Document pprDVbe9mnrOpE9LnEn1yQZXa

PPG INDUSTRIES INDUSTRIAL CHEMICAL DIVISION LAKE CHARLES, LOUISIANA SEWER SEGREGATION AND TREATMENT PLANTS OPERATING MANUAL May 4, 1977 MANUAL NO SL 104619 SEWER SEGREGATION ANL) TREATMENT PLANTS OPERATING MANUAL TABLE OF CONTENTS I. INTRODUCTION II. SAFETY A. GENERAL 1. Introduction 2. Plant Entrance 3. Tagging, Safety Permits 4. Emergency Procedures 5. Hand Tools 6. Smoking 7. Liquid Organic Treatment 8. Safety Inspections B. AREA CHEMICALS 1. Chemical Terminology 2. Chemical Names, Formulas,and Abbreviations 3. Chemical Properties, Hazards, Treatment C. SAFETY EQUIPMENT 1. Standard Personal Equipment 2. Area Gas Masks 3. Safety Showers 4. Fire Extinguishers 5. Acid Suits D. AREA EQUIPMENT 1. Electrical 2. Process Equipment Clearing III. GENERAL PROCESS DESCRIPTION A. SEWER COLLECTION B. API TYPE SEPARATOR C. SURGE POND D. STRIPPER AREA Page 1-1 2-1 2-1 2-1 2-1 2-1 2-3 2-4 2-4 2-4 2-4 2-5 2-5 2-6 2-7 2-35 2-35 2-35 2-33 2-36 2-36 2-36 2-36 2-37 3-1 3-1 3-2 3-3 3-3 SL 104620 IV. DETAILED PROCESS ANDEQUIPMENT DESCRIPTION A. SEWER COLLECTION SYSTEM B. API TYPE SEPARATOR C. SURGE POND D. STRIPPER AREA E. UTILITIES F. ELECTRICAL SYSTEMS G. INSTRUMENTATION 4-1 4-1 4-8 4-11 4-12 4-16 4-17 4-18 V. START-UP A. SEWER COLLECTION SYSTEM B. API TYPE SEPARATOR C. SURGE POND D. STRIPPER AREA VI. SHUTDOWNOF STEAM STRIPPER VII. EMERGENCY SHUTDOWNS A. LOSS OF POWER B. LOSS OF STEAM C. INSTRUMENT AIR LOSS VIII. APPENDIX A. PROCESS AND MECH. FLOW SHEETS, COLLECTION POINT SCHEMATIC FLOWSHEETS B. RUPTURE DISC LIST C. SAC LIST D. COLLECTION POINT LIST E. PERTINENT DRAWINGS ii 5-1 5-1 5-1 5-2 5-3 6-1 7-1 7-1 7-1 7-2 SL 104621 1-1 I. INTRODUCTION This operating manual for the Sewer Segregation and Treatment Plants has been compiled for the following reasons: 1. To serve as an outline for safe practices. 2. To help in training operating personnel. 3. To serve as a start-up and operating procedures manual. Both operators and supervisors should note changes in procedures and pro cesses in order that the manual can be updated. The page numbering system is designed to make additions or deletions to the manual easier without renumbering the whole manual. After this page, there is a record of change sheet which should be filled out each time the manual is revised. The material in this manual is considered confidential and the property of PPG. SL 3_04622 1-2 Date SEWER SEGREGATION AND TREATMENT PLANTS OPERATING MANUAL RECORD OF CHANGES Change No. DescriDtion Oriainator 1 | Si 104633 2-1 II. SAFETY A. GENERAL 1. Introduction This section of the manual outlines the safe practices to be used in Area B and the sewer segregation and treatment plants. Each employee must maintain a positive attitude towards safety. The employee who maintains a positive attitude will find safer ways to do his job. He will be concerned for the safety of fellow employees. He will inform supervision of unsafe conditions and suggest possible corrective measures. The primary source of safe practices is the "Employee's Manual of Accident Prevention". Each employee should be familiar with the manual. The following safe practices are to be used in conjunction with the safe ty manual. 2. Plant Entrance Deposit all lighters, matches, and non-explosion proof flashlights at the Area B entrance. Vehicles are allowed on the main roads except those that are barricaded with chains or ropes. To enter barricaded roads a "Vehicle Entry" permit from the respective control room is required. All personnel and visitors are required to have a hard hat, safety glasses and a respirator before entering Area B. Non-operating personnel must ask for permission from the operators before entering a process area. 3. Tagging, Safety Permits See the section in the safety manual entitled "Tags and Tagging Procedure". There are essentially four tags used in Area B. SL 104624 2-2 Types of Tags: 1. "DO NOT OPERATE" This Is a plastic tag that should be placed on faulty equipment, or equipment requiring maintenance, by leadmen and foreman by both maintenance and operations. The tag should be signed, dated, and the reason given for tagging in pencil. "DO NOT OPERATE" tags may be pulled by employ ees of the same job classification if the situation is fully known. When tagging a piece of equipment, all control points should be closed and tagged by operations first. 2. "PERSONAL TAG" This is a white plastic tag with name, man number, and "DO NOT OPERATE" inscribed on the tag. This tag can be used by maintenance workers who are working on process equipment where they may be endangered. Only the named person can use and pull his personal tags. 3. "INSTRUMENT SHUT-OFF TAG" This is a white cardboard tag used to indicate when an Instrument is out of service for repairs or calibration. 4. "SUPERVISOR'S TAG" This is a red plastic tag with the supervisor's name in scribed on it. Supervisor's use their tag like a "PERSONAL TAG". Types of Permits: See the section called "Safe Work Permits" in the safety manual for more details on permits. 1. "BURNING OR WELDING PERMITS" All burning, welding, or hot work in Area B requires a "BURNING OR WELDING PERMIT". The operating foreman should check the area with an explosion meter for flammable organics before issuing a burning permit. Both the operating supervisor and the maintenance foreman or field engineer must fill out the permit. The burning permit is good up to four hours. New permits must be issued after lunch or an interruption in work. 2. "STRUCTURAL CHANGE, DRILLING, AND EXCAVATION PERMIT" This yellow cardboard permit is required when maintenance or construction must change structures, do drilling, or do excavation work. Engineering or the area maintenance general foreman sign this permit. 3. "TANK ENTRY PERMIT" This is an orange cardboard permit issued to maintenance for entry into vessels, tanks, manholes, pipes, and sumps. Both SL 104625 2-3 operations and maintenance supervisors will sign this permit. The tank must be tested for flammable organics content and oxygen content. A second man should be available to pull the man inside the tank out with the safety harness rope. Air bottles and masks should be provided for both men. All lines going into the vessel must be blinded. See clearning procedure. 4. "VEHICLE ENTRY PERMIT" This is a green cardboard permit issued by operating leadmen or foreman for vehicles or spark producing equipment in process or barricaded areas. 4. Emergency Procedures a. Escape Routes EAST FENCE - 1. 2. 3. 4. Main Area "B" Gate. Emergency Gate at P/T and OHC. Emergency Gate at the Organic Outfall. Construction Gate. NORTH FENCE - 1. 2. Emergency Gate east of Ethylene Meter Station. Locked Gate north-east EC-VC Control Room. Key in VC-EC. SOUTH - Foot path over Sportsman's Lake to wooded area. WEST FENCE - Emergency Gate west of VC Tank Car Loading Rack. b. Call 216 to report fires for first aid. Give your zone number (17). c. Plant Warning Devices 1. Area "B" Evacuation Horns Area "B" evacuation horn is the regular plant horn blown in short blasts. It may be activated from every Area B control room or from the guard office. At the sounding of this horn all non-processing equipment should be shutdown and non-essential personnel cleared from the area. This horn will be sounded in case of a major break or impending disaster. The guards should be notified as to the scope of the emergency. 2. Stripper, Treatment Area Evacuation of non-essential personnel will have to be done by the operating personnel unless the Area "B" evacuation horn has been activated. SL 204626 2-4 Revised 10-18-79 5. Hand Tools Special spark-proof or olloy steel tools are not required in the stripper, treatment areas. Care should be used when using non-sparkproof tools when flammable organics are in the atmosphere. The greatest concentration of flammable organics will be in the API Separator heavy layer, and in the heavy layer in the stripper phase separators. Care should be exercised when burning or welding is being done near these points. Only explosion-proof flashlights should be used in Plant "B". 6. Smoking Lighters will be provided in the control rooms for smokers. No smoking is allowed outside the control room and in the control room labs. 7. Treatment for Liquid Organic Exposure All contaminated clothing will be removed from the victim. Wash all contacted areas with soap and water to prevent extensive chemical burns. Clean all contaminated clothing before reusing. 8. Safety Inspections Once per week an inspection of all safety equipment in the sewer segregation, treatment areas shall be made. This includes fire extinguishers, protective masks, safety showers, etc. There is a two fold purpose in the inspection: 1. To determine if equipment is operable. 2. To familiarize personnel with the location of equipment. 2-5 B. AREA CHEMICALS 1. Chemical Terminology a. Flash Point - The flash point of a solvent is the lowest temperature at which a vapor is given off in sufficient quantities so that the vapor-air mixture above the surface of the solvent will propagate a flame away from the source of ignition. It is the temperature below which a solvent may be used or stored in open containers without formation of an explosive vapor-air mixture. b. Explosive Limits - When combustible vapor is mixed with air in the proper proportions, ignition will produce an explosion. The vapor-air mixture which will form this proper proportion is called the explosive range. The explosive range includes all concentrations of a mixture at which a flash will occur or a flame will travel if the mixture is ignited. The lowest percentage at which this oc curs is the lower explosive limit and the highest percentage is the upper explosive limit. Explosive limits are expressed in percent by volume of vapor in air. c. Maximum Allowable Concentration (MAC) - The maximum allow able concentration for a material is the maximum concentra tion of that material that can be tolerated by personnel for a continuous 8-hour exposure with no ill effects. Si l0462g 2-6 Page 2-7 2-9 2-10 2-11 2-13 2-14 2-15 2-17 2-19 2-20 2-21 2-22 2-23 2-24 2-25 2-27 2-28 2-29 2-30 2-25 2-32 2-33 2. Chemical Names, Formulas, and Abbreviations Chemical Name Formula Carbon Tetrachloride cci4 Caustic NaOH Cell Liquor (Caustic) NaOH Chloroform CHC13 Cis 1,2 Dichloroethylene ClHC=CHC1 Dowtherm A - Ethyl Chloride h3c-ch2ci 1,1 Dichloroethane hci2c-ch3 1,2 Ethylene Dichloride cih2c-ch2ci Hexachloroethane Cl3C-CC13 Hydrogen Chloride HC1 Methyl Chloroform Cl3C-CH3 Nitrogen n2 Pentachloroethane ci3c-chci2 Perchloroethylene Symmetrical Tetrachloroethane ci2c=cci2 Cl2HC=CHC12 Sodium Carbonate (Soda Ash) Na2C03 Trans 1,2 Dichloroethylene ClHC=CHC1 1,1,2 - Trichloroethane ci2hc-ch2ci Trichloroethylene Cl2=CHC1 Unsymmetrical Tetrachloroethane (See Sym) Cl3C-CH2C1 Vinyl Chloride H2C=CHC1 Vinylidene Chloride C12C=CH2 Abbreviati cci4 NaOH NaOH CHC13 Cis EC DCE tuc Hexa HC1 MC ;i2 Penta Per Sym Na2C02 Trans TCE Tri Unsym VC VDC SL 104629 2-7 NAME: Carbon Tetrachloride FORMULA: CC14 MOLECULAR WEIGHT: 154 BOILING POINT: 170.2F MELTING POINT: N/A VAPOR PRESSURE: 90.0 mm Hg @ 68F FREEZING POINT: -9F SOLID DENSITY: N/A VAPOR DENSITY: 5.32 (Air = 1.0) AUTOIGNITION: N/A FLASH POINT: None EXPLOSIVE LIMITS: Nonflammable and Non-explosive in air at ordinary temperatures and pressures. MAXIMUM ALLOWABLE CONCENTRATION: 10 ppm for 8 hours DETECTABLE ODOR CONCENTRATION: Carbon tetrachloride has a distinctive odor but, unfortunately, can be detected only in concentrations exceeding the maximum allowable concentration. LIQUID DENSITY: 98.9 lbs. per ft3 @ 77F HAZARDOUS PROPERTIES: The principal hazard in the industrial use of this chemical is from inhalation of the vapor. The effects of excessive ex posure of carbon tetrachloride may be both immediate and delayed. The Immediate effects may include headache,symptoms resembling Inebriation or drowsiness and abdominal discomfort. The delayed effects may include severe damage to the heart, liver, and kidneys which may not be evident until 1-10 days after the exposure. Skin contact with the liquid leads to dryness through the removal of natural oils from the skin. Repeated or prolonged exposure may cause dermatitis, cracking of th skin and danger of secondary infections. Eye contamination by liquid carbon tetrachloride causes burning, intense irritation and other sumptoms of inflammation. Subacute or chronic carbon tetrachloride poisoning may result from pro longed or repeated exposure to the vapors or the liquid. A threshold limit value of 10 ppm by volume in air has been set by some agencies as a maximum safe concentration for a daily 8 hour exposure. Si 10463o Carbon Tetrachloride (Continued) 2-8 TREATMENT: Skin - Immediately wash with water. Contaminated clothing and shoes should be removed under the shower. Do not put on again without washing. Eyes - Flush with water immediately. The eyelids should be held apart during the irrigation to ensure contact of water with all the tissues of the surface of the eyes and lids. Swallowing - Induce vomiting by having the patient stick his finger down his throat or by giving large quantities of warm salt water (2 tablespoons to a glass of water). If vomiting occurs, give more water in order to attempt to wash out the stomach. Call a physician imnediately. Inhalation - Remove patient to fresh air. Give artificial respiration and oxygen if necessary. Note: In all cases, report to First Aid. Persons exposed to carbon tetrachloride should not be given alcohol, oils fats, or epinephrine. SL 104631 2-9 NAME: Caustic Soda (Sodium Hydroxide) (Lye) FORMULA: NaOH MOLECULAR WEIGHT: 40.00 BOILING POINT: 2534F (100%); 288F (50%) MELTING POINT: 605.1F (100%) VAPOR PRESSURE: 0 1362F, 1 m Hg (100%) FREEZING POINT: 50F (50% solution) VAPOR DENSITY: N/A AUTOIGNITION: N/A FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 1.2 ppm by volume DETECTABLE ODOR CONCENTRATION: Odorless SPECIFIC GRAVITY: 1.52 (50% solution 0 77F) HAZARDOUS PROPERTIES: This material, both solid and solution, has markedly corrosive action upon all body tissue. Caustic solution is detectable by the slippery feeling of soapy water. Its corrosive action on tissue causes burns and frequently deep ulceration, with ultimate scarring. Prolonged contact with dilute solutions has a destructive effect upon tissue. Mists, vapors, and dusts of this compound cause small burns, and contact with the eyes, either in the solid or solution form, rapidly causes severe damage. Ingestion either in the solid or solution form causes very serious damage to the mucous membranes or other tissues with which contact is made. It can cause perforation and scarring. Effects of inhalation vary from mild irritation of the mucous membranes to a severe pneumonitis. It can cause an irritant dermatitis of skin. Caustic soda will react with water or steam to produce heat and will attack organic tissue. Where large quantities are handled, the area should be well venti lated and face masks should be worn. TREATMENT: Skin - Speed in removing the caustic from contact with the skin is important. Remove all contaminated clothing at once, then flush the skin with large quantities of cool or cold water thoroughly. The use of small portions of water, such as by sponging, may cause more serious in jury due to heat liberated on dilution. Eyes - If any caustic soda contacts the eyes, they should be irrigated imnediately with an .abundant amount of water for at least 15 minutes. The eyelids should be held apart during irrigation. A physician should be seen immediately after the eye is thoroughly washed. SL 104632 2-10 NAME: Cell Liquor FORMULA: Aqueous solution of NaOH MOLECULAR WEIGHT: N/A BOILING POINT: N/A MELTING POINT: N/A VAPOR PRESSURE: N/A FREEZING POINT: N/A SOLID DENSITY: N/A VAPOR DENSITY: N/A AUTOIGNITION: N/A FLASH POINT: N/A EXPLOSIVE LIMITS: N/A MAXIMUM ALLOWABLE CONCENTRATION: See Caustic Soda DETECTABLE ODOR CONCENTRATION: N/A LIQUID DENSITY: (0 77F) 10.0 lb/gal, 1.1 gm/ml HAZARDOUS PROPERTIES: Cell liquor is an aqueous solution of sodium hydroxide (lye, caustic) and salt and as such should be handled with the caution given any caustic solution. This material has a markedly corrosive action upon all body tissues, and skin contact may result in moderate to severe chemical burns if the exposed surface is not washed immediately. Eye contact is quite painful and can result in impairment of vision. TREATMENT: Skin - Speed in removing cell liquor from contact with the skin Is important to avoid injury. Removal of all contaminated clothing and thorough washing of the exposed surface is essential. Eyes - If any cell liquor contacts the eyes they should be irrigated immediately with an abundant amount of water for at least 15 minutes. The eyelids should be held apart during irrigation. A physician should be seen immediately after the eye is thoroughly washed. l04 633 2-11 NAME: Chloroform FORMULA: CHC13 MOLECULAR WEIGHT: 119.5 BOILING POINT: 143F MELTING POINT: N/A VAPOR PRESSURE: 160 mm Hg @ 68F FREEZING POINT: -82F SOLID DENSITY: N/A VAPOR DENSITY: 4.13 (Air = 1.0) AUTOIGNITION: N/A FLASH POINT: None EXPLOSIVE LIMITS: Will not burn in air MAXIMUM ALLOWABLE CONCENTRATION: 25 ppm for 8 hours DETECTABLE ODOR CONCENTRATION: 200 ppm (Note that this is higher than the maximum allowable concentration) LIQUID DENSITY: 93 lbs per ft3 0 68F HAZARDOUS PROPERTIES: The most important hazard of chloroform arises from the fact that repeated exposure to low atmospheric concentrations may result in damage to the liver and kidneys. In high concentrations it has narcotic properties and is an effective surgical anesthetic. Contact with skin and mucous membranes may produce irritation. In the presence of excess water or at very high temperatures, such as occur in open flames, chloroform decomposes to give phosgene, hydrogen chloride, and other products. In the presence of strong alkalis and water, chloroform may become violently explosive. On exposure to air and sunlight, chloroform slowly oxidizes to phosgene. TREATMENT: Skin - If chloroform is spilled upon the skin, the contaminated clothing should be removed promptly and the affected skin area should be flushed with plenty of water. The contaminated clothing should not be worn again until free of the material. SL 104634 Chloroform (Continued) 2-12 TREATMENT: Eyes - If the eyes are contaminated, they should be flushed with plenty of flowing water for 15 minutes while holding the eyelids apart. Obtain medical attention. Swallowing - If chloroform has been swallowed, vomiting should be induced as soon as possible by tickling the throat with a finger or by giving an emetic, such as two tablespoonfuls of common salt in a glass of warm water. CALL A PHYSICIAN. Inhalation: Anyone showing signs of ill effects from breathing the vapor of chloroform should be removed to fresh air, kept warm and quiet and be made to rest. If breathing stops, artificial resuscitation should be given. Get medical attention promptly. NOTE: IN ALL CASES, REPORT TO FIRST AID. X04635 SL 2-13 NAME: Cis-1, 2-Dichloroethylene FORMULA: CHC1:CHC1 MOLECULAR WEIGHT: 96.950 BOILING POINT: 140.4F MELTING POINT: -112.9F VAPOR PRESSURE: (? 105.8F, 400 mm Hg. FREEZING POINT: N/A SOLID DENSITY: N/A VAPOR DENSITY: 3.34 (Air = 1.0) AUTOIGNITION: N/A FLASH POINT: 430F EXPLOSIVE LIMITS: 9.7 to 12.8% by vol. MAXIMUM ALLOWABLE CONCENTRATION. 200 ppm, 794 mg/m3 DETECTABLE ODOR CONCENTRATION: N/A LIQUID DENSITY: @ 77F, 79.54 lbs. per ft3 HAZARDOUS PROPERTIES: In high concentrations it is irritating and narcotic. It has produced liver and kidney injury in experimental animals. It is a dangerous fire hazard when exposed to heat or flame. It is a moderate explosion hazard when exposed to flame. When heated to decompo sition it emits highly toxic fumes of chlorides. It can react vigorously with oxidizing materials. TREATMENT: Skin - Remove contamainated clothing and wash thoroughly with soap and water. Eyes - Flush with copious amounts of water. Notify a physician. Swallowing - Report to First Aid immediately. Inhalation - Remove patient from contaminated area. Give aritifical respiration and oxygen if necessary. Report to First Aid. SL 104636 2-14 NAME: Dowtherm A FORMULA: 26.5% diphenyl, 73.5% diphenyl oxide BOILING POINT: 500F 0 1 atmosphere FREEZING POINT: 53F FLASH POINT: 255F MOLECULAR WEIGHT: Heavier than air. HAZARDOUS PROPERTIES: Dowtherm A is used in Area B as both a liquid and vapor. It is not normally toxic or otherwise hazardous. It has a very distinctive odor. Unless the fumes are so strong as to cause oxygen deficiency, there is no hazard. The odor is irritating to intolerable below the safe toxic 1imit. Skin irritation is of minor consequence, however, contact should be avoided. The best fire extinguisher is water, because its vapor concentration is very low at water temperatures. 6*1 ^04 2-15 NAME: Ethyl Chloride FORMULA: CHgCHgCl MOLECULAR WEIGHT: 64.52 BOILING POINT: 54F (Gas under normal conditions) MELTING POINT: N/A VAPOR PRESSURE: @ 75F, 1130 mm FREEZING POINT: -228F SOLID DENSITY: N/A VAPOR DENSITY: 2.22 (Air = 1.0) AUTOIGNITION: 966F FLASH POINT: Open Cup -45F, Closed Cup -58F EXPLOSIVE LIMITS: 3.6 - 12.0% MAXIMUM ALLOWABLE CONCENTRATION: 1000 ppm DETECTABLE ODOR CONCENTRATION: Pungent LIQUID DENSITY: @ 68F, 0.893 HAZARDOUS PROPERTIES: The liquid is harmful to the eyes, and if spilled on the skin will cause frostbite. The vapor gives some warning of its presence because it is irritating, but it is possible to tolerate exposure to it until one becomes unconscious. EC is the least toxic of all the chlorinated hydrocarbons. It can cause narcosis, but the effects are usually transient. Continued exposures may cause some kidney deterioration. Inhalation of EC vapor in concentrations of 1% (by volume) produces narcotic and anesthetic effects, concentrations of 4% or greater may produce deep or even fatal anesthesia. Although EC is not extremely poisonous, any exposure is very dangerous because of the extreme flammability of the material. When EC is burned, phosgene and HC1 are formed, so never approach burning EC without a gas mask. Any spill of EC will result in an explosive mixture being formed and because of the high density of the EC gas, the mixture will tend to stay near the ground. It will take very little to explode EC vapors; static electricity spark, friction spark, or an arcing device are all dangerous when EC is spilled. TREATMENT: Skin - Immediately remove clothing and wash the area with copious amounts of water. If inflammation is severe or if freezing has occurred notify a physician. Eyes - The eyes should be washed continuously with large amounts of.water for at least 15 minutes. Notify a physician. Continue washing until the doctor arrives. SL 104638 Ethyl Chloride (Continued) 2-16 TREATMENT: Inhalation - Remove from contaminated area. Give artificial respira tion and oxygen if necessary. NOTE: For all cases, report to FIRST AID. St io4 639 2-17 NAME: Ethylene Dichloride (1,2-dichloroethane) (EDC) FORMULA: CH2C1CH2C1 MOLECULAR WEIGHT: 98.966 BOILING POINT: 182.3F MELTING POINT: -31.9F VAPOR PRESSURE: @ 84.9F, 100 mm Hg FREEZING POINT: N/A SOLID DENSITY: N/A VAPOR DENSITY: 3.35 (Air = 1.0) AUTOIGNITION: 840F FLASH POINT: 64.9F open cup; 55.4F closed cup EXPLOSIVE LIMITS: 6.2 to 15.9% by volume MAXIMUM ALLOWABLE CONCENTRATION: 50 ppm, 220 mg/m3 DETECTABLE ODOR CONCENTRATION: much less than maximum allowable LIQUID DENSITY: @ 68F, 78.47 lbs per ft3 HAZARDOUS PROPERTIES: Ethylene dichloride is a flammable liquid and a dangerous fire hazard. Short exposures to high concentrations will cause irritation of the eyes, nose, and throat, followed by dizziness, nausea, vomiting, increasing stupor, cyanosis, rapid pulse, and loss of consciousness. TREATMENT: Skin - All contaminated clothing should be removed at once. Cloth ing including shoes, soaked in ethylene dichloride should be removed and not worn again until thoroughly dry. All affected areas should be washed thoroughly with warm water and soap. After this an ointment containing lanolin should be applied in order to replace the natural skin oils. For serious or persistent cases of skin trouble and for signs and symptoms of generalized poisoning, a physician should be consulted. Eyes - If liquid ethylene dichloride has entered the eyes, they should be washed promptly with copious quantities of water for at least 15 minutes. It is advisable to irrigate the eyes gently with water at room temperature in order to minimize additional pain or discomfort. Ethylene dichloride vapor can produce injury to the eyes if the exposure is intense or prolonged to higher concentrations. Eyes should be irrigated for vapor in the same manner as for the liquid. Medical attention should be obtained in all these contacts with the eyes. XOA6AO S"L> 2-18 Ethylene Dichloride Treatment (Continued) Swallowing - If EDC has been swallowed, vomiting should be induced as soon as possible by tickling the throat with a finger, or by giving an emetic, such as two tablespoons of common salt in a glass of warm water. Call a physician. Inhalation - Remove from contaminated area. Give artificial respiration or oxygen if necessary. Seek medical attention. Fire - Use water, foam, carbon dioxide or dry chemical. 2-19 NAME: Hexachloroethane FORMULA: C2Clg BOILING POINT: 367F VAPOR PRESSURE: 1 mm at 32.7C FREEZING POINT: 186.6C (sublimes) LIQUID DENSITY: 2.091 VAPOR DENSITY: N/A FLASH POINT: N/A EXPLOSIVE LIMITS: N/A MAXIMUM ALLOWABLE CONCENTRATION: N/A DETECTABLE ODOR CONCENTRATION: Camphor-like odor HAZARDOUS PROPERTIES: Dangerous disaster hazard. Slight explosive hazard by spontaneous chemical reaction with alkalies, metals, etc. When heated to decomposition, it emits highly toxic fumes of phosgene. TREATMENT: Skin - Remove contaminated clothing. Wash with soap and water. Eyes - Flush with copious quantities of water for at least 15 minutes Inhalation - Remove patient from contaminated area. Give artificial respiration. Give oxygen if necessary. Keep quiet and warm. Report to First Aid. 2-20 NAME: Hydrogen Chloride FORMULA: HC1 MOLECULAR WEIGHT: 36.47 BOILING POINT: -121F MELTING POINT: -173.7F VAPOR PRESSURE: @ 64F, 30,4000TM HQ, (588 psia) FREEZING POINT: N/A SOLID DENSITY: N/A VAPOR DENSITY: 1.268 (Air = 1.0) AUTOIGNITION: N/A FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 5 ppm for 8 hour working day DETECTABLE ODOR CONCENTRATION: Unknown LIQUID DENSITY: Normally a gas HAZARDOUS PROPERTIES: Anhydrous hydrogen chloride Is a gas which has a corrosive action upon the skin or mucous membranes. In this form it will cause rapid and severe burns. It is particularly dangerous to the eyes. It is not flammable; however, the gas is highly soluble in water forming hydrochloric (muriatic) acid, which attacks most metals with the evolution of explosive hydrogen. TREATMENT: Immediate removal from the toxic area and thorough flushing of the patient's body and/or eyes with large quantities of water is of primary importance. Contaminated clothing should be removed from patient while he is being showered with water. It is essential that all affected body surfaces be washed with copious quantities of water for a sufficient time to remove all hydrochloric acid. No attempt should be made to neutralize the acid with alkaline solutions. Medical assistance should be summoned at the earliest possible moment. Skin - Immediately wash with large amounts of water. Contaminated clothing and shoes should be removed while the patient is showering. Continue washing for a sufficient time to remove all muriatic acid. Eyes - Flush with water immediately. The eyelids should be held apart during the irrigation to insure contact of water with all the tissues of the surface of the eyes and lids. si 104643 2-21 NAME: Methyl Chloroform (MC, also known as 1,1,1 Trichloroethane) FORMULA: CC13CH3 MOLECULAR WEIGHT: 133.42 BOILING POINT: 165F MELTING POINT: N/A VAPOR PRESSURE 77F, 125 m FREEZING POINT -22.7F SOLID. DENSITY N/A VAPOR DENSITY: 4.60 (Air = 1.0) AUTOIGNITION: N/A FLASH POINT: None EXPLOSIVE LIMITS: N/A MAXIMUM ALLOWABLE CONCENTRATION: 350 ppm for 8 hour exposure DETECTABLE ODOR CONCENTRATION: 20 - 100 ppm LIQUID DENSITY: @ 77F, 11.1 #/gal., 1.3314 gm/ml HAZARDOUS PROPERTIES: Methyl chloroform is not as toxic as other chlorinated hydrocarbons such as carbon tetrachloride; however, it can still cause damage to the body upon repeated or continuous exposure to large quantities of vapor or liquid. Moderate exposure is unlikely to produce injury. Methyl chloroform is readily absorbed through the lungs. In acute exposure, the most important toxic action is a functional depression of the central nervous system leading ultimately to respiratory failure. As with most solvents, dermatitis may result from repeated skin contact, but methyl chloroform is only poorly absorbed through the skin. Eye contact may result in pain and discomfort, but no impairment of vision is likely. TREATMENT: As with other materials of this nature, remove the victim to an uncontaminated atmosphere and apply artificial respiration if breathing has stopped. Remove wet clothing and do not allow it to be reworn until it is thoroughly dry. If eyes are contaminated, they should be flushed with large amounts of water. Notify a physician immediately. SL 104644 2-22 NAME: Nitrogen FORMULA: N2 MOLECULAR WEIGHT: 28.02 PHYSICAL APPEARANCE: Colorless, odorless, inert gas SPECIFIC GRAVITY: 1.0 with relation to air. (Air is 78% N2) HAZARDOUS PROPERTIES: Even though nitrogen is an inactive gas, it has some inherent dangers since it is used so universally throughout the plant. Its .prime use is for padding and sweeping of equipment that has, or has had, flammables in it. The hazard involved is that a vessel may have insufficient oxygen or that nitrogen is used to purge the vessel instead of air, before man-entry. Therefore, every vessel that is entered must not only be first checked for flammability, etc., It must also be checked for sufficient oxygen. Not only that, nitrogen lines, as well as other toxic lines, must be isolated from the vessel before entry and a clean air sweep provided. TREATMENT: Remove person from the oxygen deficient area. Administer artificial respiration if necessary. SL 104645 2-23 NAME: Pentachloroethane (PCE) FORMULA: CC13CHC12 MOLECULAR WEIGHT: 202.31 BOILING POINT: 321F MELTING POINT: N/A VAPOR PRESSURE: G> 75F, 4rrm FREEZING POINT: -20F SOLID DENSITY: N/A VAPOR DENSITY: 6.98 (Air = 1.0) AUTOIGNITION: N/A FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: Below 121 ppm DETECTABLE ODOR CONCENTRATION: Unknown LIQUID DENSITY: @ 77C 14.0 lbs/gal., 1.681 gm/ml HAZARDOUS PROPERTIES: Pentachloroethane is a nonflammable and toxic liquid. It has a chloroform-like odor and can cause chronic intoxication. It is considered a stronger narcotic than chloroform and is about as poisonous as tetrachlorethane, which it resembles in its action as a metabolic poison. It has a pronounced irritating effect upon the mucous membranes, causing an inflammation of the nose, throat, and respiratory passages. Chronic poisoning causes fatty degeneration of the liver, inflammation of the kidneys, bronchitis, pronounced hyperemia of the lungs, and purulent penumonia. TREATMENT: As described under tetrachloroethanes. NOTIFY A PHYSICIAN. SL 104646 2-24 NAME: Perchloroethylene (Tetrachloroethylene) FORMULA: CCT 2:CC12 MOLECULAR WEIGHT: 165.85 BOILING POINT: 249.7F MELTING POINT: -8.07F VAPOR PRESSURE: @ 71.6F, 15.8 run Hg FREEZING POINT: N/A SOLID DENSITY: N/A VAPOR DENSITY: 5.83 (Air = 1.0) AUTOIGNITION: N/A FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 100 ppm by volume DETECTABLE ODOR CONCENTRATION: N/A LIQUID DENSITY: 9 59F, 101.82 lbs per ft3 HAZARDOUS PROPERTIES: Not corrosive or dangerously reactive, but toxic by inhalation, by prolonged or repeated contact with the skin or mucous membranes, or when ingested by mouth. The liquid can cause injuries to the .eyes; however, with proper precautions it can be handled safely. The symptoms of acute intoxication from this material are the result of its effects upon the nervous system. Skin - Remove contaminated clothing and thoroughly wash with soap and water. Eyes - Flush with water for at least 15 minutes while holding eyelids open. Notify a physician. Swallowing - Induce vomiting by drinking soapy or salt water. Induce vomiting three times. Follow with a tablespoon of epsom salt in a glass of water. Notify a physician. Inhalation - Remove patient from contaminated area. Give artificial respiration or oxygen if needed. NOTE: IN ALL CASES ABOVE REPORT TO FIRST AID. SL 104647 2-25 NAME: Symmetrical and Assymmetrical Tetrachloroethane (S. TeCE & A, TeCE) FORMULA: CHC12CHC12 and CC13CH2C1 MOLECULAR WEIGHT: 167.86 BOILING POINT: S. TeCE 295F; A. Te.CE 267F VAPOR PRESSURE: @ 75F S. Te.CE 4 mn; A. TeCE 13 mm FREEZING POINT: S. TeCE -47F; A. TeCE -97F LIQUID DENSITY: @ 77F S. TeCE 1.588 gm/ml; A. TeCE 1.533 gm/m] RELATIVE VAPOR DENSITY: 5.78 (Air = 1.0) FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 5 ppm for 8 hour exposure DETECTABLE ODOR CONCENTRATION: Approximately 5 ppm HAZARDOUS PROPERTIES: The tetrachloroethanes are not flaimable or explosive but are the most toxic of the chlorinated ethanes that will be handled in the plant. The tetrachloroethanes are toxic by inhalation, by prolonged and repeated contact with skin or mucous membranes or by oral intake. Although toxic, tetrachloroethanes may be handled safely if proper precautions are constantly observed. Prolonged or repeated exposures to the product in any form are hazardous. The signs and symptoms of excessive absorption usually appear gradually and only after repeated exposures. In order of appearance they commonly are unusual fatigue, loss of appetite and weight, sick stomach and vomiting, constipation, abdominal pain, jaundice, drowsiness, going on in severe cases to unconsciousness and death. Some cases show marked involvement of the nervous system with headache, numbness and tingling in fingers and toes, trembling and twitching of muscles and even paralysis of some muscles. The signs and symptoms of tetrachloroethane poisoning given above are due to systematic poisoning characterized by marked damage to the liver, kidneys, heart, blood cells, and nervous system. 104648 SL 2-26 Summetrical and A$symroetrical (Continued) TREATMENT: Most important in the case of any poisoning is quick removal from exposure. In the case of tetrachloroethane poisoning, this means first removing the patient from the contaminated atmosphere and, insofar as possible, removing the tetrachloroethane from the patient's skin, or gastrointestinal tract, if those areas are involved. The patient should be kept quiet and comfortably warm, but not hot. A physician should be called immediately. He should be told briefly and clearly what has happened and the exact location of the patient. SL 104649 2-27 NAME: Sodium Carbonate or Soda Ash FORMULA: Na2C03 MOLECULAR WEIGHT: 106 COLOR (IN SOLUTION): Milky white FLASH POINT: None EXPLOSIVE LIMITS: None HAZARDS: This is a weak to moderate caustic solution. It is not as corro sive or dangerous to the skin as sodium hydroxide solutions but any spill or splash should be washed off instantly. Contact with the eyes will cause permanent eye damage. Sodium carbonate should be treated with the same respect as sodium hydroxide. X04&50 SI* 2-28 NAME: Trans - 1,2 - Dichloroethylene FORMULA: CHC1:CHC1 MOLECULAR WEIGHT: 96.95 BOILING POINT: 118.4F MELTING POINT: -58F VAPOR PRESSURE: 0 87.4F, 400 mm Hg FREEZING POINT: N/A SOLID DENSITY: N/A VAPOR DENSITY: 3.34 (Air = 1.0) AUTOIGNITION: N/A FLASH POINT: 43F EXPLOSIVE LIMITS: 9.7 to 12.8% by volume MAXIMUM ALLOWABLE CONCENTRATION: Unknown DETECTABLE ODOR CONCENTRATION: Unknown LIQUID DENSITY: @ 77F, 79.54 lbs per ft3 HAZARDOUS PROPERTIES: Exposure to high concentrations of vapor.can cause nausea, vomiting, weakness, tremor, and cramps. Recovery is usually prompt following removal from exposure. Dermatitis may result from defatting action on skin. TREATMENT: Skin - Remove contaminated clothing and wash thoroughly with soap and water. Eyes - Flush with copious amounts of water while holding eyelids open. Notify a Physician. Swallowing - Report to First Aid Immediately. Inhalation - Remove patient from contaminated area. Give artificial respiration and oxygen if necessary. Report to First Aid. Fire - Use water, foam, carbon dioxide, or dry chemical. SL 104651 2-29 NAME: 1,1,2 - Trichloroethane (TCE) FORMULA: CHC12CH2C1 MOLECULAR WEIGHT: 133.415 BOILING POINT: 236.8F MELTING POINT: N/A VAPOR PRESSURE: (s> 75F, 22mm Hg FREEZING POINT: -31F SOLID DENSITY: N/A VAPOR DENSITY: 4.6 (Air = 1.0) AUTOIGNITION: N/A FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 25 ppm DETECTABLE ODOR CONCENTRATION: Unknown LIQUID DENSITY: Q 77F, 89.39 lbs per ft3 HAZARDOUS PROPERTIES: Trichloroethane can cause burns of the eyes and has a seriously harmful effect upon the liver. It has a local irritating effect upon the mucous membranes, particularly of the eyes and nose. All contact with the eyes and skin should be avoided. This material should generally be handled with caution, because its toxicological properties have not as yet been adequately evaluated. TREATMENT: Skin - Remove patient from toxic area. Remove all contaminated clothing and wash all exposed skin surfaces thoroughly with soap and water. Eyes - Flush with copious amounts of water holding eyelids open. Notify a physician. Swallowing - Report to First Aid immediately. Inhalation - Remove patient from contaminated area. Give artificial respiration and oxygen if necessary. Report to First Aid. Fire - Use water, foam, carbon dioxide or dry chemical. 2-32 NAME: Vinyl Chloride (Chloroethylene , VCM, or VC} FORMULA: H2C:CHC1 MOLECULAR WEIGHT: 62.501 BOILING POINT: 7.9F MELTING POINT: N/A VAPOR PRESSURE: 0 77F - 2660 rrm Hg (51.5 psia) FREEZING POINT: -224.7F SOLID DENSITY: N/A VAPOR DENSITY: 2.15 (Air = 1.0) AUTOIGNITION: N/A FLASH POINT: -108.4F - open cup, -162F - closed cup EXPLOSIVE LIMITS: 4 to 22% by volume MAXIMUM ALLOWABLE CONCENTRATION: 1 ppm for 8 hrs./5 ppm for 15 min. ceiling DETECTABLE ODOR CONCENTRATION: Faintly sweet LIQUID DENSITY: 0 77F, 61.92 lbs per ft3 VISCOSITY: @ 77F, 0.187 cp. HAZARDOUS PROPERTIES: Vinyl chloride is very much like ethyl chloride. It is not very poisonous, it is extremely flammable and it has a narcotlceffect. Continued exposures may cause some kidney deteriora tion. Inhalation of vapors greater than 500 ppm may produce a slight narcotic effect. At concentrations of 4% or greater, VC vapors may produce a deep or fatal anesthesia. The Department of Labor has declared Vinyl Chloride to be a carcinogenic (cancer-causing) compound. The main danger with VC is the extreme flammability of the vapors. VC when burning will form phosgene and HC1, so never approach a fire without a gas mask. Any spill of VC will result in an explosive mixture being formed and because of the high density of the VC gas, the misture will tend to stay near ground. It will take very little to explode the VC vapors - static electricity spark, friction spark, or an arcing device are all dangerous when VC is spilled. TREATMENT: Remove the injured person from the contaminated area; if breathing has stopped, perform artificial respiration. In any case, make sure the person injured is reported to First Aid immediately. If any liquid enters the eye, wash the eye continuously with a large amount of water for at least 15 minutes; then get the person to First Aid. All exposed persons should be referred to the Medical Department. SL 104653 2-33 NAME: Vinylidene Chloride (VDC) FORMULA: C12C:CH2 MOLECULAR WEIGHT: 96.950 BOILING POINT: 88.9F MELTING POINT: N/A VAPOR PRESSURE: 0 75F, 560 mm Hg FREEZING POINT: -187.6F SOLID DENSITY: N/A VAPOR DENSITY: 3.35 (Air = 1.0) AUTOIGNITION: N/A FLASH POINT: 50OF - open cup EXPLOSIVE LIMITS: 7 to 16% by volume MAXIMUM ALLOWABLE CONCENTRATION: 2.5 ppm/8 hrs. TWA, 10 ppm/15 min. DETECTABLE ODOR CONCENTRATION: 500 to 1000 ppm LIQUID DENSITY: 0 77F, 76.04 lbs per ft3 HAZARDOUS PROPERTIES: Vinylidene Chloride is a flammable and toxic material. Vinylidene chloride is moderately irritating to the eyes and to the skin. The greatest danger from vinylidene chloride is inhalation. A single exposure for a few minutes to a high concentration of vinylidene chloride vapor rapidly produces a "drunkenness" which may progress to unconsciousness if exposure is continued. Even concentrations too low to cause an anesthetic effect, may produce organic injury to the liver and kidneys. A secondary danger from vinylidene chloride exists. Unstabilized vinylidene chloride in contact with air will decompose and form explosive peroxides. These peroxides are evident by the presence of a white solid. For this reason, all vinylidene chloride will be stabilized and all equipment will be padded with an inert gas such as nitrogen or methane. All pipelines, tanks, etc., in contact with vinylidene chloride after its phenol inhibitor has been removed should be thoroughly rinsed with water if they are to be drained and left standing for any length of time. TREATMENT: Skin - When the skin is contacted by vinylidene chloride it should be thoroughly washed with soap and water and all contaminated clothing removed and washed. SL 104654 Vinylidene Chloride (Continued) 2-34 TREATMENT: Eyes - If the eyes become contaminated they should be flushed with water for 15 minutes or more while holding the eyelids open. Inhalation - If a person is affected or overcome from breathing vinylidene chloride vapors, he should be removed to fresh air at once. Medical attention should be obtained irmiediately. Artificial respiration should be administered if breathing stops. Si 1o46SS 2-35 Revised 10-18-79 C. SAFfTY EQUIPMENT 1 . Standard Personnel Equipment All operating personnel will be required to wear hard hats, safety shoes, protective goggles, respirators, and neoprene gloves. The small respirator should be used only in light concentrations of organic, HCI, and chlorine vapors for escape purposes only. Goggles will be worn in processing areas and labs by operating personnel. Vacuum truck operators should wear respiratory protection in the lift station areas and around the API separator. 2. Area Gas Masks a. Canister Gas Masks There are two canister gas masks in the steam stripper process area. These masks absorb gas by breathing through a charcoal filter. It will protect against acid and organic gases in concentrations not exceeding 2%. The tape covering the opening in the bottom of the charcoal canister must be removed before using. The masks are located at the first and third levels of the stripper area. b. Scott Air-Pak There are four Scott air paks in the OHC control room. The units provide a maximum of 30 minutes air supply when fully charged. There is approx imately five minutes air supply left when the unit alarm sounds. These units are designed to go into contaminated process areas. c. MSA Escape Unit There are six MSA escape units located in the OHC control room for emergency escape of operating personnel only. The unit is designed to give six minutes breathing air time in a contaminated atmosphere. Before escape, the mask can be attached to the air line rig in the control room so that the unit air bottle can be saved for escape only. 3. Safety Showers There are six safety showers located in the steam stripper area. Each safety shower is equipped with eye was hose and sprinkler to wash off organics or acid. The safety shower on the first level is equipped with a body wash station. SL 104656 2-36 Revised 10-18-79 The body wash should be used to neutralize acid on the body and not the eyes. The stripper area safety showers are located on: 1st Level S.E. Corner Stripper Pad 2nd Level S. Side 3rd Level S.E. Corner 4th Level E. Side 1st Level NW Corner Stripper Pad 3rd Level N.W, Corner 4. Fire Extinguishers Locations of 30^ Dry Chemical Type in the Stripper Area: 1 - N. Side Plant on Piperack Column 1 - S. Side Plant on Piperack Column 1 - 2nd Deck Stair Platform 5. Acid Suits When handling concentrated acid and caustic solutions, acid suit, rubber gloves, rubber boots and face shield should be used. All contaminated clothing should be washed off before storing. D. AREA EQUIPMENT 1 . Electrical Equipment The physical properties of the liquid organic mixtures in the stripper, API Phase separator area require electrical materials to be classified in Class I, Group D, Division 2 by the National Electrical Code. Motors are TEFC (totally enclosed, fan cooled), with the exception of the stripper feed pumps 3 and 4 which are explosion proof, lighting is vapor-tight, and all arcing devices are explosion-proof with seal-offs . Since the OHC control room is pressurized and 2-37 isolated from the process area, general purpose equipment is used and can be used. The only exception to the control room require ments is the laboratory exhaust fan. Relamping - Vapor tight fixtures in the stripper and treatment area are used, lights should be shut-off before relamping. Globes and Guards must be replaced after relamping before turning on lights. Grounding - Grounding in the plant has been considered due to flanmable organics in the area. Pumps and structural steel has been grounded to prevent a build up of static charge in the equip ment. When equipment has been worked on by maintenance, grounds should be checked to see if they are replaced. 2. Process Equipment Clearing The operations supervision and maintenance forman will see that all vessels or tanks are properly isolated and blinded and purged. Before issuing the "TANK ENTRY PERMIT" the tank should be checked for flammable organics and 21% oxygen content. It should be noted that an explosive check is valid only in an atmosphere that con tains air. Clearing Procedure a. Empty vessel and close and tag all valves. b. Purge contents with N2 c. Insert blinds in all connecting lines. d. Purge equipment with air until meter indicates 21% O2 and 0% explosive condition. SL 104658 3-1 Revised 10-18-79 HI. GENERAL PROCESS DESCRIPTION The sewer segregation system is composed of a collection system which utilizes lift stations and overhead piping; an API type separator for phase separation; a surge pond; and two steam stripper units for recovering soluble chlorinated hydrocarbons. The purpose of this system is to separate out and keep concentrated the chlorinated hydrocarbon contaminated aqueous streams; recover phase chlorinated hydrocarbons; and remove and recover soluble chlorinated hydrocarbons from the aqueous stream. A. SEWER COLLECTION SYSTEM The organic contaminated effluent streams from the following areas are collected: 1. Liquid Phase EDC Plants 2. Tri-Ethane Plant 3. Per/Tri Plant 4. Ethyl Chloride Plant 5. Vinyl Chloride Plant 6. Oxyhydrochlorination EDC Plant 7. Waste Recovery (Bottoms) Plant 8. Tetra Plant 9. HCI Plant 10. Waste Disposal (incineration) Plant 11 . Shipping Building 12. Tri-Ethane II 13. Sewer Segregation Plant 14. New Lab Building 15. VCM II (Future) SL 104659 3-2 Revised 10-18-79 Streams collected include all the continuous contaminated streams, the intermittently contaminated streams, the contaminated intermittent streams and the effluent from trenches. > Effluent from the individual collection points within Plant B 1 and B 2 flows by gravity to one of nine lift station sumps. Each lift station consists of two self priming pumps that operate automatically based on the sump level. On-off indicator lights for these pumps are located in the control rooms. The effluent in the sumps is pumped into two overhead headers, which discharge into the API separator. The headers are of Furan-a fiberglass reinforced furfuryl alcohol resin. By segregating out and collecting the chlorinated hydrocarbon streams, the effluent from Plant B 1 and B 2 requiring treatment for organic removal is reduced from approximately 3500 GPM to less than 500 GPM. This results in a much smaller treatment system. The effluent from the new lab building is conveyed in a separate.line to the API type separator. VCM II has its own API type separator. Its effluent is pumped to the surge pond. B. API TYPE SEPARATOR The API Type Separator is o dual unit, acid brick lined, above ground, phase separator. Each unit is sized to handle approximately 1100 GPM throughput. Each inlet bay has a diffusion screen to minimize turbulence and short circuiting. Light material is skimmed off the top and concentrated in a scum compartment; heavy organics are phase separated out and are pumped to the Per/Tri DH still feed tanks. The effluent containing dissolved organics overflows by gravity to the surge pond. Either bay can be isolated for maintenance. SL 104661 3-3 Revised 10-18-79 C. SURGE POND The surge pond is a Bentonite clay lined earthen pond with sloped sides. It is sized to have approximately 24 hours of surge capacity at 500 GPM. Flow into the surge pond is by gravity from the API separator; it is pumped from VCM II. The stripper feed pumps for both stripper units pump out of the surge pond to the stripper area. An overflow pipe to the existing outfall is provided. The purpose of the surge pond is to level out the flow to the two steam stripper units and to provide surge capacity during short outages. D. STRIPPER AREA The old stripper unit(South) consists of a preheater, steam stripper, condenser, phase separator, economizers, various pumps, and a vent scrubber. Feed is pumped from the surge pond through the condenser, the economizers, and into the preheater. The preheater heats the effluent with live steam to near its boiling point. Feed flows by gravity from the preheater to the top of the steam stripper - a packed column. Live steam is injected into the bottom of the steam stripper to give a small boilup. The overhead vapors containing azeotropes of organics and water are condensed and phase separated. The phase organics are returned to P/T; the water phase returns to the API separator. Non-condensible vapors are scrubbed; this water also returns to the API separators. The hot effluent from the steam stripper is pumped through the economizers and on to the combination of sewers for neutralization. The new stripper unit (North) consists of a Pick preheater, steam stripper, condenser, phase separator, economizers, and various pumps. Feed is pumped from the surge SL 104660 3-4 Revised 10-18-79 pond through the condenser, the economizers, and into the Pick preheat r. The Pick preheater heats the effluent with live steam before it is fed to the top of the steam stripper - a packed column. Live steam is injected into the bottom of the steam stripper togive a small boilup. The overhead vapors containing azeotropes of organics and water are condensed and phase separated. The phase organics are returned to Per/Tri using the stripper product pumps in the old stripper unit. The water phase is returned to the API separator. Non condensible vapors are piped to the old stripper units scrubber. The hot effluent from the steam stripper is pumped through the economizers and on to the combination of sewers for neutralization. SL 104662 4-1 Revised 10-18-79 !V. DETAILED PROCESS AND EQUIPMENT DESCRIPTION Refer to the process flowsheets, mechanical flowsheets, collection point schematic flowsheet, and collection point list located in the back of this manual as needed in following the process description. A. SEWER COLLECTION SYSTEM Nine lift stations within Plants B1 and B 2 collect the organic contaminated effluent streams from the following areas: 1. Liquid Phase EDC Plants 2. Tri-Ethane Plant 3. Per/Tri Plant 4. Ethyl Chloride Plant 5. Vinyl Chloride Plant 6. Oxyhydrochlorination EDC Plant 7. Waste Recovery (Bottoms) Plant 8. Tetra Plant 9. HCI Plant 10. Waste Disposal (incineration) Plant 11. Shipping Building 12. Tri-Ethane II Plant 13. Sewer Segregation Plant These effluent streams are then pumped to the API type separator. The effluent from the new lab building is conveyed in a separate line to the API type separator. SL 104663 4-2 Revised 10-18-79 Effluent from the individual collection points flows by gravity to one of the I ift station sumps. In general, the lines from the individual collection points are underground and are of vitrified clay tile construction. Each underground line contains a "P" trap to prevent vapors from backing up the line. A restricting orifice has been installed on major trench discharges to minimize the amount of rainfall that will be collected. Excessive rainfall will be diverted to the storm sewers. Continuously contaminated streams that were goirg to trenches have been rerouted directly to the lift stations to prevent their bypassing the collection system during periods of heavy rainfall. No. 1 thru No. 7 lift stations pump the organic contaminated effluent to an overhead 8" furan line that discharges into one or both inlet bays of the API type separator. No. 8 lift station discharges into either inlet bay of the API separator. The Triethane II Plant has its own header.It's an 8" Furan line that enlarges to 10" in the rack west of No. 3 incinerator. An 8" jumper header ("Parallel Header") with a PCV is used to relieve excessive flow from the 8" Furan header to the Triethane II Header. Plans are underway to have flow indication on both headers. Each lift station contains a sump, two self-priming lift pumps that operate automatically based on the sump level, a level transmitter, vent line and a N2 connection. On-off indicator lights for these pumps are located in the respective control rooms. Each pump has a check valve on its discharge to prevent flow from short-circuiting through the spare pump. SL 14 664 2-30 NAME: Trichloroethylene (Ethylene Trichloride) FORMULA: Cl2C:CHC1 MOLECULAR WEIGHT: 131.399 BOILING POINT: 188.8F MELTING POINT: -124.3F VAPOR PRESSURE: @ 89.6F, 100 m Hg FREEZING POINT: -99F SOLID DENSITY: N/A VAPOR DENSITY: 4.53 (Air = 1.0) AUTOIGNITION: 770F FLASH POINT: None EXPLOSIVE LIMITS: None MAXIMUM ALLOWABLE CONCENTRATION: 100 ppm DETECTABLE ODOR CONCENTRATION: Unknown LIQUID DENSITY: (? 77F, 90.87 lbs per ft3 HAZARDOUS PROPERTIES: Inhalation of high concentrations causes narcosis and anesthesia. A form of addiction has been observed in exposed workers. Death from cardiac failure due to ventricular fibrillation has been reported. Prolonged inhalation of moderate concentrations causes headache and drowsiness. There is some question as to damage to liver or other organs from chronic exposures. Cases have been reported but are of questionable validity. Reacts with strong alkalies, such as caustic soda, to form highly flammable and toxic dichloracetylene. High concentrations of trichloroethylene vapor in high temperature air can be made to burn mildly if plied with a strong flame. Though such a condition is difficult to produce, flames or arcs should not be used in closed equipment which contains any solvent residue or vapor. Trichloroethylene is dangerous when heated to decomposition. It emits highly toxic fumes of chlorides. ^04665 SL Trichloroethylene (Continued) 2-31 TREATMENT: In general, remove the patient from the contaminated atmosphere and insofar as possible, remove the trichloroethylene from.the patient's respiratory tract, skin, or gastrointestinal tract. Vomiting may be induced if taken internally. Skin - Skin areas affected by a spill should be washed thoroughly with soap and water (except the eyes). A 15 minute eye wash should be used for a spill in the eyes. Inhalation - If a person is overcome by vapors, he should be removed from the area immediately and given artificial respiration if a respirator is not available. Notify a physician. 4-3 Revised 10-18-79 Each sump basically is a reinforced concrete box with a furan membrane inside to protect the concrete from the acidic water. The furan membrane is overlayed with acid brick and furan motor for further strength and protection. The sumps have been equipped with an overflow pipe which ties into the existing storm sewers to prevent overfilling the lift stations during excessive flows or pump failures. For a complete description of the level control system and alarm sequence see Section IV. G. on Instrumentation. Refer to Table IV. A1 for a composite lift station data listing. The table includes the location, dimensions, holding capacity, overflow height, pump data, SAC numbers, breaker location and circuit numbers for each lift station. Refer to Table IV. A2 for a listing of the collection points for each lift station. CC refers to continuously contaminated, Cl refers to contaminated intermittent and 1C refers to intermittently contaminated. Trenches are indicated with a TR, Some of the collection points have a diverter valve setup that allows the effluent to go either to the storm sewer or to the contaminated sewer. Since the construction of the system our Environmental permit states that the effluents should not go to the storm system. The diverter valves are operated manually or automatically depending on the location. Below is a list of collection points with this set up. Drawing no. 20A-10015 may also be of help. Point No. 31 HCI Scrubber at VCM (C-210) Point No. 16VDC Reactor (T-52.SAC #59-20) Normally the flow goes to the combination of sewers. When the VDC reactor is upset and organics are coming out the bottom,the flow is automatically diverted to the contaminated sewer. SL 104667 LIFT STATION DATA TABLE IV A 1 Revised 10-18-79 LIFT STATION No. 1 No.2 No. 3 LOCATION VCM OHC (Acid Pit) TE INSIDE DIMENSIONS 5'-5" x 5'-5" 4*-5" x 4*-5" 5'-l" x 5'-l" x 8* -6" x 9'-0" x 7*-O'* OVERFLOW HEIGHT 5'-6" 6l-0" 2'-8`* No. 4 No. 4 No.5 P/T Shipping P/T Shipping EDC 4'-r* x 4'-l" 4'-!" x 4*-r 4'-l" x 4,-l" x8'-0" x8*-0" x9`-0" 4'-6" 4'-6" 4* -1" No.6 P/T Still Line HOLDING CAPACITY 1200 GAL. 875 GAL. 515 GAL. 561 GAL. 561 GAL. 509 GAL. PUMP DATA (all Have John Crane Type 20 Mechanical Seal) PUMP SAC NO. A B Durco Self- Durco Self- Priming Pr iming Chloromet-3 Mark II GP II 4x3-10 Haste Hoy C 8-3/4" impeller 13'* Impeller 305 GPM at 67 20 HP 1750 ft. head 10 HP. RPM MOTOR 1750 RPM Motor 4x3 S-13 WEST 55-2296 EAST 55-2297 WEST 55-2564 EAST 55-2565 Durco SelfPriming Chloromet-3 4x3-10 8j" impeller 260 GPM at 58 ft. head 10 HP, 1750 RPM motor EAST 55-2294 WEST 55-2295 Goulds SelfPriming Model 3796 MT Hastelloy C 3x3-13 13" Impeller 10 HP, 1750 RPM motor SOUTH 55-2642 Durco SelfPriming Mark II Gp II Hastelloy C 4x3 S-10 10" Impeller 10 HP, 1750 RPM Motor Goulds Self Priming Model 3796 MT Hastelloy C 3x3-13 13" impeller 10 HP, 1750 RPM Motor Goulds Self Priming Model 3796 MT Hastelloy C 3x3 - 13 13" Impeller 10HP, 1750 RPM Motor NORTH 55-2701 SOUTH 55-2702 NORTH 55-2704 EAST 55-2705 WEST 55-2703 PUMP BREAKER LOCATION VCM Control Old OHC EDC Control EDC Control Room Control Room Room Room EDC Control EDC Control Room Room Old OHC Control Room CIRCUIT NO. A B 9,415 9,416 16,302 17,610 17,310 17,434 17,336 17,445 17,345 17,446 16,309 17,615 LIFT STATION LOCATION No. 7 OHC LIFT STATION DATA TABLE IV A I No. 8 SEWER SEGREGATION PLANT INSIDE DIMENSIONS OVERFLOW HEIGHT 5l-5H x S'-S" x 9`-6,` 5'-4" HOLDING CAPACITY 1170 GAL. PUMP DATA (all Have John Crone Type 20 Mechanical Seal) PUMP SAC No. A B PUMP BREAKER LOCATION Durco Self Priming Chloromet-3 4 x 3 -10 Bi" impeller 340 GPM at 53 ft. head 10 HP, 1750 RPM Motor WEST 55-2286 EAST 55-2287 Old OHC Control Room Goulds SelfPriming Model 3796-ST Haste Hoy C li x li - 8 6.12 " Impeller 40 GPM @ 30 ft. Head 3 HP, 1750 RPM Motor 55-2733 Sabine Water Substation CIRCUIT No. A 16,301 11720 B 17,614 O'i '\DJ O ft acn CIO o LIFT STATION DATA TABLE IV A Z i*-4 SL 104670 No. 2 No. 3 VCM OHC {at Acid Pit) T/E Collection Point 1 1 2 3 4 5 98 99 V Description D Collection Point 1 VCH Heavy Still Stack Seal VCM/EC lab Drain CC Cl HC1 Scrubber at VCH IC EC Trench HCl Header Drain TR Cl VCH Trench EC Vent K.O. Pot TR CC 23 39 44 67 72 79 80 61 84 86 101 111 112 ] | 1l Description .. P/T Pump Pad Drain P/T Entrainment Separator Drain P/T R.( Trench/ Catalyst Scrubber Chloral Drain Absorber Acid Pump Suction Drain Dowtherm Pump Drain Acid Brick Pad Drain (3rd deck) Dowtherm Pump Drain Pad Drain (2nd deck) OHC Trench Acid Pit Pad Drain {2nd deck) Start-up Scrubber Collection Point < Description Cl 6 AIBN Pad Drain Cl Cl 7 VDCM Pump Pad Drain Cl TR 8 Pump Pad Drain Cl CC CC 9 HCl Surge Drum Drain Cl Cl 10 HC Plant Trench TR nCl Catalyst Pot Drain CC Cl 12 MC Section Scurbber Drain CC Cl 13 VDCM Dryer Reactivation Cl Drain Cl 14 VDC Phase Separator Drain Cl TR 15 TCE Storage Tank Scrubber CC Drain CC 16 VDC Rx Drain IC CIt 17 T/E Scrubber Stack Drain CC 1C 18 VDC DH Still Reflux Drum Cl Drain 19 VDC Pad Drain Cl 20 T/E Scrubber Drain 1C 28 Heavy Still Pad Drain 29 Pad Drain Cl Cl 30 VDC Retention Tank Pump Cl Drain 31 Pad Drain Cl 32 Pad Drain Cl 34 Utility Drain Cl 35 Reboiler Drain Cl 36 VDCH HQKflt Tank Drain Cl 37 VDCM Rx Heater Pad Drain Cl 38 Condensate Pump Pad Drain IC 94 HC Plant Trenches 95 HC Plant Trenches 96 MC Lab Drain TR TR Cl 97 ASH Liquor Tank Drain 102 Overhead Drain 103 Drain Cl Cl Cl 104 Scrubber Drain CC 105 [Control Valve Drain Cl 106 Tank Drain Cl 104671 LIFT STA-I0M DATA TABLE IV A 2 (ccrtt'd) No. 4 j Mo. 5 | No. 5 Col lection Pcint 7 *5 0 41 2 43 8? CO SO Cl 107 108 ICO 110 P/T - Shipping EDC ?/T - Still Line 1 ! Description i '.Collection ' Point !a 1 Sump Pump Discharge ci; jLoading Rack Drain CI. 1P/T Reactor Trench ; Recycle Scrubber TR. 1 Au,:. Still Line Scrubber cc ITren':'1 Arpunc SK Feed TR' 7ar<s L Aureous Waste Pump Pad Drain P/T Lab Drain i Shipping Bldg. Drain CI, ci! ci; 'shipoing Bldg. Drain t CI, 21 22 24 25 26 27 Shipoing Area Storaae ' Slab Drain ditto d i tto di tto ci I cr. CI; ci; Description i 1 No. 1 EDC Scrubber No. : 0C Plant Trench No. 2 EDC Plant Trench 1 Collection Paine At l IC 45 TR, 46 iR, 47 ,G. C. Pet CC , Ko. 2 EDC Plant Scrubber IC 48 49 G. C. Pot CC 50 51 52 53 54 55 56 57 58 60 83 52 93 Descripticn P/T Bottoms Tank Scrubber CC Tank Drain C! Tank Drain CI Hvy--'Still Feed Filter Erai r: SI Still Line Scrubber Drain CC P/T Still Feed Filter Crai n CI Tank Drain Nc. 1 Per Phase Sep Overt!cw No. 2 Per Wash Column V'* Gr i iCvi No. 1 Per Wash Colunn CI CC CC cc no. 1 Per Dryer Drain No. 2 Per Dryer Drain Tri Product Dryers Drain No. 2 Per Phase Separator Overt 1ov Tri Neutralizer Overflow Scrubber Drain Tri Neutralizer Bottoms Psro Pad Drain Dryer Recovery Crain ?/T Distillation Trench Per Deodorizer P/T C-ryer Filter CI CI cc cc CI Cl TR Cl Cl C-i=iT1 LIFT STATION DATA TABLE IV A 2 cont'd 1 : f 1 (Collection ; Point ,* | 61 1 62 , 63 i 64 , 65 , 66 , 68 i 69 , 70 i 71 , 73 i 74 , 75 i 76 , 83 , 85 , 100 , 113 114 No. 7 OHC -- Description Tetra Compressor Pad Drain Cl Pump Pad Drain Cl Tetra Plant Trench TR Tetra Emergency Scrubber IC TCE Storage Tank Scrubber CC Pump Pad Drain Cl DH Still Feed Tank S.G. Drain Cl Int. Crude Tank S.G. Drain Cl Pump Pad Drain Cl Int. Crude Tank S.G. Drain Cl Bottoms Scrubber Drain CC Bottoms Plant Trench TR Incinerator Pump Pad Drain Cl Incinerator Header Drain Cl Incinerator Pad Drain Cl OHC-Tetra Lab Drain Cl Tetra AIBN Tank Drain Cl New Bottoms Plant Trench TR Incinerator Header Drain Cl SL 104672 4-8 Revised 10-18-79 Point No. 20 T/E Scrubber (C-7) Point No. 21 No. 1 EDC Scrubber (SAC *67-65) Point No. 26 No. 1 EDC Scrubber (SAC ^67-29) Point No. 64 Tetra Emergency Scrubber (C-108) Point No. 112 P/T Start-up Scrubber B. API TYPE SEPARATOR 1. Equipment a. API TYPE SEPARATOR (Dwg. 20A-30103, 20A-30105-20A-30108) fine API type separator is constructed above ground of reinforced concrete with a furan membrane inside to protect against the acidic waters. The furan membrane is overlayed with acid brick and furan mortar for further protection. The separator will have a cover installed to reduce organic vapors. A slight pressure will be held by means of a seal loop. The API type separator consists of two separate sides. Each side contains an inlet bay, separator bay, middle compartment and scum compartment. Each separator bay is approximately 9' wide x 49' long x 4'-3" high and holds approximately 14,000 gallons. b. Heavy Layer Pumps SAC No. 55-2274 and 55-2275 These are Durco Mark II FRP (Durcon 700), lix 1-6 pumps; designed for 10 GPM at 75 ft of head. The impeller diameter is 4-3/8". They are drived by 2 HP, 3500 RPM motors. 2. Operation: See Figure II. B. 1 The API type separator is a liquid-liquid phase separator designed by the American Petroleum Institute's method. The separator has been modified from its original design. There are now two distinct sides. Originally the sides were connected at a common inlet bay. Due to repairing cracks in the wall a divider was installed to completely isolate the North and South sides. The inlet piping has been modified so that either side can be isolated for maintenance. Each side consists of an inlet bay, separator bay, middle compartment and scum compartment. SL 104673 4-9 Revis d 10-22-79 Each separator bay is capable of handling 1100 GPM before inefficient separation between the heavy organics and water occurs. Each inlet bay has a diffusion screen to minimize turbulence and short circuiting. At the end and in the bottom of each separator bay is a heavy organics sump. Each sump is capable of holding-approximately 200 gallons before overflowing into the separator bay. A high level alarm on the OHC control room board is incorporated on the separator bays to indicate when the organics should be pumped to Per-Tri. The heavy layer pumps are piped up so that either pump can pump organics from either bay to the Per/Tri DH still feed tank. It is not possible to pump the heavy organics from one bay to the other bay. Motor alarms are in the OHC control room. At the end of each separator bay and in the top is a skimmer, inverted weir, and overflow weir. The light phase will collect in the skimmer and be diverted to the rear scum compart ment. The skimmer height is adjustable as it consists of a rotatable horizontal 10" pipe with a slot cut lengthwise. The aqueous underflows the inverted weir, overflows the weir, and goes into the middle compartment. The rear compartment consists of an inverted weir and an overflow weir. This traps the scum while allowing the excess aqueous to flow to the middle compartment. The light phase will buildup in the rear compartment and will require periodic removal by vacuum truck. Each rear compartment can hold approximately 775 gallons of lights before break through to the middle compartment will occur. The middle compartment overflows to the surge pond. Piping from the separator to the surge pond for the aqueous overflow is Furan; the piping for the organic return to Per/Tri is also Furan. SL 104674 4-10 API TYPE SEPARATOR Figure II. B. 1 Revised 10-22-79 OUTLET TO PLAN SIDE VIEW SL 104675 4-11 Revised 10-22-79 C. SURGE POND The surge pond is a bentonite clay lined earthen pond with sloped sides. The purpose of the surge pond is to level out the flow to the two steam stripper units and to provide surge capacity during short outages. The design criteria was to provide 24 hours of surge capacity based on 500 GPM of flow. Flow into the surge pond is by gravity from the API type separator and by pumping from VCM II. The purpose of the bentonite lining is to provide a water impervious membrane. The bentonite clay used was Volclay "Saline Seal 100"; it was applied at the rate of three pounds per square foot. Details of application are listed on drawing 57A-20060. The surge pond dimensions are approximately 8' deep x 135' x 195' giving an aqueous storage capacity of 1.2 million gallons. To prevent overflowing the pond, an overflow line to the 30" storm sewer was installed on the east side. A liner protector is installed under the inlet line as the liner can easily be destroyed if high velocity water is allowed to flow into the pond against the membrane. Dredging of the hold pond should not be done. Surge Pond pertinent elevations are: Bottom of pond-108 ft. Bottom of pump suction line-109 ft. Top of pump suction - 111 ft. 7 in. Overflow line - 115 ft. Top of dike- 116 ft. X046T6 Sb 4-12 Revised 10-22-79 The stripper feed pumps are not self-priming. Therefore, it is necessary to fill the surge pond above the 1111--7" level before starting the pumps. The surge pond level can then be lowered down to the 110' level without danger of cavitation. The feed pumps for both stripper systems use a common suction line. Between the 111' level and the overflow line there is sufficient holding capacity to hold 500 GPM for a 24 hr. period. The surge pond level is monitored by a high (114') and low (110') level alarm in the OHC control room. All level reading must be made outside by gauging. STRIPPER AREA 1 . Equipment (Old Stripper Unit) a. Stripper Feed Pumps A and B SAC No. 55-2560 and 55-2561 These are Durco Mark II 4 x 3-13 pumps, designed for 600 GPM at 144 ft of head. The material of construction is Hastelloy C. The impeller diameter is 13 inches. They are driven by 50 hp, 1750 RPM motors. b. Preheater SAC No. 60-1421 The preheater is a 5'-0" I.D. x 7'-0" T/F vertical vessel constructed of Furan. It was designed for 15 psig pressure and 10 psia vacuum at 350 F and is protected by a 4" impregnated graphite rupture disc rated at 15 pst. A six inch diameter sparger with four rows 90 apart of six 3/4" diameter holes is used for live steam injection. c. Steam stripper SAC No. 67-114 The steam stripper is a 4'-0" I.D. x 25'-3" T/F vertical vessel constructed of Furan. It was designed for 15 psig pressure and 10 psia vacuum and is protected by a 4" impregnated graphite rupture disc rated at 15 psi. The stripper contains one 15' section of 2" ceramic intalox stoneware packing. A four inch diameter sparger with one row of sixteen 3/4" diameter holes is used for live steam injection. d. Stripper Bottoms Pumps SAC No. 55-2562 and 55-2563 These are Durco Mark II 443-13 pumps, designed for 600 GPM at 99 ft of head. The material of construction is Hastelloy C. The impeller diameter is 11-7/8 inches. They are driven by 30 hp, 1750 rpm motors. SL 104677 4-13 10-22-79 e. Economizers SAC No. 71-1655 There are six horizontal single pass economizers piped up in two banks of three each in series. Each economizer contains eightyeight 3/4" O.D. 20 BWG 33'-2" long tubes of Ti-38A (Titanium). The shell is also constructed of Ti-38A. Ti-38A is a titanium alloy containing 0.3% molybedenum and 0.8% nickel and is suitable for boiling 5% HCl. Surface area per-individual unit is 572.9 sq.ft.; total surface area is 3437.4 sq. ft. Design shell side temperatures were 215F in and 120F out; design tube side temperatures were 90 F in and 185F out. Design pressure was 50 psig for both shell and tube sides. f. Stripper Condenser SAC No. 71-1656 The stripper condenser Is a vertical downflow single pass condenser constructed of T1-38A. Ti-38A is a titanium alloy containing 0.3% molybdenum and 0.8% nickel and is suitable for boiling 5% HCl. There are one hundred thirty-seven 3/4" O.D. 20 BWG 15'-6" long tubes of Ti-38A. Surface area is 417.6 sq. ft. Design shell side temperatures were 90F in and 115F out; design tube side temperatures were 215F in and 115F out. De sign pressure was 75 psig on the shell side and 30 psig on the tube side. g. Phase Separator SAC No. 60-1422 The" phase separator is a 4'-0" I.D. x 8' T/F vertical vessel constructed of Furan. It was designed for 15 psig pressure and 10 psia vacuum at 350F and is protected by a 2" Impregnated graphite rupture disc rated at 15 psi. h. Stripper Product Pumps Sac No. 55-2280 and 55-2281 These are Durco Mark II, FRP (Durcon 700), 1^ x 1-6 pumps, designed for 2.5 GPM at 73 ft of head. The Impeller diameter is 4 1/8". They are driven by 2 hp, 3500 rpm motors. Stripper Vent Scrubber SAC No. 67-115 The stripper vent scrubber Is an 18" I.D. vertical, open top vessel containing 4' of 1" ceramic intalox stoneware packing. j. Instruments All of the controllers in the stripper area are on the board in the OHC-Tetra control room. Recorders, indicators, and alarms are likewise on the board in this control room. Si l04678 4-13 a Revised 10-22-79 Equipment (New Stripper Unit) a. Stripper Feed Pumps 3 and 4 SAC No. 55-2933and 55-2934 These are Durco Mark 11 4 x 3-13 pumps, designed for 600 GPM at 144 ft of head. The material of construction is Hastelloy C. The impeller diameter is 13 inches. They are driven by 50 hp, 1750 rpm motors. b. WTU Preheater SAC ^ 71-2104 The pick preheater is an in line steam injection header providing direct contact of steam and the feed. The injection tube, rated at 15,000Vstearq/hr, is constructed of Hastelloy C. It is housed in a teflon lined 10" 150^ ANSI Tee. c. Steam Stripper ^2 SAC No. 67-171 The steam stripper is a 4'-0" I.D. x 25'-3" T/F vertical vessel constructed of Furan. It was designed for 15 psig pressure and 10 psia vacuum and is protected by a 6 " impregnated graphite rupture disc rated at 15 psi. The stripper contains one 15' section of 2" ceramic intalox stoneware packing. A four inch diameter sparger with one row of sixteen 3/4" diameter holes is used for live steam injection. d. Stripper Bottoms Pumps 3 and 4 SAC No. 55-2931 and 55-2932 These are Durco Mark II 443-13 pumps, designed for 600 GPM at 99 ft of head. The material of construction is Hastelloy C. The impeller is 11-7/8 inches. They are driven by 30 hp, 1750 rpm motors. e. Economizers SAC No. 71-2100, 71-2101, and 71-2102 There are three horizontal single pass economizers piped up in one bank of three each in series. Each contains eighty-eight 3/4" O.D. 20 BWG 33'-2" long tubes of Tk-code 7 or Ti-code 12 titanium. The shell is constructed of Ti code 7 titanium. Surface area per individual unit is 572.9 sq. ft.; total surface area is 1718.7 sq. ft. Design shell side temperatures were 215F in and 120 F out; design tube side temperature were 90F in and 185F out. Design pressure was 50 psig for both shell and tube sides. f. Stripper ^ 2 Condenser SAC $ 71-2103 The stripper ^2 condenser is a vertical downflow single pass condenser constructed of Ti code 7 and Ti code 12 titanium tubes and Ti code 7 titanium shell. There are one hundred thirty-seven 3/4" O.D. 20 BWG 15'-6" long tubes of Ti-38A. Surface area is 417.6 sq. ft. Design shell side temperatures were 90F in and 115F out; design SL 104679 4-13 b Revised 10-22-79 tube side temperatures were 215F in and 115F out. Design pressure was 75 psig on the shell side and 30 psig on the tube side. g. Phase Separator ^2 SAC No, 60-1889 The phase separator is a 4*-0" I.D. x 8' T/F vertical vessel constructed of Furan. It was designed for 15 psig pressure and 10 psia vacuum at 350F and is protected by a 2" impregnated graphite rupture disc rated at 15 psi. h. WTU Steam Desuperheater SAC No. 71-2105 The WTU Desuperheater is a Copes-Vulcan 8"-300 lbs, WCB VO-76 desuperheater designed to supply 30,000 LBS/Hr of steam at 50 psi and 318 F. I. Instruments All of the controllers in the stripper area are on the board in the OHCTetra control room. Recorders, indicators, and alarms are likewise on the board in this control room. 3. Operation The function of the stripper area is to remove and recover soluble chlorinated hydrocarbons from the aqueous effluent. It is composed of two steam stripper units. Identical equipment in the two units are the feed pumps, bottoms pumps, strippers, economizers (the old unit has six; the new unit has three) condensers, and phase separators. The preheaters are different, the new unit used the stripper product pumps and the vent scrubber of the old unit. In addition three of the economizers from the old unit can be used in the new unit, a. Old Stripper Unit Feed from the surge pond is pumped to the shell side of the stripper condenser by the stripper feed pumps. Since the stripper feed pumps are not self-priming, it Is necessary to fill the surge pond about the 111'- 7" level before starting. A small (5GPM) stream takes off before the stripper condenser for use on the vent scrubber. The effluent from the SL 104680 4-14 Revised 10-23-79 vent scrubber is returned to the API type separator. The feed from the surge pond is flow controlled. This flow is recorded. There is a low flow alarm set at 100 GPM. Feed is used as the cooling medium on the stripper condenser since cooling tower water was not available in the area and because the feed must be preheated, A bypass around the condenser was installed to increase rates on the stripper. The original design of the plant was 500 gpm. It is possible to flow more through the condenser but increased flow causes tube vibration. Tube vibration can be heard as a rapid knocking sound in the condenser. If this condition persists it will destroy the tubes. Under normal conditions the bypass valve is adjusted to give a 10 temperature 3ifferential on the water side of the condenser. This ensures that enough water is being bypassed so the tubes won't be damaged and that a good job of condensing is being accomplished. At rates of less than 450 gpm the bypass is not needed and should be blocked in. The feed then goes to the economizers. At low rates it may also be necessary to block in one bank of economizers to prevent water hammer in the system. In the economizers the feed is heated with the bottoms effluent from the steam stripper. This recuperation step saves both steam and cooling tower water. Feed is on the tube side and the steam stripper bottoms effluent is on the shell side. The feed leaves the economizers at about 185 F and enters the bottom of the preheater. There are Tl's and Pi's on the inlet and outlet of each economizer to adequately monitor their performance. The temperature leaving the last economizer is recorded. SL 104681 4-14 a Revised 1 0-25-79 The feed enters the preheater and is heated with live steam to around 200 F. The flow of 30 psi steam is controlled based on the temperature of the feed leaving the preheater. Liquid is prevented from backing up the steam line by an 8' seal loop. A valve is provided at the top of the seal loop for N2 addition. The steam flow and the temperature of the feed leaving the preheater are recorded. A 10" emergency overflow in the preheater to the API type-separator is provided for upset conditions. There is a 6' seal loop on the emergency overflow. Vapors are vented to the stripper condenser. The feed leaving the preheater flows by gravity through a 4` seal loop to two feed spargers on the steam stripper. Live 30 psi steam is injected in the bottom of the steam stripper to give a small (1%) boil up. The steam is mass flow controlled and the flow is recorded on the board. Liquid is prevented from backing up the steam line by a seal loop. Steam is supplied from two sources in the OHC plant. The primary source is 30 psi steam generated from the two small OHC reactors. (Actual pressure is about 34 psi). The other source is superheated 30 psi steam controlled at the EDC control room. Whenever both small OHC reactors are down superheated steam automatically flows to the header. It may be necessary to have EDC adjust the pressure at their station. A desuperheater is located in the OHC plant. Condensate is added automatically to control the temperature of the steam. This is important because the spargers in the stripper are good to 350 F and the superheated steam is above 500F. There is a temperature alarm on the steam going to the stripper. |t is located at the desuperheater in OHC. SL 104682 4-15 Revised 10-25-79 A constant liquid level is kept on the bottom of the steam stripper by a control valve on the stripper bottoms stream. High and low level alarms are provided on the liquid level. In addition, there is a 6" emergency overflow to the API type separator. This overflow has an 8' seal loop. The temperature of both the stripper bottoms and stripper overhead is recorded. The overhead from the steam stripper as well as the vapors from the preheater are fed to the stripper condenser. These vapors consist of azeotropes of water and chlorinated hydrocarbons and are condensed in the stripper condenser and collected in the phase separator. The water phases out on top of the more dense chlorinated hydrocarbons and is drained off to the API type separator. The chlorinated hydrocarbons are pumped from the phase separator to the Per/Tri DH Still feed tanks. A common line carries the organics from the separator bays of the API type separator and from the stripper phase separator. The total flow is indicated on the OHC board and recorded on the Per/Tri board. An interface level controller governs the flow of stripped product from the phase separator. This flow is recorded. There is a low interface level alarm on the phase separator and a low flow alarm on the flow of stripped product to Per/Tri. The stripper condenser is vented to the vent scrubber. The effluent from the bottom of the steam stripper is pumped to the shell side of the economizers. After leaving the economizers it goes to the combination of sewers for neutralization. SL 104683 4-16 Revised 10-29-79 b. New Stripper Unit Feed from the surge pond is pumped to the shell side of stripper ^2 condenser by the stripper feed pumps ^ 3 and ^4. Since the stripper feed pumps are not self-priming it is necessary that the level in the surge pond be above the 111'-7" level before starting. The feed from the surge pond is flow controlled and recorded. There is a low flow alarm set at 100 gpm. Feed is used as the cooling medium on stripper $ 2 condenser. There is a bypass around the stripper condenser #2 for use at rates above 450 gpm. It is possible to flow more through the condenser but increased flow causes tube viberation. Tube vibration can be heard as a rapid knocking sound in the condenser. If this condition persists it will destroy the tubes. Under normal conditions the bypass valve is adjusted to give a 10 temperature differential on the water side of the condenser. This ensures that enough water is being bypassed so the tubes won't be damaged and that a good job of condensing is being accomplished. At rates of less than 450 gpm the bypass is not needed and should be blocked in. The feed then goes to the economizers. As the new stripper unit has only three economizers, rates above 400 gpm are possible only by using the center bank of economizers in addition to the top bank. This could happen only if the old stripper unit was down or at reduced rates (running on only the lower bank of economizers). Thus the total through put of the stripper area is around 1000 gpm(600 gpm through one unit and 400 gpm through the other.) SL 104684 4-16 a Revised 10-29-79 In the economizers the feed is heated with the bottoms effluent from the steam stripper. This recuperation step saves both steam and cooling tower water. Feed is on the tube side and the steam stripper bottoms is on the shell side. The feed leaves the economizers at about 185 F and enters the preheater. The^e are Tl's and Pi's on the inlet and outlet of each economizer to adequately monitor their performance. The temperature leaving the last economizer is recorded. The feed enters the preheater and is heated with live steam to around 200 F. The flow of steam is controlled based on the temperature of the feed leaving the preheater. In addition the steam pressure must be kept above but not more than 10 psi greater than the feed pressure at the preheater. A globe valve and gauges are provided. Liquid is prevented from backing up the steam line by a seal loop. The steam flow and the temperature of the feed, leaving the preheater are recorded. The feed leaving the preheater flows to two feed spargers on the steam stripper. Live 50 psi steam is injected in the bottom of the steam stripper to give a small (1%) boilup . The steam is mass flow controlled and the flow is recorded on the board. Liquid is prevented from backing up the steam line by a seal loop. Steam to the new stripper unit is supplied by pressure reducing 175 psi steam generated in No. 3 incinerator and then desuperating it. If No. 3 incinerator is down, steam will come from the 175^ system but will be at a higher temperature (up to 725F). Condensate for the desuperheater comes from the boiler feed pumps at No. 3 Incinerator. The steam coming into the unit is at 50 psi and 318F (20 F superheat). Th re is a high temperature alarm after X04685 Sk 4-16-b Revised 10-29-79 the desuperheater. A constant liquid level is kept on the bottom of the steam stripper by a control valve on the stripper bottoms steam. High and low level alarms are provided on the liquid level. In addition, there is a 6" emergency overflow to the API type separator. This overflow has an 8' seal loop. The temperature of both the stripper bottoms and stripper overhead is recorded. The overhead from the steam stripper as well as the vapors from the preheater are fed to the stripper condenser. These vapors consist of azeotropes of water and chlorinated hydrocarbons and are condensed in the stripper condenser and collected in the phase separator. The water phases out on top of the more dense chlorinated hydrocarbons and is drained off to the API type separator. The chlorinated hydrocarbons are pumped from the phase separator to the Per/Tri DH Still feed tanks using the old stripper unit's stripper product pumps. The phase separators in both stripper units are connected and piped such that the organic level will be the same with both units running. The interface level on either phase separator can be used as the signal to interface level controller governing the flow of stripped product from the phase separators. There is a selector switch allowing one to choose which phase separators interface level is used. Valving will allow either phase separator to be isolated. This flow is recorded. There is a low interface level alarm on the phase separator and a low flow alarm on the flow of stripped product to Per/Tri. The stripper condenser is vented to the old stripper unit's vent scrubber. The effluent from the bottom of the steam stripper is pumped to the shell side of the economizers. After leaving the economizers it goes to the SL 104686 4-16 c Revised 10-29-79 combination of sewers for neutralization. 4. Abnormal Operating Conditions The following is intended to be a brief description of the most common operating problems in the stripper units: a. Stripper Bottom pump seal failures It is necessary to keep cooling water on the seals to promote their life. Without the cooling water the seal faces overheat due to friction. This leads to early failures. b. Running liquid over the phase separator vaccum breaker The primary cause of this is too high of a pressure on the system. This is caused by one of two things: Either excess N2 or excess steam is being used on the system. c. Screen plugging There are ten screens located in the unit. The purpose of the screens is to keep solids from collecting inside the economizers. There locations are: two at the feed pumps two at the vent condenser two on the feed inlet to the economizers two on the bottoms inlet to the economizers two on the stripper bottoms pump Inability to obtain feed flow is most often due to screens being plugged. By considering pressures and position of the feed valve it is possible to tell if the plug is before or after the feed FCV. Most often the problem will be located in the feed screens. By noting temperature differential and position of the vent condenser bypass valve it is possible to estimate the condition of the screens at the vent condenser. SL 104687 4-17 Revised 10-29-79 If one of the feed inlet screens is plugged more than the other and the bottoms flow is equivalent on both sides then it is possible to distinguish the plugged screen by outlet temperatures on the feed side of each row of economizers. When the stripper bottom screens plug it will be evident due to high level in the stripper and cavitating pumps. Since there screens are on the suction, it is advisable to shut one pump down and let the remaining pump run. This may back flush enough solids away from the screen on one pump that it will no longer cavitate when running. The other pump can then be shut down and the screen cleaned, d. High pH High pH (above 7.0) can not be tolerated in the unit. High pH will attack the titanium and eventually destroy it. E. UTILITIES The sewer segregation plant is supplied with well water, steam, instrument air, and nitrogen. 1 . Well Water Well water is supplied to the area with a 2" line from the incinerator area. Well water is used for safety showers and utility stations. 2. Steam Thirty pound steam is supplied to the old stripper unit with an 8" insulated line from the OHC area. Steam is used on the steam stripper and the preheater. Both flows are metered and recorded. Thirty pound steam is also supplied to all the utility stations in both stripper units. The source SL 104688 4-17 b Revised 10-29-79 Substation and Powerhouse "A", Note: Switching of the Organics Sub station is carefully controlled to prevent a direct tie berween Powerhouse"A" bus 5 and 2. If switching from organics bus No. I to bus No. 2 becomes necessary, care should be exercised not to tie the two powerhouse buses together. Damaging circulating currents resulting from voltage differences in buses may result if tied together. Plant electrical assistance should be obtained before any switching. 104689 SD 4-18 Revised 10-29-79 G. INSTRUMENTS 1 . General Operation Smooth control of the steam stripper is essential to ensure the efficient removal of chlorinated hydrocarbons from the waste water. The steam stripper and preheater cannot be operated with varying flows. To obtain the proper control, both steam stripper units have been equipped with automatic instruments and alarms. The discussion that follows relates to the interpretation of alarms, controller operation, control valve fail safe positions, instrument power, and the lift station level control system. 2 . Process and Motor Alarms When an upset occurs in the process, it will be alarmed by a horn and flashing light which identifies the location of the abnormality. Normal operation is indicated by a green light. A flashing red light indicates either a high or low temperature, level, etc. The flashing red light and horn blasts can be stopped by pushing the acknowledge button on the control board. If the process variable is still abnormal, the light will remain red. Pumps are alarmed in the same manner as process variables. A green light indicates that the pump is running. If the pump motor is shutdown or shuts down for various reasons, the indicator light will flash and the horn will sound until acknowledged. The indicator light will remain red until the pump is started up. 3. Controller Operation The controllers used for the steam stripper area are Taylor electronic. They can be operated on manual or automatic control. 104690 SL 4-19 Revised 10-29-79 Normally, the controller will be operated on automatic to insure the proper response to process variations. During upset conditions or start-up or shutdown periods the controller can be operated on manual. While operating on automatic, care should be exercised to minimize process upsets when making setpoint changes. If a set- point change is desired, it must be made in small increments to prevent the controller from fully opening or closing the control valve. When switching from automatic to manual becomes necessary, the control mode can be switched without balancing the controller output with the manual output since this is done automatically by the electronic controller. When switching from manual to auto matic, always adjust the set-point to the existing process variable value or the red pen before switching the mode. 4. Control Valve Fail Safe Position All the control valves in both steam stripper units are actuated by instrument air. However, the signal to the valve is electronic. Therefore, the loss of power to the controller or loss of instrument air to the valve will cause the control valve to go to the fail safe position. Table IV. H. I gives the failed positions for all the valves. The operator should memorize the failed position of the valves for proper emergency response. 5. Instrument Power Power to the Steam Stripper instruments in the OHC control room Is normally supplied from the 480 VAC MCC bus No. 17816 which is located in the new OHC control room. There is a transfer panel (8801A-3) in MCC center 8801A which is located in the new OHC control room. The transfer panel will automatically switch the instrument panels from bus No. 17816 to bus No. 8801A which is the alternate Si l469l 4-20 emergency 480 VAC source. The alternate source comes from the liquefaction area. The 480 VAC supply from the transfer panel is reduced down to 120/240 VAC by a transformer before going to the instrument breaker panels. With a complete loss of power to the instrument panels, the 24 VDC back-up battery system will keep all the con trollers operational. A number of the recorder chart drives and indicator pens will not be operational since they operate off 120 VAC. 6. Lift Station Level Control System (See Table JV. A. I for Lift Station Data) All the lift stations have the same level control and alarm system. The lift stations are equipped with a high level alarm which is located in the area control rooms. Also, the motors have lights in the area control rooms to indicate the operational status of the pumps. An on-off control system was incorporated into the lift station pumps to control the sump level. When there is a normal operating level, only one sump pump will be operating. If the level drops to a low level, the primary pump will be shut off. It will then be started up again when the level reaches the normal operating level. If the first pump cannot keep up with the water flow, the second pump will be started. Both pumps will stay on until the low level switch shuts them down. There is a control panel for each lift station mounted near the sump. Mounted on the control panel are three control switches. One switch is the master control while the other two are for the sump pumps. The two control switches for the sump pumps have an SL 104692 4-21 auto, manual, and stop position. In the auto position the pumps will be automatically turned off and on by the level control system. The manual position allows the pumps to be turned on and off in dependent of the control system. Between the two pump switches is the master control switch. The master control switch has two positions for selecting the primary pump. SL 104693 4-22 Revised 10-29-79 CONTROL VALVES FAIL SAFE POSITION TABLE IV. H I (BOTH UNITS) Stream Steam Stripper Feed FCV Preheater Steam TCV Steam Stripper Bottoms LCV Steam to Stripper FCV Phase Separator LCV Failed Position Open Closed Open Closed Open SL 104694 5-1 Revised 10-30-79 V. START-UP A. SEWER COLLECTION SYSTEM: See Dwgs. 20A-20027-20A-20031 Refer to Tables IV. A. I and IV. A. 2 in the detailed process and equipment description for lift station and collection source data. If inlet water flows to the API separator are excessive, these tables can be used to determine the water sources in Area B. To get waste flow into the API separator, call the individual control rooms to get the lift station pumps put in service. The lift stations are located at the following areas: Lift Station No. 1 2 3 4 5 6 7 8 9 Area VC OHC TE P/T EDC P/T OHC Sewer Segregation Plant T-E II B. API TYPE SEPARATOR: See Dwgs: 20A-10012, 10A-10014 Once waste begins to flow into the API separator, heavy organics will settle out in the separator bays. Upon getting a high level alarm on the heavy layer organics, call Per-Tri to inform them that organics will be pumped into the DH feed tanks.Per-Tri hasa total organics flow recorder which includes the heavy layer and stripped product; OHC has only a flow indication on the combined streams. The heavy layer pumps should only be used to lower the heavy layer level in the API separator intermittently to prevent unnecessary aqueous flow going into the DH feed tanks. SL 104695 5-2 Revised 10-30-79 The skimmers should be adjusted at the east end of the separator bay compartments to divert oil scum to the rear scum compartments. An inverted weir in the rear scum compartments will prevent scum from overflowing into the middle compartments. Periodic vacuum truck cleaning of the rear scum compartments will be necessary. The aqueous phase will overflow from the separator bays into the middle compartments then into the surge pond. Excess water in the rear scum, compartments will overflow into the middle compart ments. C. SURGE POND: See Dwg: 20A-10012 With a normal operating level of three feet in the surge pond, the total surge capacity is 790,000 gal. This amounts to 500 GPM for 24 hours of excess flow. The pond level will need to be at least 4 feet before starting the stripper feed pumps to insure a sufficient priming level. Operation of the stripper feed pumps with a surge pond level below 2 feet may cause cavitation and loss of prime. A low level alarm will be activated at 2 feet and a high level alarm will be activated at 6 feet. The surge pond level must be checked during start-up and normal operation each shift since there is no control room board level indication. D. STEAM STRIPPER AREA: See Dwgs: 20A-10010, 20A-10012, 20A-10014 1. Steam Header From OHC SL 104696 5-3 Revised 10-30-79 a. Block all downstream block valves on the stripper and preheater steam stations. Crack open the header steam traps strainer valve and bypasses and the steam station purge valves. Close all header vent valves. b. Crack open the 30 psig steam valve at the OHC header on the second deck. c. Purge condensate and air at the strainers and steam stations until live steam blows out. All condensate should be purged before putting the steam stations in service to prevent damage to the spargers in the stripper and preheater. Close the header steam trap strainer and bypass, valves and open the steam header valve fully. Check the header steam traps to make sure they are operating properly. Leave the steam station purge valves cracked open until the steam stripper and preheater are put in service. d. Allow sufficient time for the steam header to come to equilibrium temperature. 2. Steam Header from No. 3 Incinerator a. Block all downstream block valves on the stripper and preheater steam stations. Crack open the header steam trips strainer valve and bypasses and the steam station purge valves. Close all header vent valves. b. Insure that condensate is available at the desuperheater. Set the desired temperature on the field mounted controller for the steam leaving the desuperheater. c. Open the manual block valves at the 150 psi to 50 psi reducing station. Begin bleeding steam at the pressure reducing station. d. Slowly pressurize the header by raising the set point on the field mounted controller. e. Purge condensate and air at the strainers until live steam blows out. Put the 175 to 50 psi reducing station in service. Close the bleed valve. f. After all the condensate is purged out of the header, put the stripper and preheater steam stations in service. Close the header steam trap strainer and bypass valves and open the steam header fully. Check the header steam traps to make sure they are operating properly. Leave the preheater and stripper steam station purge valves cracked open until they are put in service. SL 104697 5-4 Revised 10-30-79 Stripper Area Check List a.__ Stripper Feed Pumps Activate switch gear ____ Close drain and sample valves ____ Open one suction valve ____ Crack discharge valve on same pump ____ Close discharge valve on other pump ____ Check pump operation and oil ____ Check PI guage valve b. Stripper Feed FCV Close purge valve Close bypass ____ Stroke valve ____ Open FCV block valves Leave partially open on manual c. Condenser Close feed out purge valve Check PI guage valve on feed out Open scrubber water valve d. Economizers Close stripper feed and bottoms bypass valves Open remaining process stream valves on economizer Check PI guage valves e. Preheater (old Unit) Fill emergency overflow line - seal loop with water SL 104698 5-5 Revised 10-30-79 f. Stripper Close IT drain valves. Open block valves Close sight glass purge valves. Open block valves Fill emergency overflow line with water g. Stripper Bottoms Pumps Activate switch gear Close drain and sample valves Open one suction valve Crack discharge valve on same pump _ Close discharge valve on other pump Check pump operation and oil Check PI guage valve h. Stripper Bottoms LCV Close purge and bypass valves Stroke LCV Open LCV block valves Open recycle valve to surge pond. Close outfall valve. 1. Phase Separator Close sight glass cleanout valves Open sight glass block valves Fill seal loop with water j. Phase Separator Pumps Activate switch gear Close drain valves Open one suction valve SL 104699 5-6 Revised 10-30-79 _____ Crack discharge valve on same Close discharge valve on other pump Check pump operation and oil k. Phase Separator LCV Close bypass and drain valves Stroke valve Open LCV block valves Start-Up Procedure (Either Unit) a. Put N_ on the steam line going into the preheater and stripper to prevent water build-up in the spargers during the initial steam injection. b. Start-up stripper feed pump and circulate surge pond water through the condenser, economizers, preheater, and into the stripper. Start-up the stripper bottoms pumps after an operating level In the bottom is reached. In crease stripper feed up to about 200 GPM for heat-up purposes. c. Check the stripper bottoms LCV operation to make sure that it controls the level. Also, check the bottoms flow to make sure it is returning to the surge pond. Check the piping system and vessels for leaks. Check scrubber water flow. d. With the downstream steam stations block valves closed, stroke the preheater TCV and the stripper FCV to check for smooth operation and control action. Check the N2 flow to the sparger to Insure that water is not backed up into the steam system. If there are no apparent leaks or.operational problems, the steam can be cracked into the stripper sparger. After heating up the steam line and sparger, the steam to the stripper can be gradually increased. e. Once the preheater overflow reaches 160 to 180F, the steam can be cracked into the preheater. Care should be exercised at this time since condensate and water will cause water harmer and possible damage to the steam sparger. When water hanmering slows down, gradually raise the steam flow on manual control. Once flow is established, the TCV can be put on automatic. Increase the temperature setpoint by one degree increments until the preheater overflow temperature is 200F. SL 104700 5-7 Revised 10-30-79 f. The stripper steam flow will need to be adjusted to approximately 8 1b/hr/gpm of water fed. At 200 GPM of feed water the stripper steam flow will be 1600 Ib/hr. Once the stripper operation is established the ratio of steam to water may be reduced or increased. g. The Ng flow can now be blocked off on both spargers. h. Periodic samples of the stripper bottoms should be taken to check the organics level. When the organics is below 25 ppm, the bottoms can be switched to the outfall rather than the surge pond. The steam flow to the stripper should be Increased if the organics level is above the acceptable level. i. After the stripper operation Is stabilized, the feed can be adjusted until the stripper rate equals the API separator inlet rate. - j* When a phase separator organics level of approximately 502 Is reached call P/T to insure that the DH feed tank header valve is opened. Start the phase separator pump to maintain a proper level. The aqueous phase will overflow by gravity into the API separator. Check the phase separator LCV operation to insure proper level control. k. With the steam stripper operating smoothly at tne same rate as the API separator, samples of the stripper feed and bottoms should be caught and run for total ppm organics to check for efficiency of separation. SL 104701 6-1 Revised 10-30-79 VI. SHUTDOWN OF STEAM STRIPPER (EITHER UNIT) If Either Steam Stripper Unit must be shutdown for repairs, the waste feed to the API separator can continue to overflow to the surge pond. With a normal operating level in the surge pond, the surge capacity is approximately 500 GPM for 24 hours. There should be sufficient time for maintenance to make repairs to a steam stripper unit without overflowing the surge pond into the outfall. The following shutdown sequence can be used as a guide for shutting down either or both Steam Stripper Units. Shutdown Sequence 1. Open the return valve to the surge pond. Block off the water to the combination of sewers. 2. Put N2 on the preheater and steam stripper inlet steam lines. This will reduce corrosion In the preheater inlet steam line and will reduce backflow of water into the spargers. 3. Shut off steam to the preheater and steam stripper. Block off both steam station control valves. 4. Shutdown the steam stripper feed pumps. 5. Shutdown the stripper bottoms pumps and close the discharge valves. 6. Block off the Phase Separator to the stripped product pumps line. Shutdown the Phase Separator stripped product pumps and close the discharge valves if both units are shutting down. 7. Drain the system as required. For any extended outage the preheater in the old unit should be drained. SL 1047Q2 6-2 kevised 10-30-79 8. If it is necessary to take the steam header to the existing unit out of service, the steam can be blocked at OHC on the second deck. Drain off the live steam and condensate at the steam stripper steam stations. The steam header to the new unit can be blocked at the pressure reducing station in the No. 3 incinerator area. 0^> 7-1 Revised 10-30-79 VII. EMERGENCY SHUTDOWNS A. LOSS OF POWER: 1. Results of Power Loss a. The instrument power will automatically be switched to the auxiliary power if there is a loss of the main power. This will allow full control of instruments. If the auxiliary instrument power is lost, the control valves will still be operational since they are backed up by the 24 VDC battery system. 2. Response to Power Loss a. Since there will be no feed to the steam stripper, the steam to the preheater and stripper should be shut off immediately. b. Put N2 on the preheater and stripper inlet steam lines. c. If the power loss is for a long period of time, the steam stripper should be shutdown according to the Shutdown Procedure on page VI - 1. Start-up according to the Start-up Procedure whenever power is available. B. LOSS OF STEAM 1 . Results of Steam Loss a. Temperatures on the preheater overflow and stripper bottoms will decrease. The stripper bottoms will be out of specification on total organics. b. Water will backflow into the steam spargers. 2. Response to Steam Loss a. Close the preheater and stripper steam control valves and block valves, b. Put N2 on the inlet steam lines into the preheater and stripper. c. Divert the stripper bottoms from the neutralization plant or outfall to the surge pond. <bV 7-2 d. Shutdown the stripped product pumps on the phase separator and block the pump discharges. e. If the steam loss is for a long period of time, the Steam Stripper should be shutdown according to the Shutdown Procedure on page VI. - 1. Start-up accord ing to the Start-up Procedure whenever the steam is available. C. INSTRUMENT AIR LOSS 1. Results of Instrument Air Loss a. All the control valves will fail in their fail safe position. See Table IV. H. I for the fail safe positions. b. Steam flow will be shut off. The temperatures will then begin to fall off. The stripper feed, stripper bottoms, and phase separator level control valves will completely open. 2. Response to Instrument Air Loss a. Put the steam control valves in the closed position. b. Shutdown the stripped product, stripper feed, and stripper bottoms pumps. c. Put N2 on the inlet steam lines to the preheater and stripper. This should be done, regardless of the time the steam is shut-off, to prevent water hammer in the spargers during start-up. d. If the instrument air loss is for a period of time, the steam stripper should be shutdown according to the "Shut down Procedure" on page VI. - 1. Start-up according to the "Start-up Procedure" on Page V. - 6 whenever the instrument air is regained. Sb 104705 SL 104708 SL 104710 SL 104711 SL 104712 SL 104713 'Hf- *' SL 104714 A&EA U M /TJ SL 1 04716 $ 8k wtmy t'O J?2/? UMtTS* 2 \ /\ / 0 O z \ /\ / 0 O / \/ \ REVISIONS /\meq,veti wwi --*(1*1)1 MD CUM. C3H-1S3.P--7J6TT WFW B.rrt. BA*-2 ISO cmt. R-6- S-I0-7S ffea im/rs (ts) ruMp no xm.un n)T**)**wt sspiOATos ai tPK-Tot eeAcidir sciubisk tU @ eut-oiCAL ptt*iD @pn pLL f*p TAd* 4<T SLABS PBAIH i*UO* TAMIt. SISHT dLASS PSAIN puup no pbaih BlTtt>*eP1ATBUD TAN* SCdUT dLABS OTCAIjJ POMP Viixuni PKAIII @pun^>J- stnctiuioe* poaiM @ B077PMB 7UMCH PBAtK <ts) mcioeiATPa pump pap poaiw @ |Mdl(JSKATPg HtAPBK PCAlM @ ppv/iukm pump pbaih @ PPWJKBBM PUMP PBAIH @ ppwpl(BM PUMP PBA1N acip eaten pw? pbaih (sri p*eu.) @ poytjimtu puup pbaih @ BieiM*BA?PII PAP PSAlH @ PAP PBAid (l^pdIt) MATCH UNE FOE CaNTtAtilATfiN SEE OWS,. 20A-Z003O @oe |t*Neu (SJacip ptj @PHe fAP-pgAiN nu) 6fAPT up egBUBISCg ipp, PAP pgAIH ([3I NEW BOTTOMS PLANT PAD DHAIKl (^PEft-TPI VCMT HEACCASUIM 1.0 *+ dpLtus-ppti petHfs. 1. pOg t*Y pl*H pp 71-IN pimp's 4 qcN* BAL- (WfBO, PW<(. TPA-TPOH. INDUSTRIAL JLiv CHEMICAL DIVISION MBUniHl LAO CHA1LCL L0UB1AMA -- g*Aiir. wa-/a.l& 70031.1 SL 104717 RUPTURE DISC SCHEDULE Vessel Preheater (T-l) Steam Stripper (C-l) Phase Separator (T-2) M Graphite/Insert Size 4" Graphite/Insert 4" Graphite/Insert 2" Rating 15#/225F 15#/225F 15#/225F Order No./Loc. 23-851-0085 1-11-05-05 23-051-0085 1-11-05-05 NOTE: Safety heads required with 150# FLG Si IO4 ?2l Revised 10-31-79 SAC LIST SEWER SEGREGATION PLANT Vessels Existing Stripper Unit Preheater T-l Phase Separator T-2 Steam Stripper C-l Vent Scrubber C-2 Economizers E-l Condenser E-2 New Stripper Unit Phase Separator ^ 2 Steam Stripper ^2 Economizers Stripper ^2 Condenser WTU Preheater WTU Steam Desuperheater Pumps API Separator S. Heavy Layer Transfer N. Heavy Layer Transfer Old Stripper Unit S, Stripper Feed Pump N. Stripper Feed Pump W. Stripper Product Pump E. Stripper Product Pump W. Stripper Bottoms Pump E. Stripper Bottoms Pumps New Stripper Unit Stripper Feed Pump ^3 Stripper Feed Pump ^ 4 Stripper Bottoms Pumps ^ 3 Stripper Bottoms Pump % 4 SAC * 60-1421 60-1422 67-114 67-115 71-1655 71-1656 60-1889 67-171 71-2100,71-2101 71-2102 71-2103 71-2104 71-2105 55-2419 55-2418 55-2560 55-2561 55-2280 55-2281 55-2562 55-2563 55-2933 55-2934 55-2931 55-2932 SL 104722 SAC LIST (continued) Lift Station Pumps W. Lift Station No. 1 Pump E. Lift Station No. 1 Pump W. Lift Station No. 2 Pump E. Lift Station No. 2 Pump W. Lift Station No. 3 Pump E. Lift Station No. 3 Pump S. Lift Station No. 4 Pump N. Lift Station No. 4 Pump S. Lift Station No. 5 Pump N, Lift Station No. 5 Pump W. Lift Station No. 6 Pump E. Lift Station No. 6 Pump W. Lift Station No. 7 Pump E. Lift Station No. 7 Pump Lift Station No. 8 Pump rol Valves Old Stripper Unit Valve ^ Stripper Bottoms Stripper Feed Steam to Preheater Steam to Stripper Stripper Product Desuperheater LCV 1015 FCV 1002 TCV 1010 FCV 1016 LCV 1024 TCV New Stripper Unit 175 to 50 psi steam Reducing Station Desuperheater Steam to Preheater Steam to Stripper Stripper Feed Stripper Bottoms PCV 1103 TCV 1104 TV 1109 FV 1129 FV 1141 LV 1130 55-2296 55-2297 55-2564 55-2565 55-2295 55-2294 55-2642 55-2701 55-2702 55-2704 55-2703 55-2705 55-2286 55-2287 55-2733 SAC * 80-13201 80-13202 80-13203 80-13204 80-13205 80-15166 80-18429 80-18430 80-18401 80-18402 80-18403 80-18404 COLLECTION POINT LIST Collection Point Number 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 Description VCM Heavy Still Stack Seal VCM/EC Lab Drain HC1 Scrubber at VCM EC Trench HC1 Header Drain Tri-Ethane AIBN Pad Drain VDCM Pump Pad Drain Pump Pad Drain HC1 Surge Drum Drain MC Plant Trench Catalyst Pot Drain MC Section Scrubber Drain VDCM Dryer Reactivation Drain VDC Phase Separator Drain TCE Storage Tank Scrubber Drain VDC Reactor Drain T/E Scrubber Stack Drain VDCM DM Still Reflux Drum Drain VDC Pad Drain T/E Scrubber Drain No. 1 EDC Scrubber No. 1 EDC Plant Trench P/T Pump Pad Drain No. 2 EDC Plant Trench GC Pot NC - Not Continuous Flow* 20 gpm 1 gpm Max 200 gpm NC NC NC NC NC NC 1 gpm NC 5 gpm NC NC 5 gpm Max 200 gpm NC 1 gpm NC 47 gpm Max 50 gpm NC NC NC 1 gpm Collection Point Number 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 Description No. 2 EDC Plant Scrubber GC Pot Heavy Still Pad Drain Pad Drain VDC Retention Tank Pump Drain Pad Drain Pad Drain Sump Pump Discharge Utility Drain Reboiler Drain VDCM HQMME Tank VDCM Reactor Heater Pad Drain Condensate Pump Pad Drain P/T Entrainment Separator Drain Loading Rack Drain Per-Tri Reactor Trench Recycle Scrubber Auxiliary Still Line Scrubber Trench Around DH Still Feed Tanks Per-Tri Reactor Scrubber Trench Per-Tri Bottoms Tank Scrubber Tank Drain Tank Drain Heavy Still Feed Filter Drain Still Line Scrubber Drain Per-Tri Still Feed Filter Drain *NC- Not Continuous Flow* Max 50 gpm 1 gpm 5 gpm 25 gpm NC 2 gpm 10 gpm 10 gpm 5 gpm 15 gpm 15 gpm 5 gpm 10 gpm 1 gpm NC NC 15 gpm from scrubber 5 gpm NC 60 gpm 10 gpm NC NC NC 20 gpm NC 1.04-1o2S Collection Point Number 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 Description Flow* Tank Drain NC No. 1 Per Phase Separator Overflow NC No. 2 Per Wash Column Overflow NC No. 1 Per Wash Column Overflow NC No. 1 Per Dryer Drain NC No. 2 Per Dryer Drain NC Tri Product Dryers Drain NC No. 2 Per Phase Separator Overflow NC Tri Neutralizer Overflow Scrubber Drain 5 gpm Tri Neutralizer Bottom Pump Pad Drain NC Tetra Compressor Pad Drain NC Pump Pad Drain NC Tetra Plant Trench NC Tetra Emergency Scrubber Max 250 gpm TCE Storage Tank Scrubber 5 gpm Pump Pad Drain NC Chloral Drain 1 gpm DH Still Feed Tank Sight Glass Drain NC Intermediate Crude Tank Sight Glass Drain NC Pump Pad Drain NC Intermediate Crude Tank Sight Glass Drain NC Absorber Acid Pump Suction Drain NC Bottoms Scrubber Drain 5 gpm Bottoms Trench Drain NC Incinerator Pump Pad Drain NC NC - Not Continuous Collection Point Number 76 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 Description Incinerator Header Drain Acid Brick Pad Drain Dowtherm Pump Drain Aqueous Waste Pump Pad Drain Incinerator Pad Drain Acid Brick Pad Drain OHC-Tetra Lab Drain 0HC Trench Dryer Recovery Drain Per-Tri Distillation Trench Per-Trl Lab Drain Shipping Building Drain Shipping Building Drain Per Decolorizer Per-Tri Dryer Filter MC Plant Trenches MC Plant Trenches MC Lab Drain Ash Liquor Tank Drain VCM Trench EC Vent Knockout Pot Tetra AIBN Tank Drain Acid Pit Overhead Drain Drain NC - Not Continuous Flow* NC NC NC NC NC NC 1 gpm NC 50 gpm 50 gpm to scrubber 1 gpm NC NC NC NC NC NC 1 gpm NC NC 15 gpm NC 100 gpm NC NC Collection Point Number 104 105 106 107 108 109 110 111 112 113 114 Description Scrubber Drain Control Valve Drain Tank Drain Shipping Area Storage Pad Drain Shipping Area Storage Pad Drain Shipping Area Storage Pad Drain Shipping Area Storage Pad Drain Pad Drain (2nd deck) Start-up Scrubber New Bottoms Plant Trench Incinerator Header Drain Flow* 4 gpm C NC NC NC NC NC NC 6 gpm NC NC NC