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1-2 A TABLE OF CONTENTS OPERATING MANUAL OLD UNIT PVC REACTORS ABERDEEN, MISSISSIPPI I. INTRODUCTION Page No. A. Operator Responsibilities ---------------------------------------------------------------------B. Process Information----------------------------------------------------------------------------------- * 3 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 5 5 14 15 16 17 III. OPERATING PROCEDURES A. Reactor Evacuation B. Reactor Precharge 18 >?1b.0001132435 - nr : r 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 P. Housekeeping------------------------------------------------------------------------------------- p no. 24 28 36 44 46 50 51 55 57 58 67 68 VAB.0001132436 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 1-2 VAB.0001132437 r Operating Manual Old Unit PVC Reactors Page 3 1-2 A 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. * i 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 VAB.0001132438 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 pumped tanks in the Dryer Room for drying. Dump requires about 25 minutes for rD -37r0m0, tD-'i -4A0nn0, tD\ -5i~ 0nn0, and, D-s6n0n0 and 35 minutes for D-700V.AB.0001132439 1-2 A Operating Manual Old Unit PVC Reactors Page 5 11. 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. Th is portion of the cycle requires about 10 minutes. B. 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. VAB.0001132440 1-2 Operating Manual Old Unit PVC Reactors Page 6 II. 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. * 2. After evacuation is completed, the interlock selector switch is moved to the "charge" position. If the following precharge con-- tions are met, the charge sequence is ready to begin: VAB.0001132441 --^ -M*' l - Operating Manual Old Unit PVC Reactors Page 7 II. GENERAL PROCESS DESCRIPTION (Cont.) 1-2 * B. 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. VAB.0001132442 Operating Manual Old Unit PVC Reactors Page 8 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 "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 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. p <i --I--**-- ! r. !P.T ^. ri". di -4 K 'RV'r - VAB.0001132443 Operating Manual Old Unit PVC Reactors Page 9 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 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 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 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. VAB.0001132444 Operating Manual Old Unit PVC Reactors Page 10 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. * D. 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. VAB.0001132445 t m: . h- 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 VAB.0001132446 r 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. h 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 compressors, a VCM backpressure system is used. This is done to prevent VAB.0001132447 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 VAB.0001132448 f Operating Manual Old Unit PVC Reactors Page 14 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 VAB.0001132449 r Operating Manual Old Unit PVC Reactors Pace 15 1-2 II. 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 p 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 190F. 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. VAB.0001132450 *t * ^ h i-.l : , 1-2 Operating Manual Old Unit PVC Reactors Page 16 II. GENERAL PROCESS DESCRIPTION (CONTINUED) r 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 T 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 VAB.0001132451 1-2 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. VAB.0001132452 Operating Manual Old Unit PVC Reactors Page 17 1-2 * II. 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. VAB.0001132453 r -f Operating Manual Old Unit PVC Reactors Page 18 1-2 K 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 MAM 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: ^ __ , .. - I'. M' - +m r m *! j frlf L--4 - . VAB.0001132454 Operating Manual Old Unit PVC Reactors Page 19 1-2 b III. OPERATING PROCEDURES (CONTINUED) A. Reactor Evacuation (Continued) a. For D-300, D-400, D-500 and D-600, the operator will open v&lves 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 "A" 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 h 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. VAB.0001132455 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 MAM 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 "A" 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. VAB.0001132456 Operating Manual Old Unit PVC Reactors Page 21 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. b 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 150pt e. Check to see that all valves on the reactor are closed.VAB.0001132457 Operating Manual Old Unit PVC Reactors Page 22 1-2 * 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. "A" 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 F - ..H.r VAB.0001132458 Operating Manual Old Unit PVC Reactors Page 23 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 VAB.0001132459 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 cnarged by dialing recipe number on the recipe selector on the board. g. Push meter reset button, which resets all charge meters. VAB.0001132460 Operating Manual Old Unit PVC Reactors Page 25 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 4 reactor, close the VCM charge valve. * VAB.0001132461 Operating Manual Old Unit PVC Reactors Page 26 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. * VAB.0001132462 Operating Manual Old Unit PVC Reactors Page 27 t 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 p charge pump start. p f. At set point No. 3 on the water meter, "B,f 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. r VAB.0001132463 r | ,1 Operating Manual Old Unit PVC Reactors Page 28 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 Close. i. At set point No. 5 on the water meters MA" 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 i reactor cycle is mainly accomplished by accurate instrumentation. The primary area of responsibility for the * t ' *F . I-1 VAB.0001132464 Operating Manual Old Unit PVC Reactors Page 29 1-2 K 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 reactorvl hour after reaching 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 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. VAB.0001132465 Operating Manual Old PVC Reactors Page 30 1-2 III. OPERATING PROCEDURES (Cont.) d. (continued) If either of the above conditions are observed, have the "An operator take samples every fifteen minutes until the shift supervisor makes the decision as to what 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 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 r valve. Set the controller on 35 PSIG and put it back in automati VAB.0001132466 Operating Manual Old Unit PVC Reactors Page 31 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. VAB.0001132467 * Operating Manual Old Unit PVC Reactors Page 32 1-2 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 dangermis level. If outage is prolonged, the pressure will build. If this situation occurs, fo.llow the procedure in Section III.C.3, which outlines action to be taken during emergency shutdown (such as during a power failure). 2. "An 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. VAB.0001132468 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 1-2 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: i 5305 (Normal) - 1% gallons AMS 5305 (CTA) - 3^ gal. AMS/3^ gal. Naugard 5425 - 1^ gal. AMS/2^ Naugard initially and again at 170F 5465 - 2^ gal. AMS/3^ gal. Naugard initially and again at 170 r. 5385 - V'i gal. AMS/3^ 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. VAB.0001132469 1-2 Operating Manual Old Unit PVC Reactors Page 34 III. OPERATING PROCEDURES (Cont.) D. Polymerization (Cont.) 3. Emergency Shutdown (Cont.) Resin Maximum Temperature 5385, 5425, 5465 142F 5305 (CTA) 155F 5305 (Normal) 162F Maximum Pressure 145 PSIG 155 PSIG 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 orange- colored 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) (1) 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. VAB.0001132470 Operating Manual Old Unit PVC Reactors Page 35 1-2 III. OPERATING PROCEDURES (Cont.) 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 VAB.0001132471 Operating Manual Old Unit PVC Reactors Page 36 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 Belief valve vent system will allow the reactor to vent off and on thru* the relief valves to control the A 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. VAB.0001132472 h Operating Manual Old Unit PVC Reactors Page 37 1-2 k III. OPERATING PROCEDURES (CONTINUED) E. Recovery and Steam W 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. 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. VAB.0001132473 r Operating Manual Old Unit PVC Reactors Page 38 1-2 A III. OPERATING PROCEDURES (CONTINUED) E. Recovery and Steam Stripping (Continued) 1. "A" Operator Duties (Continued) b. Check the blowdown tank level and pressure. Level and pressure must 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 mid--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. VAB.0001132474 Operating Manual Old Unit PVC Reactors Page 39 1-2 A III. OPERATING PROCEDURES (CONTINUED) E. Recovery and Steam Stripping (Continued) .2 Lead Operator Duties 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 will automatically 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. VAB.0001132475 Operating Manual Old Unit PVC Reactors Page 40 1-2 A III. OPERATING PROCEDURES (CONTINUED) E. Recovery and Steam Stripping (Continued) .2 Lead Operator Duties (Continued) f. (4) When the reactor is at 215 F, 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. 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. VAB.0001132476 Operating Manual Old Unit PVC Reactors Page 41 1-2 A III. 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. VAB.0001132477 Operating Manual Old Unit PVC Reactors Page 42 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. VAB.0001132478 . Operating Manual Old Unit PVC Reactors Page 43 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. VAB.0001132479 Operating Manual Old Unit PVC Reactors Page 44 1-2 A 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. 1. MAM 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 VAB.0001132480 Operating Manual Old Unit PVC Reactors Page 45 1-2 h 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 VAB.0001132481 Operating Manual Old Unit PVC Reactors Page 46 1-2 A 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 VAB.0001132482 Operating Manual Old Unit PVC Reactors Page 47 1-2 III. OPERATING PROCEDURES (CONTINUED) G. 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. VAB.0001132483 Operating Manual Old Unit PVC Reactors Page 48 1-2 A III. OPERATING PROCEDURES (CONTINUED) G. Chem Mash and Rinse (Continued) Procedure (Continued) 6. The Reactor"A" operator willcheck to see that the cleaning solution heater temperature controller is set at 190 F. 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. VAB.0001132484 'T 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. m VAB.0001132485 t r k* Operating Manual Old Unit PVC Reactors Page 50 1-2 k 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 must 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. VAB.0001132486 Operating Manual Old Unit PVC Reactors 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 VAB.0001132487 Operating Manual Old Unit PVC Reactors Page 52 1-2 h 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,f operator aids in colloid solution transfer by notifying the lead operator when the colloid charge tank needs to be refilled. VAB.0001132488 Operating Manual Old Unit PVC Reactors Page 53 1-2 * III. OPERATING PROCEDURES (CONTINUED) X, Colloid Solution Makeup (Continued) 2. "A11 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 "AM 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 \ 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 f VAB.0001132489 Operating Manual Old Unit PVC Reactors Page 54 1-2 III. OPERATING PROCEDURES (CONTINUED) I. Colloid Solution Makeup (Continued) 2. "A11 Operator Duties (Continued) 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, 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. VAB.0001132490 ' < "It* V Operating Manual Old Unit PVC Reactors Page 55 1-2 * 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 r ' = - .| . -..u-1-|. I A * - VAB.0001132491 1-2 Operating Manual Old Unit PVC Reactors Page 56 III. 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. VAB.0001132492 r Operating Manual Old Unit PVC Reactors Page 57 1-2 b III. OPERATING PROCEDURES (CONTINUED) 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 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-1 operator to transfer new caustic to the tank. Note: Notify the utility operator that the cleaning solution has been dumped to the sewer. VAB.0001132493 - Operating Manual Old Unit PVC Reactors Page 58 1-2 * 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 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. 'rl r a- 'i* VAB.0001132494 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. VAB.0001132495 '* - < Operating Manual Old Unit PVC Reactors Page 60 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). VAB.0001132496 Operating Manual Old Unit PVC Reactors 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 VAB.0001132497 i : r i Operating Manual Old Unit PVC Reactors Page 62 1-2 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 VAB.0001132498 Hf " ' T- Operating Manual Old Unit PVC Reactors Page 63 1-2 * 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 VAB.0001132499 m: in rm a. , Operating Manual Old Unit PVC Reactors Page 64 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 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. VAB.0001132500 Operating Manual Old Unit PVC Reactors Page 65 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 the^ outage 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. b VAB.0001132501 Operating Manual Old Unit PVC Reactors Page 66 III. 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 * NOTE: If compressors should go out on a freezer, make sure the fans are turned off to that freezer. Middle freezer 1 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. VAB.0001132502 Operating Manual Old Unit PVC Reactors Page 67 1-2 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 nust 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. VAB.0001132503 T Operating Manual Old Unit PVC Reactors Page 68 III. 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 reactor manhead. tfrf -r- n't j. VAB.0001132504 1-2 Operating Manual Old Unit PVC Reactors Page 69 m. 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 "0M 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 VAB.0001132505 Operating Manual Old Unit PVC Reactors Page 70 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 Cleaningc>and Entry This section will .cover 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 0,, 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. VAB.0001132506 Operating Manual Old Unit PVC Reactors Page 71 1-2 * HI. 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. (?) Safety harness (8) 12 volt explosion proof light. 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 VAB.0001132507 Operating Manual Old Unit PVC Reactors Page 72 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. A P 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 fliberation. Except in cases of high contamination, these b VAB.0001132508 Operating Manual Old Unit PVC Reactors Page 73 1-2 III. OPERATING PROCEDURES (CONTINUED) O. 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 Water Filters Type: Diamond Filter Tube, 10 micron, 30-inch Change: Performed by operations VAB.0001132509 Operating Manual Old Unit PVC Reactors Page 74 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. 5 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. VAB.0001132510 Operating Manual Old Unit PVC Reactors Page 75 1-2 b % III. OPERATING PROCEDURES (CONTINUED) 0. Filters (Continued) 5. b. Have lead operator pull a vacuum on the blowdown tank using the recovery system. 0 * 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 4 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. VAB. Operating Manual Old Unit PVC Reactors Page 76 1-2 * III. 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. VAB.0001132512 Operating Manual D-700 PVC Reactors Page 77 IV. EQUIPMENT INDEX A. Reactors 1. 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 o Temperature, F Pressure, psig B. Heat Exchangers Shell Jacket 250 200 200(and full 45 vacuum) 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 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 win -- ii 250 120 * 2. Cleaning Solution Heater 55-357 Tubes ------- --c- -- j 250 200 (and full vacuum) 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 VAB. Operating Manual D-700 PVC Reactors Page 79 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 175F and leave at 190F with a pressure of 125 psig. d. Design Conditions Shell Tube Temperature, F Pressure, psig 175 200 400 400 C. Tanks and Vessels 1. Initiator Injection Pot 45-778 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. VAB.0001132515 * 1-2 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 VAB.0001132516 Operating Manual D-700 RVC Reactors Page 81 IV. EQUIPMENT INDEX (CONTINUED) 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. VAB.0001132517 Operating Manual D-700 FVC Reactors Page 82 IV. EQUIPMENT INDEX (CONTINUED) D. Filters 1. Agitator Seal Water Outlet Filters 64-763, 64-764 c. Normal Operating Conditions b 7,5F and 230 psig d. Design Conditions 105F, 350 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 o'. 200 F, 20 psig, 500 gpm, particle retention on four-mesh screen. VAB.0001132518 Operating Manual D-700 PVC Reactors Page 83 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. VAB.0001132519 Operating Manual D-700 PVC Reactors Page 84 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. VAB.0001132520 Operating Manual Old Unit PVC Reactors Page 85 1-2 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 FCI-108 Reactor Steam Stripping Flow controllers Reactor Agitator Mechanical Seal Oil Supply Flow Regulators Flow nozzle with D/P cell, board mounted indicator Kates Model MFA1-1 Flow Regulator 20,000 lbs/hour 1 .0 gpm NOTE: FCi-108 controls the seal water flow to reactor 45-741 doub1e mechanical seal. B. Flow Totalizers Item No. FQI-103 Service Type 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 i VAB.0001132521 Operating Manual Old Unit PVC Reactors Page 86 1-2 V. INSTRUMENT INDEX (CONTINUED) D. Pressure Controllers (Continued) Item No. Service Set Point PCV- 100 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 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 225F with boardmounted Foxboro Controller NOTE: TIRC-102 controls reactor 45-101 steam stripping temperature. TIC-104 o Cleaning Solution Heater Filled System with 190 F Outlet Temperature Controller Local Foxboro Controller VAB.0001132522 Operating Manual Old Unit PVC Reactors Page 87 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. Operating Manual Old Unit PVC Reactors Page 88 1-2 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. * VAB.0001132524 Operating Manual Old Unit PVC Reactors Pa op. 90 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. 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 four fire monitors located around the perimeter of the reactor P area. 2. Hydrocarbon Analyzer i 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 VAB.0001132525 Operating Manual Old Unit PVC Reactors Page 91 VI. ALARMS AND SAFETY EQUIPMENT (CONTINUED) + C. Firewater System (Continued) * 3. Deluge System (Continued) recovery building with a 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. VAB.0001132526 * APPENDIX A EQUIPMENT LIST Reactors 45-755 Heat Exchangers 55-356 55-357 Educators and Edjectors 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 VAB.0001132527 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 VAB.0001132528 Item No. Flow Instruments FQI-103 FRC-101 FI-100 FI-102 FI-105 FCV-108 FI-109 OF-106 RO-107 FIC-302 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) Initiator Iniection 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 \' VAB.0001132529 1-2 APPENDIX B INSTRUMENT LIST (CONTINUED) Item No. Safety-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 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 VAB.0001132530