Document oD3LoZqzdNv7Q2D0J4wwr5K2g

Operating Procedures i'CK>~Q65& Unit PVC Reactors Page f III. OPERATING PROCEDURES (CONTINUED) V. Incinerator General Information The incinerators remove VCM from the recovered monomer (RVCM) receivers inert vent stream via combustion with air. The vinyl chloride emission standard limits the maximum concentration of vinyl chloride in atmospheric vents to 10 ppm. To reduce the VCM level in the RVCM receiver inert vent stream, the inerts stream is first cooled to 40F by the chillers on top of the receivers to condense the majority of the contained VCM. Inerts (and VCM) are ourtucl in a high efficiency burner at an operating temperature of -------------Hydrogen chloride is aQ>product)of combustion. V-VOC The liquid seal flame arrestor prevent s-Jmrning VCM ui uamrgT gay from flashing back through the inert vent line to the VCM re ceivers. The flame arrestor is a small vessel filled 1/3 to 1/2 full with an ethylene glycol solution. The inert vent line from the recovered VCM receivers enters the flame arrestor just above the liquid level. Internal baffles direct the flow of gases downward, into the liquid. The inerts and VCM vapors pass {mder neatly) the baffle and exi/ft out the top of the flame arrestor. A separate line runs to each incinerator from the flame arrestor. DTH 000110058 Operating Procedures Unit PVC Reactors Page 2- III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) General Information (Continued) The combustion gases from the incinerator are scrubbed with water in the quench tank and the packed scrubber. The incinerator's effluent gases are cooled and the hydrogen chloride is absorbed in the water, forming hydrochloric Both^the incinerators are not to be operated at the same time. Each incinerator has a double block and bleed valve assembly in the inerts feed line. These block valves will be closed whenever the incinerator is not in "high fire". This prevents flashback from one incinerator to the other. A manual block valve at the flame arrestor should be closed for the incinerator that is being used as the spare. The major operating parameters of incinerator operations are as follows: 1. Both incineratorswill operate continuously, either in the "high-fire"^* "low-fire" position orA"pilot-on" position, a. The "high-fire", or vent position is used when venting the inerts stream to the incinerator. This position provides maxijimuj^ombustion air flow to the incinerator's combustion chamber to insure that sufficient air is available for com bustion. DTH 000110059 Operating Procedures -944-Unit PVC Reactors Page III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Safety Procedures Items which are of particular concern for working safely around the incineration system are as follows: 1. Hydrochloric Acid - One of the byproducts from the combustion of vinyl chloride is hydrogen chloride. The hydrogen chloride is absorbed in water forming hydrochloric acid. Hydrochloric acid and hydrogen chloride are poisonous and very corrosive. Contact with either one causes burns and ulceration of the skin. A safety shower and eyewash basin are provided at the incinerator site. The eyes or skin should be flushed immedi ately with water for five minutes or more following contact with hydrochloric acid. Any water in the incinerator area When working around the quench chamber or scrubber where there is any possibility of coming in contact with the process . streams, full facefmaskj protective rubber gloves (not cloth or leather) and clothing are required to avoid skin contact. The quench chamber and scrubber water should be drained to the sewer and then flushed with city water before opening the unit# for maintenance or inspection. 000110060 DTH Operating Procedures Unit PVC Reactors Page III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Safety Procedures (Continued) 2. Hot Metal Temperature - The shell of the combustion chamber is u, not insulated. If it were insulated, high temperatures would be generated at the carbon steel surface which would affect the integrity of the metal. When the incinerator is operating, the outside surface temperature of the combustion chamber will ex ceed 300F. Contact with the combustion chamber must be avoided unless protective clothing is worn. Exploslve^lixtures^--ywhen the fuel gas and combustion air con trol valves are adjusted for proper firing rates, an oxygen is analyzer should be used to determine the quantity of oxygen ir the stack gases.C Excess oxygen should (alwasy) be present in the 1---------------------- -------<yn& h prev**$ srM>k\>-j stack gases to avoid forming explosive gas mixtures/ * Ai_ amount of oxygen in the stack gases should range from three to seven percent on a dry gas basis under all firing conditions. The unit should never be run during oxygen deficient conditions (that is, when no oxygen is detected in the stack gases). If this happen^ the incinerator must be shutdown and placed in the purge cycle to remove the flammable gases. / DTH 000110061 Operating Procedures /J&u/Q&d Unit PVC Reactors Page ^ III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Relighting Procedure (Continued) tj/B- Record on the incinerator checklist the time that venting K, #. begins. m mmb When the receiver pressure falls to below the am&MHfe vent receltA^ pressure, the lead operator will put the incinerator back in low-fire. The control* valves/(will close and the incinerator flow should drop to zero. The lead operator will record) the time that the vent msmb shut off on the incine-r--a--t-o--r- 1 checklist. Glycol Supply Drum Fill Procedure The glycol supply drum holds ethylene glycol for filling the incin erator liquid seal flame arrestor as needed. Pressure is main tained at 10 psig on the supply drum using nitrogen. When the supply drum level gets below 1/4 full, glycol must be made up into the drum using the following procedure: DTH 000110062 Operating Procedures New Unit PVC Reactors Page III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Control Room Panel Alarms (Continued) 3. High Firebox Temperature (Setpoint 2600F))( a. Check the pyrometer signals for error. Switch to the other pyrometer if this is the source of the problem. b. Check the temperature controller to make sure the fuel gas valve is closed. The setpoint for the fuel gas temperature control valve should always be less than the setpoint for the steam temperature control valve. If the fuel gas valve is closed, the steam valve should be open. c. Switch to low-fire if venting. In the low-fire mode have an outside operator check steam flow and pressure. If the temperature continues to rise, the unit will automatically shut down. (iVOi^ , ., /ncJy;S d. Check the combustion air pressure/and line for sufficient air supply to the burner. i$co A. Low Firebox Temperature (Setpoint F)X a. Check the temperature indicators to see if the controlling pyrometer signal is in error. If it appears to be drift ing, switch to the other pyrometer for control. b. Cheeky steam temperature control valve for steam addition The steam valve should be closed. the setpoint for the V7 fuel gas temperature control valve should always be greater than the setpoint for the steam temperature control valve. DTH 000110063 Operating Procedures New Unit PVC Reactors Page p_ 3 III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Control Room Panel Alarms (Continued) Check the fuel gas temperature controller to make sure the fuel gas valve is fully open. If the temperature continues to drop while venting, switch to low-fire. d. If the temperature is decreasing in the low-fire mode, -five have aa-wfcsAde operator check the fuel gas flow and burner pressure. If the burner pressure is not normal, the burner may be plugged or the gas regulator may be malfunctioning. Shut the unit downiV^' aPi'uici , 4^ ?ruur<eu3 e. Check the combustion air pressu/e and lin^for^ufficient pa.^cS' air supply to the burner. , -f , (i'JuJcL hti-C P'lx'Mv /c>udi cai 4l~ sUJirS/W 30*f<- - n~r S(FH^ f/i fas rdisf I,nlu`;e 4o ri is/&&& & Steam Valve Open - This alarm comes on when the steam valve 7 ^ ' f ^ fJ, &*'aC' that is used for cooling comes on. Upon acknowledging the | '-ttv I'lhttcLWk' alarm, the lead operator should check the fuel gas valve tol make sure it is closed. If it is not closed, either the fuel gas temperature control valve setpoint is set incorrectly or there is a malfunction in the instruments, requiring a main tenance work order The setpoint for the fuel gas temperature ontrol valve should always be set below the steam temperature control valve setpoint./ The lead operator will also check the flow of inerts to the incinerator and may need to reduce the flow if it is too high. The flow should normally be set at 3 roots of flowl 3?C S(Fft) < DTH 000110064 Operating Procedures New Unit PVC Reactors Page ij.. III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Control Room Panel Alarms (Continued) 6. Malfunction Alarm (or Malfunction Summary Alarm) - This alarm Ihtiud'-fcs `Ma/ cl- C< r /<1 /TjSfcMi at the local incinerator panel. The lead operator will notify the chief operator who will check the local panel and correct the alarm condition as soon as possible. 7. Total Water Low Flow (Setpoint 30 gpm) - A water flow less than 30 gpm through the total water flow meter will shutdown either incinerator if it is in the RUN mode. a. Check the water pressure before and after the strainer. If the pressure drop is excessive (more than 20 psig), switch to the spare strainer and clean the dirty strainer as soon as possible. &cl I HC (ajr.:\ hoc 0. *1 b. Check the water valves to make sure they are open from the cooling water blowdown line to the total water flow meter. c. Check the total water flow globe valve and open it as needed to get the flow back to the required 46 gpm. 8. Exhaust Stack Low 0^, Concentration (Setpoint % Oxygen) - This alarm comes on if the oxygen in the exhaust stack gases jgalls below 2 percent. DTH 000110065 JVlus f Operating Procedures New Unit PVC Reactors Page 5" III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Control Room Panel Alarms (Continued) If this alarm comes on, the incinerator must be shutdown and ^J}arr) ^ placed in the purge cycle to remove the flammable gases. uel /b 7and combustion 'make /sure contrplrTvalyejl f als fight and that proper amount^ IS c,s(ou) 9. Incinerator Feed, High VCM Concentration (Setpoint % VCM) This alarm comes on in high fire if the VCM concentration in the inert gas stream rises to % VCM according to the inlet gas analyzer. The following should be checked: a. Check the receiver pressure. If it is below the set venting pressure, put the incinerator in low-fire to stop the flow of VCM to the incinerator. b. Have the chief operator check the operation of the Frick refrigeration unit. The chief operator should make sure that the switch is on to the receivers that are in service and that the suction ( 35 psig) and discharge pressures (125-150 psig) are normal. DTH 000110066 Operating Procedures New Unit PVC Reactors Page 2 7 III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Control Room Panel Alarms (Continued) 12. City Water On (Setpoint 35 gpm) - Cooling water flow switches automatically to city water if the total water, flow drops to below 35 gpm. A manual switch^north of the D-500/600/700 cooling tower/tis used to/\ switch dawk to^tower waters c\ Vw t a. Check to make sure the cooling water blowdown line is not blocked in or plugged. b. If the switch was caused by a power outage, do not reset the valve until the power has been restored completely. C, RyaSl'k 'fh Si.t'l'/f/ '/o U0-& 4utk. V'-O- ~f /(tO^r/3 54& The following alarms for the liquid level in the liquid seal flame arrestor are also located in the control room near the pushbuttons for tlie-west ^Ancineggfeqrt- 13. High Liquid Level, Flame Arrestor - Have the chief operator check the flame arrestor and the glycol supply drum to make -ff4> l/s-Wj 4-4->~i AO- sure 14. Low Liquid Level, Flame Arrestor - Have the chief operator check the flame arrestor for leakage, especially the sample valve and bleed valve on the level gauge. / 4^ DTH 000110067 Operating Procedures New Unit PVC Reactors Page jcj III. OPERATING PROCEDURES (CONTINUED) V. Incinerator (Continued) Local Panel Alarms (Continued) 3. High Quench Tank Level (Setpoint 10" Water Column) ) a. Check the water flow at the tot^al water flow indicator. If the flow is above 50 gpm (100% on the scale), close the globe valve at the quench tank until flow is about 46 gpm (90% on the scale). b. Open the drain valve on the quench drain seal leg. Close the valve after the level drops below the high level setpoint. c. If the incinerator is in the high-fire mode of operation, put it in the low-fire mode. If the level does not de- .W crease immediately, close the glo|0e valve for the quench tank feed. Do not decrease the flow below the setpoint for the low total water flow (60% on the scale). d. If a high level continues and burner operation becomes erratic (increased gas and air pressure at the burner, poor temperature control, etc.), shut the unit down before the water level reaches the firebox. After the unit is shutdown, block in water flow to the unit and drain the I e tail' , level until it reaches ^normal operating eendit-ions. DTH 000110068 Operating Procedures . New Unit PVC Realtors \ Pae 3 j > III. OPERATING PROCEDURES (CONTINUED) l V. Incinerator (Continued) / Local Panel Alarms (Continued) 8. Waste Gas (Inerts High Pressure (Setpoint 5 psig) - The incin erator being vented to will shut down if the inerts pressure at the incinerator exceeds 5 psig. Check the pressure control, tf-f ceceiv&u tuK/i -fioui r^((L "Hz- (na'vh* valve setpoint^and reduce prior to re-starting the incin- erator. Monitor the pressure following startup. Watch for ex cessive cycling or the pressure switch may be defective. Write "ft) instrument maintenance work orders repairing thes^as soon as possible. 9. Low Fuel Gas Pressure (Setpoint 0.3 psig) - The incinerator flame may not be able to be sustained if the fuel gas pressure falls below 0.3 psig. Check the fuel gas regulator and pres sure switch and make sure the valves are fully open. 10. Fuel Gas High Pressure (Setpoint 5 psig) - Follow the same steps given for the malfunction alarm, number 4 (above). DTH 000110069 t JOperating Manual/ \ fold Unit PVC Reactors 'Page\ I I III. OPERATING PROCEDURES (CONTINUED) F. Chem Wash General Information Chem wash and rinse is not done as a matter of routine on all re actors. The sequence for chem washing reactors is given on the reactor control panel. The product to next be charged in the re actor determines the sequence to be followed. If the reactor is not to be chem washed following rinsing to the blend tanks, proceed to rinse the reactor per procedures in section G. -te-H*. bl&J-kuds ^ After the reactor has been rinsed it is 7) ready to be chem washed, if needed. The chem wash aflseaan9gB>b removqS 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, -f-L2. buildup and will make reactor dumping very difficult i^4hay get5 large enough to break off and plug dump valves and lines. The reactor uSln.l ettufiN condenser and shell are chem washedAftmtag theAprocedure and then -- the chem wash solution must be removed from the reactor. Reactor chem washing must be followed by reactor rinsing (section G) to avoid chem wash contamination of the next batch of resin in the w reactor. Operator must exercise caution during chem wash due to ^-------------- 1 the caustic in the solution. DTH 000110070 Operating Manual Old Unit PVC Reactors Page 2. III. OPERATING PROCEDURES (CONTINUED) F. Chem Wash (Continued) Jyi ^. J , fyg IM.oS' If any solution should get on an operator,Aflush immediately with water. Caustic feels slick to the touch and will start burning the skin just a few seconds after contact. If the solution sprays over the body, immediately get under a safety shower and remove cloth- f^Zing. If any should get in the eyes, flush/leyes for at least fif teen minutes but until all the burning stops. Report any contact --^ --=5> with the chem wash solution to the Shift Supervisor. *TP Ctaw j j>^ococLa-S- Procedure ----------------- fC <?-y 'ffaj 0 MD 1. The reactor should be in the CLEANARINSE mode (Dump Procedure Step^ Ilk). 2. The lead operator will check and make sure that all the reactor valves are closed. 3. The lead operator then checks to see that the chem wash tank 75% level is at the maximum level. NOTE: Any loss of chem wash from the tank to the ground or sewer must be reported to the Shift Supervisor immedi ately. He must contact the utility operator if chem wash went to the sewer and the Operations Supervisor to report a spill of a hazardous substance. 4. Only one reactor at a time may be chem washed. The lead opera tor will check to make sure the chem wash system is available for use and will use the following procedure to chem wash the --* reactor! DTH 000110071 Operating Manual Old Unit PVC Reactors Page y III. OPERATING PROCEDURES (CONTINUED) F. Chem Wash (Continued) " al Open the chem wash tank outlet valve. This valve allows chem wash to go to either of the two chem pumps from the chem wash tank. NOTE: The chem wash pumps will only start if one of the suction valves, either from the tank or from the reactors, is open. b. Turn on the selected chem wash pump. One pump will be used and the other is a spare (and is valved off in the field). at c. Open the chem wash heat exhanger inlet valve. This sends the chem wash through the preheater where it is heated with steam to a temperature specified on the field controller. d. Open the reactor condenser chem wash valve. On D-300 through D-600, this involves only pushbutton which operates double block valves on the chem wash line. At the present time only one of the double block valves operates and the other one stays open all of the time. On D-700, one pushbutton operates a valve on the chem wash header and two other pushbuttons allow either the condenser or reactor shell to be chem washed by operat ing valves to the "condenser" spray nozzle or "reactor" spray nozzle respectively. DTH 000110072 Operating Manual Old Unit PVC Reactors Page If. III. OPERATING PROCEDURES (CONTINUED) F. Chem Wash (Continued) VraaedLtA r To chem wash D-700, open the chem wash header valve and the condenser spray nozzle valve. e. Record on the batch sheet the time when chem wash to the condenser was started. f. Chem wash the reactor condenser until the level in the chem wash tank reaches 50%. NOTE: A small rise in pressure (10-20 psig) on the reactor is normal during chem wash. This is caused by the hot chem wash contacting residual VCM in the reactor. re*c(* ue*d~ remain uth'le chem t g. When the chem wash tank level reaches 50% for D-300 D-600, shut the valve opened in d(above) and open the reactor shell chem wash valve. One pushbutton operates double block valves on the chem wash line to the reac tor. One valve is operable and one is not at the present time (this is the same valve mentioned in d (above) that stays open all of the time). On D-700, close the condenser spray nozzle valve and open the reactor spray nozzle valve. h. Record on the batch sheet the time when chem wash to the reactor was started. i. Chem wash the reactor shell until the level in the chem wash tank reaches 25%. DTH 000110073 Operating Manual Old Unit PVC Reactors Page S III. OPERATING PROCEDURES (CONTINUED) F. Chem Wash (Continued) Vrcc.eAjjJL 1. When the cheem wash tank level reaches 25%, shut the valves to the reactor spray nozzle (one pushbutton on D-300 - D-600, two pushbuttons on D-700). k. Open the chem wash return valve on the reactor. Luk) l. Open the chem wash tank^return valve. m. the chem wash pump suction valve from the reactors. n. Close the chem wash pump suction valve from the chem wash tank. o. Close the chem wash heat exchanger inlet valve. The chem wash should now be returning from the reactors to the chem wash tank and the tank level will begin to rise- 0m p. When the pressure on the reactor falls tomm, open the atmospheric vent valve. q. When the chem wash tank high level alarm sounds (at 75%), close the chem wash tank return valve. This will dead-head the pump momentarily but will keep positive pressure on the chem wash header. r. Close the chem wash pump suction valve from the reac tors. This will shut off the chem wash pump also. s. Close the valves to the reactor spray nozzle (one push button on D-300 - D-600, two pushbuttons on D-700) and close the reactor chem wash return valve. DTH 000110074 Operating Manual Old Unit PVC Reactors Page III. OPERATING PROCEDURES (CONTINUED) F. Chem Wash (Continued) " Chem wash is now complete and the residual chem wash left in the reactors must be rinsed out of the reactor using the reactor rinse procedures in the following section of id* \AMuh kahJi dbvdt 5. Extended periods of chem washing may be required if a condenser is fouled or if chem wash is used during periods of excessive reactor downtime. The following procedure/insiife be used: a. Follow steps a-e in procedure number 4(above) to set up chem wash flow to the condenser. $0% b. When the level in the chem wash tank reaches MK, open the Pumf Jej/M -fro** lUi chem wash tank return valve^and the reactor chem wash re- no *> turn valve. Chem wash will^ne^ be circulating from the reactor through the heat exchanger into the reactor spray nozzle for the condenser. NOTE: The atmospheric vent valve must remain closed while chem wash is flowing to the reactor condenser or shell. This is to prevent chem wash from splashing out the atmospheric vent. c. The lead operator may switch the chem wash back and forth to the condenser or to the reactor as needed during ex tended chem washing by operating the respective spray nozzle valves on the reactor. d. When ready to return the chem wash back to the tank, return Pr*t*cb*,f -S-fep . to wader DTH 000110075 t