet differential head. ABD00286874 A 1-3 Operating Manual D-745 PVC Reactors Page 106 IV. EQUIPMENT INDEX (CONTINUED) E. Pumps (Continued) 5. Colloid Charge Pumps 72-883 and 72-884 a. Purpose Used to charge colloid to the reactor. b. Description Centrifugal type, Goulds Model 3736, 1X2-11B, 50-HP, 3,550 rpra. The casing and impeller are stainless steel. c. Normal Operating Conditions Rated for 100 gpm at 470 feet differential head. 6. High Pressure Service Water Pumps 72-885 and 72-886 a. Purpose To provide high pressure water for a variety of uses. b. Description Centrifugal type, Goulds Model 3196 LTC, 2X3-13, 60-HP, 3,550 rpm. The casing and impeller are stainless steel. c. Normal Operating Conditions Rated for 150 gpm at 415 feet of differential head. 7. Mechanical Seal Purge Water Pumps 72-887 and 72-888 a. Purpose To supply high pressure water to the reactor agitator seals and the reactor cleaning nozzle flush. b. Description Centrifugal type, Goulds 3196 MT, 1X2-10, 30-HP, 3,500 rpm. The casing and the impeller are stainless steel. ABD00286875 1-3 Operating Manual D-745PVC Reactors Page 1^7 IV. EQUIPMENT INDEX (CONTINUED) E. Pumps (Continued) c. Normal Operating Conditions Rated for 40 gpra at 413 feet of differential head. 8. Water Recirculation Pumps 72-889 and 72-890 a. Purpose To circulate water in the recovery knockout drums. b. Description Centrifugal type, Goulds Model 3196 MT, 2X3-10, 7 1/2 HP, 1,750 rpra. The casing is stainless steel and the impeller is cast iron. c. Normal Operating Conditions Rated for 200 gpm at 68 feet differential head. 9. Seal Water Pumps 72-891 and 72-892 a. Purpose To circulate the seal water used by the recovery vacuum pumps and compressors. b. Description Centrifugal type, Goulds Model 3196 MT, 2X3-10, 10-HP, 1,750 rpm. The casing is stainless steel and the impeller is cast iron. c. Normal Operating Conditions Rated for 160 gpra at 94 feet of differential head. ABD00286876 A 1-3 Operating Manual D-745 PVC Reactors Page IV. EQUIPMENT INDEX (CONTINUED) E. Pumps (Continued) 10. Recovered VCM Transfer Pumps 72-893 and 72-894 a. Purpose To transfer recovered VCM from the recovered VCM collect tank to a recovered VCM storage tank. b. Description Centrifugal type, Goulds Model 3196 MT, 1X2-10, 3-HP, 1,750 rpm. The casing is stainless steel and the impeller is ca6t iron. c. Normal Operating Conditions Rated for 50 gpm at 75 feet of differential head. 11. Hydroquinone Injection Pump 72-895 a. Purpose To supply hydroquinone solution for injection into recovery system seal water during reactor recovery. b. Description Reciprocating type, Milton-Roy Model DB-1-30R, 1/4 HP, 1,750-rpm, carbon steel construction. c. Normal Operating Conditions 0.081 gph at approximately 282 feet of differential head. 12. Slurry Transfer Pumps 72-896 and 72-897 a. Purpose To transfer slurry from the reactor to the slurry blend tanks. ABD00286877 1-3 & Operating Manual D-745pvc Reactors Page 109 IV. EQUIPMENT INDEX (CONTINUED) E. Pumps (Continued) b. Description Centrifugal type, Goulds Model 3196 MT, 4X6-13, 40-HP, 1,770 rpm. The casing and impeller are stainless steel. c. Normal Operating Conditions Rated for 600 gpm at 126 feet of differential head. 13. Cleaning Solution Pumps 72-898 and 72-899 a. Purpose To supply chem wash solution to the reactors during chem wash. b. Description Centrifugal type, Durco Model Mark II, Group II, 4X3-10/80, 75-HP, 3,550 rpm. stainless steel casing and impeller. c. Normal Operating Conditions Rated for 500 gpm at 165 feet of differential head. 14. Blowdown Tank Pump 72-900 a. Purpose To pump water which has been stripped of VCM from the blowdown tank to the sewer. b. Description Centrifugal type, Durco Model Mark II, Group II, 4X3-10/84, 7 1/2 HP, 1,750 rpm. The casing is stainless steel and the impeller is cast iron. c. Normal Operating Conditions Rated for 200 gpm at 63 feet of differential head. ABD00286878 & 1-3 Operating Manual D-74J5 PVC Reactors Page 110 IV. EQUIPMENT INDEX (CONTINUED) F. Compressors and Fans 1. Recovery Vacuum Pumps 72-901 and 72-902 a. Purpose To recover unreacted VCM from the polymerization reactors. b. Description Bingham Model 4G-M, 75-HP, 1,200 rpm. Constant volume liquid ring with a water seal. The liquid ring is driven by a multivaned impeller in a circular pumpcase. Construc tion is cast iron casing and ductile iron impeller. c. Normal Operating Conditions 24 inches Hg vacuum to 7 psig inlet, 0-10 psig dishcarge, and 100-150F. 2. Recovery Compressors 72-903, 72-904, and 72-905 a. Purpose To recover unreacted VCM from the polymerization reactors. b. Description Nash Model 1256, 150-HP, constant volume liquid ring with water seal. The liquid ring is driven by a multivaned impeller in a circular pumpcase. Construction is cast iron casing and stainless steel impeller. c. Normal Operating Conditions 0-35 psig inlet, 40-80 psig outlet, and 100-150F. ABD00286879 A 1-3 Operating Manual I)-743 PVC Reactors Page HI IV. EQUIPMENT INDEX (CONTINUED) F. Compressors and Fans (Continued) 3. Slurry Strainer Exhauster 49-368 a. Purpose To keep personnel exposure to VCM vapors to a minimum. b. Description Centrifugal fan, Buffalo Forge Model 365 DL, 3-HP, 1,800 rpm, stainless steel construction. c. Normal Operating Conditions Near atmospheric pressure and 150-200F. / G. Agitators 1. Reactor Agitators 51-101, 51-102, 51-103, and 51-104 a. Purpose To keep the colloid, VCM, and water in the reactor well mixed. b. Description Bottom entering, single speed, four blades at 45 angle, 200-HP, 125 rpm, stainless steel construction. c. Normal Operating Conditions 15,000 gallons of liquid or slurry in vertical vessel, 22-foot straight wall by 12-foot diameter, at about 120F and 130 psig. ABD00286880 \ 1-3 Operating Manual D-745 pvc Reactors Page 112 IV. EQUIPMENT INDEX (CONTINUED) G. Agitators (Continued) 2. Colloid Makeup Tank Agitator 51-103 a. Purpose To provide agitation needed to dissolve F-50 methocel in water. b. Description Top entering, single speed, "Lightnin" Model 73-Q-5, 5-HP, 1,750 rpra. Wetted parte are stainless steel. c. Normal Operating Conditions 3,000 gallons of colloid solution; tank is vertical; sevenfoot diameter by 11'6" tall; temperature ranges from 70-250F and atmospheric pressure. 3. Hydroquinone Storage Tank Agitator 51-106 a. Purpose To provide agitation needed to dissolve hydroquinone powder in water. b. Description Top entering, single speed, "Lightnin" Model N33-33, 1/3-HP, 1,750 rpm. c. Normal Operating Conditions Approximately fifty gallons hydroquinone solution in vertical tank 2*6" high by two-foot diameter, 1 psig, and 70F. ABD00286881 A 1-3 Operating Manual D-745 PVC Reactors Page 113 IV. EQUIPMENT INDEX (CONTINUED) H. Package Units 1. Seal Oil Pressure Units 95-299 and 93-300 a. Purpose To supply seal oil to the reactor agitator seals at the required temperature and pressure. b. Description Dura circulator Model SWAR-40-25. c. Normal Operating Conditions 245-250 psig, 100-150F. The seal oil is Di(2-Ethylhexy) phthalate (DOP) which has a viscosity of 35 cp. ABD00286882 A 1-3 Operating Manual D-745 PVC Reactors Page 114 V. INSTRUMENT INDEX A. Flow Controllers Item No. Service IXP.f Set Point FIRC-710 FIRC-711 FIRC-712 FIRC-713 FRC-201 ' Reactor Cooling Water Flow Controllers Meter run with orifice plate, board-mounted indicators and recorders. Cascade control; the temperature controller of each reactor sets the set point. NOTE: FIRC-710 controls the cooling water to reactor 45-741. FIRC-711 controls the cooling water to reactor 45-742. FIRC-712 controls the cooling water to reactor 45-743 FIRC-713 controls the cooling water to reactor 45-744. FRC-201 controls the cooling water to reactor 45-781. FIC-738 Recovery Vacuum Pump Brooks Model 3611 50 gpm FIC-739 FIC-740 and Compressor Seal Water Flow Control lers Rotameter with trans mitter and a local Foxboro flow con troller NOTE: FIC-738 controls the seal water to vacuum pump 72-901 and compressor 72-903. FIC-739 controls the seal water to vacuum pump 72-902 and compressor 72-904. FIC-740 controls the seal water to compressor 72-905. FCi-749 FCi-750 FCi-751 FCi-752 Reactor Agitator Mechanical Seal Oil Supply Flow Regulators Kates Model MFA1-1 Flow Regulator 1.0 gpm NOTE: FCi-749 controls the seal oil flow to reactor 45-741 double mechanical seal. FCi-750 controls the seal oil flow to reactor 45-742 double mechanical seal. FCi-751 controls the seal oil flow to reactor 45-743 double mechanical seal. FCi-752 controls the seal oil flow to reactor 45-744 double mechanical seal. ABD00286883 A 1-3 Operating Manual ti-745 PVC Reactors Page 115 INSTRUMENT INDEX (Cont.) B. Flow Totalizers Item No. FQIC-701A FQIC-701B Service VCM Charge Totalizers TyPe Foxboro Turbine Meter, Board-Mounted Read out Set Point Determined by specific batch recipe. FQIC-702 Recovered VCM Charge Totalizer Fischer/Porter Vortex Determined by Shedding Meter, Board specific batch Mounted Readout recipe. FQIC-704 Hot Water Charge Totalizer Foxboro Turbine Meter, Board-Mounted Read out . Determined by specific batch recipe. FQIC-705 Colloid Charge Totalizer Brooks Oval Meter, Board-Mounted Read out . Determined by specific batch recipe. FQIC-706 Colloid Makeup Water Flow Totalizer Brooks Oval Meter, Local Colloid Board Readout Hot Water, 538 GalIons Cold Water, 2,62 Gallons FQI-798 Reactor Steam Stripping Flow Totalizer Flow Nozzle with D/P Cell, Board-Mounted Readout. None; totalizes only. FQI-757 Hot Water Charge Totalizer Orifice Plate with D/P Cell, Board-Mounted Readout. None; totalizes only. FQI-S11 Steam to Reactor Module Flow Totalizer Orifice Plate with D/P Cell, Board-Mounted Readout None; Totalizes only. FIC-708 Reactor Steam Stripping Flow Control Flow Nozzle with D/P Cell, Board-Mounted Controller 23,000 lbs/hr. FQI-203 Initiator Injection Pot Service Water Flow Totalizer--D-745 Reactor Neptune Displacement Meter, Local Read out only Determined in Field ABD00286884 A 1-3 Operating Manual D-745 PVC Reactors Page lib V. INSTRUMENT INDEX (CONTINUED) C. Level Controllers Item No. Service Type Set Point LC-720 LC-722 Seal Water Separator Level Controllers Displacer, Fisher Model 2500T 16 Inches from Bottom of Dis placer Float NOTE: LC-720 controls the water level in seal water separator 45-762. LC-722 controls the water level in seal water separator 45-763. LIC-725 Slurry Dump Tank 45-766 Level Controller Displacer, Fisher Model 2500T To be determined in field. D. Pressure Controllers Item No. PCi-704 Service gype Recovered VCM Storage Tanks 89-520 and 45317 Inert Vent Back pressure Regulator Self-Contained Pres sure Regulator Set Point 60 psig PCi-706 Steam Stripping Header Steam Supply Backpressure Regu lator Self-Contained Pres sure Regulator 100 psig PIC-725 Recovery Knockout Drum 45-760 Inlet Pressure Controller Diaphragm with Foxboro Controller 35 psig PIC-726 VCM Bleed Stream to Recovery System Pressure Controller Vacuum D/P Transmit ter with a Local Foxboro Controller 3" Hg Vacuum PCi-729 Hydroquinone Storage Tank 45-765 Nitrogen Pressure Regulator Self-Contained Pres sure Regulator 1 psig PCi-731 Mechanical Seal Purge Water Surge Drum 45-759 Nitrogen Supply Pressure Regulator Self-Contained Pres sure Regulator 180 psig ABD00286885 A 1-3 Operating Manual D-745pvc Reactors Page 117 V. INSTRUMENT INDEX (CONTINUED) D. Pressure Controllers (Continued) Item No. Service Type Set Point PCi-739 Seal Oil Pressure Unit 95-299 Nitrogen Supply Pressure Regulator Self-Contained Pressure Regulator 200 psig PCi-741 Seal Oil Pressure Unit 95-300 Nitrogen Supply Pressure Regulator Self-Contained Pressure Regulator 200 psig PCi-743 PCi-744 PCi-745 PCi-746 PCi-747 PCi-752 Breathing Air Station Supply Pressure Regu lator Self-Contained Pres sure Regulator 20 psig NOTE: PCi-743 regulates breathing air to the reactor area, ground level, PCi-744 regulates breathing air to the reactor area, second level, PCi-745 regulates breathing air to the recovery building, first floor. PCi-746 regulates breathing air to the recovery building, second floor. PCi-747 regulates breathing air to the charge area. PCi-752 regulates breathing air to the reactor area, third level. PCi-754 PCi-755 PCi-756 PCi-757 NO Short Stop Supply Pressure Regulator Self-Contained Pressure Regulator 200 psig NOTE: PCi-754 regulates PCi-755 regulates PCi-756 regulates PCi-757 regulates NO supply pressure NO supply pressure NO supply pressure NO supply pressure to reactor 45-741. to reactor 45-742. to reactor 45-743. to reactor 45-744. PIC-759 Blowdown Tank 45-319 Pressure Controller Vacuum D/P Transmitter with Local Foxboro Controller To be Determined in Field ABD00286886 Operating Manual D-745 pvc Reactors Page 118 V. INSTRUMENT INDEX (CONTINUED) E. Temperature Controllers Item No. Service TIC-701 Hot Water Tank 45-748 Temperature Control ler lype Resistance Bulb with Board-Mounted Foxboro Controller Set Point 140F TIC-702 Hot Water Preheater 55-332 Discharge Temperature Con troller Filled System with Local Foxboro Con troller 145F TRC-703 Charge Water Temper ature Controller Resistance Bulb with Board-Mounted Fox boro Controller Determined by Specific Batch Recipe TIRC-706 TIRC-707 TIRC-708 Reactor Polymerization Temperature Control lers Resistance Bulb with Foxboro Controller Determined by Specific Batch Recipe C TIRC-709 TIRC-201 NOTE: TIRC-706 controls reactor 45-741 polymerization temperature. TIRC-707 controls reactor 45-742 polymerization temperature. TIRC-708 controls reactor 45-743 polymerization temperature. TIRC-709 controls reactor 45-744 polymerization temperature- TIRC-201 controls reactors 45-781 polymerittion temperature. TIRC-710 Reactor Steam Strip Resistance Bulb with 22S*F TIRC-711 ping Temperature Board-Mounted TIRC-712 Controller Foxboro Controller TIRC-713 TIRC-202 NOTE: TIRC-710 controls reactor 45-741 steam stripping temperature. TIRC-711 controls reactor 45-742 steam stripping temperature. TIRC-712 controls reactor 45-743 steam stripping temperature. TIRC-713 controls reactor 45-744 steam stripping temperature. TIRC-202 controls reactor 45-781 steam stripping temperature. TIC-716 Seal Water Temperature Filled System with l'o be Determined TIC-717 Controller Local Foxboro in Field Controller NOTE: TIC-716 controls seal water cooler 55-335 outlet temperature. TIC-717 controls seal water cooler 55-336 outlet temperature. ABD00286887 Operating Manual D-745 pvc Reactors Page 119 V. INSTRUMENT INDEX (CONTINUED) E. Temperature Controllers (Continued) Item No. Service Type TIC-718 Cleaning Solution Heater 55-339 Outlet Temper ature Controller Filled System with Local. Foxboro Controller TIC-730 Water Stripper 45-319 Temperature Controller Filled System with Local Foxboro Controller Set Point 190F 175F 1-3 A ABD00286888 A 1-3 Ope*racing Manual D-745 PVC Reactors Pap,c 121) VI. ALARMS AND SAFETY EQUIPMENT A. Continuous Flew Fresh Air System In order to provide personnel protection, a continuous flov: fresh air system has been installed. This system consists of i - 'sonnel fresh air masks and a constant flow breathing air supply. The supply lines are piped to all affected areas of the plant. The individual hookup stations consist of quick Connert/diseonnocttype fittings. The individual lines to the designated areas are designed lo allow a minimum flow of 6 SCFM to each mask at approximately !0-l*> psig. An air pressure regulator, shutoff valve, and an air filter are provided at the piping header to each individual area. The air sup{ly system utilizes two Nash compressors supplying 100 SCFM each at a maximum pressure of 80 psig. Each compressor will supply about fifteen masks with air at one time. The com pressors normally are both in operation at the same time, except in cases of mechanical failure. The system is equipped with both visable and audible low pressure alarms which are activated at 50 psig. The revolving beacon light is mounted on a pole to give wider visibility, and the hor- is mounted at the compressor. An on-off switch is provided each compressor. ABD00286889 1-3 Operating Manual D-745 PVC Reactors Page 121 VI- ALARMS AND SAFETY EQUIPMENT (Cont.) A. Continuous Flow Fresh Air System (Cont.) The following job operations will REQUIRE the wearing of a continuous flow fresh air mask supplied through the fresh air lines or a Scott Air Pak: 1. Opening any piece of process equipment in vinyl chloride service including: a. Pumps b. Compressors c. Filters d. Vessels e. Piping 2. Opening a Lenape manway on a reactor without using steam jet evacuation. 3. Entering vessels or may confined area that have contained vinyl chloride. 4. While on top of the large blend tanks which are regulated areas. 5. When using the portable vinyl chloride detector to pinpoint a vinyl chloride leak detected by the continuous monitoring system when the VCM conentration is expected to exceed 10 ppm. 6. Reactor dumping normally does not require the use of a fresh air respirator. Abnormal conditions which would require a fresh air mask are: a. When working on a plugged reactor dump valve or line. b. Dumping a coarse batch. c. Inoperative Sweco exhauster. 7. Sampling of reactors, VCM railcars, or storage tanks. 8. The heated water vapor coming from vents in the old unit sewer during pump-out of the blowdown tank contain concentrations of VCM above 1 ppm. If an employee must perform work in an area where these vapors exist, an air mask must be worn. ABD00286890 1-3 Operating Manual D-745 PVC Reactors Page 122 VI. ALARMS AND SAFETY EQUIPMENT (Cont.) A. Continuous Flow Fresh Air System (Cont.) 9. Any other operation which has the possibility of resulting in exposure greater than the permissible exposure limit. The per missible exposure limit is defined as: a. No employee may be exposed to vinyl chloride at concentra tions greater than 1 ppm averaged over any 8-hour period, and b. No emplyee may be exposed to vinyl chloride at concentrations greater than 5 ppm averaged over any period exceeding 15 minutes. c. No empoyee may be exposed to vinyl chloride by direct contact with liquid vinyl chloride. ABD00286891 A 1-3 Operating Manual D*-745 PVC Reactors Page 123 VI. ALARMS AND SAFETY EQUIPMENT (CONTINUED) B. Alarms and Switches 1. Amperage Alarms Item No. Service Type Sot Point AAHL-701 AAHL-702 AAHL-703 AAHL-704 Low or High Amperage to the Reactor Agi tator Motor Board-Mounted Alarm To he deter mined in the field. IAHL-200 NOTE: AAHL-701 indicates abnormal amperage to reactor 45-741 agitator motor. AAHL-702 indicates abnormal amperage to reactor 45-742 agitator motor. AAHL-703 indicates abnormal amperage to reactor 45-743 agitator motor. AAHL-704 indicates abnormal amperage to reactor 45-744 agitator motor. IAHL-200 indicates abnormal amperage to reactor 45-781 agitator motor. 2. Flow Alarms and Switches Item No. Service FSL-701A Low VCM Flow during and B Charge Type Switch that ,vctivates Alarm (FAL-701) on Board Sot Point 400 gpm FAL-701 Low VCM Flow during Charge Board-Mounted Alarm 400 gpm FAL-714 FAL-715 FAL-716 FAL-717 Low Seal Water Flow to the Reactor Agitators Board-Mounted Alarm 2 gpm NOTE: FAL-714 indicates low flow to reactor 45-741. FAL-715 indicates low flow to reactor 45-742. FAL-716 indicates low flow to reactor 45-743. FAL-717 indicates low flow to reac tor 45-744. ABD00286892 A 1-3 Operating Manual D-745PVC Reactors Page 174 VI. ALARMS AND SAFETY EQUIPMENT (CONTINUED) B. Alarms and Switches (Continued) 3. Level Alarms and Switches Item No. Service Type Set Point LAH-701 High VCM Level in Fresh VCM Storage Tank 45-745 Board-Mounted Alarm 252 Indies above Bottom Tangent LSH-701A High VCM Level in Fresh VCM Storage Tank 45-745 Switch Activates LAH-701 252 Inches above Bottom Tangent LSH-701B High VCM Level in Fresh VCM Storage Tank 45-745 Switch that Serves . as Charge Permis sive 252 Indies above Bottom Tangent LSH-701C Level Control of Fresh VCM Receiver 45-745 Switch which Stops 225 Inches Above VCM Transfer Discharge Nozzle LSL-701D Level Control of Fresh VCM Receiver 45-745 Switch which Starts Transfer 219 Inches Above Di -charge Nozzle LAH-710 High Level in Col loid Makeup Tank 45-751 Alarm on Colloid Local Board 8 Inches from Top of Tank LSH-711B High Water Level in Hot Water Tank 45-748 Switch that Serves as Charge Permis sive 129 Inches above Discharge Nozzle LSH-711C Hot Water Tank 45-758 Level Control LSL-711D Hot Water Tank 45-748 Level Control Switch which Stops Water Transfer on High Level 360 Inches above Bottom Tangent Switch which Starts Water Transfer 350 Inches above Discharge Nozzle LAH-713 High Level in Col loid Storage Tank 45-752 Board-Mounted Alarm 6 T no lies from Top of Tank ABD00286893 Operating Manual D-745PVC Reactors Page 12S VI. ALARMS AND SAFETY EQUIPMENT (CONTINUED) B. Alarms and Switches (Continued) 3. Level Alarms and Switches (Continued) Item No. Service Type Sct Point LAH-714 High Level in Col loid Charge Tank 45-753 Board-Mounted Alarm 8 Inches from Top of Tank LSL-715 Low Level in Col loid Charge Tank 45-753 Switch Serves as Charge Permis sive 24 Indies above Bottom Tangent LSH-716 Level Control of Recovery Knockout Drum 45-760 Switch Opens Valve to Blowdown Tank on High Level 28 Inches above Bottom Tangent LSL-717 Level Control of Recovery Knockout Drum 45-760 Switch Closes Valve to Blow down Tank on Low Level 18 Indies above Bottom Tangent LSH-718 Level Control of Recovery Knockout Drum 45-761 Switch Opens Valve to Blowdown Tank on High Level 28 Inches above Bottom Tangent LSH-719 Level Control of Recovery Knockout Drum 45-761 Switch Closes Valve to Blow down Tank on Low Level 18 Inches Above Bottom Tangent LAH-720 High Level in Seal Water Separator 45-762 Local Alarm 44 Inches above Bottom Tangent LAL-720 Low Level in Seal Water Separator 45-762 Local Alarm 16 Inches above Bottom Tangent LAH-722 High Level in Seal Water Separator 45-763 Local Alarm 44 Inches above Bottom Tangent LAL-722 Low Level in Seal Water Separator 45-763 Local Alarm 16 Inches above Bottom Tangent ABD00286894 1-3 Operating Manual D-745 PVC Reactors Page 126 VI. ALARMS AND SAFETY EQUIPMENT (CONTINUED) B. Alarms and Switches (Continued) 3. Level Alarms and Switches (Continued) Item No. Service Set Point LAH-725 High Level in Slurry Dump Tank 45-766 Board-Mounted Alarm 6 Inches from Top of Tank LAH-727 High Level in Cleaning Solu tion Tank 45-767 Board-Mounted Alarm 6 Inches from Top of Tank LAL-729 Low Level in Cleaning Solu tion Tank 45-767 Board-Mounted Alarm 6 Inches from Bot tom of Tank LSL-730 Low Level In Seal Oil Reservoir 95-299 Switch Activates LAL-730, Starts Spare Seal Oil Unit 95-300, and Turns Off 95-299 To be Defined by Vendor LAL-730 low Level in Seal Oil Reservoir 95-299 Board-Mounted Alarm To be Defined by LSL-731 Low Level in Seal Switch Activates To be Defined by Oil Reservoir LAL-731, Starts Vendor 95-300 Spare Seal Oil Unit 95-299, and Turns Off 95-300 J LAL-731 Low Level in Seal Board-Mounted To be Defined by Oil Reservoir Alarm Vendor 95-300 LAL-733 Low Level in Hydroquinone Storage Tank 45-765 Board-Mounted Alarm 6 Inches above Bottom Tangent LAH-734 High Level in Cleaning Solution Tank 45-767 Switch Shuts Down 6 Inches from Cleaning Solution Top of Tank Pumps 72-898 and 72-899 and Caustic Transfer Pumps LAL-739 Low Level in Col loid Makeup Tank 45-751 Board-Mounted Alarm One Inch above Bottom Tangent A ABD00286895 1-3 Operating Manual D-745 PVC Reactors Page 127 VI. ALARMS AND SAFETY EQUIPMENT (CONTINUED) B. Alarms and Switches (Continued) 3. Level Alarms and Switches (Continued) Item No. Service LAH-740 High Level in Blow down Tank 45-319 Type Board-Mounted Alarm Set Point 22 Inches from Top of Tank LSL-741 Low Level in Blow down Tank 45-319 Switch will Shut Off Blowdown Tank Pump 72-900 and Close Valves CV-880 and CV-891 12 Inches from Bottom of Tank 4. Pressure Alarms and Switches Item No. Service PSH-703 High Pressure in Initiator Injec tion Pot 45-750 TyPe Set Point Switch turns on high pressure light on the board and is a precharge condition. 180 psig PSL-707 Low Presjure in Steam Stripping Header Switch closes control valve that supplies steam to the reactor during steam strip ping. 100 psig PSL-712 PSL-713 PSL-714 PSL-715 PSL-205 Low Pressure in Reactor during Recovery Switch prevents opening of reactor dump valve unless pres sure during recovery has been at least as low as set point. 8 psig NOTE: PSL-712 senses pressure in reactor 45-741. PSL-713 senses pressure in reactor 45-742. PSL-714 senses pressure in reactor 45-743. PSL-715 senses pressure in reactor 45-744. PSL-20S senses pressure in reactor 45-781 A ABD00286896 Operating Manual D-745 PVC Reactors Page 128 VI. ALARMS AND SAFETY EQUIPMENT (Cont.) B. Alarms and Switches (Cont.) 4. Pressure Alarms and Switches (Cont.) Item No. Service las PSl-716 PSL-717 PSL-718 PSL-719 Low Pressure in Reactors during Evacuation Sv;itch keeps charge from starting by preventing main reactor charge valve from opening unless pres sure is at low set point/ or above. NOTE: PSL-716 senses pressure in reactor 45-741. PSL-717 senses pressure in reactor 45-742. PSL-718 senses pressure in reactor 45-745. PSL-719 senses pressure in reactor 45-744. PAH-720 PAH-721 PAH-722 PAH-723 PAH-206 High Pressure in Reactors Board-Mounted Alarm NOTE: PAH-720 indicates high pressure in reactor 45-741. PAH-721 indicates high pressure in reactor 45-742. PAH-722 indicates high pressure in reactor 45-743. PAH-723 indicates high pressure in reactor 45-744. PAH-206 indicates high pressure in reactor 45-781 PSL-727 Low Recovery Com pressor Suction Pressure Switch will start recovery vacuum pumps 72-901 and 72-902 and activate proper valving sequence during recovery PDS-728 High Differential Pressure Between Recovery Vacuum Pump Suction and Recovery Compres sor Discharge Switch shuts off recovery compressors 72-903, 72-904, and 72905 and vacuum pumps 72-901 and 72-902. PSL-732 Low Pressure on High Pressure Service Water System Switch prevents automatic matic charge sequence from beginning and activates PAL-732 PAL-212 Low Pressure on AMS kill Pot Switch alerts operator to low nitrogen pressure on Emer gency AMS kill pot. Set Point 25" Hg Vacuum 160 psig 7 psig 80 psig 150 psig 275 psig ABD00286897 1-3 Operating Manual D-745 PVC Reactors Page 129 VI. ALARMS AND SAFETY EQUIPMENT (CONTINUED) B. Alarms and Switches (Continued) 4. Pressure Alarms and Switches (Continued) Item No. Service Type PAL-732 Low Pressure on High Pressure Service Water System Board-Mounted Alarm PSL-737 Low Pressure on Mechanical Seal Purge Water System (MSPW) Switch activates PAL-737 and turns on spare (MSPW) pump 72-887 or 72-888. PAL-737 Low Pressure on Mechanical Seal Purge Water System Board-Mounted Alarm PSL-738 Low Pressure from Seal Oil Unit 95-299 Switch activates spare seal oil unit 95-300, turns off 95-299, acti vates the necessary valves, and acti vates PAL-738. PAL-738 Low Pressure from Seal Oil Unit 95-299 Board-Mounted Alarm PSL-740 Low Pressure from Seal Oil Unit 95-300 Switch activates spare seal oil unit 95-299, turns off 95-300, activates the necessary valves, and acti vates PAL-740. PAL-740 Low Pressure from Seal Oil Unit 95-300 Board-Mounted Alarm PAH-750 High Pressure on Initiator Injec tion Pot 45-750 Board-Mounted Alarm Sot Point 130 psig 180 psig 180 psig 205 psig 205 psig 205 psig 205 psig 225 psig ABD00286898 1-3 Operating Manual D-745 PVC Reactors Page l 50 VI. ALARMS AND SAFETY EQUIPMENT (CONTINUED) B. Alarms and Switches (Continued) 4. Pressure Alarms and Switches (Continued) Item No. Service Type PAH-751 High Seal Oil System Board-Mounted Alarm Pressure Ser Point 255 psig PAL-753 Low Pressure on NO Short Stop Bottles Board-Mounted Alarm 350 psig PSL-758 Low Pressure on High Pressure Service Water System (HPSW) Switch turns on spare HPSW pump 72-885 or 72-886. 180 psig PAH-760 High Pressure in Blowdown Tank 45-319 Board-Mounted Alarm 10 psig PSL-762 Low Steam Pressure to Blowdown Tank 45-319 Switch closes TCV-730 and PCV-759 and re sets on rising steam pressure of 50 psig. 40 psig PAL-763 Low Instrument Air Pressure Board-Mounted Alarm 85 psig TAH-706 TAH-707 High Temperature in the Reactors Board-Mounted Alarm 160F TAH-708 TAH-709 TAH-201 NOTE: TAH-706 indicates high temperature in reactor 45-741. TAH-707 indicates high temperature in reactor 45-742. TAH-708 indicates high temperature in reactor 45-743. TAH-709 indicates high temperature in reactor 45-744. TAH-201 indicates high temperature in reactor 45-781. TAH-715 High Discharge Board-Mounted Alarm 150F Temperature on the Recovery Compressors TAH-719 High Seal Oil Temperature Board-Mounted Alarm 125F TAH-720 High Temperature in Initiator Injec tion Pot 45-750 Board-Mounted Alarm 75F A ABD00286899 1-3 Operating Manual D-745 PVC Reactors Page 131 VI. ALARMS AND SAFETY EQUIPMENT (CONTINUED) C. Firewater System The firewater system consists of a deluge system, combustible hydrocarbon analyzer, and fire monitors with hose connections. 1. Fire Monitors The fire monitors are normally supplied from the city water system. A tie-in with the firewater system allows the fire monitors to operate off either water system. There are six fire monitors located around the perimeter of the recovery building and reactor area. 2. Hydrocarbon Analyzer A continuous combustible hydrocarbon analyzer is used to detect major VCM leaks. When the VCM level at any sample point reaches the set point, the deluge system is activated automatically. 3. Deluge System The deluge system is normally supplied from the firewater system. It can be operated on process water. The deluge system is a sprinkler system which will cover the reactors, dump system, fresh and recovered VCM storage tanks, and both floors of the recovery building with a water spray. The deluge system is designed to lower VOi concentrations in the reactor and recovery building area in the event of a VCM leak and as a sprinkler system to help put out fires. The deluge system can be acti vated manually, Uy the combustible hydrocarbon analyzer, or by thermal sensors. ABD00286900 1-3 Operating Manual D-745PVC Reactors Page 132 VI. ALARMS AND SAFETY EQUIPMENT (CONTINUED) C. Firewater System (Continued) 3. Deluge System (Continued) The revised firewater system contains three new post indicator valves (PIV) and one PIV was relocated. These are valves which have indicators on them to show whether the valve is open or closed. These valves are used to direct water to either the D-700 reactor area or the V-ll area. The valves are located at: 1. The southwest corner of the new cooling water tower. 2. East wall of the V-ll building. 3. Two are located at the northwest corner of the intersec tion of the entrance road and second street. D. Fixed Point VCM Monitor A fixed point VCM monitor is used to detect VCM and record the VCM concentration at various locations in the reactor and recovery building. The readout is on a chart in the control room. ABD00286901 k 1-3 Operating Manual D-745PVC Reactors Page 153 VII. EQUIPMENT ENTRY PROCEDURE EPA standards for VCM emissions and OSHA regulations on personnel exposure to VCM require that certain operating procedures be followed when there is the possibility of VCM emission to the atmosphere or personnel exposure to VCM. For this reason and to ensure safe working conditions at all times, the "Engineering and Work Practice Control Program for the Reduction of Employee Exposure to Vinyl Chloride" manual should be consulted whenever equipment in the reactor area is opened for any reason. This manual contains a list of detailed procedures as well as safety precautions for equipment opening. Every vessel has an entry check list that must be filled out by the Shift Supervior. The entry check list contains a building list for opening a vessel. Tanks and Vessels (Continued) 45-759 45-760 45-761 45-762 45-763 45-764 45-765 45-766 45-767 45-768 45-770 45-778 45-786 Filters 64-716 64-718 64-719 64-720 64-721 64-722 64-723 64-724 64-725 64-726 64-727 64-728 64-731 64-732 64-733 64-734 64-735 64-736 64-737 64-738 64-739 64-740 64-741 64-742 ABD00286902 APPENDIX A EQUIPMENT LIST - CONTINUED 1-3 6^ Service Mechanical Seal Purge Water Surge Drum South Recovery Knockout Drum North Recovery Knockout Drum South Seal Water Separator North Seal Water Separator Recovered VCM Collect Tank llydroquinone Storage Tank Slurry Dump Tank Cleaning Solution Tank Reactor Evacuation Ejector Cyclone Separator Reactor Sampling Bomb Initiator Charge Pot for Reactor 45-781 AMS Emergency Kill Pot for Reactor 45-781 Process Water Charge Filter North VCM Charge Filter Recovered VCM Filter Process Water Filter Colloid Makeup Water Filter North Colloid Transfer Filter South Colloid Transfer Filter Service Water Filter Seal Oil Supply Filter for Seal Oil Pressure Unit 95-299 Seal Oil Supply Filter for Seal Oil Pressure Unit 95-300 Seal Oil Return Filter for Seal Oil Pressure Unit 95-299 Seal Oil Return Filter for Seal Oil Pressure Unit 95-300 South Seal Water Filter North Seal Water Filter Slurry Strainer Cleaning Solution Strainer Breathing Air Filter (Reactors, First Level) Breathing Air Filter (Reactors, Second Level) Breathing Air Filter (Recovery Building First Floor) Breathing Air Filter (Recovery Building, Second Floor) Breathing Air Filter (Charge Aren) Breathing Air Filter (Reactors, Third Level) Blowdown Tank Drain Strainer South VCM Charge Filter ABD00286903 1-3 Reactors 45-741 45-742 45-743 45-744 45-781 Heat Exchangers 55-328 55-329 55-330 55-331 55-358 55-332 55-333 55-334 55-335 55-336 55-337 55-338 55-339 Eductors and Ejectors EE-701 EE-702 EE-703 EE-704 EE-705 EE-201 A, B, fi C EE-200 Tanks and Vessels 45-301 45-317 89-520 45-319 45-745 45-748 45-750 45-751 45-752 45-753 45-754 45-755 45-756 45-757 45-758 APPENDIX A EQUIPMENT LIST Polymerization Reactor Polymerization Reactor Polymerization Reactor Polymerization Reactor Polymerization Reactor Reactor 45-741 Condenser Reactor 45-742 Condenser Reactor 45-743 Condenser Reactor 45-744 Condenser Reactor 45-781 Condenser Hot Water Preheater Hot Water Tank Heater Water Recirculation Cooler West Seal Water Cooler East Seal Water Cooler West Recovered VCM Condenser East Recovered VCM Condenser Cleaning Solution Heater Reactor 45-741 Jacket Eductor Reactor 45-742 Jacket Eductor Reactor 45-743 Jacket Eductor Reactor 45-744 Jacket Eductor Reactor Evacuation Ejector Reactot 45-781 Jacket Eductor Reactor Evacuation Ejector Instrument air Capacity Tank East Recovered VCM Storage Tank West Recovered VCM Storage! Tank Blowdown Tank Fresh VCM Storage Tank Hot Water Tank Initiator Injection Pot Colloid Makeup Tank Colloid Storage Tank Colloid Charge Tank Seal Oil Storage Drum AMS Short Stop Charge Pot for Reactor 45-741 AMS Short Stop Charge Pot for Reactor 45-742 AMS Short Stop Charge Pot for Reactor 45-743 AMS Short Stop Charge Pot for Reactor 45-744 ABD00286904 APPENDIX A EQUIPMENT LIST - CONTINUED Pumps Motor 72-875 72-876 72-877 72-878 72-879 72-880 72-881 72-882 72-883 72-884 72-885 72-886 72-887 72-888 72-889 72-890 72-891 72-892 72-893 72-884 72-895 72-896 72-897 72-898 72-899 72-900 70-875 70-876 70-877 70-878 70-879 70-880 70-881 70-882 70-883 70-884 70-885 70-886 70-887 70-888 70-889 70-890 70-891 70-892 70-893 70-894 70-895 70-896 70-897 70-898 70-899 70-900 Compressors and Fans Motor 72-901 72-902 72-903 72-904 72-905 49-368 70-901 70-902 70-903 70-904 70-905 70-864 Agitators Motor 51-101 51-102 51-103 51-104 51-105 51-106 51-110 70-814 70-815 70-816 70-817 70-818 70-819 70-971 Service VCM Charge Pump VCM Charge Pump Recovered VCM Charge Pump Recovered VCM Charge Pump Hot Water Charge Pump Hot Water Charge Pump Colloid Batch Transfer Pump Colloid Circulation Pump Colloid Charge Pump Colloid Charge Pump High Pressure Service Water Pump High Pressure Service Water Pump Mechanical Seal Purge Water Pump Mechanical Seal Purge Water Pump Water Recirculation Pump Water Recirculation Pump Seal Water Pump Seal Water Pump Recovered VCM Transfer Pump Recovered VCM Transfer Pump Hydroquinone Injection Pump Slurry Transfer Pump Slurry Transfer Pump Cleaning Solution Pump Cleaning Solution Pump Blowdown Tank Pump 1 Recovery Vacuum Pump Recovery Vacuum Pump Recovery Compressor Recovery Compressor Recovery Compressor Slurry Strainer Exhauster Reactor 45-741 Agitator Reactor 45-742 Agitator Reactor 45-743 Agitator Reactor 45-744 Agitator Colloid Makeup Tank Agitator Hydroquinone Storage Tank Agitato Reactor 45-781 Agitator A 1-3 Package Units 95-299 95-300 PA-703 PA-704 PA-705 PA-706 PA-707 PA-708 PA-709 PA-710 PA-711 PA-712 PA-713 PA-714 PA-715 PA-716 PA-717 PA-200 PA-201 ABD00286905 A 1-3 APPENDIX A EQUIPMENT LIST - CONTINUED Service Seal Oil Pressure Unit Seal Oil Pressure Unit Deluge System Deluge System Combustible Hydrocarbon Analyzer Fire Monitor Fire Monitor Fire Monitor Fire Monitor Fire Monitor Fire Monitor Deleted Fixed Point VCM Monitor Emergency NO Short Stop Bottles Emergency NO Short Stop Bottles Emergency NO Short Stop Bottles Emergency NO Short Stop Bottles Programmable Logic Controller Emergency NO Short Stop Bottles Nitrogen Supply bottle to AMS Emergency Kill Pot. ABD00286906 th 1-3 APPENDIX B INSTRUMENT LIST Item No. Service Amperage Instruments AI-701 AAHL-701 AI-702 AAHL-702 AI-703 AAHL-703 AI-704 AAHL-704 Al-705 AI-706 AI-707 AI-708 AI-709 Reactor Agitator 51- 101 Motor Amperage Indicator Reactor Agitator 51- 101 Motor High or Lov Amperage Alarm Reactor Agitator 51- 102 Motor Amperage Indicator Reactor Agitator 51- 102 Motor High or Low Amperage Alarm Reactor Agitator 51- 103 Motor Amperage Indicator Reactor Agitator 51- 103 Motor High or Low Amperage Alarm Reactor Agitator 51- 104 Motor Amperage Indicator Reactor Agitator 51- 104 Motor High or Low Amperage Alarm Recovery Vacuum Pump 72-901 Motor Amperage Recovery Vacuum Pump 72-902 Motor Amperage Recovery Compressor 72-903 Motor Amperage Recovery Compressor 72-904 Motor Amperage Recovery Compressor 72-905 Motor Amperage Control Valves CV-701 CV-702 CV-703 CV-704 CV-705 CV-706 CV-707 CV-708 CV-709 CV-710 CV-711 CV-712 CV-713 CV-714 CV-715 CV-716 CV-717 CV-718 CV-719 CV-720 CV-721 CV-722 CV-723 CV-724 CV-725 CV-726 CV-727 CV-728 Fresh VCM Storage Tank 45-745 Outlet Valve Deleted Recovered VCM Valve to VCM Charge Pumps 72-875 and 72-876 VCM Charge Pump 72-875 Discharge Valve VCM Charge Pump 72-876 Discharge Valve Hot Water Tank 45-748 Outlet Valve Colloid Charge Pump 72-885 Discharge Valve Deleted Hot Water Valve to Colloid Makeup Tank 45-751 Reactor 45-741 Main Charge Valve Reactor 45-741 Colloid Charge Valve Reactor 45-741 Steam Stripping Valve Reactor Condenser 55-328 Cleaning and Rinse Valve Reactor 45-741 Vent Valve Reactor 45-741 Inert Vent Valve Reactor 45-741 Recovery and Evacuation Valve Reactor 45-741 Cleaning and Rinse Valve Deleted Deleted Reactor 45-742 Main Charge Valve Reactor 45-742 Colloid Charge Valve Reactor 45-742 Steam Stripping Valve Reactor Condenser 55-329 Cleaning and Rinse Valve Reactor 45-742 Vent Valve Reactor 45-742 Inert Vent Valve Reactor 45-742 Recovery and Evacuation Valve Reactor 45-742 Cleaning and Rinse Valve Deleted ABD00286907 A 1-3 APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Control Valves (Continued) CV-729 CV-730 CV-731 CV-732 CV-733 CV-734 CV-735 CV-736 CV-737 CV-738 CV-739 CV-740 CV-741 CV-742 CV-743 CV-744 CV-745 CV-746 CV-747 CV-748 CV-749 CV-750 CV-751 CV-752 CV-753 CV-754 CV-755 CV-756 CV-757 CV-758 CV-759 CV-760 CV-761 CV-762 CV-763 CV-764 CV-765 CV-766 CV-767 CV-768 CV-769 CV-770 CV-771 CV-772 Deleted Reactor 45-743 Main Charge Valve Reactor 45-743 Colloid Charge Valve Reactor 45-743 Steam Stripping Valve Reactor Condenser 55-330 Cleaning and Rinse Valve Reactor 45-743 Vent Valve Reactor 45-743 Inert Vent Valve Reactor 45-743 Recovery and Evacuation Valve Reactor 45-743 Cleaning and Rinse Valve Deleted Deleted Reactor 45-744 Main Charge Valve Reactor 45-744 Colloid Charge Valve Reactor 45-744 Steam Stripping Valve Reactor Condenser 55-331 Cleaning and Rinse Valve Reactor 45-744 Vent Valve Reactor 45-744 Inert Vent Valve Reactor 45-744 Recovery and Evacuation Valve Reactor 45-744 Cleaning and Rinse Valve Deleted Deleted Reactor 45-741 lot Water Rinse Supply Valve Reactor Condenser 45-741 Chera Wash Solution Supply Valve Reactor 45-741 Recovery Valve Reactor 45-741 Initiator Charge Valve Reactor 45-741 VCM Charge Valve Reactor 45-741 Water Charge Valve Deleted Reactor 45-741 Initiator Charge Line Sewer Valve Reactor 45-741 Slurry Dump Valve Reactor 45-741 Sewer Drain Valve Reactor 45-741 Chem Wash Solution Return Valve Deleted Reactor 45-741 Evacuation Valve Reactor 45-741 Initiator Charge Valve Reactor 45-742 Hot Water Rinse Supply Valve Reactor 45-742 Evacuation Valve Reactor 45-742 Chem Wash Solution Supply Valve Reactor 45-742 Recovery Valve Reactor 45-742 Initiator Charge Valve Reactor 45-742 VCM Charge Valve Reactor 45-742 Water Charge Valve Deleted Reactor 45-742 Slurry Dump Valve ABD00286908 A 1-3 ( APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Control Valves (Continued) CV-773 Reactor 45-742 Chem Wash Solution Return Valve CV-774 Reactor 45-742 Sewer Drain V.alve CV-775 Deleted CV-776 Reactor 45-742 Initiator Charge Valve CV-777 Reactor 45-742 Initiator Charge Line Sewer Valve CV-778 Reactor 45-743 Hot Water Rinse Supply Valve CV-779 CV-780 Reactor 45-743 Evacuation Valve Reactor 45-743 Chem Wash Solution Supply Valve CV-78I Reactor 45-743 Recovery Valve CV-782 Reactor 45-743 Initiator Charge Valve CV-783 Reactor 45-743 VCM Charge Valve CV-784 Reactor 45-743 Water Charge Valve CV-785 Deleted CV-786 CV-787 Reactor 45-743 Slurry Dump Valve Reactor 45-743 Chem Wash Solution Return Valve CV-788 Reactor 45-743 Sewer Drain Valve CV-789 Deleted ( CV-790 Reactor 45-743 Initiator Charge Valve CV-791 Reactor 45-743 Initiator Charge Line Sewer Valve CV-792 Reactor 45-744 Hot Water Rinse Supply Valve CV-793 Reactor 45-744 Evacuatioi Valve CV-794 Reactor 45-744 Chem Wash Solution Supply Valve CV-795 Reactor 45-744 Initiator Charge Valve CV-796 Reactor 45-744 VCM Charge Valve CV-797 Reactor 45-744 Water Charge Valve CV-798 Deleted CV-799 Reactor 45-744 Slurry Dump Valve CV-800 Reactor 45-744 Chem Wash Solution Return Valve CV-801 Reactor 45-744 Sewer Drain Vlave CV-802 Deleted CV-803 Reactor 45-744 Initiator Charge Valve CV-804 Reactor 45-744 Initiator Charge Line Sewer Valve CV-805 Reactor 45-744 Recovery Valve CV-806 Colloid Charge Puny 72-884 Discharge Valve CV-807 Deleted CV-808 Cold Water Addition Valve for Swirl CV-809 Cold Water Addition Valve for Charge CV-810 Recovery Vacuum Pump 72-901 Suction V*lve CV-811 Recovery Vacuum Pump 72-901 Discharge Valve CV-812 Recovery Vacuum Pump 72-901 Seal Water Supply Valve CV-8I3 .Recovery Vacuum Pump 72-901 Mechanical Seal Water Supply Valve CV-814 Reactor Jacket Eductor EE-701 Steam Valve c ABD00286909 1-3 APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Pressure Instruments (Continued) PSL-718 PSL-719 PR-720 PAH-720 PR-721 PAH-721 PR-722 PAH-722 PR-723 PAH-723 PI-724 PIC-725 PIC-726 PSL-727 PDS-728 PCI-729 PC1-7.J0 PCi-731 PSL-732 PAL-732 PCi-733 PCi-734 PCI-735 PSL-737A and B PAL-737 PSL-738 PAL-738 PCi-739 PSL-740 PAL-740 PCi-741 PA-742 Reactor 45-743 Pressure Switch (Prevents charge before evacuation) Reactor 45-744 Pressure Switch (Prevents charge before evacuation) Reactor 45-741 Pressure Recorder Reactor 45-741 High Pressure Alarm Reactor 45-742 Pressure Recorder Reactor 45-742 High Pressure Alarm Reactor 45-743 Pressure Recorder Reactor 45-743 High Pressure Alarm Reactor 45-744 Pressure Recorder Reactor 45-744 High Pressure Alarm Reactor Recovery Pressure Indicator Recovery Knockout Drum 45-760 Inlet Pressure Controller VCM Bleed Stream to Recovery System Pressure Controller Recovery Compressors 72-903, 72-904, and 72-905 Suction Low Pressure Switch Recovery Vacuum Pumps 72-901 and 72-902 Suction and Re covery Compressors 72-903, 72-904, and 72-905 Discharge Differential Pressure Switch Hydroquinone Storage Tank 45-765 Nitrogen Pressure Regulator Deleted Mechanical Seal Purge Water Surge Drum 45-759 Nitrogen Supply Pressure Regulator High Pressure Service Water System Low Pressure Switch High Pressure Service Water System Low Pressure Alarm Deleted Deleted Deleted Mechanical Seal Water System Low Pressure Switches Mechanical Seal Water System Low Pressure Alarm Seal Oil Pressure Unit 95-299 Discharge Low Pressure Switch Seal Oil Pressure Unit 95-299 Discharge Low Pressure Alarm Seal Oil Pressure Unit 95-299 Nitrogen Supply Pressure Regulator Seal Oil Pressure Unit 95-300 Discharge Low Pressure Switch Seal Oil Pressure Unit 95-300 Discharge Low Pressure Alarm Seal Oil Pressure Unit 95-300 Nitrogen Supply Pressure Regulator Deleted ABD00286910 1-3 APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Pressure Instruments (Continued) PCi-743 PCi-744 PCi-745 PCi-746 PCi-747 PCi-748 PCi-749 PAH-750 PAH-751 PCI-752 PAL-753 PCi-754 PCi-755 PCi-756 PCI-757 PSL-758 PIC-759 PAH-760 PI-760 PS-761 PSL-762 PAL-763 Breathing Air Station Supply Pressure Regulator (Reactors, Ground Level) Breathing Air Station Supply Pressure Regulator (Reactors, Second Level) Breathing Air Station Supply Pressure Regulator (Recovery Building, First Floor) Breathing Air Station Supply Pressure Regulator (Recovery Building, Second Floor) Breathing Air Station Supply Pressure Regulator (Charge Area) Deleted Deleted Initiator Injection Pot 45-750 High Pressure Alarm Seal Oil Supply High Pressure Alarm Breathing Air Station Supply (Reactors, Third Level) Emergency NO Short Stop Bottles Low Pressure Alarm PA-713 NO Supply Pressure Regulator to Reactor 45-741 PA-714 NO Supply Pressure Regulator to Reactor 45-742 PA-715 NO Supply Pressure Regulator to Reactor 45-743 PA-716 NO Supply Pressure Regulator to Reactor 45-744 High Pressure Service Water Low Pressure Switch Blowdown Tank 45-319 Pressure Controller Blowdown Tank 45-319 High Pressure Alarm Blowdown Tank 45-319 Pressure Indicator Deleted Blowdown Tank 45-319 Stripping Steam Low Pressure Switch Reactor Area Instrument Air Low Pressure Alarm Rupture Discs RD-701 RD-702 RD-703 RD-704 RD-705 RD-706 RD-707 RD-708 RD-709 RD-710 RD-711 RD-712 RD-713 RD-714 Reactor 45-741 Rupture Disc Reactor 45-742 Rupture Disc Reactor 45-743 Rupture Disc Reactor 45-744 Rupture Disc Reactor Condenser 55-328 Rupture Disc Reactor Condenser 55-329 Rupture Disc Reactor Condenser 55-330 Rupture Disc Reactor Condenser 55-331 Rupture Disc Reactor 45-741 First of Double Rupture Discs Reactor 45-742 First of Double Rupture Discs Reactor 45-743 First of Double Rupture Discs Reactor 45-744 First of Double Rupture Discs Reactor 45-741 Second of Double Rupture Discs Reactor 45-742 Second of Double Rupture Discs ABD00286911 1-3 A c APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Rupture Discs (Continued) RD-715 RD-716 RD-717 RD-718 RD-7I9 RD-720 RD-721 RD-722 RD-723 RD-724 RD-725 RD-726 RD-727 RD-728 RD-729 RD-730 RD-731 RD-732 RD-733 RD-734 RD-735 RD-736 RD-737 RD-738 RD-739 RD-740 RD-74I RD-742 RD-743 RD-744 RD-745 to RD-759 RD-760 RD-761 RD-762 RD-763 RD-764 RD-765 RD-766 RD-767 Reactor 45-743 Second of Double Rupture Discs Reactor 45-744 Second of Double Rupture Discs Fre9h VCM Storage Tank 45-745 Rupture Disc Recovered VCM Storage Tank 89-520 Rupture Disc Recovered VCM Storage Tank 45-317 Rupture Disc Dele ted Deleted Deleted Deleted Deleted Deleted Recovery Knockout Drum 45-760 Rupture Disc Recovery Knockout Drum 45-761 Rupture Disc Initiator Injection Pot 45-750 Rupture Disc Deleted Dele ted Recovery Vacuum Pump 72-901 Inlet Rupture Disc Recovery Vacuum Pump 72-902 Inlet Rupture Disc Deleted Deleted Seal Water Separator 45-762 Rupture Disc Seal Water Separator 45-763 Rupture Diic Deleted Deleted Recovered VCM Condenser 55-337 VCM Outlet Rupture Disc Recovered VCM Condenser 55-338 VCM Outlet Rupture Disc Recovered VCM Collect Tank 45-764 Rupture Disc Deleted Deleted Blowdown Tank 45-319 Rupture Disc Deleted Recovered VCM Collect Tank 45-764 Inlet Line Rupture Disc Deleted Deleted Deleted Deleted Slurry Dump Line Rupture Disc Cleaning Solution Strainer 64-734 Inlet Piping Rupture Disc Deleted Safety-Relief Valves SV-701 C SV-702 SV-703 Reactor 45-741 Relief Valve Reactor 45-742 Relief Valve Reactor 45-743 Relief Valve ABD00286912 A 1-3 APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Safety-Relief Valves (Continued) SV-704 SV-705 SV-706 SV-707 SV-708 SV-709 SV-7I0 SV-711 SV-712 SV-713 SV-714 SV-715 SV-716 SV-717 SV-718 SV-719 SV-720 SV-721 SV-722 SV-723 SV-724 SV-725 SV-726 SV-727 SV-728 SV-729 SV-730 SV-731 SV-732 SV-733 SV-734 SV-735 SV-736 SV-737 SV-738 SV-739 SV-740 SV-741 SV-742 SV-743 Reactor 45-744 Relief Valve Reactor Condenser 55-328 Relief Valve Reactor Condenser 55-329 Relief Valve Reactor Condenser 55-330 Relief Valve Reactor Condenser 55-331 Relief Valve Reactor 45-741 Jacket Relief Valve Reactor 45-742 Jacket Relief Valve Reactor 45-743 Jacket Relief Valve Reactor 45-744 Jacket Relief Valve Hot Water Preheater 55-332 Relief Valve Deleted Deleted Deleted Freeh VCM Storage Tank 45-745 Relief Valve Recovered VCM Storage Tank 89-520 Relief Valve Recovered VCM Storage Tank 45-317 Relief Valve VCM Charge Pumps 72-875 and 72-876 Suction Piping Relief Valve Recovered VCM Charge Pumps 72-877 and 72-878 Suction Piping Relief Valve Recovered VCM Charge Filter 64-719 Relief Valve Recovered VCM Charge Pumps 72-877 and 72-878 Discharge Piping Relief Valve VCM Charge Filter 64-718 Relief Valve VCM Charge Line Relief Valve (Down Stream of VCM Charge Totalizers FQIC-701A and B) Recovery Knockout Drum 45-760 Relief Valve Recovery Knockout Drum 45-761 Relief Valve Deleted Water Recirculation Cooler 55-334 Relief Valve Deleted Recovery Vacuum Pump 72-901 Inlet Relief Valve Recovery Vacuum Pump 72-902 Inlet Relief Valve Hydroquinone Storage Tank 45-765 Relief Valve Hydroquinone Injection Pump 72-895 Discharge Relief Valve Seal Water Separator 45-762 Relief Valve Seal Water Separator 45-763 Relief Valve Seal Water Filter 64-731 Relief Valve Seal Water Filter 64-732 Relief Valve Recovered VCM Condenser 55-337 VCM Outlet Relief Valve Recovered VCM Condenser 55-338 VCM Outlet Relief Valve Recovered VCM Collect Tank 45-764 Relief Valve Cleaning Solution Heater (Tubes) 55-339 Relief Valve Mechanical Seal Purge Water Surge Drum 45-759 Relief Valve ABD00286913 1-3 A APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Safety-Relief Valves (Continued) SV-744 SV-745 SV-746 SV-747 SV-748 SV-749 SV-750 SV-751 SV-752 SV-753 SV-754 SV-755 SV-756 SV-757 SV-758 SV-759 SV-760 SV-761 SV-762 SV-763 SV-764 SV-765 SV-766 SV-767 SV-768 Blowdown Tank 45-319 Relief Valve Breathing Air Station Supply Piping Relief Valve (Reactors, Ground Level) Breathing Air Station Supply Piping Relief Valve (Reactors, Ground Level) Breathing Air Station Supply Piping Relief Valve (Recovery Building First Floor) Breathing Air Station Supply Piping Relief Valve (Recovery Building Second Floor) Breathing Air Station Supply Piping Relief Valve (Charge Area) AMS Short Stop Charge Pot 45-755 Relief Valve AMS Short Stop Charge Pot 45-756 Relief Valve AMS Short Stop Charge Pot 45-757 Relief Valve AMS Short Stop Charge Pot 45-758 Relief Valve Reactor 45-741 Steam Stripping Line Relief Valve Reactor 45-742 Steam Stripping Line Relief Valve Reactor 45-743 Steam Stripping Line Relief Valve Reactor 45-744 Steam Stripping Line Relief Valve Deleted Deleted Recovered VCM Collect Tank 45 764 Inlet Line Relief Valve Recovered VCM Transfer Pumps 12-893 and 72-894 Discharge Relief Valve Recovered VCM Storage Tanks 89-520 and 45-317 Inlet Line Relief Valve VCM Charge Pumps 72-875 and 72-876 Discharge Relief Valve Breathing Air Station Supply Piping Relief Valve (Reactors, Third Level) Cleaning Solution Filter 64-734 Relief Valve Deleted VCM Charge Filter 64-742 Relief Valve Instrument Air Capacity Tank 45-301 Relief Valve Temperature Gauges TG-701 TG-702 TG-703 TC-704 TG-705 TG-706 TG-707 TG-708 Hot Water Preheater 55-332 Outlet Temperature Gauge Recovered VCM Storage Tank 89-520 Tanperature Gauge Recovered VCM Storage Tank 45-317 Temperature Gauge Colloid Makeup Tank 45-751 Temperature Gauge Colloid Storage Tank 45-752 Temperature Gauge Colloid Charge Tank 45-753 Temperature Gauge Reactor Jacket 45-741 Cooling Water Return Temperature Gauge Reactor Condenser 55-328 Cooling Water Return Tempera ture Gauge ABD00286914 1-3 A ( APPENDIX B V INSTURMENT LIST - CONTINUED Item No. Service Temperature Gauges (Continued) TG-709 TG-710 TG-7I1 TG-712 TG-713 TG-714 TG-715 TG-7I6 TG-717 c TG-718 TG-719 TG-720 TG-721 TG-722 TG-723 TG-724 TG-725 TG-726 TG-727 TG-728 TG-729 TG-730 TG-731 TG-732 TG-733 \ Reactor Jacket 45-742 Cooling Water Return Temperature Gauge Reactor Condenser 55-329 Cooling Water Return Tempera ture Gauge Reactor Jacket 45-743 Cooling Water Return Temperature Gauge Reactor Condenser 55-330 Cooling Water Return Temperature Gauge Reactor Jacket 45-744 Cooling Water Return Temperature Gauge Reactor Condenser 55-331 Cooling Water Return Temperature Gauge Water Recirculation Cooler 55-334 Outlet Temperature Gauge Deleted Water Recirculation Cooler 55-334 Cooling Water Return Temperature Gauge W?ter Recirculation Cooler 55-334 Inlet Temperature Gauge Seal Water Cooler 55-335 Cooling Water Return Temperature Gauge Seal Water Separator 45-762 Seal Water Cutlet Temperature Gauge Deleted Seal Water Cooler 55-336 Cooling Water Return Temperature Gauge Seal Water Separator 45-763 Seal Water Outlet Temperature Gauge Recovered VCM Condenser 55-337 Cooling Water Return Temperature Gauge Recovered VCM Condenser 55-337 VCM Outlet Temperature Gauge Deleted Recovered VCM Condenser 55-338 Cooling Water Return Temperature Gauge Recovered VCM Condenser 55-338 VCM Outlet Temperature Gauge Deleted Cleaning Solution Tank 45-767 Temperature Gauge Seal Oil Return Temperature Gauge Seal Oil Pressure Unit 95-299 Cooling Water Return Temperature Gauge Seal Oil Pressure Unit 95-300 Cooling Water Return Temperature Gauge ABD00286915 I-3 k APPENDIX B INSTRUMENT LIST - CONTINUED Item No Service Temperature Gauges (Continued) TG-734 TG-735 TG-736 TG-737 TG-738 TG-739 TG-740 Seal Oil Supply Temperature Gauge Colloid Makeup Tank Jacket 45-751 Cooling Water Return Temperature Gauge Fresh VCM Storage Tank 45-745 Temperature Gauge Process Water Temperature Gauge Hot Water Tank 45-748 Temperature Gauge Initiator Charge Pot 45-750 Temperature Gauge Blowdown Tank 45-319 Temperature Gauge Temperature Instruments TIC-701 TIC-702 TRC-703 TR-704 TSH-704 TSL-704 TI-705 TIRC-706 TAH-706 TIRC-707 TAH-707 TIRC-/08 TAH-708 TIRC-709 TAH-709 TIRC-710 TIRC-711 TIRC-712 TIRC-713 TR-714 TAH-715 TIC-716 TIC-717 TIC-718 TAH-719 ' TAH-720 TW-721 TW-722 Hot Water Tank 45-748 Temperature Controller Hot Water Preheater 55-332 Discharge Temperature Controller Charge Water Temperature Controller Colloid Makeup Tank 45-751 Temperature Recorder Colloid Makeup Tank 45-751 High Temperature Switch Colloid Makeup Tank 45-751 Low Temperature Switch VCM Charge Temperature Indicator Reactor 45-741 Polymerization Temperature Controller Reactor 45-741 High Temperature Alarm Reactor 45-742 Polymerization Temperature Controller Reactor 45-742 High Temperature Alarm Reactor 45-743 Polymerization Temperature Controller Reactor 45-743 High Temperature Alarm Reactor 45-744 Polymerization Temperature Controller Reactor 45-744 High Temperature Alarm Reactor 45-741 Steam Stripping Temperature Controller Reactor 45-742 Steam Stripping Temperature Controller Reactor 45-743 Steam Stripping Temperature Controller Reactor 45-744 Steam Stripping Temperature Controller Reactor Multipoint Temperature Recorder (For all Four Reactors) Recovery Compressors 72-903, 72-904, and 72-905 Discharge High Temperature Alarm Seal Water Cooler 55-335 Outlet Temperature Controller Seal Water Cooler 55-336 Outlet Temperature Controller Cleaning Solution Heater 55-339 Outlet Temperature Controller Seal Oil Pressure Units 95-299 or 95-300 Discharge High Temperature Alarm Initiator Injection Pot 45-750 High Temperature Alarm Cleaning Solution Heater 55-339 Steam Inlet Thermowell Cleaning Solution Heater 55-339 Solution Inlet Thermowell ABD00286916 !-3 A APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Temperature Instruments (Continued) TW-723 TW-724 TW-725 TR-726 TW-727 TW-728 TW-729 TIC-730 TW-731 TW-732 TW-733 TW-734 Deleted Cleaning Solution Heater 55-339 Solution Outlet Thermowell VCM Charge Filters 64-718 and 64-742 Outlet Piping Thermowell Recovery System Multipoint Temperature Recorder Water Recirculation Cooler 55-334 Cooling Water Supply Thermowell Seal Water Cooler 55-335 Cooling Water Supply Thermowell Recovered VCM Condenser 55-337 Cooling Water Supply Thermowell Blowdown Tank 45-319 Temperature Controller Reactor 45-741 Cooling Water Return Thermowell Reactor 45-742 Cooling Water Return Thermowell Reactor 45-743 Cooling Water Return Thermowell Reactor 45-744 Cooling Water Return Thermowell Amperage Instruments 11-200 IR-200 IAH-200 IAL-200 Reactor Agitator 51-110 Motor Amperage Indicator Reactor Agitator SI-110 Motor Amperage Recorder Reactor Agitator 51-110 Motor Amperage High Alarm Reactor Agitator 51-110 Motor Amerpage Low Alarm Item No. Control Valves CV-200 CV-201 CV-202 CV-203 CV-204 CV-205 CV-206 CV-207 CV-208 CV-209 CV-210 CV-2II CV-213 CV-214 CV-215 CV-216 CV-217 CV-218 CV-219 CV-220 CV-221 CV-222 CV-223 CV-224 CV-225 CV-226 CV-227 CV-228 CV-891 CV-892 CV-893 CV-894 CV-895 CV-896 CV-897 Flow Instruments FQIC- 701A and B FSL-701A and B ABD00286917 1-3 A APPENDIX B INSTRUMENT LIST - CONTINUED Service Reactor 4S-781 Main Dump Valve Reactor 45-781 VCM Charge Valve Reactor 45-781 Slurry Dump Valve Reactor 45-781 Chem Wash Return Valve Reactor 45-781 Hot Water Charge Valve Reactor 45-781 Sewer drain Valve Reactor 45-781 Steam Stripping Valve Reactor 45-781 Steam Stripping Valve Reactor 45-781 Colloid Charge Valve Reactor 45-781 Initiator Charge Valve Reactor 45-781 Resin Sampling Valve Reactor Jacket Educator EE-201 Steam Valve Reactor 45-781 Chem Wash Supply Valve Reactor 45-781 Rinse Supply Valve Reactor Condenser 55-358 Cleaning and Rinse Valve Reactor 45-781 Cleaning and Rinse Valve Reactor 45-781 Evacuation Valve Reactor 45-781 Recovery Valve Reactor 45-781 Recovery and Evacuation Valve Reactor Condenser 55-358 Inert Vent Valve Reactor 45-781 Vent Valve Evacuation Ejector First Stage Steam Valve Evacuation Ejector Second.Stage Steam Valve Evacuation Header Valve to EE-200 Reactor 45-781 VCM Charge Valve Evacuation Header Valve to EE-705 Reactor 45-781 AMS Emergency Kill Valve Reactor 45-781 AMS Emergency Kill Valve Steam Valve for Blowdown Tank 45-319 Pressure Regulation Water Drain Valve from Recovered VCM Storage Tank 89-520 to the Blowdown Tank 45-319 Water Drain Valve from Recovered VCM Storage Tank 45-317 to the Blowdown Tank 45-319 VCM Recovery Valve for Blowdown Tank 45-319 VCM Recovery Valve for VCM Storage Tank 45-745, 89-520, and 45-317 Instrument Air Supply Valve to Reactors 45-741, 45-742, 45-743, 45-744, and 45-781 Hot Water Rinse Header Valve to Reactors 45-741, 45-742, 45-743, 45-744, and 45-781 VCM Charge Totalizers VCM Charge Low Flow Switches ABD00286918 1-3 APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Flow Instruments (Cont.) Service FAL-701 FQIC-702 FQIC-704 FQIC-705 FQIC-706 FI-707 FR-708 FQI-708 FIC-708 FIRC-710 FIRC-711 FIRC-712 FIRC-713 FI-714 FAL-714 FI-715 FAL-7I5 FI-716 FAL-716 FI-717 FAL-717 FI-718 FQI-203 FIRC-201 FI-200 FI-202 FI-205 OF-206 RO-207 VCM Charge Low Flow Alarm Recovered VCM Charge Totalizer Hot Water Charge Totalizer Colloid Charge Totalizer Colloid Makeup Tank 45-751 Makeup Water Flow Totalizer Deleted Reactor Steam Stripping Flow Recorder Reactors Steam Stripping Flow Totalizer Reactor Steam Stripping Flow Controller Reactor 45-741 Cooling Water Flow Controller Reactor 45-742 Cooling Water Flow Controller Reactor 45-743 Cooling Water Flow Controller Reactor 45-744 Cooling Water Flow Controller Reactor Agitator 51-101 Inboard Seal Water Flush Rotameter Reactor Agitator 51-101 Seal Water Low Flow Alarm Reactor Agitator 51-102 Inboard Seal Water Flush Rotameter Reactor Agitator 51-101 Seal Water Low Flow Alarm Reactor Agitator 51-103 Inboard Seal Water Flush Rotameter Reactor Agitator 51-103 Seal Water Low Flow Alarm Reactor Agitator 51-104 Inboard Seal Water Flush Rotameter Reactor Agitator 51-104 Seal Water Low Flow Alarm Reactor 45-741 Spray Nozzle Flush Rotameter Reactor 45-781 Initiator Injection Pot 45-778 Flow Totalizer Reactor 45-781 Cooling Water Flow Controller Reactor Agitator 51-110 Lip Seal Flush Rotameter Reactor 45-781 Spray Nozzle Flush Rotameter Reactor Agitator 51-110 Mechanical Seal Oil Supply Rotameter Reactor Condenser 55-358 Cooling Water Supply Orifice Reactor 45-781 Inert Vent Restriction Orifice ABD00286919 1-3 APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Flow Instruments (Continued) FI-719 FI-720 FI-721 FI-722 FI-723 FI-724 FI-725 FI-726 FI-727 FI-728 FI-729 FI-730 FI-731 FI-732 FI-733 FI-734 FI-735 FI-736 FI-737 FIC-738 FIC-739 FIC-740 FI-741 FI-742 FIC-743 FI-744 FI-745 FI-746 FI-747 FI-748 FCi-749 Reactor 45-742 Spray Nozzle Flush Rotameter Reactor 45-743 Spray Nozzle Flush Rotameter Reactor 45-744 Spray Nozzle Flush Rotameter Deleted Deleted Deleted Deleted Recovery Knockout Drum Level Controller LC-716 Water Flush Rotameter Recovery Knockout Drum Level Controller LC-718 Water Flush Rotameter Recovery Vacuum Pump 72-901 Double Mechanical Seal Water Rotameter Recovery Vacuum Pump 72-901 Inboard Flush Water Rotameter Recovery Vacuum Pump 72-902 Double Mechanical Seal Water Rotameter Recovery Vacuum Pump 72-902 Inboard Flush Water Rotameter Rocovery Compressor 72-903 Double Mechanical Seal Water Rotameter Deleted Recovery Compressor 72-904 Double Mechanical Seal Water Rotameter Deleted Recovery Compressor 72-905 Double Mechanical Seal Water Rotameter Deleted Recovery Vacuum Pump 72-901 and Recovery Compressor 72-903 Seal Water Flov Controller Recovery Vacuum Pump 72-902 and Recovery Compressor 72-904 Seal Water Flov Controller Recovery Compressor 72-905 Seal Water Flow Controller Seal Water Separator Level Controller LC-720 Flush Water Rotameter Seal Water Separator Level Controller LC-722 Flush Water Rotameter Deleted Recovered VCM to Recovery Knockout Drum 45-760 Bullseye Deleted Deleted Slurry Dump to Slurry Strainer FD-717 Bullseye Deleted Reactor Agitator 51-101 Mechanical Seal Oil Supply Flow Regulator ABD00286920 1-3 APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Flow Instruments (Continued) FCi-750 FC1-751 FC1-752 FI-753 FI-754 FI-755 FI-756 FQI-757 RO-758 OF-759 OF-760 OF-761 OF-762 FI-763 FI-764 FI-765 FI-766 FI-767 FI-768 FI-769 FI-770 RO-771 RO-772 fcO-773 RO-774 Reactor Agitator 51-102 Mechanical Seal Oil Supply Flow Regulator Reactor Agitator 51-103 Mechanical Seal Oil Supply Flow Regulator Reactor Agitator 51-104 Mechanical Seal Oil Supply Flow Regulator Reactor Agitator 51-101 Mechanical Seal Oil Supply Rotameter Reactor Agitator 51-102 Mechanical Seal Oil Supply Rotameter Reactor Agitator 51-103 Mechanical Seal Oil Supply Rotameter Reactor Agitator 51-104 Mechanical Seal Oil Supply Rotameter Hot Water Charge Totalizer Colloid Makeup Water Supply Restriction Orifice Reactor 45-741 Cooling Water System Orifice Flanges Reactor 45-742 Cooling Water System Orifice Flanges Reactor 45-743 Cooling Water System Orifice Flanges Reactor 45-744 Cooling Water System Orifice Flanges Slurry Transfer Pump 72-896 Inboard Seal Flush Water Rotameter Slurry Transfer Pump 72-897 Inboard Seal Flush Water Rotameter Deleted Deleted VCM Charge Pump 72-875 Double Mechanical Seal Water Rotameter VCM Charge Pump 72-876 Double Mechanical Seal Water Rotameter Recovered VCM Charge Pump 72-877 Double Mechanical Seal Rotameter Recovered VCM Charge Pump 72-878 Double Mechanical Seal Rotameter VCM Charge Pump 72-875 Double Mechanical Seal Water Back Pressure Restriction Orifice VCM Charge Pump 72-876 Double Mechanical Seal Water Back Pressure Restriction Orifice Recovered VCM Charge Pump 72-877 Mechanical Seal Water Back Pressure Restriction Orifice Recovered VCM Charge Pump 72-878 Mechanical Seal Water Back Pressure Restriction Orifice ABD00286921 APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Flow Instruments (Continued) FI-775 FI-776 FI-777 FI-778 FI-779 RO-780 RO-781 RO-782 RO-783 RO-784 RO-785 RO-786 FI-787 FI-788 FI-789 Water Recirculation Pump 72-889 Inboard Seal Flush Water Rotameter Deleted Water Recirculation Pump 72-890 Inboard Seal Flush Water Rotameter Seal Water Pump 72-891 Inboard Seal Flush Water Rotameter Seal Water Pump 72-892 Inboard Seal Flush Water Rotameter Recovery Vacuum Pump 72-901 Double Mechanical Seal Water Back Pressure Restriction Orifice Recovery Vacuum Pump 72-902 Double Mechanical Seal Water Back Pressure Restriction Orifice Recovery Compressor 72-903 Double Mechanical Seal Water Back Pressure Restriction Orifice Recovery Compressor 72-904 Double Mechanical Seal Water Back Pressure Restriction Orifice Recovery Compressor 72-905 Double Mechanical Seal Water Back Pressure Restriction Orifice Recovered VCM Transfer Pump 72-893 Mechanical Seal Water Back Pressure Restriction Orifice Recovered VCM Transfei Pump 72-894 Mechanical Seal Witer Back Pressure Restriction Orifice Recovered VCM Transfer Pump 72-893 Mechanical Seal Water Rotameter Recovered VCM Transfer Pump 72-894 Mechanical Seal Water Rotameter Recovery Vacuum Pump 72-901 Inboard Flush Water Rotameter FI-790 FI-791 FI-792 FI-793 FI-794 FI-795 FI-796 FI-797 FI-798 Recovery Vacuum Pump 72-901 Double Mechanical Seal Water Rotameter Recovery Vacuum Pump 72-902 Inboard Flush Water Rotameter Recovery Vacuum Pump 72-902 Double Mechanical Seal Water Rotameter Deleted Recovery Compressor 72-903 Double Mechanical Seal Water Rotameter Deleted Recovery Compressor 72-904 Double Mechanical Seal Water Rotameter Deleted Recovery Compressor 72-905 Double Mechanical Seal Water Rotameter 1-3 A ABD00286922 APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Flow Instruments (Continued) RO-799 RO-800 RO-801 RO-802 RO-803 FI-804 FI-805 FI-806 FI-807 FI-808 FI-809 FI-810 FQI-811 RO-812 RO-813 FI-814 FI-815 RO-816 Recovery Vacuum Pump 72-901 Double Mechanical Seal Water Back Pressure Restriction Orifice Recovery Vacuum Pump 72-902 Double Mechanical Seal Water Back Pressure R'estriction Orifice Recovery Compressor 72-903 Double Mechanical Seal Water Back Pressure Restriction Orifice Recovery Compressor 72-904 Double Mechanical Seal Water Back Pressure Restriction Orifice Recovery Compressor 72-905 Double Mechanical Seal Water Back Pressure Restriction Orifice AMS Short Stop Charge Pot 45-755 Water Flush Rotameter AMS Short Stop Charge Pot 45-756 Water Flush Rotameter AMS Short Stop Charge Pot 45-757 Water Flush Rotameter AMS Short Stop Charge Pot 45-758 Water Flush Rotameter Blowdown Tank 45-319 Level Cage Water Flush Rotameter Recovered VCM Sampling System Bullseye Recovered VCM Sampling System Bullseye Steam to Reactor Module Flow Totalizer Deleted * Deleted Blowdown Tank Pump 72-900 Double Mechanical Seal Water Rotameter Blowdown Tank Pump 72-900 Inboard Seal Water Flush Rotameter Blowdown Tank Pump 72-900 Double Mechanical Seal Water Back Pressure Restriction Orifice Level Gauges LG-701A, B, C, and D LG-702A, B, C and D LG-703A, B C and D LG-704A, B, C and D LG-705 LG-706A, B, and'C LG-707A, B and C LG-708 LG-709 LG-710 Fresh VCM Storage Tank 45-745 Level Gauge Recovered VCM Storage Tank 89-520 Level Gauge Recovered VCM Storage Tank 45-317 Level Gauge Hot Water Tank 45-748 Level Gauge Deleted Colloid Storage Tank 45-752 Level Gauge Colloid Charge Tank 45-753 Level Gauge Recovery Knockout Drum 45-760 Level Gauge Recovery Knockout Drum 45-761 Level Gauge Hydroquinone Storage Tank 45-765 Level Gauge ABD00286923 APPENDIX B INSTRUMENT LIST - CONTI NURD Item No. Service Level Gauges (Continued) LC-711 LG-712 LG-713 LG-714 LG-715 LG-716 LG-717 Seal Water Separator 45-762 Level Gauge Seal Water Separator 45-763 Level Gauge Recovered VCM Collect Tank 45-764 Level Gauge Seal Oil Storage Drum 45-754 Level Gauge Deleted Blowdown Tank 45-319 Level Gauge Mechanical Seal Purge Water Surge Drum 45-759 Level Gauge Level Instruments LI-701 LAH-701 LS-701A, B, C and D LA-702 LA-703 LI-704 LA-705 LA-706 LI-707 LA-708 LA-709 LAH-710 LI-711 LS-711A LA-711B, C, and D LA-712 LAH-713 LAH-714 LSL-715 LSH-716 LSL-717 LSH-718 LSL-719 LC-720 LAH-720 LAL-720 LA-721 LC-722 LAH-722 LAL-722 LA-723 LC-724 LIC-725 LAH-725 Fresh VCM Storage Tank 45-745 Level Indicator Fresh VCM Storage Tank 45-745 High Level Alarm Fresh VCM Storage Tank 45-745 Level Switches Deleted Deleted Recovered VCM Storage Tank 89-520 Level Indicator Deleted Deleted Recovered VCM Storage Tank 45-317 Level Indicator Deleted Deleted Colloid Makeup Tank 45-751 High Level Alarm Hot Water Tank 45-748 Level Indicator Deleted Hot Water Tank 45-748 Level Switches Deleted Colloid Storage Tank 45-752 High Level Alarm Colloid Charge Tank 45-753 High Level Alarm Colloid Charge Tank 45-753 Low Level Switch Recovery Knockout Drum 45-760 High Level Switch Recovery Knockout Drum 45-760 Low Level Switch Recovery Knockout Drum 45-761 High Level Switch Recovery Knockout Drum 45-761 Low Level Switch Seal Water Separator 45-762 Level Controller Seal Water Separator 45-762 High Level Alarm Seal Water Separator 45-762 Low Level Alarm Deleted Seal Water Separator 45-763 Level Controller Seal Water Separator 45-763 High Level Alarm Seal Water Separator 45-763 Low Level Alarm Deleted Recovered VCM Collect Tank 45-764 Level Controller Slurry Dump Tank 45-766 Level Controller Slurry Dump Tank 45-766 High Level Alarm 1-3 ABD00286924 Item No. Temperature Gauges TG-201 TG-202 APPENDIX B INSTRUMENT LIST - CONTINUED 1-3 Service Reactor 45-781 Jacket Cooling Water Return Temperature Reactor Condenser 55-358 Cooling Water Return Tempera ture Temperature Instruments TIRC-201 TAH-201 A 5 B TRC-202 TR-203 TW-205 Reactor 45-781 Polymerization Temperature Controller Reactor 45-781 High Temperature Alarms Reactor 45-781 Steam Stripping Temperature Controller Reactor Condenser 55-358 Temperature Recorder Reactor 45-781 Cooling Water Return Thermowell ABD00286925 1-3 Item No. Pressure Gauges PG-200 PG-202 PG-205 PG-206 PG-212 PG-213 PG-222 Pressure Instruments PS-205 PAH-206 A & B PR-206 PT-206 PI-211 PS-212 PCV-216 PCi- Rupture Disc RD-200 RD-201 RD-204 RD-206 RD-207 RD-208 RD-209 RD-210 RD-211 Safety-Relief Valves PSV-200 PSV-201 PSV-202 PSV-203 PSV-206 PSV-207 PSV-208 PSV-209 PSV-2I1 PSV-212 PSV-213 APPENDIX B INSTRUMENT LIST - CONTINUED Service Reactor 45-781 Pressure Gauge Initiator Charge Pot 45-784 Pressure Gauge Reactor Condenser 55-358 Pressure Gauge Reactor 45-781 Steam Stripping Pressure Gauge Reactor 45-781 VCM Charge Pressure Gauge Reactor 45-781 Nitric Oxide Pressure Gauge Steam Tracina Manifold Pressure Gauge Reactor 45-781 Pressure Switch (Prevents dump before recovery) Reactor 45-781 High Pressure Alarm Reactor 45-781 Pressure Recorder Reactor 45-781 Pressure Transmitter Reactor 45-781 Pressure Indicator (Manometer) Initiator Charge Pot Pressure Switch Steam Tracing Pressure Reducing Valve AMS Emergency Kill System Nitrogen Pressure Regulator Reactor 45-781 Rupture Disc Reactor Condenser 55-358 Rupture Disc Initiator Charge Pot 45-778 Rupture Disc Reactor 45-781 Rupture Disc Reactor 45-781 Rupture Disc Reactor 45-781 Rupture Disc Reactor 45-781 Rupture Disc AMS Emergency Kill Pot 45-786 Rupture Disc Reactor Condenser 55-358 Rupture Disc Reactor 45-781 Relief Valve Reactor Condenser 55-358 Relief Valve AMS Emergency Kill Pot 45-786 Relief Valve Reactor 45-781 VCM Charge Header Relief Valve Reactor 45-781 Relief Valve Reactor 45-781 Relief Valve Reactor 45-781 Relief Valve Reactor 45-781 Relief Valve Reactor Condenser 55-358 Shell Relief Valve Reactor 45-781 Jacket Relief Valve Reactord Condenser 55-358 Relief Valve ABD00286926 OPERATING MANUAL AMS EMERGENCY KILL SYSTEM ABERDEEN PVC PLANT September 1, 1981 FINAL ISSUE Work by: Richard v. neinng Senior Process Engineer Chemicals Division Phocess Engineering Department ABD00286927 (conoco) 1-3 Interoffice Communication To C. L. Miller, Aberdeen, Mississippi from R.D. Mel ling, Ponca City, Oklahoma Date September 1, 1981 Subject Emergency Kill System Operating Manual The final issue of the Emergency Kill System Operating Manual is attached. This issue incorporates comments and suggestions from the August 18 plant review meeting. [3. Richard D. Mel Iing Senior Process Engineer Chemicals Division Process Engineering Department ms Enc CC: RAF: SJV:PEM:JAD:MPB CRM:JAB:JLW:JHM File: A-20.3 A ABD00286928 A 1-3 TABLE OF CONTENTS OPERATING MANUAL AMS EMERGENCY KILL SYSTEM ABERDEEN PVC PLANT Page No. I. INTRODUCTION........................................................................................................................ 1 A. PURPOSE......................................................................... 1 B. OPERATOR RESPONSIBILITIES ............................................................................... 1 C. PROCESS INFORMATION ............................................................................................ I II. GENERAL PROCESSDESCRIPTION ..................................................................................... 3 III. SAFETY...................................................................................................................................... 5 IV. OPERATING PROCEDURES.......................................................................................................... 8 A. INJECTION PROCEDURES.................................................................................................. 8 B. ROUTINE OPERATION....................................................... 12 C. TESTING PROCEDURES..................................................................................................... 15 V. APPENDIX.................................................................. 17 VI. PS I DIAGRAMS................................................................................................................................ 26 ABD00286929 Page I INTRODUCTION A. Purpose The purpose of the Emergency Kill System is to increase the re liability and effectiveness of equipment and procedures used to safely and quickly stop the polymerization reaction in the reactors. Stopping the reaction prevents excessive pressure buildup which can cause emergency releases through the reactor relief valves. This system allows any or all reactors to be shut down in an orderly and safe manner. This manual describes the system and the operator's responsibilities for operating and maintaining the system. B. Operator Responsibilities The operator is responsible for producing quality products in a safe and efficient manner. He fulfills his responsibilities by knowing the following and passing a written exam: 1. Understanding how his equipment functions. 2. Understanding what role each piece of equipment plays in the process. 3. Keeping a close and regular check on equipment. k. Knowing how to spot malfunctions and correct them. 5. Keeping his area of responsibility safe and clean. 6. Keeping complete and accurate records. C. Process Information The polymerization reaction of VCM to form PVC gives off heat and accelerates as temperature increases. As the temperature increases, the reactor pressure also increases. It is -there fore necessary ro remove the heat of reaction with cooling ABD00286930 Page 2 A 1-3 INTRODUCTION (CONTINUED) C. Process Information (Continued) water in the reactor jacket and condenser. Reactor agitation is also required to maintain uniform reactor mixing and efficient heat removal. If reactor cooling and/or agitation is lost, the reaction must be stopped. Failure to do so would result in a runaway reaction with increasing temperature and pressure. The reac tor pressure could increase until the rupture disk/safety valve assemblies would vent the reactor contents to the atmosphere. The new Emergency Kill System provides the capability of in jecting up to 25 gallons of killing agent into each reactor either remotely from the control room or manually at the re actor top head platform. Killing agent can be injected into a reactor as soon as agitation is lost to take advantage of mixing caused by residual swirling motion. Maintaining cool ing water flow after loss of agitation will also help mixing by refluxing in addition to removing heat of reaction. ABD00286931 Rage 3 A 1-3 GENERAL PROCESS DESCRIPTION Refer to the attached P&l diagrams for the complete system layout for each reactor area. Emergency kill injection pots are provided at grade level for each reactor. All injection pots are to be maintained at 300 psig pressure using high pressure nitrogen cylinders. A separate nitro gen cylinder and spare are provided for each injection pot. Level gauges and pressure gauges are provided on each pot in addition to board-mounted low pressure alarms and low level Indicators. The A operator should check the appropriate Injection pot level and pressure before starting each reactor charge sequence. Killing agent can be injected into the reactor either remotely by the lead operator or locally by the A operator. Normally, the emergency kill system will be activated from the board to minimize time and maximize mixing. One switch for each reactor operates automatic double block valves at the reactor top head level. Placing the switch in automatic mode opens the valves and allows a low level switch in the injection pot to close the valves. Placing the switch in the momentary-contact manual mode also opens the valves but the valves close when the switch is released. Each injection pot low level switch also activates a local light at the manual injection point at the reactor top head level. The auto matic closure of the remote injection valves and the local low level indicator light are provided to prevent nitrogen from being injected into the reactor, blanketing the condenser and reducing coo ling efficiency. ABD00286932 Page k GENERAL PROCESS DESCRIPTION (CONTINUED) Emergency injection headers are provided at the reactor top head level in each reactor area. These headers will allow any injec tion pot to be used to kill any reactor in each area or to inject additional killing agent if needed. The procedure requires two hoses, one to connect an injection pot to the header, and one to connect the header to the reactor. Killing agent can then be in jected locally by the A operator or remotely by the lead operator. It should be noted that when the emergency injection header is used, the injection pot low level switch will neither automatically close the remote injection valves nor light the appropriate local indicator light. Caution should be taken to prevent charging nitro gen into the reactor. The remote injection automatic valves will be operated by nitrogen supplied by a high pressure nitrogen cylinder and spare. A boardmounted low pressure alarm is provided for each area to alert the board operator when the cylinder in use has dropped below 600 psig. A cylinder with less than 600 psig pressure does not contain enough nitrogen to operate the control valves and should be immediately changed out with a full cylinder. A 1-3 ABD00286933 Page 5 SAFETY The operation of the emergency kill system does not present any extremely hazardous situations. In fact, it's main purpose is to reduce the potential for having hazardous situations in the reactor area. However, some potential hazards are present and precautions should be taken to prevent serious incidents. A. The killing agent AMS has been in use for some time in the plant and the operators should already be familiar with the corresponding safety hazards and proper handling procedures. The attached vendor literature describes chemical properties and safe handling procedures. It should be emphasized that AMS is highly reactive in the presence of the peroxide ini tiators used in the plant. AMS AND INITIATOR SHOULD NEVER BE MIXED UNDER ANY CIRCUMSTANCES. B. The new AMS injection pots will be maintained at 300 psig by high pressure nitrogen cylinders. Due caution should be exer cised in the handling of nitrogen cylinders. Operators should avoid damaging the outlet valves on these cylinders. The AMS injection pots will contain AMS under 300 psig pressure, so proper safety precautions should be taken while working with or near these vessels. The injection pots must be depressurized before the block valves on the pot funnel or AMS fill line are opened. The nitrogen supply to a pot should be turned off at the pot prior to vent ing the pot. The pots should only be vented through the bleed valve on the pressure gauge/pressure switch piping on the top of the pots. POTS SHOULD NEVER BE VENTED THROUGH THE FUNNELS ON THE SIDE OF THE POTS. ABD00286934 1-3 Page 6 A III. SAFETY (CONTINUED) C. The rupture disk and relief valve assemblies for each injec tion pot are set to relieve at ^00 psig, the vessel design pressure. Since nitrogen bottle regulators occasionally leak through, a potential exists for overpressuring the injection pots and causing the rupture disk to burst. Even if the killing ! agent didn't spray out when the relief devices opened, it is probable the relief valve would not completely reseat and the nitrogen bottle would slowly depressure through the pot and relief valve to atmosphere. The outside operator should routinely check injection pot pressures to insure it is neither too low nor too high. D. The AMS killing agent is a volatile hydrocarbon, and thus fire and explosions are theoretica11y possible. Precautions should be taken to prevent spills and excessive accumulation of flam mable vapors. E. Since the injection pots are connected to the reactors, a poten tial exists for backing VCM into the pots. This poses no serious immediate problem since the AMS would kill any reaction that was occurring. However, it could present an exposure problem later when the injection pot is opened. The injection pots should be maintained at 300 psig pressure except when re fill ing. F. Finally, operators should keep in mind that this system will be used when the plant is in an upset condition, i.e., power failure, loss of cooling water, reactor runaway, etc. It is ABD00286935 1-3 Page 7 II!. SAFETY (CONTINUED) critical that this system must operate properly in such an emergency. System maintenance and operator familiarity with this system are equally important factors ensuring the dependability of this system. ABD00286936 1-3 Page 8 IV. OPERATING PROCEDURES A. Injection Procedures 1. The emergency kill system should be activated under the following circumstances: a. Extended Joss of cooling water to a reactor in poly merization mode. b. Extended loss of agitation to a reactor in polymeriza tion mode. When agitation is lost, it is Important to kill the reaction as soon as possible. The reactor contents will continue to swirl for about four minutes after agitator shutdown, and AMS injection during this period is much more effective. c. A runaway reaction with increasing temperature and pres sure which is not responding to small AMS Injections (short stop) from the initiator charge pot. d. Any other circumstance considered by the operator to represent a significant chance of over pressuring the reactor or affecting safe operation of the plant. 2. The emergency kill system must be activated If the reactor reaches the following pressures for the following products: a. 5305 with CTA 155 psig b. 5305 without CTA 165 psig c. A11 other products 145 psig 3. Lead Operator Duties a. The lead operator should remotely inject AMS into the polymerizing reactors which require killing by placing the appropriate hand switches in the AUTO mode. A ABD00286937 Page 9 1-3 A IV. OPERATING PROCEDURES (CONTINUED) A. Injection Procedures (Continued) 2. Lead Operator Duties (Continued) b. The lead operator should then check for confirmation of AMS Injection from the board-mounted low level indicat ing lights, and from the A operator via radio. In jection time should be about 30 seconds. The boardmounted injection pot low pressure alarms will normally be tripped during AMS injection. If the pressure and level alarms are not tripped, the automatic AMS injection line may be plugged requiring manual injection. c. After AMS injection, the lead operator should closely monitor the reactor temperature and pressure. If cool ing water has been lost, he should take steps to restore cooling as soon as possible. d. If additional killing is required, the momentary-contact manual switch can be used. Caution should be exercised to prevent nitrogen from entering the reactor and blanket ing the condenser. e. If excess nitrogen does enter the reactor, the condenser should be vented to the recovery system. 3 A Operator Duties a. The A operator is responsible for field-checking AMS injection to each of the reactors to be killed. He should confirm that the injection pot level is at the low level mark on the level gauge. Too high a level ABD00286938 Page 10 4 1-3 IV. OPERATING PROCEDURES (CONTINUED) A. Injection Procedures (Continued) 3* A Operator Duties (Continued) means not enough AMS was injected. No level may mean nitrogen has entered the reactor. b. The A operator should also check the pressures of the nitrogen cylinders used for AMS injection. Any cylinder with a pressure lower than 750 psig should be changed out to allow for a second AMS in ject i on. c. After checking the injection pot and nitrogen cylinders, the A operator should proceed to the reactor top level to confirm that the automatic injection valves are closed. If the valves are open, he should man ually block in the line and inform the lead operator that nitrogen has entered the reactor. It may be necessary to vent nitrogen to the recovery system to maintain reactor cooling. d. If the automatic injection system failed to work, the A operator should manually inject AMS to the re actor. He should open the manual double block injection valves, wait for the injection pot low level indicator light to light, then immediately close the double block valves. The valves should also be immediately closed if the line begins to vibrate from flowing nitrogen. ABD00286939 Page 11 A 1-3 1V. OPERATING PROCEDURES (CONTINUED) A. Injection Procedures (Continued) 3 A Operator Duties (Continued) e. If additional injection is required, the A operator should prepare the emergency injection header for use. This header is supplied to allow any injection pot to be used for any reactor. This is accomplished by connect ing one hose from a full and pressurized pot to the header and connecting a second hose from the header to the appropriate reactor. Injection can then proceed either locally or from the board. Caution should be exercized when using this header since the injection pot low level switches will not work correctly and nitrogen may enter the reactor. f. As soon as possible after injection, the A opera tor should refill the empty AMS pots and prepare for a second injection if needed. 1. Close the block valve on the nitrogen supply line at the pot. 2. Depressure the pot through the pressure gauge vent valve. 3. Refill the pot with AMS from a 55-gallon drum using the air operated drum pump supplied with the system. An alternate filling procedure is to manually pour AMS into the funnel on the side of the injection pot. ABD00286940 Page 12 IV. OPERATING PROCEDURES (CONTINUED) A. Injection Procedures (Continued) 3. A Operator. Duties (Continued) f. (Continued) 4. Block in the pot and repressure with nitrogen from the nitrogen bottles. g. Radio communication between the lead operator and the A operator should be maintained. The A operator should inform the lead operator how the system is operating and what is being done in the field. The lead operator should keep the A operator informed of reactor pres sures and any apparent need for additional AMS injec tion. B. Routine Operation 1. A reactor should not be charged unless its AMS injection system is in proper operating condition. It is the respon sibility of the A operator to check this in the field and notify the lead operator, prior to each reactor charge. The following items should be checked immediately before each charge: a. The AMS level in the injection pot should be at the full mark on the level glass. b. The pressure in the injection pot should be 300 psig. This should be checked both on the injection pot pressure guage and on the nitrogen cylinder regulator outlet pressure guage. ABD00286941 1-3 Page 13 A IV. OPERATING PROCEDURES (CONTINUED) B. Routine Operation (Continued) c. The block valve in the AMS line near the injection pot should be fully open. d. The block valve in the AMS line at the reactor top head level near the hose connection should be fully open. e. Both block valves on the manual AMS injection line should be fully closed. If any of the above conditions are not met, they should be corrected before the reactor is charged. 2. To insure proper operation of the system, the following items should be checked by the A operator at the beginning of each shift: a. The pressure of the nitrogen cylinders being used for AMS injection should be at least 1200 psig. Cylinders with lower pressures should be changed out with full cylinders. EMPTY BOTTLES ARE NOT TO BE LEFT IN THE BOTTLE RACKS. b. The pressure of the nitrogen cylinder being used to actuate the automatic AMS injection valves should be at least 600 psig. Cylinders with lower pressures should be changed out with full cylinders. The pres sure on the outlet of the regulator for this cylinder should be 100 psig. ABD00286942 a Page 1A IV. OPERATING PROCEDURES (CONTINUED) B. Routine Operation (Continued) , c. The pressure gauges between the double block valves on both the automatic and the manual injection lines should routinely be bled to 0 psig. If pressure sub sequently builds up on these guages, it indicates that one or both of the double block valves are leaking. Note: These gauges will have pressure on them after AMS injection. d. All spare nitrogen cylinders in the racks should be full, i.e., cylinder seals are intact. The above items are vital to the proper operation of the emergency kill system. If any of these conditions are not met, they should be immediately corrected. 3. Other items which should be checked on a routine basis are: a. The automatic AMS injection line reactor nozzles should be checked for plugging. This can be done while the reactor is being rinsed. Full port ball valves have been provided on this line so that a rod or long wire brush can be run through the line to knock out plugging. This line should be checked once a week when the system Is being tested. b. The manual AMS injection line reactor nozzles should also be checked for plugging on a weekly basis. This should be done in a manner similar to that used for checking the automatic injection line. 1-3 ABD00286943 Page 15 1-3 IV. OPERATING PROCEDURES (CONTINUED) C. Testing Procedures 1. The AMS injection system for each reactor will be tested weekly on a schedule set up by the process superintendent. Each system will be checked for line pluggage and valve operation. The testing procedure is outlined below: a. The A operator should perform a complete visual check of the system to be tested both at grade level and at the reactor top head level. b. He should then contact the lead operator on the radio and confirm that the reactor and Emergency Kill System are ready to be tested. c. He may then manually inject approximately one gallon of AMS to the reactor by opening the manual injec tion valves for approximately two seconds. d. After AMS has been injected manually, the A operator i should close the block valve near the hose connec tion and notify the lead operator that the automatic system is ready for testing. The lead operator may then remotely cycle the Injection valves using the momentary-contact MANUAL mode of the control valve hand switch. e. During automatic AMS injection testing, the A operator should be checking for proper operation of the system, i.e., control valves, actuators, and solenoids. ABD00286944 Page 16 1-3 IV, OPERATING PROCEDURES (CONTINUED) C. Testing Procedures (Continued) f. After automatic injection testing, the A operator should rod out the vertical sections of line at both reactor injection nozzles to confirm the nozzles are not plugged. 3. The following must be done following a test prior to charging the reactor: a. The pot should be refilled with AMS. b. The pot should be pressurized to 300 psig. c. The AMS injection nitrogen cylinder pressure should be checked (above 1200 psig). d. The pressure of the nitrogen cylinder used to supply instrument air to the automatic AMS injection control valves should be checked (above 600 psig). e. The manual block valve at the reactor top head level near the hose connection should be reopened. ABD00286945 V. APPENDIX ABD00286946 STORAGE AND IIANDTJNG OE ALPHA-METHYL STYRENE A Page I 8 1-3 Alpha-Methyl styrene Is usually stored and handled in steel equipment. It is also compatible with stainless steel, aluminum, and galvanized iron. Copper and copper alloys are not recommended for this service. This product lias a fairly low freezing point (about -TOT7) and low viscosity. Underground storage tanks and lines should be considered, as their use will prevent freezing in winter and keep the product cool in summer. Storage temperature should not exceed 100E. Storage under a nitrogen blanket is preferred; exclusion of air (oxygen) will reduce the chances of polymerization, peroxide formation, and fire. Piping can be of the materials listed above. A centrifugal pump is suggested for transfer service. "Teflon" is suitable for gaskets and packing. An inhibitor, para-tertiary butyl catechol (10-20 ppm), is used in alpha-methyl styrene to inhibit polymerization. If storage time is prolonged, the inhibitor concentration should be checked occasionally ami more inhibitor added, if needed. Alpha-Methyl styrene is a toxic chemical; contact with liquid or vapors should be avoided. ABD00286947 Of- M E T I! Y I. S T Y R E fl E Page 19 1-3 chemical NAME: SYHOHYMS: CHEMICAL FORMULA: CHEMICAL STRUCTURE: (X-Methy Is tyrene I sop ropenylbenzene, alpha-methyIstyrene, 2-phenylpropene, 1-methyl-1-phenylethylene c9h10 Appearance............................................................................................ Molecular weight................................................................................. fl atiurcabi 1 i ty limits, vol *, upper................................................. lower................................................. Flash point, open cup, C'C (Tag).................................................... closed cup, DC (Tag)................................................. Autoignition temperature in air, C............................................. Water-white liquid 113. IB 6.1 1.9 52 (126*0 44 (U2UF) 575 (1066F) Boi 1 ing point at 760 mm Hg, C...................................................... 165.A at 10 mm Hg, C........................................................... 48.5 Freezing point, C............................................................................. -23.2 V.-jpor pressure, mw Hg at 20C........................................................ 1.9 Solubility, wt l in water.................................................................. <0.1 (20C) water in.................................................................. <0.1 Specific gravity at 20/46C............................................... .............. 0.9106 Heat of vapori :e l icn at 1 atm, Btu/lb......................................... 140 Heat of combustion ot 25C, Btu/lb............................................. 17,748 Coefficient of expansion at 20C, vol/C................................... 0.00096 Viscosity at 20C, cps........................................................................ 0.94 Revised 3/15/76 ABD00286948 it ("(-Mi. inv! srvw:;it. |] ' .......: Page 20 Some significant reaction'; with {.he ir.o t'O common chemical'; are jriefly d i scuss t:d or iww: I-3 forms aKlehy(In', and peroxides i f exposed to air (oxygen)- Can be epoxidi zed and is attacked by strong oxidizing agents. \>sdrogena tion. - C<ni be hydrogenated ca laly tical ly in the presence or metals. The unsacurated vinyl group and the aromatic ring can both be hydrogenated under selec ts ve contii tions. r.alogenation Charac teris tic addition to the vinyl group and substitution on the aromatic ring can occur with halogens such as chlorine or bromine. These exothermic addition reactions generally require catalysts and/or elevated temperatures and are not considered hazardous if properly controlled. However, reaction with chlorine which occurs at ambient tem peratures can be violent in the presence of light. Accidental contact of CX-methy1 styrene with halogens or halogen-containing compounds must be prevented. Acjds. - Under special conditions, the aromatic ring may be attacked by concentrated nitric or sulfuric acids. These reactions must be carefully controlled to avoid hazardous consequences. Also, hazardous oxidation may occur by contact with concentrated nitric acid. He thoxyl a t ion - -'"^-Methylstyrene can be reacted under special condi tions with formaldehyde or CO-H^ in the presence of a catalyst to yield an aldehyde or alcohol. This reac tion is considered to be nonhazardous as it is un likely to occur accidentally. The above discussed reactions other than oxidation, halogenation, or.a polymer* ration are generally considered to be nonhazardous. However, when conducted in tin? plant or laboratory, all of the reactions of f/X-methy 1 styrene should be properly controlled to avoid hazardous consequences. Rfvised a/15/70 if the UCG customer wants to use rubber hoses for unloading tank lrucks, the recommended materials care Vifcm A or polyethylene lining! and steel or .TOA SS fittings. Both Uni royal and Goodyear manufacture^ rubber host:-, with a Vi ton A or polyethylene liner. . Other elastomers such as neoprene, butyl, buna-N, etc., are not recommended for handling AMS because they will be chemically attacked by the AMS. Another type of hose that can be used is 30A SS flexible metal hose, y?Je'f/# s?" a^. ABD00286949 / A-METHYL STYRENE TNi u (i luiunwr/ of imyli* exposure itudiqi <m cmiuujli. )hr; dni<: indicolo llie rcfntivq .l-.-yim j> lio.ui'd in lioiuUim.) tin; product. Utcrc'ii'inii tlnprocc of ho:ufd ore expreisoi! by lb, n; terms: xlitjhl, mueferute, cfcfuiilr, serious. Jl must lie remembered (fust results of Vipennn-nts on onimai'. eon not be nunitvictilly Jromioted to prcihohle humors response. Die Nu'.ioiijl Pi.wrucli Covn'l define* io*><'Xy o tKo (apathy of <i lubituncc to produce injury. Doiord it dm pr<,`joL/i.!y ihcn injury lit resuli from tfic botu.fbny or use of 1 f'r lubstnncc in the qvurtlijy, frequency ond manner fouCc'y Is only one factor important iq delermining tlsc id bpjerd in bundling o chi'micoi or in a propon'd ns-, riivdinf pi opi'i lies <jl 1)1 c ihrmicol logclhe* v.iih 1*1,on <jn(J Inquc'iuy of C'poiurc ore equally imporloot. Singh; sVin penr-truiian refers to a covered 24-hour 'Vin conicct with rite liquid ilu-mico). Single inbololicrs refers lo coniinuously breathing o CC'Wnn eo'iceniroiion of ehenucal >epo' for o specified period of lime. Primary irriloiipn refers to the slin response following uncovered sir in conloc'. A cov-.-red comoci con be expcc'od to hove o rnorc severe i-ffcci. Die lerm lien been odopted m n uniform expres sion of smyle do-.t- So * icily for compelling one chemical s.itli cinoiher. It refer* to that quomiiy of cl'cmiccsl v.hich i.lh 50 pur Ci'ni of exposed onimofs. for further unifornuiy. 11-.1111ititn-s on- e*pri'ssetf in grants or milliliters of (Isemicol per lilugrom of oniniol body weight. Cye injury refers to surface damage produced by contod of the rye will) tbe rheruicul. legal rcspnnsibdiiy is assumed only for iha fad that oil studies rnponed here, and oil opinions, oto llsoso of quobfied rxperts. Staple oral dose in rats: moderate hazard. 3 6.50 ml per kilogram of body weight. For comparison, isopropnnol has an LD^q of 5.84 grams/k-g. Single skin penetration in rabbits: slight hazard. 16.0 tnl/kg body weight killed 3 of 7 animals from a 24 hour covered exposure. This result auggests that ckin penetration in harmful amounts Is not apt to occur. Single inhalation by rats: slight hazard. Breathing vapors in a state approaching saturation in room air for 8 hours killed 2 of 6 animals. Skin irritation, rabbit belly: moderate hazard. The undiluted chemical coused redness of short duration on the tender skin of the robbit belly. Eye injury, rabbits: slight hazard. The undiluted chemical caused no irritation when an excess was instilled in the rabbit eyes. TYPED 5/24/77 For Further Information Writo To: industrial Medicine and Toxicology Department I i '' II ABD00286950 -- <rt >r> ' cS o (u ;> r. o o n iu ZJ Oo - 'I -: cr 4 Page 22 ;< I"3 ut t cc O M o O ,,- O NU U G Cl .-- C ft c a. o' ^ O EEgVij rn . . r.". <o o* -- 5* mcv w> mG''sQ'c*s--EScio O CM O o' CM "- o ro o i - *. k -- DO" u O' o M , c So 5 c oo il 12 b = ^ oGo _: c ^c 3 ' a h = * ci >K J W* Gc o. uo o O - j a; ; i o o >> -O *; o. *.3 5! o. w rz ?= OO G.VOV) V) -- *\> c TlO o o 0 i: ^ C :: r r t rr o v .^2 .o .V? u Hf^cl 2 U " M ~ f'?;? r u >>> > e3 >- o rZ Eo -- O <-> -- n r: >ET*'0O Eo Jo.- c -5- /> ru l- XI < UUl- O " c .is .3 I oL'io L: i ss i a i i o I | mo O cxi eg -- o n N O in OTM !{: V c; io n in o o io m m oto < o veg m SE| "" h i =w=t i" ~ Z: r, o g .. 9 - *Z %o >io V u'.x O i* O O * i v> s : 1 oi-io c c: c - o^ gC-> wrec>g* Ci ?s|s.e rf-M <o/rcmtOq O m ui rj o - eg o - o n cn 'I- .!*> eo j w> <- Q ex .s M!s 5 s u c: tj _ -v 12C ^3 OV OU *J JCCO I 5 ?xi vj WO>*>**8< . ti* o ,0 0Q , cij ^ Ci o OV f UJ O -1 l- .V o c; -i i/> o C fl fierj -" TJ J< ?o I t -- "o > O -7Z T-5 i; o <> -H fftt> >ex .!? o K '-" fc c rs u c: zi o cj e* -- o & l' -3 5--. O fc O ,`J * 2<X> -| - V4 <- <- o a o Hi wS _ O si__________a x= e-gf >. :-. 5>x fr 'ovi ` ZUi ^C.. ;c s: -- r*> i I O I I vn f-H U"> oo O ff> v <N# I! u u f: --.J " c-> o :> rw is< 'C O C. li o CM t : I O *> c< o ... (.) o * o in in (xi O CM -- < oo cm cm m .' o O <i* Vt :*. *o o a o c? .V ; -O o5 \Tt O cz oe^ CH o oo o o ci o r>i < 3 Xi < <` u t ; ; O 'O IMi .r. c; r. ct e* o _ 4J 'i: r . -? '.: ou g _C Sg5i - *S ir r. o '> w ^zr. ^ ^1 % |5 ^ R5 : * uu i; .S I ABD00286951 MA'IEHIAL SAFETY DATA SHEET t A i>i i n v*'i t by \) f of l, "l h .Ilf y *> ut%I.' * to f u r in Li> B OOK 4) P.ag.e 23 ,lC_3 I- M PRODUCT NAME: a/p/iaMETNYLSTYRENE CHEMICAL NAME. -- FORMULA: C I^CICH.^CH, CHEMICAL FAMILY: Arylj MOLECULAR WEIGHT: 118.18 SYNONYMS: bopfopenylbenzene; a methylstyrene; 2-phcnylpropene; 1- methyl -1-phony Icthylcne V BOILING POINT. 7BO mm. Hy > PHYSICAL DATA ' ii 10S.4C.{329.7`F.) j FREEZING POINT SPECIE 1C GCAVITY (H,0 1) VAPOR DENSITY (air = 1) PER CENT VOLATILES BY VOLUME APPEARANCE AND ODOR 0.9116 at 20/20C. 4.1 -100 VAPOR PRESSURE AT ?0C. SOLUBILITY IN WATER, % by wt. EVAPORATION RATE (Butyl Acetate 1) Colorless liquid; characteristic odor. -23.2 C. 1.9 mm. Hg 0.06 0.22 II. HAZARDOUS INGREDIENTS MATERIAL Methylstyrene (See Sections III through VIII) III. FIRE AND EXPLOSION HAZARD DATA flashpoint j 112V.. Tag closed cup astm d 56 1U.-SI methodls)! I 126F.. Tagopen cup ASTM D 1310 flammable limits in air. >:. by vuiumo LOWER 1.9 UPPER EXTINGUISHING ML 01A Use carbon dioxide or dry chemical lor small fires. Use foam (alcohol, polymer, or ordinary) for lanje fires. 6.1 SPECIAL FIRE FIGHTING PROCEDURES Self-contained breathing apparatus should be available to firemen. UNUSUAL F1H AND EXPLOSION HAZARDS EMERGENCY PHONE NUMBER 304/744-3487 tins mj-ntur is av.i.ijbN slays, niglm, weekends, and holidays. w,sjp.k'h C.'iWo Coiuoranu" uo*" ws i'` ' !* 0.111 roi'iJiiw-i tspo'.n a>e l.u iuai >l ouuvons cu'tsii'd a'C moso o! Qualified Ci>Cfts regarding ir,e rcsuds ot the tests 1,.,1 ,,, noi ro Ot .n .1 \/>w " 1 rv'esunuiron liw Union C.a'l>'ilt' Corooralion assun.es legal responsibility They arc oMcrco st'luly lor your consideration. u.v .mu sfi.i.cai>on .viy sir.*.- d i''*.' u n.i amt .nuinn.iiionmud be rtcicmoncd by H: user lobe .n .:cod3>H'o with applicable Federal. 5me. ano local lows amt rcguUiiont THRESHOLD LIMIT VALUF. EFECTSOF OVb'REXPOSURE ABD00286952 IV. HEALTH HAZARD DATA 100 ppm. -- not to bo exceeded. Value from ACGIH (1976) Page 24 . 1-3 Vapors cause irritation of eyes, nose, and throat. Headache, nausea, and vomiting may occur. Eyes ore irritated by the liquid. EMERGENCY AND FIRST AID PROCEDURES Remove to fresh air and call o physician. In case of contact, flush skin or eyes with plenty of water for at least 15 minutes. Call a physician for eyes. / STABILITY V:T REACTIVITY DATA CONDITIONS TO AVOID Avoid heat and open flame. INCOMPATIBILITY (materials to avoid) Avoid contamination with oxygen, strong acids, chlorine. 1A2ARDOUS -^`COMPOSITION PRODUCTS Burning can produce carbon monoxide and/or carbon dioxide. IAZAROOUS POLYMERIZATION May Occur Will not Occur V-- CONDITIONS TO AVOID Avoid contamination with peroxides, strong mincraf acids, metaf halides, and similar polymerization catalysts. Para-tertiary butyl catechol is used as inhibitor; maintain its concentration at 10-20 ppm. ;teps to be taken F MATERIAL IS RELEASED )M SPILLED VASTE DISPOSAL METHOD Wear suitable protective equipment. Collect for disposal. Toxic to fish; avoid discharge to natural waters. See Section VIII. Incinerate in a furnace where permitted under appropriate Federal. State, and local regulations. Absorb on paper, evaporate on glass dish, then burn paper. ABD00286953 / I'.: VIL RESPIRATORY PROTECTION (specify 1 v |>cl | | j '' ' j LOCAL EXHAUGl VENTILATION I-------- --------- "" j MECHANICAL I (general) I I I PROTECTIVE GLOVES SPECIAL PROTECTION INFORMATION - ' Air-supplied mask m conf.ncd areas May be needed special OTHER Rubber EYE | PROTECT ION Page 25 1-3 TT:'r . . 4 l : 4j Monogoggles Of HI' R PROTECTIVE LOlilPMENT Eye bath and safety shower A PRECAUTIONARY LABELING VIII. ; SPECIAL PRECAUTIONS a/p/w-METHYlSTYRENE DANGER! CAUSES BURNS C0M8USTIBLE Do not get in eyes, on skin, on clothing. Keep away from heat and open flame. Avoid breathing vapor. Keep container dosed. Use with adequate ventilation. Wash thoroughly after handling. FI R$T A ID: In case of contact, immediately flush eyes or skin with plenty of water (or at least 15 minutes while removing contaminated clothing and shoes. Call a physician, Wash clothing before reuse. FOR INDUSTRY USE ONLY OTHER HANDLING AND Si GRACE CONDITIONS Store under a nitrogen atmosphere; forms acetophenone, aldehydes, and peroxides if stored under air. Dangerous concentrations of peroxides are not expected to form in normal storage and handling, but storage under a nitrogen atmosphere is recommended. This chemical floats on water, is resistant to rapid biodegradation, and is highly toxic to aquatic life. Spills should not be flushed to sewers or waterways. The preferred mc.thod of disposal is to dilute with a non reactive solvent or fuel stream and incjneratc. Ground 3reas can be covered with sand or sawdust after most of the spilled material lias been removed. Absorbing materials, after use on small spills, should be disposed of in an approved chemical landfill or by burning. CAUTION; Do not use clays, micas, or acidic materials which might catalyze polymerization, as absorbents. Personnel engaged in disposal work should avoid contact of wastes by wearing proper protective clothing. ABD00286954 <31 ABD00286955 1-3 A j - WHCACIOR C C C H '/l d ` ABD00286956 CJLU3J fJ 'J C J D 'IT ABD00286957 ABD00286958 rt ABD00286959 n & ,<AC*sny 402U4- O ABD00286960 t*s ABD00286961 ABD00286962 ABD00286963 ABD00286964 APPENDIX B INSTRUMENT LIST - CONTINUED I tern No. Service Control Valves (Continued) CV-815 CV-816 CV-817 CV-818 CV-8I9 CV-820 CV-821 CV-822 CV-823 CV-824 CV-825 CV-826 CV-827 CV-828 CV-829 CV-830 CV-831 CV-832 CV-833 CV-834 CV-835 CV-836 CV-837 CV-838 CV-839 CV-840 CV-841 CV-842 CV-843 CV-844 CV-845 CV-846 CV-847 CV-848 CV-849 CV-850 CV-851 Reactor Jacket Eductor EE-702 Steam Valve Reactor Jacket Eductor EE-703 Steam Valve Reactor Jacket Eductor EE-704 Steam Valve Fresh VCM Storage Tank 45-745 Inlet Valve Hot Water Preheater 55-332 Water Inlet Valve Recovery Vacuum Pump 72-902 Suction Valve Recovery Vacuum Pump 72-902 Discharge Valve Recovery Vacuum Pump 72-902 Seal Water Supply Valve Recovery Vacuum Pump 72-902 Mechanical Seal Water Supply Valve Deleted Deleted Deleted Deleted Colloid Makeup Tank 45-751 Process Water Valve Hot Water Charge Pump 72-880 Discharge Valve Recovery Compressor 72-903 Suction Valve Recovery Compressor 72-903 Discharge Valve Recovery Compressor 72-903 Seal Water Supply Valve Recovery Compressor 72-903 Mechanical Seal Water Supply Valve Deleted Water Recirculation Cooler 55-334 Cooling Water Return Valve Recovery Knockout Drum 45-760 Water Recirculation Inlet Valve Recovery Knockout Drum 45-760 Water Blowdown Valve Recovery Knockout Drum 45-761 Water Recirculation Inlet Valve Recovery Knockout Drum 45-761^Water Blowdown Valve Recovery Compressor 72-904 Suction Valve Recovery Compressor 72-904 Discharge Valve Recovery Compressor 72-904 Seal Water Supply Valve Recovery Compressor '72-904 Mechanical Seal Water Supply Valve Recovered VCM Condensers 55-337 and 55-338 Cooling Water Return Valve Deleted Deleted Reactor Evacuation Ejector EE-706 First Stage Steam Valve Reactor Evacuation Ejector EE-706 Second Stage Steam Valve Hot Water Charge Pump 72-879 Discharge Valve Recovery Compressor 72-905 Suction Valve Recovery Compressor 72-905 Discharge Valve ABD00286965 1-3 APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Control Valves (Continued) CV-852 CV-853 CV-854 CV-855 CV-856 CV-857 CV-858 CV-859 CV-860 CV-861 CV-862 CV-863 CV-864 CV-865 CV-866 CV-867 CV-868 CV-869 CV-870 CV-:J71 CV-872 CV-873 CV-874 CV-875 CV-876 CV-877 CV-878 CV-879 CV-880 CV-881 CV-882 CV-883 CV-884 CV-885 CV-886 CV-887 CV-888 CV-889 CV-890 Recovery Compressor 72-905 Seal Water Supply Valve Recovery Compressor 72-905 Mechanical Seal Water Supply Valve Recovery Vacuum Pumps 72-901 and 72-902 Bypass Valve Recovery Compressors 72-903, 72-904, and 72-905 Bypass Valve Colloid Makeup Tank 45-751 Water Inlet Valve Colloid Makeup Tank 45-751 Colloid Outlet Valve Colloid Recirculation Valve to Colloid Storage Tank 45-752 Colloid Circulation Pump 72-882 Inlet Valve Deleted Colloid Charge Tank 45-753 Inlet Valve Deleted Dump System Water Rinse Valve Slurry Transfer Pump 72-896 Mechanical Seal Water Valve Deleted Slurry Transfer Pump 72-897 Mechanical Seal Water Valve Deleted Deleted Deleted Deleted Cleaning Solution Heater 55-339 Inlet Valve Cleaning Solution Storage Tank 45-767 Top Inlet Valve Cleaning Solution Pumps 72-898 and 72-899 Suction Valve Reactor Cleaning Solution Return Valve to Cleaning Solution Tank 45-767 Seal Oil Pressure Unit 95-300 Seal Oil Return Valve Seal Oil Pressure Unit 95-299 Seal Oil Return Valve Seal Oil Pressure Unit 95-300 Seal Oil Supply Valve Seal Oil Pressure Unit 95-299 Seal Oil Supply Valve Initiator Injection Pot 45-750 Service Water Inlet Valve Blowdown Tank Pump 72-900 Discharge Valve 45-741 Emergency NO Short Stop Three-Way Valve 45-742 Emergency NO Short Stop Three-Way Valve 45-743 Emergency NO Short Stop Three-Way Valve 45-744 Emergency NO Short Stop Three-Way Valve 45-741 Emergency NO Short Stop Valve 45-742 Emergency NO Short Stop Valve 45-743 Emergency NO Short Stop Valve 45-744 Emergency NO Short Stop Valve Recovery Seal Water and VCM Diverter Valve Recovery Seal Water and VCM Diverter Valve ABD00286966 & 1-3 APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Level Instruments (Continued) LIC-726 LA-726 LAH-727 LI-728 LAL-729 LSL-730 LAL-730 LSL-731 LAL-73I LC-732 LAL-733 LSH-734 LA-735 LA-736 LA-737 LA-738 LAL-739 LAH-740 LSL-741 Deleted Deleted Cleaning Solution Tank 45-767 High Level Alarm Cleaning Solution Tank 45-767 Level Indicator Cleaning Solution Tank 45-767 Low Level Alarm Seal Oil Pressure Unit 95-299 Reservoir Low Level Switch Seal Oil Pressure Unit 95-299 Reservoir Low Level Alarm Seal Oil Pressure Unit 95-300 Reservoir Low Level Switch Seal Oil Pressure Unit 95-300 Reservoir Low Level Alarm Deleted Hydroquinone Storage Tank 45-765 Low Level Alarm Cleaning Solution Tank 45-767 High Level Switch Deleted Deleted Deleted Deleted Colloid Makeup Tank 45-751 Low Level Alarm Blowdown Tank 45-319 High Level Alarm Blowdown Tank 45-319 Low Level Switch Pressure Gauges PG-701 PG-702 PG-703 PC-704 PG-705 PG-706 PG-707 PG-708 PG-709 PG-710 PG-711 PG-712 PG-713 PG-714 PA-715 PG-716 PG-717 PG-718 VCM Charge Pump 72-875 Discharge Pressure Gauge VCM Charge Pump 72-876 Discharge Pressure Gauge Recovered VCM Charge Pump 72-877 Discharge Pressure Gauge Recovered VCM Charge Pump 72-878 Discharge Pressure Gauge Fresh VCM Storage Tank 45-745 Pressure Gauge Recovered VCM Storage Tank 89-520 Pressure Gauge Recovered VCM Storage Tank 45-317 Pressure Gauge Deleted Deleted Deleted Deleted Process Water Filter 64-720 Inlet Pressure Gauge Process Water Filter 64-720 Outlet Pressure Gauge Hot Water Charge Pump 72-879 Discharge Pressure Gauge Hot Water Charge Pump 72-880 Discharge Pressure Gauge Deleted Deleted Deleted ABD00286967 A 1-3 APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Pressure Gauges (Continued) PG-7I9 PG-720 PG-721 PG-722 PG-723 PG-724 PG-725 PG-726 PG-727 PG-728 PG-729 PG-730 PG-731 PG-732 PG-733 PG-734 PG-735 PG-736 PG-737 PG-738 PG-739 PG-740 PG-741 PG-742 PG-743 PG-744 PC-745 PG-746 PG-747 PG-748 PG-749 PG-750 PG-751 PG-752 PG-753 PG-754 PG-755 PG-756 PG-757 PG-758 PG-759 Colloid Makeup Water Filter 64-721 Inlet Pressure Gauge Colloid Makeup Water Filter 64-721 Outlet Pressure Gauge Colloid Batch Transfer Pump 72-881 Discharge Pressure Gauge Colloid Transfer Filter 64-722 Outlet Pressure Gauge Colloid Circulation Pump 72-882 Discharge Pressure Gauge Colloid Transfer Filter 64-723 Outlet Pressure Gauge Colloid Charge Pump 72-883 Discharge Pressure Gauge Colloid Charge Pump 72-884 Discharge Pressure Gauge Steam Stripping Header Pressure Gauge Reactor 45-741 Steam Stripping Line Pressure Gauge Deleted Reactor Condenser 55-328 Pressure Gauge Reactor Agitator 51-101 Seal Oil Return Pressure Gauge Reactor 45-742 Steam Stripping Line Pressure Gauge Reactor Condenser 55-329 Pressure Gauge Deleted Reactor Agitator 51-102 Seal Oil Return Pressure Gauge Reactor 45-743 Steam Stripping Line Pressure Gauge Reactor Condenser 55-330 Pressure Gauge Deleted Reactor Agitator 51-103 Seal Oil Return Pressure Gauge Reactor 45-744 Steam Stripping Line Pressure Gauge Reactor Condenser 55-331 Pressure Gauge Deleted Reactor Agitator 51-104 Seal Oil Return Pressure Gauge Recovery Knockout Drum 45-760 Pressure Gauge Water Recirculation Pump 72-889 Discharge Pressure Gauge Deleted Recovered VCM Bleed Back Line Pressure Gauge Recovery Knockout Drum 45-761 Pressure Gauge Water Recirculation Pump 72-890 Discharge Pressure Gauge Deleted Recovery Vacuum Pump 72-901 Inlet Pressure Gauge Recovery Compressors 72-904 or 72-905 Suction Pressure Gauge Recovery Compressors 72-903, 72-904, and 72-905 Discharge Pressure Gauge Seal Water Separator 45-762 Pressure Gauge Seal Water Separator 45-763 Pressure Gauge Seal Water Pump 72-891 Discharge Pressure Gauge Seal Water Filter 64-731 Outlet Pressure Gauge Seal Water Pump 72-892 Discharge Pressure Gauge Seal Water Filter 64-732 Outlet Pressure Gauge ABD00286968 1-3 APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Pressure Gauges (Continued) PG-760 PG-761 PC-762 PG-763 PG-764 PG-765 PG-766 PG-767 PG-768 PG-769 PG-770 PG-771 PG-772 PG-773 PG-774 PG-775 PG-776 PG-777 PG-778 PG-779 PG-780 PG-781 PG-782 PG-783 PG-784 PG-785 PG-786 PG-787 PG-788 PG-789 PG-790 PG-79I PG-792 PG-793 PG-794 PG-795 PG-796 PG-797 Recovered VCM Collect Tank 45-764 Pressure Gauge Recovered VCM Transfer Pumps 72-893 and 72-894 Discharge Pressure Gauge Recovery Knockout Drum 45-760 VCM Inlet Line Pressure Gauge Hydroquinone Storage Tank 45-765 Pressure Gauge Hydroquinone Injection Pump 72-895 Discharge Pressure Gauge Slurry Transfer Pump 72-896 Discharge Pressure Gauge Deleted Slurry Transfer Pump 72-897 Discharge Pressure Gauge Deleted Caustic Solution Pump 72-898 Discharge Pressure Gauge Caustic Solution Pump 72-899 Discharge Pressure Gauge Cleaning Solution Heater 55-339 Outlet- Pressure Gauge Service Water Filter 64-724 Inlet Pressure Gauge Service Water Filter 64-724 Outlet Pressure Gauge Service Water Pumps 72-885 and 72-886 Discharge Pressure Gauge Mechanical Seal Purge Water Pumps 72-887 and 72-888 Discharge Pressure Gauge AMS Short Stop Charge Pot 41-755 Outlet Pressure Gauge AMS Short Stop Charge Pot 45-756 Outlet Pressure Gauge AMS Short Stop Charge Pot 45-757 Outlet Pressure Gauge AMS Short Stop Charge Pot 45-758 Outlet Pressure Gauge Deleted Blowdown Tank Pump 72-900 Discharge Pressure Gauge Blowdown Tank 45-319 Pressure Gauge Seal Oil Return Header Pressure Gauge Seal Oil Pressure Unit 95-299 Pressure Gauge Seal Oil Pressure Unit 95-300 Pressure Gauge Seal Oil Supply Header Pressure Gauge Deleted Deleted Deleted Deleted Reactor Ejector Cyclone Separator 45-768 Outlet Pressure Gauge Breathing Air Header Pressure Gauge Recovery Vacuum Pump 72-902 Suction Pressure Gauge Deleted Initiator Injection Pot 45-750 Pressure Gauge Seal Oil Return Filter 64-727 Outlet Pressure Gauge Seal Oil Return Filter 64-728 Outlet Pressure Gauge ABD00286969 A 1-3 APPENDIX B INSTRUMENT LIST - CONTINUED Item No. Service Pressure Gauges (Continued) PC-798 PG-799 PG-800 PG-801 PG-802 PG-803 PC-804 PG-805 PG-806 PG-807 PG-808 PG-809 PG-810 PG-811 Emergency NO Short Stop Bottle PA-713 Pressure Gauge Emergency No Short Stop Bottle PA-714 Pressure Gauge Emergency NO Short Stop Bottle PA-715 Pressure Gauge Emergency NO Short Stop Bottle PA-716 Pressure Gauge VCM Charge Filter 64-718 and 64-742 Discharge Pressure Gauge Recovered VCM Charge Filter 64-719 Discharge Pressure Gauge Reactor 45-741 Resin Sampling System Pressure Gauge Reactor 45-742 Resin Sampling System Pressure Gauge Reactor 45-743 Resin Sampling System Pressure Gauge Reactor 45-744 Resin Sampling System Pressure Gauge Instrument Air Capacity Tank 45-301 Pressure Gauge Mechanical Seal Purge Water Surge Drum 45-759 Pressure Gauge High Pressure Service Water Header Pressure Gauge (Downstream of PCi-817) Mechanical Seal Purge Water Header Pressure Gauge (Downstream of PCi-818) Pressure Instruments PA-701 PCi-702 PSH-703 PCi-704 PI-705 PCi-706 PSL-707 PCi-708 PCi-709 PCi-710 PCi-711 PSL-712 PSL-713 PSL-714 PSL-715 PSL-716 PSL-717 Deleted Deleted Initiator Injection Pot 45-750 High Pressure Switch Recovered VCM Storage Tanks 89-520 and 45-317 Inert Vent Back Pressure Regulator Reactor Evacuation Header Pressure Indicator Steam Stripping Header Steam Supply Back Pressure Regulator Steam Stripping Header Low Pressure Switch Deleted Deleted Deleted Deleted Reactor 45-741 Pressure Switch (Prevents dump before recovery) Reactor 45-742 Pressure Switch (Prevents dump before recovery) Reactor 45-743 Pressure Switch (Prevents dump before recovery) Reactor 45-744 Pressure Switch (Prevents dump before recovery) Reactor 45-741 Pressure Switch (Prevents charge before evacuation) Reactor 45-742 Pressure Switch (Prevents charge before evacuation)