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'" '\ ' r. : t.. .......... ... MONSANTO COMPANY ANNISTON PLANT STANDARD OPERATING INSTRUCTIONS FOR AROCLORS November 1969 BSW 334440 STLCOPCB4080910 DSW 334441 STLCOPCB4080911 MONSANTO COMPANY ANNISTON PLANT STANDARD OPERATING INSTRUCTIONS FOR i' i ' AROCLORS Revised by: M. J. Williams Prod. Foreman Reviewed by: R.. A. Haydel Prod. Supervisor Approved by: H. L. Williams Prod. Superintendent Revision Issued: November 1969 Copy No DSW 334442 STLCOPCB4080912 STANDARD OPERATING INSTRUCTIONS FOR AROCLORS - DISTRIBUTION Plant Manager Production Superintendent Production Supervisor Manufacturing Specialist Maintenance Superintendent Technical Services Department Standards Department Copy No. 1 2 3 thru 12 13 14 15 & 16 17 & 18 STANDARD OPERATING INSTRUCTIONS ' FOR AROCLORS INDEX . SECTION A - SYNOPSIS OF PROCESS SECTION B - SAFETY AND HOUSEKEEPING SECTION C - DETAILED INSTRUCTIONS (Process Function Outline) . Page No. I. Therminol Heater System 1 II. Solid Chlorinator System III. No. A (Solid) Still System IV. Liquid Chlorinator System 13 A6 67 V. Liquid Still System 102 VI. Solid HC1 Clean-Up System VII. Liquid HC1 Clean-Up System 122 125 VIII. Drumming, Flaking, Milling, & Tank Car Loading 129 SECTION D - EMERGENCY PROCEDURE { DSW 334444 STLCOPCB4080914 SYNOPSIS OF STLCOPCB4080915 STANDARD OPERATING INSTRUCTIONS FOR AROCLORS SYNOPSIS OF PROCESS General Aroclors are the reaction products formed by chlorination of Biphenyl and/or Terphenyls using Ferric Chloride Catalyst. The by-product HC1 gas produced is absorbed in water to produce Muriatic Acid. Crude Aroclors are produced in the chlorinators, air blown, distilled, earth treated, filtered, (or treated by passage through porocel column), and loaded for shipment. ; Aroclor is a trade name used to designate chlorination products of | Biphenyl, Terphenyls, or mixtures of the two. The physical properties 1 vary from light free-flowing liquids to crystalline and non-crystal line solids. Depending on the degree of chlorination and the com position of the raw materials, Santowax R, and mixtures of Biphenyl and Santowax R, or Biphenyl and Santowax C, yield products of increas ing viscosity up to non-crystalline resins. A numerical system of nomenclature, consisting of four digits, has been developed for identifying the Aroclors. The thousands digit denotes the raw material used in the chlorination. The figure 1----indicates 100% technical grade Biphenyl, The hundreds digit denotes whether or not the product is distilled. The -1-- indicates un distilled, and the figure -2-- indicates distilled. The tens and units digit denote the approximate percentage of chlorine contained in the finished product. For example, 1260 is a distilled chlori nated Biphenyl containing 60% chlorine. There are deviations from the above nomenclature when Solid Aroclors are produced. These are listed below: 1. Aroclor 4465 Aroclor 4465 is a blend of 50% Aroclor 1262 and 50% Aroclor 5460 by weight. 2. Aroclors 5060 and 5460 Aroclor 5060 is the crude from which Anroclor 5460 is distilled. The starting raw material is 100% Santowax R which is chlori nated to 60%. DSW 334446 STLCOPCB4080916 Synopsis of Process Aroclors 2. 3. Aroclor 5042 and 5442 Aroclor 5042 is the crude from which Aroclor 5442 is distilled. The starting raw material is 100% Santowax R which is chlori nated to 427,. . 4. Aroclor 2565 * This is an undistilled product. The starting raw material consists of 257 Santowax C and 757, technical Biphenyl. This is chlorinated to 65%. Chlorinator Area. There are four batch operated liquid chlorinators, one batch operated solid chlorinator, and one continuous operated chlorinator system. The continuous system consists of four batch chlorinators cascaded with overflow from one unit to the next. The product from the last stage is the finished crude Aroclor. Batch operated liquid chlorinators are normally charged with 3,000 pounds' of Biphenyl with 1-1/2 pounds of Ferric Chloride Catalyst. The chlorinators may be charged with Aroclor 1142 and chlorinated to a higher chlorinated Aroclor. Charges for the solid chlorinator vary dependent upon the Aroclor to be produced. Chlorine gas added through a distributor plate reacts with the raw material to release HC1 and heat. The HC1 gas goes to the Muriatic Acid Department. Heat is taken away by use of external air cooled heat exchangers. The specific gravity of the crude is checked after chlorine feed has been on for four hours, again when 80% chlorinated, as indicated by alarm, and as needed there after. In the continuous chlorination system, Biphenyl is fed to the first stage and chlorinated. Crude. Aroclor overflows to the second stage, etc., until the final product overflows from the last stage. Each chlorinator is held at a different level of chlorination with the last stage being the final crude Aroclor desired. Normally, Aroclor 1142 is produced in this system. Crude Aroclors from the batch chlorinators and the continuous system are transferred to a blowing tank to be air blown for one (1) hour minimum before distillation. DSW 33444 7 STLCOPCB4080917 Synopsis of Process Aroclors 3. Still Area Liquid Aroclors Aerated Aroclors from a blowing tank or a feed tank are charged to a still, hydrated lime fs added, a vacuum of 720 mm Hg (AO mm Hg absolute) is applied, the still furnace is fired, and the Aroclor is distilled into a receiver. The distillation is semicontinuous, since as many as ten (10) receivers are distilled prior to drawing bottoms or residue from the still. Every two receivers (or approximately 2,000 gallons) are treated with 40 pounds of earth for two hours and then filtered. The finished product is transferred to storage tanks prior to loading into drums or tank cars. In 1967, an experimental column was installed to treat part of the plant's production by passage through a bed of Bauxite. The column has proven superior to the present method of earth treatment and intentions are to treat all electrical Aroclors by the Bauxite column method in the near future. Solid Aroclors Solid Aroclors are distilled in a similar manner to Liquid Aroclors except for 1168. Aroclor 1168 is not air blown and is charged directly to the still from the chlorinator. A vacuum of 4 mm Hg absolute is applied for distillation. Solid Aroclors have 2, 3, or 4 receivers distilled prior to drawing bottoms in the still. This is dependent upon the particular Aroclor being produced. Solid Aroclors are not earth treated or filtered. They are drummed directly from the flaker hold tank or are flaked (Aroclors 1268 apd 5460). DSW 334448 STLCOPCB4080918 STLCOPCB4080919 STANDARD OPERATING INSTRUCTIONS FOR AROCLORS SAFETY AND HOUSEKEEPING Safety of operations in the Aroclor Plant depends on the individual operator. Materials-being handled and operations must be observed closely to guard against the following: Cause and Action to Prevent 1. Chlorine Gas Chlorine gas is a very toxic corrosive gas. Leaks or high pressure can occur to liberate it. Action to Prevent a. Report Chlorine gas exposure immediately for treatment with Antidote. Milk may be used in mild cases to relieve throat irritation. Oxygen from the resuscitator in the Dispensary is available. b. Keep gas mask in good condition. Keep a good canister in the mask. Use these type masks only in chlorine concentrations to 2-3% chlorine in air. c. Use a Scott Air Pak in concentrations of chlorine gas above 3% in air. Three units are available in the Aroclor-Biphenyl Department. d. If caught in chlorine gas without a mask, hold your breath and go cross wind until you are out of range of the gas. Place a handkerchief over your nose in small quantities of chlorine. e. Report all chlorine leaks for repair immediately. Make temporary repairs with tape if possible. f. In case of a major chlorine leak, the source of chlorine gas must be stopped. Cut off chlorine from cars. DSW 334450 STLCOPCB4080920 Aroclors Safety & Housekeeping 2. Thermal Burns 2. Cause and Action to Prevent Contact with hot uninsulated product lines at the chlorinators and still areas. Contact with uninsulated steam lines and open steam. Contact with hot Aroclors from broken lines or leaks. Contact with open flames at stills or from heating lines in the department. Action to Prevent a. Know that contact with equipment and product will cause a thermal burn due to the high temperatures. Make changes in operations with this hazard in mind. b. Know the first aid treatment for burns. Cold Water Treatment (See Appendix A Emergency Section). c. Wear gloves and long sleeve shirts with the sleeves rolled down when operating. Gloves and clothing can make the dif ference between first and second degree burns. d. Pveport uninsulated lines for repair of insulation. e. Use only steam lines with hose and hose clamps in good condition. f. The following operations are hazardous and should be done with care: (1) Catching samples at the Aroclor chlorinator circulating lines. (2) Sampling the Solid Aroclor still receiver. (3) Drawing bottoms on the Aroclor stills. DS'N 334451 STLCOPCB4080921 Aroclors Safety 6c Housekeeping 3. Explosion " ' . A. Falls ' 3. Cause and Action to Prevent An explosion could occur in the chlorinators by slugging liquid chlorine to . the distributor. Slugs of liquid chlorine could react fast enough to cause excessive pressure in the vessel. A rupture of the chlorinator could occur. Action to Prevent a. Observe operation of the chlorine vaporizer and do not let liquid chlorine get into the rotameters. Pipe lines will be frosted. b. In case chlorine feed lines are frosted, close liquid chlorine feed valve to the vaporizer. Check steam addition to the vaporizer. Do not start up until source of trouble has been located. c. Do not close valve in water discharge line from the chlorinator coil. d. Observe temperature of the chlorinator periodically and be sure it is not too hot (180C. maximum). Slipping on cement floors, stairs, Aroclor on floor, ice conditions; tripping over objects (hose, pipe, valve handles, etc.); or losing footing on ladders, etc., can cause falls. Action to Prevent a. The majority of minor, serious, and near-miss injuries in the Aroclor Dept. are the result of falls. Prevention is always within the ability of the operator by use of expert operating practices. DSW 334452 STLCOPCB4080922 Aroclors Safety & Housekeeping A. Falls (Contd.) - . 5. Fires . A. Cause and Action to Prevent b. The following items should be done: (1) R.eturn hose to rack after using. (2) Keep operating areas clean of all foreign objects. (3) Return ladders to racks when not in use. (A) Keep gloves on and hands out of pockets, especially going up and down stairs. (5) Place guards around any area that presents a hazard that should be guarded. c. Poor lighting due to burned out bulbs should be corrected at once. Poor lighting due to inadequate facilities should be reported. d. Spills must be cleaned up immediately following their occurrence. Report any spill that cannot be cleaned up within the shift to the Chief Operator. Spills are to be reported in the log book. Fires can occur by: Biphenyl, Santowax R, or Santowax C ignition. Chlorine problems in the vaporizer allow ing reaction with steam to release hydrogen. Furnace burner backfire. VJood, rags, or paper on hot lines. Sparks from welding apparatus of open flames. DSW 334453 STLCOPCB4080923 Aroclors Safety and Housekeeping 5. Fires (Contd.) 5. Cause and Action to Prevent Action to Prevent a. Area must be clear of trash or flam mable materials. Use trash skips and _ cans. b. Smoke only in areas so designated. c. Use spark producing equipment only with a fire permit and proper in spection. d. Use care in lighting gas torch or the still furnaces. e. Fire fighting equipment includes: (1) Two wheeled dry powder units. (2) Hose house with 200 ft. of hose. (3) Two dry powder hand extinguishers, One CO2 hand extinguisher. (A) Two 3/4" water hoses. (5) Hose connection north of Santowax. (6) Scott Air Paks. (7) Fire truck in fire house. f. Observe visitors in the plant and be sure they observe safety rules. DSW 334454 STLCOPCB4080924 Aroclors Safety and Housekeeping 6. 6. The following is a list of chemicals handled in the Aroclor Plant operations and the precautions to be taken during their handling: a. Chlorine Gas ,, This is a corrosive gas which is toxic. Leaks or back pressure can occur and liberate chlorine gas in the area. Operators should have their cartridge type respirators handy at all times while in the area. Use of gas masks is explained in Section B.l. ' . If you are caught without a gas mask, and large amounts of chlorine gas are liberated, hold your breath and go cross wind until you are out of range of the gas.' Once out of the area, obtain an emergency gas mask and-return to the area and correct the trouble. A victim of chlorine gas fumes must be removed as quickly as possible from the . gaseous area. Place patient on his back with head and back elevated. Milk may be used in mild cases as a relief from throat irritation. If the patient has stopped breathing, start artificial respiration immediately. b. Biphenyl ' - Biphenyl is a flammable material which will burn. Burning should not be done in the presence of Biphenyl or Biphenyl vapors. The melting point is 68.7C., and the auto ignition temperature is . 258C. Inhalation of Biphenyl fumes is not recommended, since it can cause a drugged effect on the person. c. Santowax R . Santowax R is a flammable material which ' will burn. It is relatively non-toxic to human beings. However, the vapors of Santowax R are irritating to the mucous membranes and bronichial tract. Pro longed breathing of the vapors should be avoided. The melting point is 140C. d. Santowax C Same as Santowax R, since it is the crude material prior to distillation. 33445? DSW STLCOPCB4080925 Aroclors . Safety & Housekeeping 6. (Continued) e. Ferric Chloride f. Attapulgus Earth g. Hydrated Lime h.' Crude Aroclors i. Hydrogen Chlorine ' Gas j. Still Bottoms or Residue 7. Ferric Chloride is a black-brown solid. It causes only slightly irritating effects on the skin or mucous membranes. When heated it will decompose and release toxic fumes of chlorine. It will react with water to produce toxic and corrosive HC1 fumes. This material is a dried earth. No danger in handling. Wash off with water to clean. No particular hazard in handling this material. The dust is irritating to the eyes and skin, and should be washed off with water. Crude Aroclors are hot, since all are handled in steam traced or jacketed lines. They can easily cause thermal burns in contact with the skin. Prior to air blowing, the material has KC1 fumes entrained in it which are irritat ing to the skin or mucous membranes. This is a corrosive gas which is toxic. It is irritating to the mucous membranes, to the eyes, and to the respiratory tract. It will react with water to form Hydro chloric Acid. Fumes from still bottoms are toxic. They are extremely irritating to the mucous membranes, to the eyes, and respiratory tract. DSW 334456 STLCOPCB4080926 Aroclors Safety & Housekeeping 8. HOUSEKEEPING The Aroclor chlorinator and still operators are responsible for house keeping during their shift. Good housekeeping is the mark of good operations, safety practices, quality, and costs. Housekeeping duties are equal in importance with all other operating duties. Poor Practices Action to Prevent 1. Hoses, valve handles, dip ! sticks, rags, and other material on ground or floor. a. Replace after use. b. Have place to store all necessary operating aids. c. Report needs to supervision. 2. Product Leaks. a. Tighten valve packing glands and flange bolts. b. Report leaks to Chief Operator for maintenance alteration. 3. Trash and Crude Drums. a. Contact Chief to have drums moved from area. b. Use trash skip in area. 4. Product spills or clean out messes. a. Prevent necessity of clean-out by keeping tracing, insulation, or jacket in good repair by getting items turned in for maintenance work. b. Spills must be cleaned up when they are made. Clean up will continue through the following shifts to finish the job. OSNN 334457 STLCOPCB4080927 TMRTnnr.TT ONS DSW 334458 STLCOPCB4080928 STANDARD OPERATING INSTRUCTIONS FOR AROCLORS PROCESS FUNCTION OUTLINE THERMINOL HEATER 1.1 Scope This covers the charging, start-up, shutdown, normal operation, and emergency situations involving the Therminol heater in the Aroclor Department. 1.2 Description of Process Therminol FR-2 (Aroclor 1248) is circulated through a pipe system in the Aroclor Department at flow rates of 0 - 500 GPM at 60 psig. The normal operating temperature is 250C. on the discharge of the heater at 350 GPM. This heating system is used to heat up tanks, transfer lines, pumps, and material involved in producing solid Aroclors. PROCESS DIAGRAM Attached. OPERATION OF PROCESS 31 Charge System With Therminol FR-2 (Aroclor 1248) . A. Use"temporarily relocated Pyranol pump to charge Therminol surge tank. B. Position 55 gallon drum next to pump. Remove drum bung and vent cap. C. Connect flexible hose to pump suction and the stain less steel pipe to be inserted into the drum. D. Position discharge line from the pump into the tank. E. Open valve on pump suction. Insert pipe into drum and start pump. F. Adjust the suction valve on the pump until flow is steady. G. Continue to fill the tank until 30 drums or approximately 1,650 gallons total are in the surge tank (Item 627). 0SW 334459 STLCOPCB4080929 Detailed Instructions Aroclors 2. 3.1 Aroclor 1242, as well as Aroclor 1248, can be charged into Therminol surge tank. When Aroclor 1242 is used it is charged into surge tank as follows: A. Align valves in line from Aroclor 1242 storage tank to No.- 9 chlorinator surge tank. B. Check level gauge in surge tank. C. Crack valve from circulating line at No. 9 surge tank to return line to Therminol surge tank. This allows Therminol to pump from No. 9 surge tank to Therminol surge tank. D. Start Aroclor 1242 storage tank pump. E. Observe level gauge in No. 9 surge tank to maintain constant level in tank while pumping in and out of tank. F. Continue to pump from No. 9 surge tank to Therminol surge tank until you have 10" in Therminol surge tank. G. Close valve from circulating line at No. 9 surge tank to return line to Therminol surge tank. H. Observe level gauge in No. 9 surge tank. I. When you have 40" in tank, stop Aroclor 1242 storage tank pump. J. Close valves in line from storage tank to No. 9 surge tank. 3.2 Start-Up A. Initial Start-Up 1. Turn on circuit No. 5 at still panel and switch at the field control box. 2. Place TRCA-629.12 in "manual" with the output pressure at 15 psig. Blower air control valve is air to open. Set FIC-628.01 at 350 GPM in "auto" position. 3. Check to be sure Therminol is in the surge tank. Temperature should be 100C. minimum. oSnN *>4460 STLCOPCB4080930 Detailed Instructions Aroclors 3. 4. Open natural gas valves in line to furnace. 5. Open blower air valves in pilot and main air'lines. .6 Actuate red inset safety lever inside the Honeywell Protectoglo unit (lower right cover of case). You must wait 10 seconds between settings of this lever in case it has `to be redone. 7. Set the temperature shutdown control point on Honey well coil outlet temperature indicator at 325C. (617F). 8.' Align valves in the Therminol system lines to circulate main lines only. 9. Start Therminol circulating pump (Item 628). .10 Start air blower. Use pushbutton at side of field panel. Red light on Protectoglo unit should light up. Air pressure at the blower discharge should be above 1 psig. .11 Check pressure gauge at main air inlet to burner. It must be above 15 o.s.i. .12 Wait 6 minutes. Green light on Protectoglo unit lights up indicating purge period is over. 13. Press ignition "start" pushbutton on side of control box and hold in until white light on Protectoglo unit lights up. R.ed and green lights should go out. Pilot lights up indicated by 0-7 reading on micro amp meter. 14. Adjust manual valve in air line to burner until pressure is below 1-1/2 o.s.i. 15. Reset the two North American safety valves in the main gas line. Handle on both valves must be in UP position prior to opening either valve. 16. Adjust manual valve in air line to burner until pressure is between _15_ and 22 o.s.i. It must be above 15 o.s.i. 17. Adjust TRCA-629.12 to temperature at outlet of coil and transfer instrument to "auto". This is for low fire start-up. Use care to make this change since you can cause -p,, ~ ^ ~ DiiULUUWU ux. til t: xui.iiatt' DSW 334461 STLCOPCB4080931 Detailed Instructions Aroclors 4. 18. Shut steam valve to coil in the surge tank. Vent coil line to atmosphere. 19.. The furnace must be dried out prior to Step 20. Details will be provided. 20. Observe the furnace temperature at the coil outlet. Do not exceed 50C. increase for first two hours. Set TRCA-629.12 in automatic and raise the tempera ture 50C. per hour until you reach 220C. Open the manual air valve sloxvly to raise the temperature. Place TRCA-629.12 in "auto" position and put set point at 250C. System will circulate until needed. Check stack temperature and do not exceed 400C on the multipoint temperature recorder point 10. 21. Fill Therminol system in all branch lines. Open each branch valve at feed and discharge to drive out air. Fill lines one at a time. B. Start-Up Following Temporary Shutdown Assume circulating pump is running and the pilot light is burning. 1. Check to be sure Therminol is in the surge tank `(Item 627), 10" in sight glass. 2. Check temperature in surge tank (Item 627), TI-627-03. It should be 100C. Turn on steam to tank coil if necessary. 3. Check valves in Therminol system lines to be sure where the heating system is being circulated. 4. Adjust set point on FIC-628.01 at 350 GPU controller in "auto" position. 5. Adjust set point TR.CA-629.12 at 126-150C. and . controller in "auto" position. 6. White light on the Honeywell Protectoglo unit will be on indicating the pilot is on. 7. Adjust manual valve in air line to burner until pressure is below 1-1/2 o.s.i. DS\N 334462 STLCOPCB4080932 Detailed Instructions Aroclors - 5. 8. Reset the two North American safety valves in the main gas line. 9. Adjust manual valve in air line to burner until pressure is between 20-22 o.s.i. 10. Adjust TRCA-629.12 to temperature at outlet of coil and transfer instrument to "auto". Gradually raise the set point to 250C. 11. Open valves in branch Therminol system lines as ' needed. Open discharge and feed line at each feeder. 3.3 Routine Operations When the Therminol heater system is operating normally, the following conditions will exist in the process. A. FIC-628.01 pump flow set at 350 GPH. B. PI-628.02 pump discharge pressure 85-95 psig. C. PI-629.16 heater coil outlet pressure 55 psig. D. PI-628.03 Therminol line pressure 30 psig. E. TR.CA-629.12 heater coil outlet temperature set at 250C. F. Honeywell coil outlet temperature indicator at 250C. Shutdown alarm set at 325C. G. TI-627.03 surge tank temperature 245C. H. Air blower reduced discharge pressure - above 15 o.s.i. less than 22 o.s.i. I. Main natural gas pressure 40 psig. J. Natural gas reduced pressure 3-5 o.s.i. K. Natural gas feed .to burner atmospheric pressure (0 o.s.i.). DSW 334463 STLCOPCB4080933 Detailed Instructions Aroclor 6. 3.4 Safety Features . A. Honeywell Protectoglo unit has the following safety features: 1. Ignition period 10 second delay between actuation periods for warp switch to cool. 2. Blower reduced air pressure must be above 15 o.s.i. . and less than 22 o.s.i. 3. Heater coil high temperature outlet shutdown set ' at 325C. (617F.). A. Main natural gas low pressure shutdown set at 20 psig, and at 10 psig. 5. Natural gas high reduced pressure shutdown set at 5.0 psig. 6. Circulating pump low flow rate shutdown set at 200 GPU. 7. Air blower start-up sets up automatic 6 minute timed purge before next step of start-up can proceed. 8. Minimum 15 o.s.i. air pressure is necessary at the main burner for the purge period. 9. A low air pressure ignition for lighting main burner is necessary. Set for air pressure to be below 1-1/2 o.s.i. to main burner. 10. Pilot flame must be burning to start up unit, in dicated by 0-7 microamperes on current meter. Meter gives an alternating off-on reading. B. Check surge tank, Item 627, to be sure Therminol level is at least 10" in the sight glass. DSW 334464 STLCOPCB4080934 Detailed Instructions Aroclors 7. 3.5 Shutdown A. Temporary Shutdown Main gas burner off with pilot light on and circulating pump running. 1. Adjust TRCA-629.12 set point to zero (instrument in "auto"), or 2. If instrument is in "manual", adjust controller for . output pressure to zero, or 3. Close the 6" manual valve in the main air line to the furnace burner. In case it is necessary to cool the furnace quickly, leave the air valve open. A. Normally, the circulating pump is left on to cool the heater coil and prevent overheating. 5. Close one or both of the North American safety valves in the gas line to the main burner. B. Complete Shutdown Main gas burner pilot light and circulating pump off. 1. Push ignition "stop" button on side of field control panel. 2. Push "stop" button for air blower. 3. Close manual valve in the main air line. A. Close manual valves in main gas supply line. 5. Allow circulating pump to continue pumping until furnace coil outlet has cooled to 15QC. then shut off the circulating pump. 6. Check surge tank level to be sure the tank does not overflow. It should have a level of 38-A2" in the sight glass. 7. If a temperature of 100C. is to be maintained in the surge tank, it may be necessary to open the valve in the steam line to the tank coil. SW 334465 STLCOPCB4080935 Detailed Instructions Aroclors 8. . 8. Set points on TRCA-629.12, heater coil outlet, FIC-628,01, pump flow rate, and the Honeywell Protectoglo unit set point can be left in position when shut off. 9. Shut off circuit No. 5 behind the still panel if the shutdown is to be an extended one. C. Emergency Shutdown In case it becomes necessary to shut down fast, the following methods can normally be used. 1. From the Field a. Push ignition ''stop" button on side of field control panel to shut off pilot and main burner. b. Turn temperature shutdown set point on Honeywell Protectoglo unit below the furnace coil outlet temperature. c. Close manual valve in air blower discharge line or stop the air blower. ' d. Push "stop" button for the circulating pump located at side of field control panel. Main and pilot gas burner will be shut off, while air is being blown through the furnace. Item d. is the least preferred of the above methods. Normally, the circulating pump will continue to be operated. 2. At the Still Panel ' a. Move FIC-628.01 below 200 GPM. Total use of Therminol in department must be below 200 GPM for this to cause shutdown of main and pilot gas burners. b. Turn off circuit No. 5 behind still panel. 3. At Motor Control Center a. Shut off circulating pump circuit breaker. b. Shut off blower circuit breaker. DSW 334468 STLCOPCB4080936 Detailed Instructions Aroclors 9. D. Emergency Shutdown with Alarm Pilot and main gas burner off. Circulating pump still on. 1. High coil outlet temperature - above 325C. (617F.) 2. Low natural gas supply pressure - below 20 psig or below 10 psig 3. Low blower outlet pressure - below 1 psig 4. High reduced natural gas pressure - above 5 psig 5. Low coil flow - below 200 GPH 6. Failure of circuit 5 behind still panel. 7. Failure of "on-off" switch at side of field control panel or blowing 115 volt fuse in panel. 3.6 Control Loops. Interlocks, and Alarms A. Control Loops There are three major control loops in this system. 1. Circulating Pump Flow Control - FIC-628.01 The function of this loop is to maintain the flow through the Therminol system at 350 GPM. This is accomplished by measurement of flow through an orifice connection and throttling a control valve at the extremity of the loop as is needed. Low circulation rate (below 200 GPM) will shut off natural gas to the furnace and sound an alarm horn. 2. Therminol Heater Outlet Coil Temperature Control TRCA-629.12 Function of this loop is to maintain a constant temperature of 250C. at the furnace coil outlet. This is accomplished by measurement of the tempera ture with a thermocouple and controlling the heat input to the furnace with a control valve in the main combustion air line. A low temperature alarm at 220C. and a high temperature alarm at 300C. will be actuated at too low or too high a tempera ture. ' DSW 334467 STLCOPCB4080937 Detailed Instructions Aroclors 10. 3. Therminol Heater Furnace Controls - 629A The function of this loop is to provide a source of heat for the Therminol FR-2 (Aroclor 1248) circulating system. This is obtained with a North American burner and air blower which is used to heat the Therminol circulating through a direct fired coil. Control of this heating system is obtained by FIC-628.01 and TR.CA-629.12. There are .four safety features in the furnace controls to shut the system down. a. High coil outlet temperature - above 325C. b. Low natural gas supply pressure-below 20 psig or below 10 psig c. Low blower outlet pressure -below 1 psig d. High reduced natural gas pressure - above 5 psig B. Interlocks Interlocks in this system are as follows. Each, except Items l.a. and b., have alarms. 1. Start-Up of Furnace a. Actuation of pilot ignition lever on Honeywell Protectoglo unit has a 10 second delay before second try can be made. b. Ignition "start" button at the Protectoglo unit has a 6 minute purge delay after the air blower has been started before the furnace will light up. c. During purge period a minimum of 15 o.s.i. air pressure is necessary prior to completion of purge. d. To light the main burner the air discharge pressure to the main burner must be below 1-1/2 o.s.i. for low fire start-up. 2. Automatic Furnace.Shutdown with Alarms (Pilot and Main Gas Burner Off) a. High coil outlet temperature - above 325C. (617F.) DSW 334468 STLCOPCB4080938 Detailed Instructions Aroclor 11. b. Low natural gas supply pressure - below 20 psig or below 10 psig c. Low blower outlet pressure - below 1 psig d. High reduced natural gas pressure - above 5 psig e. Low coil flow - below 200 GPH f. . Failure of circuit No. 5 behind still panel. g. Failure of switch at side of field control panel ' or blowing 115 volt fuse in panel. C. Alarms 1. All shutdown items under Interlocks B.2. above. 2. Therminol heater coil outlet low temperature below 220C. 3. Therminol heater coil outlet high temperature above 300C. 3.7 Abnormal Conditions A. Unusual high or low temperature readings can occur if the thermocouple extension wire for the Honeywell Protectoglo unit and TRCA-629.12 are mixed up. See note, Section IV-C. , Page 12 . IV. COMMENTS ON PROCESS . A. It is very important to be sure the coil in the surge tank (Item 627) is covered when the system is in operation. This assures the circulating pump has a positive suction and pre vents surging in the heater coil. Surges in flow can cause coil hot spots and shorten the coil life. Normal sight glass level is 10" during operation and 40" with the pump stopped. B. Use of FIC-628.01 flow control to shut the system down at the control panel can only be used when use of Aroclor in the department is less than 200 GPM; otherwise, adjusting the controller will not throttle the control valve enough to cause automatic shutdown of the main and pilot burners. osw 334469 STLCOPCB4080939 Detailed Instructions Aroclor 12. G. At TRCA-629.12, be sure the iron constantan thermocouple extension lead wire (type J) is used to transmit to the control room and the instrument. The conduit run also contains a type K extension lead wire which is chromel alumel. If the type Jywire is used, the indicator will read correctly. If the type K wire is used by mistake, the Therminol will overheat by about 100C. The high temperature switch should shut the furnace down at 325C. D. The Therminol furnace is rated at 8,000,000 Btu/hour heat input. This corresponds to 22 o.s.i. air pressure at the air inlet of the burner. The manual valve in the air line should be set for 22 o.s.i. when the automatic valve is wide open. This will assure the heat input will not exceed the design rate if the automatic valve should open wide. E. Care must be taken not to fill the surge tank (Item 627) too full during normal operation. This can cause the tank to run over when the circulating pump is stopped. Normal level will be about 10" in the sight glass. The level in ' the tank will vary, dependent on the operating temperature of the system and the Therminol usage. F. Temperature of the Therminol system is maintained at 250C. for production of all solid Aroclors except 1168. During operation to produce 1168, the temperature is raised to 300C. The furnace high temperature shutdown alarm is kept at the same position of 325C. G. To get natural gas to the main burner the North American safety valves must be reset. Prior to opening the valves the handle of each valve must be in the u position. This sets the safety shutdown pressure switches. H. Use care when opening the inner door to the field control panel at the furnace. The high temperature shutdown in strument pointer is free floating and can go above the shut down pointer. The door must be opened slowly. I. Gas to the venturi mixing chamber for the pilot light on the furnace should be at atmospheric pressure. Air pressure will be the blower discharge pressure (22 o.s.i.). The pilot light will not burn unless this pressure ratio is maintained to give the proper gas-air mixture. J. In case of a power failure at the field panel for the Therminol Heater, the reset button on the high temperature shutdown in strument must be pushed to restart the system. There is no apparent indication that this button has been pushed. The red no flame light will not light up and furnace can not be started. DSW 334470 STLCOPCB4080940 STANDARD OPERATING INSTRUCTIONS FOR AROCLOR3 13. PROCESS FUNCTION OUTLINE C. I. WEIGH TANK, NO. 9 CHLORINATOR, AND NO. 2 TANK 1.1 Scope This covers the charging, start-up, shutdown, normal operation, and emergency situations involving the weigh (charge) tank, No. 9 chlorinator, and the No. 2 blow tank for production of Solid Aroclors. 1.2 Description of Process . . Crude Solid Aroclors are produced by batch chlorination when a weighed quantity of Biphenyl, Santowax, or a mixture of the two is chlorinated in a vertical reaction vessel with Ferric Chloride as a catalyst. Chlorine gas is added at the bottom of the vessel. . By-product HC1 gas vented at the top of the chlorinator is recovered in the Muriatic Acid Department. Crude Solid Aroclors produced in batch chlorination are trans ferred to the blowing tank operation when the chlorination is completed. Chlorine gas is . fed to the chlorinator from tank cars. ' " . .. ' . Aroclor 1168 is transferred directly from the chlorinator to the still because of its high hold point temperature . (155-175C) II. PROCESS DIAGRAM Attached. III. DESCRIPTION OF PROCESS 3.1 Start-Up A. Charges and Operating Temperatures for Various Crude Solid Aroclors Depending on the product to be produced, different quantities of the raw materials are needed. See Table I. dSVNI 33*471 STLCOPCB4080941 Detailed Instructions Aroclors 14. B. Charge Therminol Cooling System for No. 9 Chlori.nator Charge Therminol (1248 Aroclor) into the surge tank (Item 533) by the following procedure: 1. Use temporarily relocated Pyranol pump to charge ' the tank. 2. Position 55 gallon drum next to the pump. Remove drum bung and vent cap. 3. . Connect flexible hose to pump suction and the stainless steel pipe to be placed in the drum. 4. Position discharge line from the pump into the surge tank (Item 533). 5. Open valve on pump suction. Insert pipe into the drum and start pump. 6. Adjust the suction valve on the pump until flow is steady. 7. Continue to fill the tank until 7 drums or 385 gallons are in the surge tank. C. Aroclor 1242, as well as Aroclor 1248, can be charged into the surge tank (Item 533). When Aroclor 1242 is used it is charged into surge tank as follows: 1. Align valves in line from Aroclor 1242 storage tank to surge tank. 2. Check level gauge at surge tank. 3. Start Aroclor 1242 storage tank pump. 4. Observe level gauge at surge tank and allow Aroclor 1242 to pump to surge tank until you have 40" in tank. . 5. Stop storage tank pump. 6. Close valves in line from storage tank to surge tank. DSW 334472 STLCOPCB4080942 TABLE I 15. BATCH CHLORINATOR OPERATING CONDITIONS - SOLID AROCLORS 1168 5042 5060 Chlorinator Charge: Biphenyl (lbs.) Santowax C . Santowax R 9,550 11,000 11,000 Total Charge (lbs.) Approximate Pounds 100% Chlorine Re quired to Produce Batch: Totalizer Chlorine Settings (80% CI2, Assuming 10% Air) Lbs. CI2: ' Chlorinator Temp.: Beginning Ending Hold Point Softening Point Weight of Crude Batch - Lbs. ' Gallons 9,550 11,000 11,000 44,000 12,000 28,450 33,000 130C. 200C. 155175C. 22,000 1,690 9,600 20,000 160C. 210C. 5056 C. 14,050 160C. 250C. 105115C. 22,800 1,770 NOTE: ADD 5 POUNDS OF FERRIC CHLORIDE TO EACH BATCH CHLORINATOR CHARGE. NOTE: Aroclor 1142 can be used to charge chlorinator for 1168 instead of Biphenyl. When this is done, Ferric Chloride is not added to charge. DSW 334473 STLCOPCB4080943 Detailed Instructions Aroclor 16. D. Start-Up Therminol Cooling System for No. 9 Chlorinator 1. Set valves in the system to flow through the No. 9 chlorinator heat exchanger (Item 538) and through the tube side of the Aroclor cooler (Item 507). 2. Close sample valve on the suction of the circulating pump (Item 534) and at the discharge of the No. 9 chlorinator heat exchanger. 3. Close valves to put Therminol FR-2 (Aroclor 1248) from the furnace system on the No. 9 Aroclor chlorinator heat exchanger (Item 538). Tag lines closed. 4. Open steam valve to coil on the surge tank (Item 533). Controller should be set to control temperature in . this tank to 45C. 5. Check level in the surge tank (Item 533). Should have 40" in the tank. 6. Set TRCA-538.01 in "auto" with set point at 160C. Low temperature alarm set at 120C. - high temperature alarm set at 275C. 7. Set FICA-534.02 in "auto" with set point at 300 GPM. Low flow alarm should sound at 250 GPM. 8. When the material in the surge tank is at 45C., start the circulating pump (Item 534). 9. Check flow through the Terminol cooling system by observ ing the following items: a. Pump discharge pressure, PI-534.01, should be 55 psig. b. Flow through Therminol system should be 300 -GPM. . Check FICA-534.02. c. Check action of control valve to the No. 9 Aroclor heat exchanger. See TRCA-538.01. Valve should be closed on low temperature. 10. Check the following temperature points in the Therminol cooling system: a. Pump discharge temperature, No. 9 chlorinator heat - exchanger outlet temperature, and the-outlet tem perature at the head of the water-cooled heat ex changer for the Therminol system. 11. If there are no problems with the system, let it continue to circulate until needed. SW 334474 STLCOPCB4080944 Detailed Instructions Aroclor 17. E. Initial Equipment Check for Start-Up 1. Set temperature controller in weigh tank, TIC-535.01, at 150C. Controller to be in "auto". 2. Check /Therminol cooling system. a. Surge tank temperature controller TICA-5.33.01 in "auto" with the set point at 50C. b. Flow controller FICA-534.02 in "auto" with the - set point at 300 GPM. c., Pump pressure 55 psig. 3. The Therminol heater system should be circulating at 250C. Control point should be as follows: a. FIC-628.01 in "auto". Set at 350 GPM. Low flow shutdown will alarm at 200 GPM. b. TRCA-629.12 in "auto". Set at 250C. Low tem' perature alarm at 220C. - high temperature alarm at 300C. 4. No. 2 blow tank temperature controller TIC-541.01 in "auto" with the set point at 170C. 5. Open valves on steam lines to the Biphenyl and Santowax supply to the weigh tank (Item 535). Open valves in the steam lines to the coil on the weigh tank. 6. Open Therminol feeder lines to heat the following equipment: a. Transfer lines from weigh tank (Item 535) to the transfer pump and to No. 9 chlorinator (Item 505). b. Circulating line at No. 9 chlorinator through the heat exchanger (Item 538) and back to the chlorinator. c. Sample line at No. 9 chlorinator. d. Transfer line at No. 9 chlorinator to the No. 2 blow tank (Item 541). e. Coil in No. 2 blow tank (Item 541). f. Transfer line from No. 2 blow tank to the pump (Item 539). Observe temperature to be sure the Therminol system stays at 250C., or returns to this temperature after the various feed lines have been started up. DSW 334475 STLCOPCB4080945 Detailed Instructions Aroclor 18. 7. Open water valve to S&K iet (Item 531) - 20 to 25 psig water pressure. 8. Start the air blower (Item 530). Open the valve at the #2 blow tank 2 turns. 9. Check the suction on the No. 2 blow tank (Item 541) to be sure it is adequate for operation. 10. Open the manual valves in the water system to the Aroclor copier (Item 507). F. Charge Weigh Tank (Charge Tank) 1. Refer to Table I, Page 15, for the actual quantities of raw materials needed for the particular solid Aroclor to be produced. a. Set the valves to receive the charge from the Biphenyl or Santowax Departments. Notify the operator you are ready for a charge. Biphenyl is obtained from the Biphenyl storage tanks. Santowax P>. or Santowax C is obtained from the Santowax storage tanks. b. If Biphenyl is required, charge it into the weigh tank first to the desired weight. Close the manual valve in the charge line. c. If Santowax R is needed also, adjust the scale weight set point to the correct charge desired; for example, . in 4065, 5,220 lbs. of Biphenyl are added and then 3,480 lbs. of Santowax R are required. Place the scale set point at 8,700 lbs. d. Open the manual valve in the Santowax R line. e. Depress the pushbutton near the scale to open the ' automatic valve. This will put the annunciator window light out which is marked "No. 9 Chlorinator Weigh Tank Charge Complete." ' f. Start the pump to charge the weigh tank. Santowax E. is now entering the weigh tank. g. When the measured weight reaches the set point, the automatic Santowax R control valve will close and annunciator window marked "No. 9 Chlorinator Weigh Tank Charge Complete" will be actuated. h. Close the hand valve in the Santowax R line. DSW 334476 STLCOPCB4080946 Detailed Instructions Aroclors 19. i. Open the automatic valve and allow the line to drain. Then reclose the automatic valve. j. Start the agitator in the weigh tank. Allow agitation to take place for a minimum of one hour. Stop the agitator just -before material in the weigh tank is to be charged to the chlorinator. k. Open manual valve on top of the weigh tank (Item 535) and add 5 pounds of Ferric Chlorine. Close the manual valve after adding the Ferric Chloride. Close the lid on the hopper. l.' The material is now ready for the next chlorinator charge when needed. G. Charge No. 9 Chlorinator and Start Chlorination 1. Manual Operation a. Close manual chlorine valves at distributors on No. 9 chlorinator (Item 505). b. Close vent on No. 9 chlorinator to the atmosphere. c. Open HC1 vent valve to Muriatic Acid area. d. TRCA-528.01 set in "auto" and "set". Control point set at 160C. Low temperature alarm 120C. - high temperature alarm 275C. e. FRCS-505.01 in "manual". Set point at 1,500 pounds per hour. . f. Set valves to allow transfer of charge from weigh tank to the No. 9 chlorinator. Be sure to stop the agitator before starting the transfer pump. g. Close pump discharge valve, open valve at bottom of weigh tank, start transfer pump (Item 536), and gradually open the pump discharge valve. h. Stop pump when the weigh tank is empty. Close valve at bottom of weigh tank. i. Set valves to circulate chlorinator through the No. 9 chlorinator heat exchanger (Item 538) and back to the chlorinator. DSW 334477 STLCOPCB4080947 Detailed Instructions Aroclor 20. j. Start circulating pump (Item 506). k. Open manual chlorine valves at the distributors on the No. 9 chlorinator (Item 505). Chlorine header . pressure control PIC-500.07 will control the pressure to 20-25 psig. A low pressure alarm is set at 15 psig high pressure.alarm at 35 psig. l. After chlorine feed levels off at 1,500 lbs. per hour put FRCS-505.01 in automatic with set point at 1,500 lbs. per hour. Chlorine control valve should be open before manual . valves are opened. m. After one hour, increase chlorine rate to 2,000 lbs. per hour of chlorine feed. n. Check the following items after the start of the chlorination: (1) Temperature on TRCA-538.01. (2) Therminol cooling system flow on FICA-534.02 (Aroclor 1248 system) - 300 GPM. (3) Chlorine flow on FRCS-505.01 - 1,500 lbs/hour. (4) Circulating pump discharge pressure on No. 9 chlorinator, PI-506.01 - 30-45 psig. o. Check temperature points in the system as follows: No. 9 chlorinator temperature, TE-505.02. Temperature points in the circulating Therminol system for the No. 9 chlorinator (Aroclor 1248 system). p. Check pump discharge pressure on the Aroclor circulating . system, PI-534.01. q. Increase temperature set points through the chlorination as is necessary to maintain the material liquid and fluid. End temperature point will be approximately 250C. Raise set point on TRCA-538.01 as necessary to achieve desired temperature. r. Samples are taken at the discharge line of the cir culating pump (Item 506) at the second level. Depending on the material being produced the softening point, or hold point is run on the batch chlorination. At the start of the chlorination, a sample should be taken after two hours of operation on odd numbered hours (7, 9, 11, etc.). Samples will be taken every two hours through the chlorination. On some of the higher chlorinated products, example 1168, samples are not taken until the chlorinator has been on for four hours. DSW334478 STLCOPCB4080948 Detailed Instructions Aroclor 21. s. When the chlorination is near completion, it may be necessary to run the softening point or hold point every ten to fifteen minutes. t. When the chlorination has been completed (see Table I), shut off the chlorine feed valves at the distributor on the chlorinator. . 2. Programmed Chlorinator Operation a.- Close manual chlorine valves at distributors on No. 9 chlorinator. b. Close vent valve on chlorinator to the atmosphere. c. Open HCl vent valve to Muriatic Acid area. d. Set TRCA-538.01 in "auto-cascade". Set point 190C. Low temperature alarm 120C. - high temperature alarm 275C. e. Set FRCS-505.01 in "auto-cascade". Set point dependent on Aroclor being produced - see Appendix I. f. Adjust green set point knob on the Chlorine totalizer . per the Table on Page 15 for measuring the chlorine flow. . Set up flow-temperature program per Appendix I attached, g. Check the following control instruments: (1) Weigh tank temperature - TIC-535.01 at 150C Controller in "auto". (2) Therminol cooling temperature - TICA-533.01 at 70C. Controller in "auto". (3) Therminol cooling flow - FICA-534.02 at 300 GPM. Controller in "auto". (4) No. 2 blow tank temperature - TIC-541.01 at 170C Controller in "auto". , DSW 334479 STLCOPCB4080949 Detailed Instructions Aroclor 22. h. Set valves to transfer charge from weigh tank to the No. 9 chlorinator. i. Close pump discharge valve, open valve at bottom of weigh tank, start transfer pump (Item 536), and gradually open the pump discharge valve. j. Stop the pump when the weigh tank is empty. Close valve at bottom of weigh tank. k. Set valves to circulate the No. 9 chlorinator through the No. 9 chlorinator heat exchanger (Item 538) and back to the chlorinator. l. Start circulating pump (Item 506). m. Push the green reset pushbutton on the chlorinator panel for No. 9 chlorinator, (Item 505). This resets the chlorine totalizer and programmer and is the in itiating signal for the start of the new batch. The Flexopulse time will begin to time the batch as in dicated by cascade flow. The batch chlorine flow and temperature will be controlled according to a pre-set program. At 80%, of the chlorine flow as set by the chlorine totalizer, an alarm bell will ring to indicate 80% of the chlorine feed has been taken into the chlori nator. n. Open manual chlorine valves at the distributors on chlorinator No. 9. This should be done immediately after pushing the reset button so the timer will control the batch correctly. Chlorine header pressure control PIC-500.07 will control the pressure to 20-25 psig. A low pressure alarm is set at 15 psig - high pressure alarm at 35 psig. o. After four hours, take a sample of the Aroclor and check for specific gravity, softening point, or hold point as necessary, depending on the Aroclor being produced. This sample is a check to be sure a short charge was not transferred into the chlorinator. The next sample after that will be taken when the 80% alarm bell rings. p. Check the following items during operation: (1) Temperature on TRCA-538,01. (2) Chlorine flow on FRCS-505.01. . DSW 334480 STLCOPCB4080950 Detailed Instructions Aroclor (3) Therminol cooling system flow through the Therminol cooling (Aroclor 1248) system on FICA-535.02. 23. (4) Temperature points through the system on the ' No. 9 chlorinator and the Therminol cooling system (Aroclor 1248). q. The alarm bell will ring when 80% of the chlorine has been fed to the chlorinator. Immediately take a sample at the circulation line to determine the point which the chlorination level has reached. r. Continue the chlorination until complete. It may , be necessary to run the softening point or hold point more often during the last one to two hours of the chlorination. s. At completion of the chlorination (See Table I), shut off the chlorine feed valves to the distribu tors at the chlorinator, then push the green reset pushbutton,on the chlorinator panel for the No. 9 chlorinator. This reduces the chlorine flow set point to 300 lbs./hour and stops the timer. No chlorine will be flowing. t. Note the chlorine pressure on the main header as in "Manual Operation". Pressure controller alarm PIC-500.07 will indicate low pressure at 15 psig high pressure at 35 psig. u. Circulate the chlorinator for 10 minutes. Sample and check the hold point or softening point to be sure the chlorination has been completed. See Table 1, Page 15. . If the chlorination is complete, prepare to pump to the No. 2 blew tank or directly to a still if Aroclor 1168 is being produced. See next section of Operating Instructions. H. Transfer to No. 2 Blow Tank and Air Blow 1. Set transfer lines to pump to the No. 2 blow tank (Item 541). Be sure Therminol heat is on jacketed lines. The chlorinator is vented to the HC1 line. DSW 334481 STLCOPCB4080951 Detailed Instructions Aroclor 24. 2. Check the level indication instrument, LI-541.02, to be sure there is enough room to transfer into the blow tank. Level indicator must read 0-5% before transfer. 3. Change final valve in the transfer line and allow material to pump from the No. ? chlorinator to the No. 2 blow tank. Observe transfer arid note level increase in the No. 2 blow tank by LI-541.02. At the completion of the transfer, close valves in the circulating system and shut off the circulating pump (Item 506) on the No. 9 chlorinator. 4. The chlorinator is now ready to charge back for the next chlorination. 5. Record transfer information on the chlorinator data sheet and in the log book. Normal blow tank innages after a single transfer are approximately 60%,. 3.2 Rountine Operations During normal operations of the weigh tank, No. 9 chlorinator, and No. 2 blow tank system, the following conditions will exist in the process. A. Therminol Heater 1. Flow through the Therminol heater system will be indicated on FIC-628.01, 350 GPM normal. Low circulation shut down set at 200 GPM. This will alarm at the annunciator. 2. TRCA-629.12 controls the temperature of the Therminol heating system. Set point normally at 250C. Low temperature alarm set at 220C. - high temperature alarm set at 300C. B. Weigh Tank ' 1. Assuming a batch is charged into the weigh tank ready for the chlorinator, the following conditions will exist in the control room. The annunciator panel will indicate "No. 9 Chlorinator Weigh Tank Charge Complete". 2. The control valve in the Santowax R charge line will be closed. 3. TIC-535.01 will be controlling the temperature in the weigh tank at 150C. 4. Temperature on the Multipoint Recorder, TW-535.02, will indicate 150C. . DSW 334482 STLCOPCB4080952 Detailed Instructions Aroclor 25. 5. The agitator will be running to keep the Ferric Chloride in suspension. 6. The transfer pump will be shut off. C. No. 9 Chlorinator 1. Chlorine flow will be indicated on FR.CS-505.01. If in "cascade-auto" control, the Taylor Flexipulse Timer will be controlling the flow by program system. 2. Temperature will be controlled by TRCA-538.01. With the system in "cascade-auto", the temperature will be con trolled by a pre-set program. Initial starting temperature of 130C, , completion temperature 250C. dependent on Aroclor being produced - see Appendix I. 3. No. 9 chlorinator circulating pump will be in operation. The discharge pressure on this pump will be indicated by PI-506.01. Normal pressure 35-45 psig. 4. The Therminol cooling system (Aroclor 1232) should have the following checks: a. Flow will be indicated by FICA-534.02. Normal set point 300 GPM. Low flow alarm set at 250 GPM. b. Temperature in the circulating system is indicated by TIC-533.01. Normal indication is 70C. Low temperature alarm set at 60C,. - high temperature alarm set at 80C. c. Surge tank Therminol level (Item 533) should be above the steam coils - 7-10" in sightglass. d. The Therminol cooling system pump discharge pressure should be 40 psig. 5. Temperature of the No. 9 chlorinator can also be observed on the Multipoint temperature recorder. D. No. 2 Blow Tank 1. Temperature will be indicated by TIC-541.01. Normal set point 170C. 2. Level in the No. 2 blow tank will be indicated by LI-541.02. Normal level with a full charge is approximately 607,. 3. Water valve should be open to the S&K jet providing suction on the No. 2 blow tank - pressure 20-25 psig. DSW 334483 STLCOPCB4080953 Detailed Instructions Aroclor 26. 4. The air blower (Item 530) should be operating with a discharge pressure of 8-10 psig. E. Data Sheets A Solid Aroclor system data sheet is available for the weigh tank. No. 9 chlorinatot, and the blow tank. Filling out this sheet is a normal portion of the operator's duties during the shift. 3.3 Safety Features A. The weigh tank (Item 535) has an interlock system which will not allow starting the transfer pump (Item 536) when Santowax R is being charged into the weigh tank. This Interlock is to . assure that an overcharge of Santowax cannot be made to the No. 9 chlorinator. A high weigh alarm set at 15,000 pounds will sound for an overcharge. NOTE: This interlock does not apply when Biphenyl is being charged to the weigh tank. B. A high temperature alarm is set at 275C. on the No. 9 chlori nator (Item 505) to prevent excessive carryover of trappings into the KC1 off-gas header. Temperatures above this should cause excessive carryover of Santowax and/or crude Aroclor. A low temperature alarm is also provided at 120C. to prevent production of unstable Aroclors. C. Chlorine flow stops will be placed on the chlorine flow control valve to the No. 9 chlorinator set at 300 pounds per hour to prevent shutting off the chlorine feed in cases of air failure to the control valve. The control valve normally closes on air failure. ' ' ' ' ' '. D. If Biphenyl is required for the chlorinator charge, it should be charged into the weigh tank first to the desired weight. The Santowax R or Santowax C should be charged on top of the Biphenyl since the scale weight set point will close the control valve in the Santowax R line only. This will allow more accurate weight control to the chlorinator batches. E. The Therminol Heating circulation system has several safety features which can be found in the P.F.O. for this heater system. F. Check the level in the Therminol cooling system surge tank (Item 533) to be sure the Therminol level is 7"-ll" in the sightglass. . DSW 334484 STLCOPCB4080954 Detailed Instructions Aroclor 27. G. The valves in the Therminol heating system to put heat on the No. 9 chlorinator heat exchanger (Item 538) will normally be tagged out since this heat exchanger is used for cooling. The Therminol heating system is available only for cases of unplugging the heat exchanger. H. A. sight glass has been placed in the HC1 off-gas line of the No. 9 chlorinator to allow observation of the flow for possible entrainment. In case entrainment droplets are noticed being carried out in the HC1 gas, the chlorine flow should be de creased slightly to reduce this entrainment. Excessive en trainment carry-over will cause plugging of the HC1 off-gas line. I. In case the chlorine flow control valve cannot be made to work, a U-tube manometer containing 60 Baume sulfuric acid (98%) has been placed on the chlorine header. The pressure in this manometer should be noted during normal operations. This will provide a reference to let the operator know what the chlorine flow is in cases of failure of the flow meter. A chart of chlorine flow versus pressure will be in the Operating Manualsee Appendix VI. A solid chlorinator batch could be completed using this pressure manometer if the need should arise. J. When the chlorine and temperature programmed control system is in operation, the preset program should not be disturbed since this can cause excessive chlorine flow or temperature problems to result. K. Normally, when the programmed flow control system is in operation, a sample of the material being chlorinated will be taken after two to four hours of operation. This sample is taken to assure a short charge has not been made to the No. 9 chlorinator. The sample should be checked for specific gravity, softening point, or hardening point, depending on the material being produced. If this sample indicates a normal batch, the next sample would be taken when the 80% bell rings as preset by the chlorine flow totalizer. This sample is to assure a batch is not over-chlori nated and sets up in the chlorinator preventing its transfer to the blow tank and/or to the still. 3.4 Shutdown Operations of the weigh'tank, the No. 9 chlorinator, and the No. 2 blow tank can occur which will cause temporary or prolonged shutdowns. The following detailed information concerns individual shutdowns of each of the above items. If the entire system is to be shut down, the various sections can be combined to achieve this objective. Dependent on the reason for the shutdown, it may be necessary to shut down the Therminol heating system to make the system safe. This must be considered, depending on the situation. DSW 334485 STLCOPCB4080955 Detailed Instructions Aroclors 28. A. Weigh Tank (Item 535) 1.. Temporary Shutdown a. Close the manual valves in the Biphenyl and Santowax supply lines to the weigh tank. b. Close automatic valve in Santowax line to weigh tank. c. Close the valve at the bottom of the weigh tank. d. Open discharge valve to transfer pump to vent transfer line. e. Leave TIC-535.01 in "auto" with set point at 150C. f. Leave Therminol heat on the transfer lines to the No. 9 chlorinator. g. The agitator and pump will normally be shut down unless in use. 2. Prolonged Shutdown a. Close the manual valve in the Biphenyl and Santowax supply lines to the weigh tank. b. Close automatic valve in Santowax line to weigh tank. c. Close the valve at the bottom of the weigh tank. d. Open discharge valve to transfer pump to vent transfer line. e. . Move the weigh tank temperature control TIC-535.01 set point to 0C. Close the manual valve in the steam supply line. f. The agitator and transfer pump will be shut off. g. Close the valves in the Therminol heating system lines for the weigh tank transfer lines. Close valves in steam supply to Biphenyl and Santowax lines. h. The tank may or may not be empty, dependent on the work to be done or the cause for shutdown. Under normal conditions the tank will be empty. i. Note shutdown information on data sheet. DSW 334486 STLCOPCB4080956 Detailed Instructions Aroclors 29. j. Drain the weigh tank if necessary for repair work. k. Leave the system in this condition until needed. B. No. 9 Chlorinator (Item 505) Operations can occur which will require a chlorinator to be cut back or temporarily shut down. Some of these items are failure of chlorine feed, a tank car emptying, or a cut back of the Chlorine Plant. Normally, if a partial reduction in the chlorine feed occurs, the batch liquid chlorinators will be shut off and the No. 9 chlorinator will continue to be operated. 1. Temporary Shutdown a. The circulating pump (Item 506) will normally be left in operation. b. Close the chlorine valves at the distributor on the No. 9 chlorinator. c. Check the chlorine header pressure and chlorine feed to the other chlorinators. Pressure should be 20-25 psig. d. Check to see that liquid chlorine is being fed to the vaporizer and that steam is on the vaporizer. Steam pressure should be 10-12 psig. Discharge pressure on the vaporizer should be 70-100 psig. Chlorine header pressure normally 20-25 psig. e. If the shutdown is to be longer than two hours, it may be necessary to put Therminol heat on the No. 9 . chlorinator circulating lines to keep the temperature at 120C. minimum. The circulating pump will continue to run. f. Shutdowns should be minimized. If the cause of the cut back can easily be remedied, start the chlorinator back immediately. g. Leave the Therminol cooling system circulating. DSW 334487 STLCOPCB4080957 Detailed Instructions Aroclors 30. h. Adjust control valve to TRCA-538.01 for No. 9 chlorinator to stop coolant flow on the heat exchanger. i. Leave the Therminol heating system circulating on the jacketed lines. j. Notify your chief operator or department supervision immediately in case of a problem. 2. Prolonged Shutdown a., Normally, when a chlorinator will be left down for a period longer than a few hours, the chlorination will be completed and the batch pumped out prior to shutdown. If Maintenance personnel are to work on the chlorinator, it may be necessary to vent the , vessel and purge the chlorine lines and the chlori nator tank with CC^. NOTE: ' In case of a complete shutdown for maintenance work, the chlorine valves on the main header to the chlorinator, and the transfer lines into the vessel, will be tagged. The circulating pump circuit breaker box switch will also be tagged out. b. Empty chlorinator by pumping it out. Then shut off the circulating pump. Drain the chlorinator. . c. Close chlorine valves at distributor on No. 9 chlori nator. d. Check chlorine header pressure as in Item l.c. above. e. Close the KC1 vent valve on the chlorinator to the HC1 header. f. Notify your chief operator or department supervision the vessel is shut down. g. Shut down the Therminol cooling system by: (1) Shut off circulating pump (Item 534). (2) Leave FICA 534.02 in "auto" with set point at 300GPM. DSW 334488 STLCOPCB4080958 Detailed Instructions Aroclor 31. (3) TICA-533.01 will be in "auto" with the set point at 70C. (A) Leave the steam on the surge tank (Item 533). This will keep the system ready for use. (5) In case the Therminol cooling system must be worked on, it may be necessary to drain the system. If this should occur: (a) Shut off the steam to the surge tank, (b) Water to the cooler (Item 507), (c) Tag out the circulating pump (Item 534) circuit breaker; and (d) Tag out the Therminol heating valves to ' the No. 9 chlorinator heat exchanger system. i. Note shutdown information on the data sheet. C. No. 2 Blow Tank (Item 541) 1. Temporary Shutdown a. Close the valve at the bottom of the No. 2 blow tank . (Item 541). b. Vent pump discharge line into the blow tank. ' c. Transfer pump will be shut off. d. Adjust TIC-541.01 set point to 170C. Leave in "auto". e. The air blower will continue to run. f. Water will remain on the S&K jet (Item 531), 20-25 psig. g. The system will be left in this condition until need to start back up. 2. Prolonged Shutdown a. Normally if this vessel is to be shut down for any length of time, the material in the tank will be emptied. b. Close the valve at the bottom of the blow tank. Vent the discharge valve of the transfer pump to the blow tank to eliminateexpansion in the lines. DSW 334489 STLCOPCB4080959 Detailed Instructions Aroclor 32. c. Shut off the transfer pump (Item 539). d. Adjust TIC-541.01 controller to 0C. Close the manual valve in the Therminol heating system to the coils on the No. 2 blow tank and tag out valves. e. Shut off the air blower (Item 530). f. Shut off water to the S&K jet (Item 531). g. Leave the system in this condition until necessary to start back up. D. Emergency Shutdown . Normally, an emergency shutdown does not occur concerning the weigh tank (Item 535) or the No. 2 blow tank (Item 541). How ever, emergencies can occur which make it necessary to shut down the No. 9 chlorinator as fast as possible. The following methods can be used. 1. From the Field . a. Close the manual chlorine valves to the distributor, or the manual valve from the chlorine header feeding the.No. 9 chlorinator. . b. Shut valve in HC1 pipe line to the Muriatic Acid Dept, if necessary. c. Stop circulating pump (Item 506), if necessary. d. Dependent on the emergency situation which has occurred, continue to shut this system down systematically by normal procedure. 2. At the Panel a. Stop chlorine feed to the No. 9 chlorinator. This will be done as follows, dependent on operation: (1) Manual Operation Controller FRCS-505.01 in "auto". Move chlorine flow controller set point to zero. This will reduce chlorine flow to 300 lbs/hr. to the No. 9 chlorinator. Immediately, shut off manual valves feeding this chlorinator in the field. DSW 334490 STLCOPCB4080960 Detailed Instructions Aroclors 33. (2) Programmed Operation Move chlorine controller FRCS-505.01 set points from "cascade" to set or move set points for flexopulse timer to zero. . Next, adjust set point on chlorine feed con troller to zero. Proceed as in Item (1) above. b. Shut valve in KC1 pipe line to the Muriatic Acid Department if necessary. c. Stop the circulating pump (Item 506) if necessary. d. Continue shutdown of this unit as is necessary to handle the emergency which has occurred. 3. Emergency Shutdown Therminol Cooling System for No. 9 Cnlorinator a. Stop Therminol cooling system circulating pump. b. Close manual valves as necessary in the system. c. The pump can be shut off in Item a. above at the pump itself or at the motor control center circuit breaker. 3.5 Control Loops, Interlocks, and Alarms A. Control Loons There are nine (9) major control loops in this system. 1. Neigh Tank Scale Loop - 544 . The function of this loop is to allow setting the scale by the adjustable set point for Santowax R charges. When the material reaches the desired weight, it automatically closes the control valve in the feed line to the weigh tank and rings an alarm bell indicating "No. 9 Chlorinator Weigh Tank, Charge Complete". During charging of the weigh tank, the transfer pump (Item 536) cannot be started. In case the weigh tank is overcharged, an alarm horn will sound at 15,000 lbs. This should allow approximately five (5) minutes before the tank will overflow. The interlock feature for the transfer pump does not apply when Biphenyl is being charged to the weigh tank. DSW 334491 STLCOPCB4080961 Detailed Instructions Aroclor 34. 2. Weigh Tank Temperature Control - TIC-335.01 The function of this loop is to maintain a constant temperature of 150C. in the weigh tank. This is accomplished by measurement of the temperature and controlling the heat input by throttling a control valve in the steam line to the coil in the weigh tank. 3. No. 9 Chlorinator Chlorine Flow Control - FRCS-505.01 The function of this loop is to control the chlorine flow to the No. 9 chlorinator to regulate the chlori nation rate. This is accomplished by measurement of the chlorine flow with an orifice and controlling this flow with' a control valve in the chlorine feed line. This system can be operated manually, automatically on chlorine feed control, or by a preset programmed chlorine feed control. a. Manual Control The chlorine flow controller FRCS-505.01 is positioned in "manual-set". The set point is regulated to give the desired chlorine flow to the No. 9 chlorinator. b. Automatic Flow Control ' The No. 9 chlorinator chlorine flow controller FR.CS-505.01 is positioned in "auto-set". The chlorine feed desired is set on the controller which will maintain this chlorine feed by adjusting the control valve as required. c. Programmed Flow Control The chlorine flow controller has the set points in "auto cascade". The chlorine totalizer set point is adjusted for the desired chlorine alarm level dependent on the product being produced. The dial reads 0-375 and has a multiplier of 100. The range represents 0-37,500 lbs. of chlorine. When the desired quantity of chlorine has entered the chlorinator, an alarm bell will ring and an annunciator light will flash indicating "No, 9 Chlorinator, 80% Chlorinated". The totalizer settings as listed can be used with the automatic flow control above if the con troller is not in "cascade". It must be reset by pushing the green set button. When the controller is in "cascade", the Taylor Flexopulse Timer will, by a predetermined pro gram, (See Appendix I), change the chlorine flow rate to the No. 9 chlorinator. The chlorine flow program is set by turning the knob.on each flow profile set point. This program, once set up, should not be disturbed without con sulting supervision. DSW 334492 STLCOPCB4080962 Detailed Instructions Aroclors 35. A. No. 9 Chlorinator Temperature Control - TR.CA-538.01 The function of this loop is to provide temperature control of the chlorination batch in the No. 9 chlorinator. This is accomplished by measurement of the temperature in the . crude Aroclor circulating line at the heat exchanger and controlling the Therminol cooling system to the shell of this heat exchanger (Item 538). The temperature controls can be operated manually, automatically, or by a pre determined program temperature profile. The temperature system has a low temperature alarm at 120C. - a high temperature alarm at 275C. Range of the instrument is 0-300C. a. Manual Control The temperature controller TRCA-538.01 will be in "manualset". Circulating of the Therminol cooling system across the No. 9 chlorinator heat exchanger can be controlled manually by adjusting the control valve with TRCA-538.01 set point. Adjust until the desired temperature is acquired. b. Automatic Control The temperature controller TRCA-538.01 is in "auto-set". The controller set point is adjusted to the desired tem perature. It will automatically adjust the control valve to maintain the temperature as set. c. Programmed Temperature Control The temperature controller is placed in "auto-cascade". . The chlorination temperature time profile is adjusted to . the desired temperature by turning the knob on each tem perature profile set point. A predetermined program is set up on the Taylor Flexopulse Timer. After start of the program, the Flexopulse Timer will automatically advance through the temperature profile as set up by the program. These set points will be directed to the pro grammer only if TRCA-538.01 is in "auto-cascade". This program, once set up, should not be distrubed without consulting supervision. 5. Chlorine Header Pressure Control - PIC-500.07 The function of this loop is to maintain the chlorine header pressure to the Aroclor chlorinators within a range of 20-25 psig. This is accomplished by measuring the chlorine header pressure and throttling a control valve in the discharge from the chlorine vaporizer to maintain the chlorine header pressure within + 1 psig of the set point. A low pressure alarm is set ~ tetc 1C i--t at 35 psig.ctuu c-t X, - ^ls-p-----i--c-- --o------o-----u------i-c-- c^1ixcum DSW 334493 STLCOPCB4080963 Detailed Instructions Aroclor 36. 6. Therminol Cooling System Flow Control - FICA-534.02 The function of this loop is to maintain a constant flow of 300 GPM in the Therminol cooling system. This is accomplished by measurement of the flow with an orifice flow meter and adjusting a control valve to automatically bypass the No. 9 chlorinator heat exchanger (Item 538). Flow through the No. 9 heat exchanger is regulated by the temperature control TRCA538.01. Normal operation of the system is with the controller in "auto" and the set point at 300 GPM. A low flow alarm will sound' at 250 GPM. 7. Therminol Cooling System Temperature Control - TICA-533.01 The function of this loop is to control the Therminol cooling system (Aroclor 1248) in the surge tank (Item 533) at 70C. This is accomplished by measurement of the discharge ternperature from the Therminol water cooler (Item 507) and auto matically throttling the water flow on the shell side of the cooler (Item 507). The low temperature alarm on this system is set at 60C. - the high temperature alarm is set at 80C. 8. Therminol Surge Tank Temperature Control - TC-533,01 The purpose of this temperature control loop is to maintain a constant temperature of 45C. in the Therminol cooling system surge tank (Item 533). This is accomplished by measure ment of the temperature and throttling a control valve in the steam line to the coil on the surge tank. Set point of this controller is 45C. 9. No. 2 Blow Tank Temperature Control - TIC-541.01 The function of this loop is to maintain a constant temperature of 170C. in the No. 2 blow tank. This is accomplished by measuring the temperature in the blow tank and throttling the control valve in the Therminol heating system (Aroclor 1248) to the coils in the No. 2 blow tank. There are no alarms in this system. 10. No. 2 Blow Tank Level Indication - LI-541.02 This loop measures the level of crude Aroclor in the No. 2 blow tank. This is accomplished by use of a bubbler dif ferential pressure level indication instrument. A 0- 1007o dial indicates the tank level. DSW 334494 STLCOPCB4080964 Detailed Instructions Aroclor 37. B. Interlocks There is one interlock in this system. * 1. Weigh Tank System ' The Santowax transfer pump (Item 536) cannot be started while Santowax R is being filled into the weigh tank. This interlock is energized when the control valve in the feed line is open. This interlock does not apply when Biphenyl is being charged into the weigh tank. C. Alarms The following alarms exist through this system. 1. Weigh Tank (Item 535) a. ' When the measured or preset weight approaches the set point on the scales, an alarm bell will sound indicating "No. 9 Chlorinator Weigh Tank, Charge Complete". This alarm is on.the chlorinator annunciator panel. b. A high weight horn will sound if the weigh tank is filled above 15,000 lbs. This horn indicates there is approxi mately 5 minutes before the tank will overflow. 2. No. 9 Chlorinator System (Item 505) a. Chlorine Flow Alarm (1) When the chlorine totalizer is being used, an alarm bell will ring when the batch is 80%, chlorinated. The chlorine set point for the totalizer depends on the Aroclor being produced. b. Temperature Alarms Abnormal temperature alarms are set for a low chlorination temperature of 120C, and a high temperature of 275C. c. Chlorine Header Pressure Alarm The chlorine header pressure will sound an alarm at a low pressure of 15 psig and a high pressure of 35 psig. This will actuate an annunciator on the chlorinator panel indicating "High/Low Chlorine Header Pressure." DSW 334495 STLCOPCB4080965 Detailed Instructions Aroclors 38. d. Low Flow Alarm A low flow alarm will sound in the Therminol cooling system (Aroclor 1248) if the flow falls below 250 G?H. This alarm is on the chlorinator panel. e. Abnormal exit temperatures on the Therminol (Aroclor 1248) cooling system from the cooler (Item 507) will sound an alarm. The low temperature alarm is set at 60C. and the high temperature alarm at 80C. f. An annunciator will sound in case the instrument air compressor motor should stop. This will indicate air .failure in the department and will necessitate a shut down of the equipment. IV. COMMENTS ON PROCESS A. Special flexible piping joints have been made to the weigh tank (Item 535) since this tank is placed on scales. Actuation of the scale system will require movement of this tank approxi mately 1/4". These flexible piping joints should be carefully inspected to be sure there are no leaks since the material con tained in them is extremely hot. During weighing of the raw material charge, the operator should be careful to eliminate problems with excessive movement of the scale. - B. Steam is provided on the transfer lines and the coil to the weigh tank. From the bottom piping on the weigh tank, all the transfer lines and coils in process vessels have Therminol heat until the end of the process at the flaker hold tank. C. The transfer pump (Item 536) for the weigh tank has steam on the Thermon-traced and insulated section of the casing of the pump. D. The Therminol heating system has been provided for this solid Aroclor facility to eliminate use of gas torches on vessels and pipe lines. Problem areas should be noted immediately so that alterations can be made to achieve this goal. E. Care must be taken not to fill the Therminol cooling system surge tank (Item 533) too full during normal operation. This can cause the tank to run over when the circulating pump is stopped. The normal level will be 6" to 12" in the sightglass. The level in this tank will vary, dependent on the operating temperature of the' system. SW 334496 STLCOPCB4080966 Detailed Instructions Aroclors 39. *F. A change in the operating process has been made for the No. 9 chlorinator. It does not have a basket of iron turnings. Due to this change, it is absolutely necessary that (5) lbs, of Ferric Chloride be added to each chlori nator charge in the weigh tank. G. Different time dials for the flexopulse timers are used for the different Solid Aroclors produced. This eliminates more complicated changes when products are changed. See Temperature - Chlorine Flow Programs - Appendix I. *Ferric Chloride is not added when 1142 is used for an 1168 chlorinator charge. oS>N 33A** STLCOPCB4080967 Detailed Instructions Aroclors AO. APPENDIX I SOLID AROCLORS PROGRAMMED CHLORINATION TEMPERATURE & CHLORINE FLOW PROFILE 1. CHLORINE FLOW - FLOW RECORDER CONTROLLER (FRCS-505.01) Time 2565 AROCLORS 5042 5060 1st hour @ 1,000 1,000 1,500 2nd hour @ 1,500 1,500 2,000 3rd & subsequent hrs. to end of batch @ 1,700 1,500 2,500 .2 TEMPERATURE CONTROL - TEMPERATURE RECORDER CONTROLLER (TRC.A- Time 2565 AROCLORS '' " 5042 5060 1st hour 0 130 160 190 - 2nd two hours @ 130 180 200 3rd two hours @ 140 190 210 4th two hours @ 140 ' . 200 220 5th two hours Q 140 210. 230 6th two hours Q 150 .. 210 240 7-th two hours @ 160 210 250 8th two hours @ 180 210 255 Total Batch Time - Approximate hours - 10-1/2 DSW 334498 STLCOPCB4080968 Detailed Instructions Aroclors 41 APPENDIX I (Contd.) 3. CHLORINE TOTALIZER SETTINGS FOR. 80% ALARM (BASED ON 90% CHLORINE AND CHARGES INDICATED) Aroclor Product ' 80% Cl? Setting *1168 33,000 2565. 26,800 Total Charge 0 9,550 9,000 5042 5060 . 11,000 20,000 11,000 11,000 CHLORINE TEMPERATURE PROFILE AROCLOR 1168 Time Chlorine Flow 1st hour 1,000 2nd hour 1,500 3rd hour 1,700 5th hour 1,700 7th hour 1,700 9th hour 1,700 11th hour 1,700 13th hour 1,700 15th hour 1,700 Temperature 130 130 140 140 140 . ' 150 160 170 180 to end of batch *NOTE: Does not apply when 1142 is used for chlorinator charge rather than Biphenyl dSXN 334499 STLCOPCB4080969 Detailed Instructions Aroclors APPENDIX II ITEM 533: THERKINOL CIRCULATING TANK FOR NO. 9 CHLORINATOR COOLING SYSTEM TANK CALIBRATION Inches from Bottom of Sight Glass Bottom of Sight Glass 1' 2 .3 A 5 6 7 8 9 10 11 12 13 14 15 16 17 . 18 19 20 Tank Capacity Gallons 163 169 176 183 190 197 204 211 218 224 231 238 245 252 259 266 273 279 286 293 300 42. STLCOPCB4080970 Detailed Instructions Ar odors A3. APPENDIX III METHOD OF RUNNING SPECIFIC GRAVITIES 1. Catch representative sample of material in metal cylinder provided for,this purpose. On the chlorinators, the sample point is at the discharge of the circulating pump. Excess material is returned to the suction of the pump through a special pipeline. 2. Take sample to the control room. 3. Allow water to run down out side of the cylinder while stir ring sample vigorously until the sample is 10C above the temperature at which the sample is run. See Table I, Page 3. A. Cut off the water when the sample is 10C. above the desired temperature. Keep stirring until the sample is 1C. above the temperature which the sample is to be run. Stop stirring. Allow the hydrometer which has been thoroughly cleaned to sink into the sample until it reaches equilibrium. 5. Observe reading on the hydrometer. Record hydrometer reading on the operating data sheet, along with the time the sample was taken. 6. In case the temperature was off 1 or 2 when the reading was taken, a correction can be applied. It is 0.001 specific ' gravity units per C. If the sample was 2C. high, add 0.002 specific gravity units to the reading. If the sample was 2C. low, subtract 0.002 specific gravity units from the reading. 7. Carefully clean the hydrometer and thermometer. Place them in the rack provided for this purpose. Dump sample in the return line to the chlorinator pump. DSW 334501 STLCOPCB4080971 Detailed Instructions Aroclors 44. APPENDIX IV METHOD OF RUNNING HOLDING POINTS 1. Obtain representative sample of material from sample line at pump discharge line. Catch sample in a pint can. 2. The receptacle for running the sample is 1" x 4-1/2" Pyrex tube, sealed at one end. The tube is inserted in a. square 8-oz. bottle which is insulated in the bottom by a layer of 1" asbestos fibre. The tube is held in place by a large cork. Insulation is used in an effort to keep the Aroclor from cooling too rapidly. 3. Pour the material into the tube until it is filled within 1-1/2" of the top. 4. Material will probably crystallize in the cold tube and will have to be melted again. 5. When the material is melted, insert a suitable thermometer (0-360C.) which is fitted with a cork to hold it in place. The bulb of the thermometer should be fitted in the center of the sample, care being taken that it is not too close to the side of the tube. 6. Heat the tube to 200C. , place it in the asbestos jacket, then put it in the bottle. 7. Take readings on the thermometer every 30 seconds. At first the temperature will drop rapidly (4-6C. between readings). This drop will decrease and finally come to a stop and stay constant for several readings, or will start to go back up several degrees. 8. Record the point at which the temperature remains constant, or in case of a rise, the highest point of the rise is the hold point of the material. DSW 334502 STLCOPCB4080972 Detailed Instructions Aroclors 45. APPENDIX V METHOD OF RUNNING SOFTENING POINTS 1. Obtain representative sample of material from sample line at discharge of circulating pump. Catch the sample in can lid or Pyrex beaker. * 2. Heat ring and sample. 3. Place ring on can lid or metal plate and fill with sample until material stands slightly higher than edge of ring. Fill the ring from the large diameter side. 4. Cool the ring and lid from bottom of the side until sample sets up, being careful not to get any water on top of the sample. 5. Finish cooling by running water on top of the sample after it sets up. 6. Remove filled ring from lid and trim off any material that is on the outside. 7. Make slight indentation on top of the sample in the center of the ring with a heated wire to hold the ball in place. 8. Fill beaker with water or glycerin. - a. Use water when expected softening point is under 80C. b. Use glycerin when expected softening point is over 8QC. 9. Place the ring in the sample holder, place ball on sample, and put holder in the beaker. 10. Adjust the thermometer in the holder so that the tip of bulb protrudes 1/4" through the hole in the crossbar that holds sample. 11. Place the beaker on a stand with screen under it and set burner under the stand. . 12. Light burner and adjust to give a temperature rise as shown on the thermometer of 5C. per minute. 13. Bring temperature up 5C, per minute until ball falls through the sample. ' 14. Record temperature at time ball falls to lower crossbar as the softening point. DSW 334503 STLCOPCB4080973 NO. 2 BLOW TANK AROCLOR 5060 Innage Inches 1 Full Gallons Innage Inches % Full Gallons 0 0.7 1 1.2 2 1.6 3 2.0 4 2.5 5 2.9 6 3.3 7 3.8 8 4.4 9 5.4 10 6.5 11 1 7.5 12 8.7 13 9.7 14 10.7 15 11.9 16 12.9 17 14.1 18 15.1 19 16.1 20 17.3 21 18.3 22 19.3 23 20.5 24 21.5 25 22.6 26 23.-6 27 24.8 28 25.8 29 26.8 30 28.0 31 29.0 32 30.2 307 332 357 382 408 433 458 483 509 534 559 585 610 635 660 686 711 736 762 787 812 837 863 888 913 939 964 989 1,014 1,040 1,065 1,090 1,115 33 34 35 ' 3'6 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 , 55 56 57 58 59 60 61 62 63 64 . 65 31.2 32.2 33.4 34.4 35.5 36.5 37.7 38.7 39.7 40.9 41.9 42.9 44.1 45.1 46.3 47.3 48.3 49.4 50.5 51.6 52.6 53.7 54.8 55.8 57.0 58.0 59.0 60.2 61.2 62.3 63.4 64.4 65.5 1,141 1,166 1,191 1,217 1,242 1,267 1,292 1,318 1,343 1,368 1,394 1,419 1,444 1,469 1,495 1,520 1,545 1,571 1,596 1,621 1,646 1,672 1,697 1,722 1,747 1,773 1,798 1,823 1,849 1,874 1,899 1,924 1,950 Innage Inches 7, Full Gallons 66 66.6 1,975 67 67.7 2,000 68 68.7 2,026 69 69.8 2,057 70 70.9 2,076 71 71.9 2,101 72 73.1 2,127 73 74.1 2,152 74 75.1 2,177 75 76.3 2,203 76 77.3 2,228 77 78.4 2,253 78 79.5 2,278 79 80.5 2,304 80 81.6 2,329 81 82.7 2,354 82 83.8 2,379 83 84.8 2,405 84 85.8 2,430 85 87.0 2,455 86 88.0 2,481 87 89.2 2,506 88 90.2 2,531 89 91.2 2,556 90 92.4 2,582 91 93.4 2,607 92 94.5 2,632 93 95.6 2,658 94 96.6 2,683 95 97.7 2,708 96 98.6 2,733 Data for Sheet based on filling tank with water during start-up, June 1964. Straight side 25.3 gals/in. 33*50* qSnN STLCOPCB4080974 tFO Wo nr>\.Th>r~ CcnTrols F~r~ SoF". o / &ST, !W$ A.V-<i-WZ 'Richh'icntl / /z 7/c-to steeT to of /c s \ 339-120 / . T " LO G A R ITH M IC STLCOPCB4080975 STANDARD OPERATING INSTRUCTIONS FOR AROCLORS 46. PROCESS FUNCTION OUTLINE C. I. NO. 4 STILL SYSTEM . 1.1 Scope This covers the charging, start-up, shutdown, normal operation, and emergency situations involving the No. 4 Aroclor still system. 1.2 Description of Process Aerated crude Aroclor from a blowing tank is fed to the still tank. Hydrated lime is added to the crude Aroclor. Vacuum is applied to the still and the Aroclor is circulated through the furnace coil and heated to the vaporization tem perature. Vapors pass up an open column to the condenser. Distilled A.roclor is collected in a receiver. Quality of the distilled solid Aroclors is analyzed by the lab, and if in specification, it is transferred to the flaker hold tank for flaking or dumming into suitable containers. Still residue or bottoms from each 2nd distillation (each Aroclor 1268 distillation) are drawn into containers and sold as Montars, or it is discarded in trash drums. II. PROCESS DIAGRAM Attached. Ill. OPERATION OF PROCESS 3.1 Start-Up A. Initial Start-Up 1. Therminol Cooling System for No. 4 Still Condenser a. Charge system with Therminol FR-2 (Aroclor 1248) : (1) Use temporarily relocated Pyranol pump to charge Therminol surge tank (Item 622). (2) Position 55 gallon drum next to the pump. Remove drum bung and vent cap. OSW STLCOPCB4080976 Detailed Instructions Aroclors 47. (3) Connect flexible hose to pump suction and the stainless steel pipe to be inserted into the drum. (4) Position discharge line from the pump into the ^ tank. (5) Open valve on pump suction; insert pipe into drum and start pump. (6) Adjust the suction valve on the pump until the flow is steady. (7) Continue to fill the surge tank until 4 drums ' or approximately 200 gallons total are in the surge tank (Item 622). 2. Still and Furnace Start-Up a. Charges to the No. 4 Still for the Various Crude Aroclors: Under normal conditions, crude Aroclors will be charged to the No. 4 still and the charge measured by the level indication (LI-541.02) on the No. 2 blow tank. NOTE: . Aroclor 1242, as well as Aroclor 1248, can be charged into the surge tank. Same as charging No. 9 chlorinator surge tank - 6"-12" in sight glass. The No. 4 still horizontal condenser was replaced with a vertical condenser in May 1968. The charges for all crude Aroclors for chlorination in the No. 9 chlorinator are based on an output from the chlorinator of 2,100 gallons. This quantity of Aroclor can be charged to the still without any problem. The still tank size is 2,500 gallons. Aroclor 1168 is charged directly from the chlorinator to the No. 4 still. This Aroclor is not air-blown. b. Prepare No. 2 Blow Tank (Item 541) for transfer of charge: (1) Check to be sure the Therminol heating system is on the transfer pump (Item 539) and the charging lines. Material to be pumped must be hot or it will damage the mechanical seals on the transfer pumps. Cold lines can also cause plug-ups and failure to trans fer material. SW 334507 STLCOPCB4080977 Detailed Instructions ' Aroclors . 48. (2) Check temperature of material in blowing tank to be sure it is hot enough to transfer (170C. minimum). See TIC-541.01. (3) Check with the chlorinator operator to be sure crude Aroclor has been air-blown for one hour. c. Prepare still to'receive charge: (1) Close valve at the bottom line under the still (Item 615). (2) Open vent valve on the still, j (3) Open valve on vent line of the still. I (4) Set valves from the No. 2 blow tank to the No. 4 . still. Be sure the Therminol heating system is on all transfer lines. (5) Close the main valve in the vacuum line to the still just above the receiver. Set the vacuum controller PIC-615.04 in "auto" with the set point at 10 mm Hg. Start steam to the vacuum jets. Put steam on stage 3, stage 2, and stage 1, in that order. Stage 1 is the closest to the receiver. Adjust water to the intercondenser on the middle stage. The jet on the No. 4 still should pull down to 4-5 mm Hg absolute on the receiver (Item 620). The steam to the jet on the No. 4 still should have a minimum of 90 psig supply pressure. d. Start up the Therminol cooling system for the No. 4 still condenser (Item 619); (1) Set TICA-622.01 at 120C. with the controller in "auto". (2) Adjust the set point for the Therminol low temperature alarm instrument TIA-623.02 approximately 20C. below the control point for TICA=622.01. EX: 100C. (3) Open the block valves in the Therminol heating system lines to the coil on the surge tank (Item 622). Set the valves in the Therminol cooling system for the No. 4 still condenser (Item 619) to allow circulation from the surge tank through the condenser through the Therminol cooler (Item 624) and back into the surge ' tank. (4) Wait until the temperature of the Therminol cooling system is 100C. , then start the circulating pump (Item 623). DSW 334508 STLCOPCB4080978 Detailed Instructions Aroclors 49. (5) Check the level in the surge tank (Item 622) to be sure the Therminol level covers the heating coils in the surge tank. This will be 6"-12" in the sight glass. (6) Do not permit distillation to start until the >desired set point of 120C. has been reached in the Therminol cooling system. Settings for the temperature controller TICA-622.01 for the Aroclors are as follows: Aroclor No. 5460 5442 1268 Set Point, C 120 120 170 The fan on the Therminol cooler (Item 624) can be started when necessary to keep the temperature at the set point during distillation. It is operated manually or automatically. ' (7) Check the following items on the Therminol cooling system circulation: (a) Therminol cooling system circulating pump (Item 623) discharge pressure should be 37 psig. (b) Circulating pump discharge temperature TIA-623.02 should read 120C. with the low temperature alarm point set at 100C. (c) Surge tank temperature TICA-622.01 should read 120C. - e. Charging the No, 4 still and start-up: (1) Set valves in transfer line from No. 2 blow tank to the still. (2) Start the blowing tank pump and transfer a full charge into the still tank. (3) The still furnace coil can be preheated by using the pushbutton on the still control panel. This will allow by-passing the furnace interlocks to start gas into the furnace without starting the still pump. The pilot and main gas burner will be started as usual. This is to prevent plugging the still coil during start-up. Place gas flow' controller FRC-618.06 in "manual" with C" ^ TVJ f" e*. C'.l 1 r>t" -- X / 2 ^ . 0-c-^ 37 V 0 Vo stack temperature on the multipoint recorder and do not exceed 200C. DSW 334509 STLCOPCB4080979 Detailed Instructions Aroclors 50. (4) Note the level of material leaving the No. 2 blow tank (Item 541) on the level indication gauge. As soon as 157<> of the material has been transferred to the still, start the still circulating pump (Item 616). (5) "Set valves -in the No. 4 still circulating line through the heater coil (Item 618) and back into the still tank. . (6) Stop the No. 2 blow tank transfer pump when the ' charge is complete as noted on the No. 2 blow tank level gauge. Allow lines to drain and then close the charging lines to the still. (7) Close the valve under the No. 2 blow tank. (8) Add hydrated lime through the funnel provided for this purpose on the No. 4 still. Add 250 pounds of lime for each still batch. (9) Close the valve on the lime addition line. (10) Set No. 4 still condenser condensate temperature alarm TIA-619.03 at 100C. (11) Start up the No. 4 still furnace (Item 618). f. Furnace Start-Up for the First Time: (1) Open manual valves in the natural gas line to the furnace main and pilot gas lines. (2) Open damper on the furnace stack. (3) Turn on circuit No. 6 at the still panel and the switch on the outside of the field control box to "on". The "red" light at the Honeywell Protectoglo unit will light up. (4) Push pretemp "start" button to allow preheating the furnace before starting the circulating pump. (5) Set the control point on the Honeywell coil outlet temperature indicator located in the box at 400C. (6) Gas test the atmosphere inside the heater. Use a 3 foot length of copper tubing on the end of a rubber hose. If the test shows dangerous, stop and correct the cause of trouble before lighting the burner. When the heater is cold, there is no natural draft to carry away gas or fumes. After the unit gets hot, there will always be a natural draft provided the flue damper is open. DSW 334510 STLCOPCB4080980 Detailed Instructions Aroclors 51. (7) Actuate the red reset lever inside the Honeywell Protectoglo unit in the field control box. Open the door of the flame unit. This exposes the small red lever in the lower right-hand corner of the case. You must wait 10 seconds between settings of this lever in case it has to be redone. (8) The "green" light on the Protectoglo unit should come on within 6 minutes. (9) Depress the ignition start button on the side of the field control box to actuate the pilot flame. Hold the button depressed for no more than 10 seconds. If all is well, the "white" light on the Protectoglo ' unit will come on and the "green" light will go out. When this occurs, pull your finger away. The pilot is now properly lit. (10) Put the set point on the natural gas flow controller FRC-618.06 to the solid still below 2.5 psig output. The switch will be in "auto". (11) Manually open the two reset safety valves in the main gas line. The heater is now ready for operation. (12) Increase gas flow to furnace burner. Observe stack temperature. Do not exceed 150C. (13) Start up the solid still circulating pump. The Aroclor circulating flow meter FRA-618.01 will now record a flow above 150 GPM. Low flow below 50 GPH through the coil will cause the main burner to be shut off. (14) Gradually raise the set point of the natural gas flow controller FR.C-618.06 to the desired set point. The furnace refractory must be dried out prior to starting heat-up to 400C. Special instructions will be made at start-up. Temperature of the furnace will be controlled by the stack high temperature point on the multipoint recorder. Observe the coil outlet temperature on the multipoint temperature recorder. Do not exceed 50C. increase for the first two hours. Raise FRC-618.06 set point for the natural gas flow as required to increase the temperature 50C. per hour until you reach 4Q0C. The natural gas flow controller should be in "auto". The distillation or "boiling" is considered to be started when the vapor temperature mades a sudden increase. Watch for this increase during initial heat-up of the furnace for the first time. . DSW 334511 STLCOPCB4080981 Detailed Instructions Aroclors 52. (15) Check the following items in the system to be sure operations are normal. (a) Natural gas flow to the furnace on FRC-618.06. (b) No. 4 still circulating pump flow FRA-618,01. (c) Therminol cooling system temperature on TICA622.01. (d) Check the coil temperature differential on the inlet and outlet of the furnace (Item 618). g. Start-Up of Furnace after Temporary Shutdown: (1) Prior to start-up, the still coil can be preheated before starting the circulating pump, if necessary. See Section e.(3), Page 49. (2) Adjust natural gas flow controller to "auto" with the set point below 2.5 psig output pressure. This is FRC-618.06. (3) Start up the solid still circulating pump (Item 616). The Aroclor circulating flow meter FRA-618.01 should now indicate a flow in excess of 150 GPM. Shutdown - will occur at a flow below 50 GPM. (4) Open the main valve in the vacuum line to the vacuum jets above the receiver. Vacuum at the still re . ceiver should be approximately 5 mm Hg. PRC-615.04 should indicate the exact vacuum on the still, which should be 10 mm Hg. (5) Gradually raise the set point of the natural gas flow controller FRC-618.06 to the desired set point. (6) Check the multipoint temperature recording instrument for the temperature rise across the coil in the heater furnace. In case this temperature chart is not in dicating correctly, check for plugged lines or in strument problems. Check to be sure the pump flow is being measured correctly. If necessary, shut off the pump while at a low temperature to be sure the system is operating. Have the electrician check the tem perature instruments if you do not get a rise. (7) Adjust the still furnace natural gas feed with FRC618.06 to give the maximum rate of temperature rise without overheating. A spread of 4 - 6C. between the coil inlet and outlet is normal. The gas supply pressure will normally be approximately 4-1/2 psig. DSW 334512 STLCOPCB4080982 Detailed Instructions Aroclors 53. (8) Be sure the Therminol heating system is off the vacuum line to the jets during operation. (9) - Check the Therminol cooling system on the No. 4 still condenser (Item 619) to be sure the condenser does not plug up. If plugging begins to occur, raise the temperature in the Therminol cooling circulation system. Use TICA-622.01 to accomplish this. The temperature indicating alarm TIA-619.03 set at 100C. will indicate plugging of the condenser. ' If the system is too hot, the fan on the Therminol cooling system cooler (Item 624) can be started auto matically or manually. (10) Vacuum problems on the stills are usually due to flashing of product over plugged vacuum lines, leaks in the still system, leaks at pump packing, or Therminol flow problems on the condenser, water adjustment on the inter-condenser, on the jet, changes in the steam pressure to the jets, or problems in the nozzles for the jet. Flashing can be stopped by lowering the temperature of the Therminol cooling system for the No. 4 still condenser. Vacuum trouble must be traced systematically from the jet to the . receiver and then to the still. To accomplish this, manometer pressure indicators have been placed in the system as follows: . (a) On top of the trap in front of the jet (Item 625); (b) On the still receiver (Item 620); (c) On the still (Item 615). (11) During normal operation, the manual valves to the coil on the receiver (Item 620) are open. The still receiver temperature indicating controller TIC-620.02 is set at 150C. with the controller in "auto". (12) A level indication gauge has been installed in the still receiver (Item 620) to allow indication of the level of material being distilled over. The level instrument is LI-620.04. This level indication can be used to determine when the distillation is near completion. This will aid the still operator along with his normal observation of coil temperature spread across the furnace. oSVJ 3345A3 STLCOPCB4080983 Detailed Instructions Aroclors 54. (13) Batch data sheets are filled out during each dis tillation. Information includes the still lot ' number, materials being distilled, start time, finish time, the temperature spread on the still coils, the vacuum, the end time for the distillation, _ etc. See distillation table details which follow on Page 55. (14) ' As the distillation nears completion, temperature in the still pot will rise. Flow through the coil will remain steady. When the flow drops below 125 GPH, an alarm will sound. The main gas burner to the furnace will shut off if flow drops below 50 GPH. An additional aid is the level indicator . in the still receiver (Item 620). (15) At the end of the distillation, the batch is checked for color and softening point or hold point, depend ing on the material being produced. Before transfer, check that space is available in the flaker hold tank and that the hot Therminol system is on the transfer lines from the still receiver to the flaker hold tank. (16) At the end of the distillation, shut off the furnace if it has not already been shut down automatically. (17) Close the main valve in the vacuum line on top of the receiver (Item 620). This is to isolate the jet from the still system and eliminate plugging of the jet. (18) Vent the furnace coil and allow it to suck dry slowly to prevent carryover to the still condenser. . (19) Shut off the fan on the Therminol cooling system cooler (Item 624). This can be done at the control panel. 3. Operation of the Still During Distillation a. Regulate the gas pressure at the burners by use of FRC-618.06 to give the maximum distillation rate with consistent good color of the product. b. The lower the vacuum, the faster the distillation rate, normally. (See Table II - "Distillation Operating Conditions - Solid Aroclors" - Page 55) DSW 334514 STLCOPCB4080984 Detailed Instructions Aroclors 55 TABLE II DISTILLATION OPERATING' CONDITIONS - SOLID AROCLORS Approximate Temperatures at-which Various Aroclors Start Distilling @ 10 mm Vacuum. At Still: Column Coil Inlet Coil Outlet 1268 5442 5460 225C. 240C. 245C. 215C. 260C. 240C. 280C. ' 245C. 285C. Approximate Finishing Temperature When Bottoms are not to be Drawn: Column Coil Inlet Coil Outlet _ Approximate Finishing Temperature After which Bottoms are to be Drawn: Column Coil Inlet Coil Outlet Finishing Hold Point Finishing Softening Point 285C. 295C. 330C. 150170C. 315C. 355C. 340C. 375C. 380C. 400C. 4652C. 98105.5C. DSW 334515 STLCOPCB4080985 Detailed Instructions Aroclors 56. c. Coil temperature spread: (1) Coil inlet and outlet temperature must be watched closely at the end of the distillation. Still . bottoms are very viscous; therefore, if the cir- - culating pump is in poor condition, or the distil lation is carried too far, circulation may stop and the coil will become plugged or be burned. Heat from the furnace actually burns the Aroclor to carbon when overheated. If the coil outlet temperature jumps suddenly and the inlet temperature stays the same or falls, circulation is nearly stopped. In this case, shut off the furnace gas supply FRC-618.06 quickly and suck the coil. Normally, the low flow rate FRA-618.01 will alarm with a flow below 125 GPH. If the coil cannot be sucked, it is plugged and will have to be replaced. 4. Pump Out Still Receiver a. Transfer material from the still receiver (Item 620) to the flaker hold tank. b. Observe level of material in the still receiver by use of LI-620.04. c. Check to be sure Therminol heating system is on the jackets of the transfer lines. d. Set valves in the line to transfer to the flaker hold ' tank. e. When material is to be transferred to the flaker hold tank start transfer pump (Item 621) under the receiver. . Allow material to pump until the receiver is empty. . f. Close the valves and stop the transfer pump when the receiver is empty. This can be observed by checking level gauge LI-620.04. g. Start agitator in flaker hold tank. 33/V5A6 OSNN STLCOPCB4080986 Detailed Instructions Aroclors 57. III. 3.1 B. Start-Up Following Temporary Shutdown This start-up phase would normally be a situation where a previous distillation is complete and the still has been shut down for charging with a new batch. 1. Prepare No. 2 Blow Tank for Transfer Charge .a. Check to be sure that the Therminol heating system is on the transfer lines from the blow tank to the still pot. . b. Check the temperature of the material in the blow tank. It should be 170C. minimum. I c. Check with the chlorinator operator to be sure that the crude Aroclor has been air-blown one hour.. d. The No. 4 still vacuum system should be operating with the valve just above the No. 4 still receiver closed. Water should be on the intercondenser and steam on the jet stages. Vacuum on the trap (Item 625) in the vacuum pipe line should be indicating 4 - 5 mm Hg. 2. Set the vacuum control PR.C-615.04 in "auto" with the set point at 10 mm Hg. 3. The No. 4 still receiver temperature still controller TIC620.02 should be in "auto" with the set point at 150C. 4. The Therminol cooling system should be circulating through the No. 4 still condenser and back to the surge tank. The temperature controller TICA-622.01 should be in "auto" with the set point at 120C. The fan for the Therminol cooler (Item 624) should be running, if necessary, to cool Therminol. The No. 4 still temperature control TIC-615.03 will be in "auto" with the set point at 150C. 5. The natural gas flow controller FRC-618.06 will be in "auto" with the set point below 2.5 psig output pressure. 6. The No. 4 still furnace (Item 618) will be on as indicated by the Honeywell Protectoglo unit in the field panel. The "white" light on the Protectoglo unit will be on. 7. Set valves in the transfer line from the No. 2 blow tank to the No. 4 still. 8. Open the vent valve on the No. 4 still. Close the valve at the bottom of the still. ' DSW 334517 STLCOPCB4080987 Detailed Instructions Aroclors 58. 9. Start the No. 2 blow tank transfer pump and charge the No. A still. Observe level indication gauge in the No. 2 . blow tank to measure the still charge. 10. Start up the solid still circulating pump. The Aroclor circulating flow meter FRA-618.01 will now record a flow in excess of 150 GPM. 11. The still circulating pump will be started as soon as 15% of the material from the No. 2 blow tank has been charged to the still. 12. Stop the No. 2 blow tank transfer pump as soon as the blow tank is empty.Close the valves at the bottom of the blow tank and at the discharge of the transfer pump. 13. Add 250 lbs, of lime to the still charge. 14. Close the vent valve on the No. 4 still. Openthe vacuum valve on the No. 4 still receiver and start the vacuum on the system. 15. Gradually raise the set point of the natural gas flow controller FRC-618.06 to the desired set point. Watch the temperature rise across the furnace coil inlet and outlet as the temperature is raised. Normally, a 4-6C. spread will be obtained across the furnace coil. 16. During normal operation of the still system, the following items will be observed. a. Temperature spread across the still furnace. b. Flow of the Aroclor through the furnace coil. See . FRA-618.01. c. Level indication in the No. 4 still receiver. See LI-620.04. d. Natural gas flow control to the No. 4 still furnace. See FRC-618.06. e. Temperature in the Therminol circulating system. See TICA-622.01. f. Temperature control i.i the No. 4 still. See TIC-615.03. ' g. Temperature control'in the No. 4 still receiver. See TIC-620.02. DSW 334518 STLCOPCB4080988 Detailed Instructions Aroclors 59. 17. At the end of the distillation the batch is checked for color, softening point, or hold point, depending on the material being produced. As the distillation continues, the temperature in the still pot will rise; flow through the coil will remain steady. When the flow drops to 125 GPM, an alarm will sound.- Shut-off of the main gas to the still furn'ace will occur if flow drops below 50 GPM. . An additional aid to finishing the batch is the level indication in the No. 4 still receiver LI-620.04. 18. Shut off the natural gas if it has not alarmed.. Clear the coil by doing the following: a. Close the vacuum valve on top of the No. 4 still 1 receiver in the line to the jet. . b. Vent the still heater coil and suck the coil dry. c. Shut off the fan at the Aroclor cooler (Item 624). 19. Set lines to transfer material to the flaker hold tank. When material is to be transferred to the flaker hold tank, be sure the Therminol heating system is on the pump suction and discharge line. Set the valves in the transfer line and start transfer pump to the flaker hold tank. When the No. 4 still receiver is empty, stop the circulating pump and close the valves in the transfer lines. 3.2 Routine Operations When the No. 4 still system is operating normally, the following conditions will exist in the process: A. No. 4 still pressure control PRC-615.04 set at 10 mm Hg. B. No. 4 still circulating pump flow recorded on FRA-618.01 with flow above 125 GPM. - C. No. 4 still temperature control TRC-615.03 set at 150C. D. Natural gas feed to the still furnace controller FRC-618.06 set to give desired coil outlet temperature (about 900 cfh). E. Furnace high temperature alarm instrument set at 400C. F. Therminol cooling system circulating temperature controller TICA=622.01 set at 120C. G. No. 4 still receiver temperature control TIC-620.02 set at 150C. H. No. 4 still level indication gauge LI-620.04 will indicate level in the receiver. DSW 334519 STLCOPCB4080989 Detailed Instructions Aroclors 60. I. Main natural gas pressure 40 psig. J. Natural gas reduced pressure 2-1/2 to 4 psig. 3.3 Safety Features . A. The Honeywell Protectoglo unit has the following safety features for the No. 4 still furnace (Item 618): 1. Ignition period 10 second delay between actuation periods for the warp switch to cool. 2. Heater coil high temperature outlet shutdown set at 400C. 3. Natural gas high reduced pressure shutdown set at 5,0 psig. 4. Circulating pump low flow rate shutdown alarm set at 125 GPM. 5. Pilot flame must be burning to start up the unit. This is indicated by 1-1/2 to 2 microamperes on the field control panel. B. Therminol cooling system temperature control alarm set for low alarm at 100C and high alarm at 175C. C. Check surge tank (Item 622) to be sure Therminol level is at least 6"-12" in sight glass. 3.4 Shutdown A. Temporary Shutdown Main gas burner on the furnace off with the pilot light on. The No. 4 still circulating pump running and the vacuum system on. 1. Adjust FRC-618.06. Set point to 0. Instrument in "auto". 2. Close the manual valve in the natural gas feed supply line to the main burner, 3. The vacuum may be cut off by closing the manual valve above the No. 4 still receiver. The still would then be vented and shut down systematically, if necessary. B. Complete Shutdown Main gas burner and pilot light shut off in the furnace. Still circulating pump off. The vacuum shut down and the Therminol cooling system shut off. I. Push ignition stop button on side of the field control panel for the furnace control system. DSW 334520 STLCOPCB4080990 Detailed Instructions Aroclors 61. 2. After the furnace has cooled slightly, push the stop button for the No.. 4 still circulating pump (Item 616). 3. Close manual valve above the No. 4 still receiver in the vacuum line. 4. Shut off steam to the vacuum jet by closing main valve in the steam supply line. 5. Close valve in the water line to the inter-condenser on the No. 4 still jet. 6. Shut off Aroclor to the coils on the still tank and the receiver by adjusting the temperature controller set . points to 0 for each tank. ' 7. Stop the Therminol cooling system circulating pump (Item 623). 8. Check the surge tank level to be sure the tank does not overflow after this pump is shut off. 9. Adjust TICA-622.01 controller set point to 0. This will stop the Therminol heating system flow to the coils on the surge tank (Item 622). 10. Stop the fan on the Therminol cooling system cooler (Item 624). 3.5 Control Loops, Interlocks, and Alarms A. Control Loops There are nine (S) major control loops in this system. 1. Vacuum Control for the No. 4 Still - PRC-615.04 The function of this loop is to maintain a constant vacuum on the No. 4 still tank. This is accomplished by measure ment of the vacuum on the still and throttling a control valve at the suction of the No. 4 still jet. Normal setting of this instrument is 10 mm Hg. 2. No. 4 Still Circulating Pump Flow Recorder - FRA-618.01 The function of this loop is to measure and record the flow through the furnace heater coil on the No. 4 still. This is accomplished by measurement with a segmental orifice which indicates the flow to a panel recorder with alarm. This is a special flanged jacketed orifice assembly using a Taylor volumetric d/p cell to measure flow. Normal flow will be above 150 GPH. A low flow alarm shutdown for the furnace (Item 618) main gas system will be actuated if the flow drops below 125 GPH. Shutdown occurs if flow drops below 50GPM. DSW 334521 STLCOPCB4080991 Detailed Instructions Aroclors 62. 3. No. 4 Still Temperature Control - TIC-615.03 The function of this loop is to maintain a minimum tem perature in the No. 4 still, dependent on the material being produced. This is accomplished by measurement of the temperature and throttling a control valve on the discharge of the Therminol heating system from the coixs in the No. 4 still (Item 615). 4. Furnace Natural Gas Floy? Control - FRC-618,06 The function of this loop is to control the gas input to the No. 4 still furnace. This is accomplished by measure ment of the natural gas through an orifice flow meter and throttling the control valve in the reduced gas line. 5. No. 4 Still Furnace Controls - 618A The function of this control system is to control the natural gas feed pressure to the still furnace and assure a pilot light is always burning when natural gas is being fed to the furnace. This is accomplished with a Minneapolis-Honeywell Protectoglo pilot light control mechanism. There are six safety features in the furnace controls to shut the system down: a. High furnace coil outlet temperature will shut down the furnace above 400C. b. Low reduced natural gas pressure 2-1/2 psig. c. High reduced natural gas pressure 10 psig. d. Failure of circuit No.'6 at the rear of the still psnelboard, or electrical failure. e. Failure of any component in the Honey-jell pilot flame mechanism. f. Failure of the pilot system is indicated by the "red" light on the Protectoglo unit lighting up. 6. Therminol Cooling System Temperature Control - PICA-622.01 The function of this loop is to measure the temperature in the Therminol cooling system surge tank and control this temperature to 120C. This is accomplished by measuring . the temperature in the surge tank and throttling a control valve in the discharge of the coil in the surge tank. The louvers in the Therminol cooling system heat exchanger (Item 624) are also throttled to allow more or less air to pass SCiTGiiS tiiG CO-Llb. ri lOvv Lciupci'ciLUi'c cij.ai.iii SCUitCiS c L. 100C. and a high temperature alarm at 175C. DSW 334522 STLCOPCB4080992 Detailed Instructions Aroclors 63. 7. No. 4 Still Receiver Temperature Control - TIC-620.02 The function of this loop is to control the temperature in the No. 4 still receiver to 150C. This is accomplished by measuring the temperature in the receiver and throttling a control valve in the Therminol heating system discharge line on the coil from the No. 4 still receiver. 8. No. 4 Still Receiver Level Indication - LI-620.04 The function of this loop is to indicate the level of distilled product in the No. .4 still receiver. This is accomplished by a float level instrument which indicates the Aroclor level on a 0-8 ft. dial gauge. 9. No. 4 Still Condensate Temperature - TIA-619.03 The function of this loop is to indicate the temperature of the condensate from the No. 4 still condenser and sound an alarm if this temperature should become too low. Normally, a temperature of 20-30C. below the product temperature in dicates the condenser is plugging up, will sound an alarm. B. Interlocks Interlocks in this system are as follows: 1. Start-Up of No, 4 Still Furnace (Item 618) a. Actuation of the pilot ignition lever on the Honeywell . Protectoglo unit has a 10 second delay before a second try can be made. b. The ignition "start" button at the Protectoglo unit has a 3 minute purge delay after the "start" button has been pushed. This is to allow air purging of the furnace before it lights up. 2. Automatic No. 4 Still Furnace Shutdown With Alarms (Pilot and Main Gas Burner Off) a. High furnace coil outlet temperature above 400C. b. Low reduced natural gas pressure 2-1/2 psig. c. High reduced natural gas pressure 10 psig. d. Low coil flow below 50 GPM. e.. Failure of circuit No. 6 at the rear of the still panel. f. Failure of the switch at the side of the field control panel, or blowing the 115 volt fuse in the panel. . DSW 334523 STLCOPCB4080993 Detailed Instructions Aroclors 64. C. Alarms 1. All shutdown items under "Interlocks" (B-2 above) have - alarms. 2. No. 4 still circulating pump low flow alarm below 125 GPM. 3. Therminol cooling system Tj.CA-622.01 has a low temperature alarm at 100C. and a high temperature alarm at 175C. 4. Condensate temperature alarm on low temperature for the distilled product coming out of the No. 4 still condenser (Item 619). This controller TIA-619.03 is set to alarm at approximately 20-30C. below the condenser product outlet temperature. IV. COMMENTS ON THE PROCESS A. It is very important to be sure the coil in the Therminol cooling system surge tank (Item 622) is covered when the system is in operation. This assures the circulating pump . has a positive suction and prevents surging in the heater coil. This will allow more uniform control of the temperature in the Therminol cooling system. B. Care must be taken not to fill the surge tank (Item 622) too full during normal operation. This can cause the tank to run over when the circulating pump is stopped. A normal level will be about 6" to 12" in the sight glass. The level in the tank will vary, dependent on the operating temperature of the system. Normally, this will be 120C. C. Be sure that chrome1-alumel thermocouple extension lead wire is used to connect up the furnace natural gas high temperature coil outlet alarm. Type K wire is in the same conduit as Type J wire. If Type J wire is used by mistake, the indicator will read too high and cause furnace shutdowns. D. After the first two or three still batches have been run so the natural gas heat input rate is known, adjust the linkage on the reduced gas pressure control valve so a 3-15 psig instrument signal will fully stroke the valve. Make the adjust ment so that only 10-15% above the maximum needed gas pressure can be obtained. This will reduce charring of the coils in the still furnace (Item 618). In setting this instrument, a mano meter is furnished with the furnace controls for adjusting the control valve. The manometer readings across the orifice will be: DSW 334524 STLCOPCB4080994 Detailed Instructions Aroclors 65. 0.595" at 0.74 " at 0.89 " at 1.04 " at 1.19 " at oo ooo Btu/hour Input 500,000 Btu/hour Input 600,000 Btu/hour Input 700,000 Btu/hour Input 800,000 Btu/hour Input E. The flow measurement recording instrument for the still heater system FRA-618.01 is an extremely important portion of the controls for the new No. 4 still system. A segmental orifice is used for obtaining differential pressure readings to in dicate flow. This orifice system is in a specially designed Therminol jacketed pipe section. A specially designed d/p cell records the pressure readings and indicates flow. The orifice is designed to allow sucking the coil completely empty when a distillation is complete. The hole in the orifice plate is flush with the bottom of the pipe line. This flow recorder should indicate low flow rates at the end of a distillation which will aid the operator in completing a normal distillation. F. A restricting orifice has been installed in the furnace circulating line on the No. 4 still as the pipe line re-enters the still tank. This orifice is designed to maintain a pressure of 6 psig through the still furnace coil. This increased pressure at the coil outlet will suppress any boiling or vaporization within the coil. Actual vaporization and distillation should take place in the still tank (Item 615). G. During distillation of Solid Aroclors, vacuum problems occur in the pipe line to the jet system and plugging of the jet nozzles occur due to flashing and normal vapor pressure carryover. The vacuum line from the No. 4 still receiver (Item 620) has Therminol heat on the jacket of the pipe line up to the suction line on the jet (Item 626). The trap tank (Item 625) in the vacuum line has Therminol heat on the coils in the tank. It is very important that the Therminol heating system be cut off the jacketed lines and the coils in the trap tank during normal operation. If these lines are kept hot during normal operation, it will cause carry over into the jet nozzles and cause more rapid plugging than in the past. When using the Therminol heating system to clean out the lines or drain the trap tank, the jet should be isolated from the No. 4 still system. This can be done by either shutting the steam off to the jets or closing the block valve in the pipe line at the suction of the jet. DSW 334525 STLCOPCB4080995 Detailed Instructions Aroclors 66. H. In the existing No. 1 Aroclor still system, leaks occur in the still condenser where the tubes are welded to the tube sheet at the end of the condenser. The new condenser for the No. 4 still has a specially designed flexible expansion joint in the shell of the condenser. It is felt that this expansion joint will eliminate our present leakage problems in the new No. 4 still system. It is extremely important that we watch for potential leaks since the material leaking into the distilled product will be Therminol FR-2 (Aroclor 1248). DSW 334526 STLCOPCB4080996 Process Function Outline Aroclor Department ARO SOM III - 2.030 Page 30 Rev. 1 Date: 10/25/65 APPENDIX I ITEM 622: THERMINOL CIRCULATING TANK FOR NO. 4 AROCLOR STILL _______________CONDENSER COOLING SYSTEM TANK CALIBRATIONS Inches from Bottom of Sight Glass Bottom of Sight Glass 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Tank Capacity Gallons ____ 87 92 97 103 108 113 118 123 128 133 139 144 149 154 159 164 169 174 180 185 190 195 200 DSW 334527 STLCOPCB4080997 Process Function Outline Aroclor Department APPENDIX II ITEM 620: NO. 4 STILL RECEIVER TANK CALIBRATIONS Level Gallons Level Gallons 1" 2" I 3" i 5" 6" 7" 8" 9" 10" 11" l'-0" l'-l" 1* -2" 1* -3" li-4" 1.-5" l'-6" l'-7" l'-8" 1* -9" l'-10" l'-ll" 2 * -0" 2'-l" 2'-2" 2'-3" 2*-4" 2'-5" 2' -6" 2' -7" 2'-8" 2* -9" 2'-10" 2'-11" 31 -0" 224 246 269 291 314 336 358 381 403 425 448 470 493 515 538 560 583 605 627 650 672 695 717 740 762 785 807 829 852 874 897 919 942 964 986 1,009 3'-l" 3'-2" 3' -3" 3* -4" 3'-5" 3'-6" 3'-7" 3'-8" 3'-9" 3'-10" 3' -11" 4'-0" 4*-l" 4'-2" 4'-3" 4,-4" 4'-5" 4'-6" 4-7" 4*-8" 4'-9" 4'-10" 4*-11" 5'-0" 5' -1" 5'-2" 5'-3" 5'-4" 5' -5" 5' -6" 5'-7" 5' -8" 5'-9" 5*-10" 5'-11" 6* -0" 1,031 1,054 1,076 1,099 1,121 1,144 1,166 1,188 1,211 1,233 1,256 1,278 1,301 1,323 1,346 1,368 1,390 1,413 1,435 1,458 1,480 1,503 1,525 1,547 1,570 1,592 1,615 1,637 1,660 1,682 1,705 1,727 1,749 1,772 1,794 1,817 ARO SOM III - 2.030 Page 31 Rev. 1 Date: 10/25/65 Level Gallons 6'-l" 6,-2" 6' -3" 6' -4" 6'-5" 6'-6" 6' -7" 6'-8" 6'-9" 6'-10" 6'-11" 7' -0" 7.-l 7.-2" 7.-3" 7'-4" 7.-5" 7' -6" 7' -7" 1,839 1,862 1,884 1,907 1,929 1,951 1,974 1,996 2,019 2,041 2,064 2,086 2,108 2,131 2,153 2,176 2,198 2,221 2,243 STLCOPCB4080998 7. Scale 0 1 2 3 4 5 6 7 8 9 10 11 12 i 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Gallons 87 113 139 165 191 217 243 269 295 321 347 373 399 425 451 477 503 529 555 581 607 633 659 685 711 737 763 789 815 841 867 893 919 945 971 ' 997 1,023 1,049 1,075 1,101 AROCLOR 5460 FLAKER HOLD TANK Inches Aroclor . (Innage) % Scale 11" 12.3 13.6 14.9 16.2 17.5 18.8 20.1 21.4 22.7 24.0 25.3 26.6 27.9 29.2 30.5 31.8 33.1 34.4 35.7 37.0 38.3 39.6 40.9 42.2 43.5 44.8 46.1 47.4 48.7 50.0 51.3 52.6 53.9 55.2 56.5 57.8 59.1 60.4 61.7 40 41 42 43 44 * 45 46 47 48 49 50 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 76 77 78 79 Aroclor 5460 Sp. Gr. 1.544 @ 150C Temperature 150C Inst. Range - 0-200" H2O Inst. Scale - 0.100% Gallons 1,127 1,153 1,179 1,205 1,231 1,257 1,283 1,309 1,335 1,361 1,387 1,413 1,439 1,465 1,491 1,517 1,543 1,569 1,595 1,621 1,647 1,673 1,699 1,725 1,751 1,777 1,803 1,829 1,855 1,881 1,907 1,933 1,959 1,985 2,011 2,037 2,063 2,089 2,115 2,141 Inches Aroclor (Innage) 63.0" 64.3 65.6 66.9 68.2 69.5 70.8 72.1 73.4 74.7 76.0 77.3 78.6 79.9 81.2 82.5 83.8 85.1 86.4 87.7 89.0 90.3 91.6 92.9 94.2 95.5 96.8 98.1 99.4 100.7 102.0 103.3 104.6 105.9 107.2 108.5 109.8 111.1 112.4 113.7 . OS\N 334529 STLCOPCB4080999 STANDARD OPERATING INSTRUCTIONS FOR AROCLORS 67. C. I. PROCESS FUNCTION OUTLINE CHARGE TANK, BATCH & CONTINUOUS LIQUID CHIORINATORS, & BLOW TANKS 1.1 Scope - This covers the charging, start-up, shutdown, normal operation, and emergency situations involving the charge (melt) tank, the batch and continuous liquid chlorinators, and the blow tanks for production of Liquid Aroclors. 1.2 Description of Process Crude liquid Aroclors are produced by batch or continuous chlori nation when a measured quantity of Biphenyl is chlorinated in a vertical reaction vessel with Ferric Chloride as a catalyst. Chlorine gas is added at the bottom of the vessel. The reaction is cooled by circulating the reaction mass through an external air-cooled heat exchanger. By-product HC1 gas vented at the top of the chlorinator is recovered in the Muriatic Acid Department. Crude liquid Aroclors produced in the batch chlorinator are transferred to the blow tank operation when the chlorination is complete. A continuous blow tank is in stalled in the continuous chlorination system so aerated material is transferred directly to still feed tanks (or roof tanks). Chlorine gas can be fed to the chlorinators from tank cars. . II. PROCESS DIAGRAM Attached. Ill. DESCRIPTION OF PROCESS 3.1 Start-Up A. Charges and Operating Temperatures for Various Crude Liquid Aroclors - Batch Chlorinators Depending on the product to be produced, different quantities of raw materials are needed. See Table I on Page 68. i STLCOPCB4081000 68 TABLE I BATCH LIQUID CHLORINATOR OPERATING CONDITIONS ' 1121 > .P> 0 1142 C L0R 1148 1154 1160 1162 Chlorinator Charge Biphenyl (Lbs.) 3,000 Approximate Pounds 1007, Chlorine Required to Produce Batch 1,600 3,000 3,330 3,000 5,560 3,000 7,040 3,000 9,030 3,000 9,480 Totalizer Chlorine Setting (80% Cl2, Assuming 10% Air) Lbs. CI2 1,420 3,000 4,940 6,250 8,020 8,420 Chlorinator Temp. Beginning - C. Ending - C. 130 130 130 130 130 130 140 150 155 155 160 160 Final Specific Gravity 1.150 Range 1.160 Q 65C. Weight of Crude Batch Lbs. 3,750 Gallons 390 1.344 1.357 65C. 5,080 450 1.410 1.420 65C. 5,550 470 1.500 1.510 65C. 6,350 505 1.558 1.572 90C. 7,160 550 1.577 1.587 90C. 7,545 570 33*5^ 0^ STLCOPCB4081001 Detailed Instructions Aroclors 69. B. Fill Charge (Melt) Tank for Batch Chlorinators 1. Refer to Section 3.1-A. for the actual quantities of raw materials needed for the particular Aroclor to be produced (Table 1, Page 68). 2. Set the valves to receive the charge from the Biphenyl Department. Biphenyl is obtained from the Biphenyl storage tanks. A normal 3,000 pound Biphenyl charge is 35" innage in the charge tank for Biphenyl. 3. Be sure steam is on transfer lines and the coil for the Biphenyl charge tank. One and one-half (1-1/2) -pounds of Ferric Chloride are slurried in Aroclor and dumped into the charge tank with each chlorinator charge. When the correct charge of Biphenyl is in the charge tank, close the manual valve in the line to the tank. A. Start the agitator in the charge tank and let it run for one hour minimum prior to charging the chlorinator. This is after the Ferric Chloride has been added. 5. Material is the charge tank should be a minimum 100C. when charging the chlorinator. 6. The material is now ready for the next chlorinator charge when needed. C. Charge the Batch Chlorinator and Start-Up 1. Manual Operation a. Close manual chlorine valve at the distributor on the chlorinator to be charged. b. Close vent on the chlorinator to the atmosphere. c. Open KC1 vent valve to muriatic acid area. d. Set temperature recorder controller in "auto" with the set point at 150C, Low temperature alarm 120C. high temperature alarm 190C. e. Place selector switch for chlorinator fan in "auto". f. Place chlorine flow control instrument in "auto" and set. The chlorine set point will be 400 lbs/hr. DSW 334532 STLCOPCB4081002 Detailed Instructions Aroclors 70. g. Set the valves to transfer charge from charge tank to the chlorinator. Be sure to stop the agitator before starting the transfer pump. h. Start chlorinator charge pump. Stop pump when the charge tank is empty and close the valves at thp charge tank. i. Set the chlorinator valves to circulate the chlorinator through the external heat exchanger and back to the chlorinator. j. Start the circulating pump. k. Open manual chlorine valve at the distributor on the chlorinator. Chlorine header pressure control PIC500.07 will control the pressure to 20-25 psig. A low pressure alarm is set at 15 psig. - high pressure alarm at 35 psig. l. After one hour, increase the chlorine rate to 600 lbs/hr. chlorine feed. After two hours, increase the chlorine feed rate to 800 lbs/hour. m. Check the following items after the start of the chlorination. (1) Temperature at the temperature controller. (2) The chlorine flow at the flow controller. (3) Circulating pump discharge pressure. (4) Temperature of the chlorinator batch on the Multi point Recorder. n. Samples are taken at the discharge line of the circulating pump at the second level. The specific gravity is run on the batch chlorination. At the start of the chlorination, a sample is taken after two hours of operation on odd numbered hours (7, 9, 11, etc.). S amples will be taken every two hours through the chlorination. DSW 334533 STLCOPCB4081003 Detailed Instructions Aroclors 71. o. When the chlorination is near completion, it may be necessary to run the specific gravity more often to determine the exact end point. p. When the chlorination has been completed (see Table I), shut off the chlorine feed valve at the distributor on the chlorinator. q. Note the chlorine pressure on the main header. Pressure controller alarm PIC-500.07 will indicate a high pressure in case it should occur at 35 psig. r. The chlorinator is now ready to be pumped out when the operator is ready. 2. Programmed Chlorinator Operation a. Close the manual chlorine valve at the distributor on the chlorinator. b. Close the vent valve on the chlorinator to the atmosphere. c. Open the HC1 vent valve to the muriatic acid area. d. Set the temperature recorder controller in "auto" with the set point at 150C. e. Set the chlorine flow recorder controller in "auto cascade". Have the set point at 400 lbs./hour. f. Adjust the green set point knob on the chlorine totalizer per Table I on Page 68 for measuring chlorine flow. Set up the chlorine flox? program per Appendix I attached. g. Set the valves to transfer the charge from the charge tank to the chlorinator. Start the transfer pump. Stop the pump xjhen the charge tank is empty. Close the valves in the charge line. h. Set the valves to circulate the chlorinator to the external air-cooled heat exchanger and back to the chlorinator. DSW 334534 STLCOPCB4081004 Detailed Instructions Aroclors 72. i. Start the circulating pump. j. Push the green reset button on the chlorinator panel for the chlorinator to be started up. This resets the chlorine totalizer and is the initiating signal for the start of a new batch. The Flexopulse Timer will begin to time the batch as indicated by cascade flow. The batch chlorine flow will be controlled according to a preset program. At 807, of the chlorine flow as set by the chlorine totalizer, an alarm bell will ring to indicate 80% of the chlorine feed has been taken into the chlorinator. k. Open the manual chlorine valve at the distributor ' on the chlorinator. This should be done immediately after pushing the reset button so the timer will control the batch correctly. Steps j. and k. can be reversed if desired, dependent on where the operator is when starting the batch. The chlorine header pressure control PIC-500.07 will control the pressure to 20-25 psig. It will indicate a low pressure alarm at 15 psig and a high pressure alarm at 35 psig. l. After two hours, take a sample of the crude Aroclor and check for specific gravity. This sample is a check to be sure a short charge was not transferred into the chlorinator. The next sample after that will be taken when the 80% alarm bell rings. m. Check the following items during operation. (1) Temperature at the temperature recorder controller. (2) Chlorine flow at the chlorine recorder controller. (3) Circulating pump discharge pressure. (A) Temperature of the chlorination batch on the Multi point recorder controller. (5) Note program time and approximate time until completion of batch. n. The alarm bell will ring when 80%, of the chlorine has been fed to the chlorinator. Immediately take a sample at the circulation line to determine the point which the chlorination level has reached. dsvm 334535 STLCOPCB4081005 Detailed Insrructions Aroclors 73. o. Continue the chlorination until complete. It may be necessary to run the specific gravity more often during the last one to two hours of chlorination. p. At completion of the chlorination (see Table I), push the green reset pushbutton on the chlorinator panel for the chlorirfator. '''his reduces the chlorine flow to 300 lbs./hour, and stops the timer. Shut off the chlorine feed valves to the distributor at the chlori nator. q. Note the chlorine pressure.on the main header as in "Manual Operation". The chlorine header pressure controller alarm will indicate an abnormal low or high ` pressure. r. If the chlorination is complete, prepare to pump to the blow tank as desired, depending on the product being produced. See next section of Operating In structions. D. Transfer to Blow Tank 1. Set transfer lines to pump to the blow tank, dependent on the material being produced. Be sure steam heat is on the transfer line. The chlorinator is vented to the HC1 line during transfer. 2. Check the level indication instrument on the blow tank to be sure there is enough room to transfer into the tank. 3. Change the final valve in the transfer line and allow material to pump from the chlorinator to the blow tank. Observe transfer and note level increase on the blow tank level indicator. At the completion of the transfer, close the valves in the circulating system and shut off the circulating pump on the chlorinator. 4. The chlorinator is now ready to charge back for the next chlorination. STLCOPCB4081006 Detailed Instructions Aroclors 74. 5* Record transfer information on the chlorinator data sheet and in the log book. Normal blow tank innages after a single transfer are as follows: Aroclor 1121 ' Blow Tk-.nk Inn age 14 inches Blow Tank Level Instrument 1142, 1148, 1154 1160, 1162 16-17 inches 18 inches . 6. If the chlorinator which is to be shut down had 1160 or 1162 in it, it should be washed out with approximately 100 gallons of 1142 prior to complete shutdown. E. Fill Biphenyl Mix and Feed Tank for the Continuous Chlorinator System 1. Check the level in the mix tank. The tank low level alarm should have sounded (set for 25% full). Silence the alarm by pushing the acknowledge button on the control panel. 2. Set the valves to receive the charge of Biphenyl. Fill the tank to 75% full level. Close the valve in the charge line when this level is obtained. 3. Start the agitator in the mix tank. 4. Add 2 pounds of Ferric Chloride to the mix tank. Allow the Biphenyl and ferric chloride to mix until the feed tank requires filling. 5. The feed tank low level alarm sounds the annunciator system at 25% full in the feed tank. The mix tank batch can be dropped into the feed tank any time after the alarm sounds. The low alarm in the feed tank sounds approximately 30 minutes prior to the tank running empty. 6. Stop the agitator in the mix tank. 7. Open the valve under the mix tank and allow the Biphenyl- Ferric Chloride mix to drop into the feed tank. The level indicator in the feed tank should indicate approximately 85% full. ' ' DSW 334537 STLCOPCB4081007 Detailed Instructions Aroclors 75. 8. Start the Biphenyl feed tank agitator. 9. Close the valve under the mix tank when the tank is empty. 10. Prepare another mix for the Biphenyl mix tank as noted above. The low level alarm in the mix tank should have sounded and been acknowledged. F. Continuous Chlorinator Operation The continuous chlorinator operation consists of four cascade flow chlorinators in series where specific levels of chlori nation occur. Biphenyl is fed into the first chlorinator where the material is chlorinated and overflows to the second unit. This continues until the finished product comes off the final unit, flows to the catch tank, and through the continuous blow tank. This chlorination system can be reduced to three (3) chlorinators in series in case problems occur with one unit. Normally, 1142 is the only liquid Aroclor produced on the con tinuous system; however, 1148, 1154, and 1160 can also be pro duced with the chlorinators set for different levels of chlori nation. 1. Four Stage Continuous Chlorinator Operation a. Set the temperature controllers for chlorinators Nos. 5, 6, 7, and 8 at 150C. b. Set the chlorine flow controllers in "auto" with the set points at 600 lbs/hour for chlorinators Nos. 5, 6, 7, and 8. c. Set the specific gravity recorder controller for No. 8 . chlorinator in "auto" with the set point at 1.350. The Accuray controller will adjust the chlorine feed auto matically to No. 8 chlorinator to maintain the indicated specific gravity. d. Set the Biphenyl feed controller in "atuo" with the set point for 2 GPM (instrument reading 4). e. Charge each of the four chlorinators (No. 5, 6, 7, and 8) with Biphenyl as for a regular batch chlorination. Start the circulating pumps on the chlorinators. STLCOPCB4081008 Detailed Instructions Aroclors 76. Follow normal procedure to chlorinate the materia! to the following levels: Stage Chlorinator Specific Gravity . Eirst 5 1.078 - 1.104 Second Third 6 7 1*170 - 1.196 1.254 - 1.280 Fourth 8 1.336 - 1.362 g. Close the valve on the chlorine distributor on each chlorinator when the correct specific gravity level has been reached. Hold this chlorinator until all four are ready. It may be necessary to put steam on the chlorinator to keep the temperature at 120C. h. Check the Biphenyl feed tank to be sure mix has been charged and the agitator is running. i. Set the valves on the Biphenyl feed line to the No. 5 chlorinator and allow circulation back to the feed tank. j. Start the Biphenyl feed pump k. Set the valves on the overflow lines at the chlorinators as follows: Crude from No. 5 chlorinator to overflow to No. 6 chlorinator; No. 6 chlorinator to No. 7; No. 7 over flows to No. 8; No. 8 overflows to the crude Aroclor catch tank and then to the continuous air blow tank. l. When all four chlorinators have reached the correct specific gravity level, start the chlorine feed to each of the chlorinators (600 lbs./hour on each) and open the valve to start Biphenyl feed to the No. 5 chlorinator. Open manual valves at each chlorinator distributor. Chlorine feed is adjusted at the auto matic flow controllers in the control room to maintain the required specific gravity level. Normally, No. 5 chlorinator chlorine feed is lower than the other three chlorinators. This is to decrease Biphenyl carryover into the HCl header line. Be sure and close the manual valve in the Biphenyl feed . line to No. 5 chlorinator. 0S\N 334539 STLCOPCB4081009 Detailed Instructions Aroclors 77. m. Samples will be caught and specific gravity run on chlorinators Nos. 5, 6, and 7 every other hour on even hours (8, 10, 12, etc.). A sample will be run on No. 8 chlorinator every four hours (8, 12, A, 8, etc.). n. Check the following items during operation. (1) Temperature of the individual chlorinators on the automatic temperature controllers. (2) Chlorine flow on the chlorine flow controllers. (3) Discharge pressure of the circulating pumps for each chlorinator. (A) Temperature on the Multipoint temperature recorder for the chlorinator batch temperature for each unit. (5) Specific gravity of No. 8 chlorinator. o. The continuous blow tank level controller LICA-529.01 has a set point at 50%. The controller is always in automatic. p. The crude Aroclor catch tank level indicating controller LICA-5A5.01 is set at 50%. The controller is always in automatic. q. When the level in the crude Aroclor catch tank reaches the 50% set point, set the valves to allow transfer from the crude Aroclor catch tank to the continuous blow tank. Start the crude A.roclor catch tank pump. r. Set the valves to allow transfer from the continuous blow tank to the No. A blow tank. When the level in the continuous blow tank has reached 50%, start the transfer pump which will allow pumping to the No. A blow tank or the No. 1 roof tank. s. The levels in the two tanks will be maintained auto matically. Periodically the No. A blow tank must be transferred to the No. 1 roof tank to feed the No. 3 still. When the continuous blow tank system has been proven to satisfactorily air blow the crude Aroclor, valves can be set to allow pumping directly to the roof tank. CSV* s**9*0 STLCOPCB4081010 Detailed Instructions Aroclors 78. 2. Three Chlorinator System a. Routine repairs to the chlorinators requires removal of one of the four continuous chlorinators from the system. In this case, the following procedure would be followed to run three chlorinators. continuously. b. Switch valves on the overflow lines from one chlori nator to another to allow by-passing a particular chlorinator. c. Shut off the Biphenyl feed to the first stage chlori nator and chlorinate the material to the following levels: Stage Chlorinator* Specific Gravity First 5 1.108 - 1.124 0 65C Second 6 1.224 - 1.240 @ 65C Third 8 1.345 - 1.355 0 65C *Note: Indicates No. 7 chlorinator out of system; however, any one of the four can be by-passed. d. Start the chlorine and biphenyl feed again in the same manner as for the four stage continuous operation. e. Continue operation of the system as a three stage unit, merely omitting the one stage which has been by-passed. f. The chlorinator removed from service should be chlori nated to a finished Aroclor and pumped out. The chlori nator will be shut down in a routine fashion. See details in "Shutdown" section. G. Chlorine Vaporizer Liquid chlorine from tank cars is vaporized in a shell and tube heat exchanger, using steam for heat. Vaporized chlorine at 25 psig enters the chlorine header to the Aroclor chlorinators. 1. Open manual valve on the steam line to the vaporizer. 2. Set the vaporizer temperature control at 65-75C. to allow the steam control valve to open. 3. Check to be sure steam pressure to the vaporizer is 12 psig or lower. osnn STLCOPCB4081011 Detailed Instructions Aroclors 79. 4. Set the chlorine header pressure control valve in "auto" with the set point at 0. The chlorine valve feeding liquid chlorine into the header will be closed. 5. Hook up the take-off lines to the chlorine car. Wear a gas mask while making this connection. Open the valve on the car to take onchlorina when the car is connected. This valve must be opened slowly or the check valve ball will jump up in the valve and make it impossible to take chlorine out of the car. ' 6. Open the valve in the liquid chlorine line to the vaporizer located at the tank car. 7. Open the block valves on each side of the automatic liquid chlorine take-on valve. Close the by-pass valve at the control valve. 8. Check the vaporizer level control to be sure it closes the liquid chlorine control valve when the vaporizer is approxi mately one-half full. 9. Set the chlorine pressure control instrument PIC-500.07 at 25 psig with controller in "auto". 10. Open the chlorine vapor valve slowly to eliminate surges in the chlorine header system. 11. Observe operation to be sure the chlorine header pressure does not exceed 25 psig and the steam pressure to the vaporizer remains below 12 psig. DSW 33*542 STLCOPCB4081012 Detailed Instructions Aroclors . 80. 3.2 Routine Operations During normal operations of the batch and continuous chlorinators, the following conditions will exist in the process. A. 3atch Chlorinators ' 1. Chlorine flow will be indicated on the flow controller. If in "cascade-auto" control, the Taylor Flexopulse Timer will be controlling the flow by programmed system. 2. Temperature will be controlled by the temperature recorder controller with the system in "auto". Normal temperature is 150C. 3. The chlorinator circulating pump will be in operation. Discharge pressure on the pump will be 35 psig. Normal flow of the pump will be 200 GPM. A. Temperature of the chlorinator can also be observed on the Multipoint temperature recorder. 5. The chlorine pressure on the main header can be observed on PIC-500.07, the pressure indicator controller from the chlorine vaporizer. Normal pressure will be 20-25 psig. B. Continuous Chlorinators 1. Chlorine flow will be in "auto" control with the flow indicated on the flow recorder controller for the individual chlorinators, Nos. 5, 6, 7, and 8. 2. Temperature will be controlled by the temperature recorder controller for the individual chlorinators. Normally, the controller will be in "auto" with the set point at 150C. 3. The chlorinator circulating pumps will be in operation with the discharge pressure at 35 psig. Normal flow of the pumps is 200 GPM. 4. The temperature of the individual chlorinators can be observed on the Multipoint temperature recorder. 5. Biphenyl feed to the first stage of the continuous chlori nators, (normally No. 5 chlorinator), can be observed or the Biphenyl feed control instrument. Normally, this in strument is in "auto" with the set point at 3.0 GPM. DSW 334543 STLCOPCB4081013 Detailed Instructions Aroclors 81. 6. The Accu Ray specific gravity instrument for the No. 8 chlorinator will be indicating the specific gravity for the material in the No. 8 chlorinator. The controller will be set in "auto" with the control point at 1.350 specific gravity units. 7. The level in the Biphenyl mix and feed tanks will be indicated by the level indicators on the control panel. Normally, the mix tank will have a charge in it indicating 757. full. The feed tank level will vary from 25-85% full. 8. The level in the crude Aroclor catch tank will normally be ,50%. 9. The level in the continuous blow tank will normally be 50%. 10. Air pressure to the continuous air blow tank will normally be 5.0 to 10 psig. 11. The HC1 header off-gas pressure will normally be 1.5 to 3.0 psig. C. Chlorine Vaporizer 1. Chlorine level in the vaporizer will be approximately 507=,. 2. Steam to the chlorine vaporizer steam chest will be 10-12 psig. 3. Chlorine pressure from the tank car will normally be 60 psig. A. The chlorine vaporizer temperature controller will be set at 65C. Normally, the liquid chlorine will be well below this temperature which opens the steam control valve. 5. The chlorine pressure indicating controller PIC-500.07 will be set in "auto" with the controller at 20-25 psig. D. Blow Tank 1. One of the air blowers will be operating with the discharge pressure at 5-7.5 psig. 2. Water at a pressure of A0 psig will be on the S&K scrubber . jet, drowning the HC1 fumes from the blow tank. STLCOPCB4081014 Detailed Instructions Aroclors 82. 3.3 Safety Features A. A level indication instrument is on the chlorinator control panel to indicate when a new charge is needed in the mix tank. A low level alarm is indicated at 25%. B. A level indication instrument is located on the chlorinator control panel for the feed tank. A low level alarm will sound at 25% full to indicate a new charge is needed for the feed tank. Approximately 30 minutes operation time is available before the tank will be empty. C. A level indicating controller is located in the crude Aroclor catch tank to control the level to 50%. A high alarm will sound at 60% level. This allov7s approximately 1-1/2 hours prior to the tank being completely full. D. A high temperature alarm is set at 190C. on the individual chlorinators to prevent excessive carry-over of trappings into the HC1 off-gas header. Temperatures above this will cause excessive carry-over of Biphenyl or crude Aroclor. A low temperature alarm is also provided at 120C. to prevent pro duction of unstable Aroclors. E. Chlorine flow stops are placed on the chlorine flow control valves to the chlorinator set at 300 lbs/hour to prevent shutting off the chlorine feed in cases of air failure.to the control valve. The control valve normally closes on air failure. . ' F. A sight glass has been placed in the HC1 off-gas line of each chlorinator to allow observation of the flow for possible en trainment. In case entrainment droplets are noticed being carried out of the HC1 gas, the chlorine flow should be decreased slightly to reduce this entrainment. Excessive entrainment carry over will cause plugging of the HC1 off-gas line. G. Normally, when the programmed flow control system is in operation on a batch chlorinator, a sample of the material being chlori nated will be taken after- four hours of operation. This sample is taken to assure a short charge has not been made to the chlorinator. The sample should be checked for specific gravity. If the sample indicates a normal batch, the next sample should be taken when the 80% bell rings as preset by the chlorine flow totalizer. This sample is to assure a batch is not over-chlori nated and sets up in the chlorinator, preventing its transfer to the blow tank. DSW 334545 STLCOPCB4081015 Detailed Instructions Aroclors 83. I. A chlorine- pressure indicating controller has been installed to regulate the chlorine pressure to the main header. Chlorine pressure is regulated by feeding liquid chlorine from a tank car and vaporizing it into the header. PIC-500.07 will be set for a normal chlorine header pressure of 20-25 psig, with a high alarm point at 35 psig and a low alarm point at 15 psig. J. The chlorine vaporizer has several safety features and equip ment items built into its design. They are: 1. A high level alarm shut-off in case the level should exceed 50% in the vaporizer shell. This shut-off stops liquid chlorine feed to the vaporizer by closing a control valve. 2. Steam pressure to the chlorine vaporizer is regulated to 10-12 psig. A pressure relief valve is installed in the system to relieve any pressure above 12 psig. 3. Steam supply pressure to the chlorine vaporizer is regulated by the. temperature of the liquid chlorine feeding the vaporizer. Normally, the temperature indicator set point is above 40C. Liquid chlorine from a tank car is normally QQC. at 36 psig. 4. The chlorine header pressure is regulated to 20-25 psig by a pressure indicating controller which regulates a control valve on the discharge side of the chlorine vaporizer. 5. A rupture disc is installed on the chlorine vaporizer to relieve the pressure at 275 psig and a relief valve is installed on the discharge of the rupture disc to relieve at 300 psig. 3.4 Shutdown - Operations of the charge tank, the batch chlorinators, the con tinuous chlorinator system, and the blow tanks can occur which cause temporary or prolonged shutdowns. The following detailed information concerns individual shutdowns of each of the above items. If the entire system is to be shut down, the various items can be combined to achieve this objective. DSV-J M4546 STLCOPCB4081016 Detailed Instructions Aroclors 84. A. Charge Tank 1. Temporary Shutdown a. Close the manual valve in the Biphenyl feed line to the charge tank. b. Close the valve' at the bottom of the charge tank and at the discharge of the chlorinator charge pump. c. Leave steam heat on the transfer lines to the charge tank. d. Leave steam heat on the coil to the charge tank. e. The agitator and charge tank pump will normally be shut down unless in use. 2. Prolonged Shutdown a. Normally, the tank will have been emptied prior to a prolonged shutdown. b. Close the manual valve on the biphenyl feed line into the charge tank. c. Drain the charge tank, if necessary, for repair work. d. Close the valve at the bottom of the charge tank and at the discharge of the chlorinator charge tank pump. e. Shut off the steam to the transfer lines to and from the charge tank. f. The agitator and charge tank pump will be shut off. g. Shut off the steam supply to the discharge line from the charge tank pump. h. Leave the system in this condition until needed. i. Note shutdown information on data sheet. B. Batch Chlorinator Operations can occur which will require a batch chlorinator to be cut back or temporarily shut down. Some of these items are failure of chlorine feed, a tank car emptying, or a cut back of the chlorine plant. Normally, if a partial reduction of the chlorine feed occurs, the batch liquid chlorinators will l. ^ ____j i____k _______________________- i -------<- 7* ^ G L/C.' i iCi i_ oli ciiiCi CiiC- wuil c J-Uuuuo uii j.C/i. luci i. vx. j u uviu win. chlorinator will continue to be operated. DS\N 334547 STLCOPCB4081017 Detailed Instructions Aroclors 85. 1. Temporary Shutdown a. The circulating pump will normally be left in operation. b. Close the chlorine valve at the distributor of each chlorinator. ,, ' c. Check the chlorine header pressure : and chlorine feed to the other chlorinators. The pressure should be 20-25 psig. d. Check to see that liquid chlorine is being fed to the vaporizer and that steam is on the vaporizer. Steam ' ' pressure should be 10-12 psig. Discharge pressures on the vaporizer should be 1-2 psig greater than the pressure on the chlorine header (normally 20-25 psig). e. If the shutdown is to be longer than two hours, it may be necessary to put steam heat on the coil of the chlori nator to keep the temperature at 120C. minimum. Normally, the circulating pump will be in operation. f. Shutdowns should be minimized. If the cause of the cut back can easily be remedied, start the chlorinator back immediately. g. Notify your chief operator or department supervision immediately in case of a problem. h. Note shutdown information on data sheet.. 2. Prolonged Shutdown a. Normally, when a chlorinator is to be left down for a period longer than a few hours, the chlorination will be completed and the batch pumped out prior to shutdown. If maintenance personnel are to work on the chlorinator, it may be necessary to vent the vessel and purge the chlorine lines and the chlorinator tank with CC>2. NOTE: i In case of a complete shutdown for maintenance work, the chlorine valves on the main header to the chlorinator will be tagged, the transfer lines into the vessel, and the steam valves to the chlorinator coils. The pump motor circuit breaker box switch will be tagged out. oSNN 334548 STLCOPCB4081018 Detailed Instructions Aroclors 86. b. Close chlorine valves at distributor on the chlorinator. c. Empty chlorinator by pumping out, then shut off the circulating pump and drain the chlorinator. d. Check chlorine header pressure as in Item 1. c. above. e. Close the HC1 vent valve on the chlorinator to the HC1 header. f. Leave the chlorine flow controller in "auto" with the set point at C). g. Leave the temperature recorder controller in "auto" with the set point at 150C. h. Notify your chief operator or department supervision the vessel is shut down. i. Note shutdown information on the data sheet. C. Continuous Chlorinator System 1. Temporary Shutdown a. The circulating pumps will normally be left in operation. b. Close the valves to the chlorine distributor on chlorinators Nos. 5, 6, 7, and 8. Adjust the chlorine feed control valves to (D with the instrument still in "auto". c. Close the automatic Biphenyl feed valve to the No. 5 chlorinator using the automatic controller; then shut the manual valve in this line to assure feed stops to the No. 5 chlorinator. Set valves to allow circulation back into the feed tank. . d. Proceed to check out the system to determine the reason for the cut back if you have not been informed. e. Check the chlorine header pressure and chlorine feed * to the other chlorinators. The header pressure should be 20-25 psig. DSW 334549 STLCOPCB4081019 Detailed Instructions Aroclors 87. f. If the shutdown is to be longer than two hours, it may be necessary to put steam on the circulating lines or the coil of the chlorinator to maintain 120C. mifiimum temperature. g. Shutdowns should be minimized. If the cause of the cut back can easily be remedied, start the continuous chlorination system up immediately. h. Notify your chief operator or department supervision immediately in case of a problem. i. Note shutdown information on data sheets. 2. Prolonged Shutdown a. Normally, when the continuous chlorinator system is to be shut down for a period longer than a few hours, the system is handled in the same manner as for a temporary shutdown except that steam may be cut off of some of the supply lines. For a prolonged shutdown, this system would not be emptied except when the shutdown becomes greater than A8 hours. In that case, the chlorinators might be finished batchwise and then emptied. Normally, the chlorine vaporizer must be shut down when the continuous chlorinators are shut off. b. Shut off the automatic Biphenyl feed valve to the No. 5 chlorinator using the automatic controller. c. Shut off the chlorine feed to chlorinators Nos. 5, 6, 7, and 8, using the chlorine flow controllers in the con trol room. d. Close the manual valves at the chlorine distributors on chlorinators Nos. 5, 6, 7, and 8. e. Close the manual block valve at the automatic Biphenyl feed valve to assure no leakage occurs. Direct Biphenyl feed back into the feed tank. DSW 334550 STLCOPCB4081020 Detailed Instructions Aroclors 88. f. The Biphenyl feed tank pump can be shut down if necessary. Close the discharge valve in the line from the pump to No. 5 chlorinator. Stop the pump. Close the suction valve to the pump on the bottom of the Biphenyl feed tank. g. Stop the agitator in the Biphenyl feed tank if necessary; otherwise, leave the agitator operating. h. Stop the agitator in the Biphenyl mix tank if necessary; otherwise, leave this agitator operating. i. When the crude Aroclor catch tank level is at 50%, stop the transfer pump. Close the valve in the discharge line to the continuous air blow tank. j. Stop the continuous air blow tank transfer pump. Close the discharge valve in the line from this pump to the blow tank or the roof tank. k. Shut off the air to the continuous air blow tank if necessary. There are four valves in the air header to the continuous air blow tank. l. Check the chlorine header pressure as in Item l.e. above. m. Close the HC1 vent valves on the chlorinators to the HC1 header. n. Steam must be placed on the coil or the circulating lines of the chlorinators if the material is not pumped out. A minimum temperature of 120C. must be maintained. 6. Notify your chief operator or department supervision the continuous chlorinator system is shut down. . Note the shutdown information on the data sheet. D. Chlorine Vaporizer 1. Temporary Shutdown a. Close block valve on each side of liquid chlorine control valve. b. Allow steam to vaporize liquid chlorine in the vaporizer. . Shut off block valve in steam line into the vaporizer or close the steam control valve by adjusting the set point on the vaporizer temperature controller. DSW 334551 STLCOPCB4081021 > i. Detailed Instructions Aroclors 89. d. Close the automatic chlorine feed valve to the chlorine header by adjusting the chlorine pressure controller PIC-500.07 to 0. Leave the instrument in "auto". Close the block valve in the line to the chlorine header. e. If. there is a particular problem with the vaporizer, notify your chief operator or department supervision the vessel is shut down. f. Note shutdown information on the data sheet. 2. Prolonged Shutdown a. In case the chlorine vaporizer is to be shut down for ' a period greater than three days, the system should be completely empty of chlorine. b. Disconnect the liquid chlorine car from the chlorine feed line to the vaporizer. (1) Put on gas mask for use in connecting and dis connecting car. (2) Close manual valve in 1" liquid chlorine line to vaporizer. (3) Close angle valve on top of the chlorine tank car. (A) Open the bleed valve on the pipe connection line. Slowly let the chlorine pressure bleed off. When the pressure is released, remove the piping. c. Connect a CO2 cylinder to the chlorine feed line to the vaporizer. Use pressure from the CO2 cylinder to push . the liquid chlorine to the vaporizer. Normally, 80-90 psig is all that will be required. d. When the liquid chlorine has been pushed through the transfer line from the tank car to the vaporizer, close the block valve on each side of the liquid chlorine control valve to the vaporizer. e. Allow steam to vaporize the liquid chlorine in the vaporizer. f. Shut off block valve in steam line to the vaporizer. g. Connect CO2 to the.vaporizer at the pressure gauge on the line to the vessel. Purge the chlorine vaporizer with CO2. 40 psig. Do not exceed DSW 334552 STLCOPCB4081022 Detailed Instructions Aroclors 90. h. Close the automatic chlorine feed valve to the chlorine header. Adjust the chlorine pressure controller PIC-500.07 to 0 with the controller in "auto". Close the block valve in the line to- the header._ - i. Notify your chief operator or department super vision the chlorine vaporizer has been shut down. j. Note shutdown information on the data sheet. E. Blow Tanks and HC1 Drowning Facilities 1. Temporary Shutdown This temporary shutdown applies to a single blow tank. It can apply to all blow tanks. a. Close the valve at the bottom of the blow tank. b. Close the discharge valve on the blow tank transfer pump. c. Shut off the transfer pump. d. Leave the air blower running. e. Water will remain on the S&X jet. f. 'The system can be left in this condition until needed. Actually, the blow tanks are still being air blown. 2. Prolonged Shutdown This procedure applies to a single blow tank; however, it can apply to all blow tanks by merely extending the work to the other vessels. a. Normally, if the vessel is to be shut down for any length of time, the material in the tank will be emptied. b. Shut off the blow tank pump. c. Drain the blow tank. Close the valve at the bottom of the blow tank and at the discharge of the transfer pump. d. Close the steam supply valve to the coil on the blow tank. ' DSW 334553 STLCOPCB4081023 Detailed Instructions Aroclors 91. e. Shut off the steam on the transfer lines to the blow tank and from the blow tank. f. Shut off the air blower or blowers. g. Shut off water to the S&K. jet. h. When air is shut off the air blowers if the continuous chlorinator system is to continue to be operated, the crude Aroclor being produced must be re-directed from the roof tank to an individual blow tank (Ncs. 1, 3, or A). i.' Leave the system in this condition until needed. j. Notify your chief operator or department supervision the system is shut down. k. Note shutdown information on the department data sheet. F. Continuous Chlorinator Air Blow Tank 1. Temporary Shutdown a. In case the continuous air blow tank is to be shut down for a lack of air on a temporary basis, crude Aroclor from the Aroclor catch tank must be directed from the roof tank to an individual blow tank. b. -Close air valves to distributor header on the continuous air blow tank. Crude Aroclor can still be allowed to flow through the tank and it will not be used as an air blow tank. c. Notify your chief operator or department supervision this tank is temporarily shut down. d. Determine the nature of the problem. If possible, start the system back up. . e. Note the downtime for this vessel on the department data sheet. 2. Prolonged Shutdown a. In case the continuous air blow tank is to be shut down for a long period of time, this vessel may be by-passed by directing flow from the catch tank to blow tanks Nos. 1, 3, or A. DSW 334554 STLCOPCB4081024 Detailed Instructions Aroclors 92. b. Close the air valves to the distributor on the con tinuous air blow tank. c. Start the circulating pump on the continuous air blow tank. _ d. Close the discharge valve from the continuous air blow tank pump to the roof tank. e. Close the valve in the line from the crude Aroclor catch tank to the continuous air blow tank. f. Notify department supervision the vessel has been shut down. ' g. If necessary, the tank can be drained through a bottom outlet. Normally, the tank cannot be pumped empty due to the baffles in the tank. h. The system can be left in this condition until needed. i. Note shutdown information on department data sheet. G. Emergency Shutdown Ordinarily, an emergency shutdown does not occur concerning the charge tank or the blow tanks; however, emergencies can occur which make it necessary to shut down the batch chlorinators and the continuous chlorinators as fast as possible. The following methods can normally be used: 1. From the Field a. Close the manual chlorine valves to the distributors on the individual chlorinators. b. Close the manual valve in the Biphenyl feed line to the continuous chlorinator system. c. Shut off the chlorine vaporizer. Stop liquid chlorine feed. d. Stop the circulating pumps if necessary. Normally, these pumps would be left operating. e. Shut the valves in the KC1 pipeline to the Muriatic Acid Department if necessary. ' DSW 334555 STLCOPCB4081025 Detailed Instructions Aroclors 93. f. Stop the flow of crude Aroclor from the catch tank to the continuous air blow tank to the roof tank if necessary. g. Dependent on the emergency situation which has occurred, continue to shut the system down systematically by normal procedures for both the batch and continuous chlorinator systems. 2. At the Panel a. Stop chlorine feed to the chlorinators as follows: (1) Close chlorine automatic valves by adjusting flow controllers to 0. This reduces chlorine flow to 300 lbs/hour on each of these chlorinators. Immediately go into the field and shut off manual valves feeding these chlorinators. b. Stop Biphenyl feed to the continuous chlorinator system using the automatic Biphenyl feed control instrument. Adjust set point to (). Immediately go into the field and shut off the block valve to the No. 5 chlorinator. c. Continue shutdown of this unit as is necessary to handle the emergency which has occurred. The remainder of the shutdown will have to be carried out from the field. 3.5 Control Loops, Interlocks, and Alarms DSW 334556 A. Control Loops There are 14 major control loops in this system. 1. Chlorinator Temperature Controls - TRCA-508.01 The function of this loop is to provide temperature control for the chlorination batch in the chlorinator. This is accomplished by measurement of the temperature in the crude Aroclor circulating line at the discharge of the external heat exchanger and controlling the position of the dampers at the cooler and automatically turning the fan for the cooler on and off by temperature. The temperature controls for the fans can be operated manually. The control in struments can be operated manually or automatically. STLCOPCB4081026 Detailed Instructions Aroclors 94. The temperature system has a low temperature alarm at 120C. and a high alarm at 190C. . Each chlorinator has the same control system. a. Manual Control The :temperature controller will be in "manual". Adjustment of the louvers on the air cooler can be controlled manually by adjusting the control valve with the TRCA instrument set point. The fan can either be in "auto" or "manual". Adjust until the desired temperature is acquired. The fan can be stopped or started as desired. b. Automatic Control The temperature controller is in "auto" with the set point at 150C. The cooler fan will be in "auto". The controller will automatically adjust the louvers on the cooler and the fan to amintain the temperature of the set point. 2. Chlorine Header Pressure Control - PIC-500.07 The function of this loop is to maintain the chlorine header pressure within a narrow range. This is accomplished by measuring the chlorine header pressure and throttling a control valve at the discharge of the chlorine vsnorizer. Normal operation of the system'is with the controller in "auto" and the set point at 20-25 psig. A low pressure alarm will sound at 15 psig and a high alarm at 35 psig. 3. Batch Chlorinator Chlorine Flow Control - FRCS-551.01 The function of this loop is to control the chlorine flow to the batch chlorinators and regulate the chlorine chlori nation rate. This is accomplished by measurement of the chlorine flow with an orifice and controlling this flow with a control valve in the chlorine feed line. This system can be operated manually, automatically, on chlorine feed control, or by a preset programmed chlorine feed control. Each batch chlorinator has this same system. a. Manual Control The chlorine flow controller is positioned in "manualset". The set point is regulated to give the desired chlorine flow to the chlorinator. DSW 334557 STLCOPCB4081027 Detailed Instructions Aroclors 95. b. Automatic Flow Control The chlorinator chlorine flow controller is positioned in "auto-set". The chlorine feed desired is set on the controller which will maintain this chlorine feed by adjusting the control valve as required. c. Programmed Flow Control The chlorine flow controller has the set points in "auto-cascade". The chlorine integrator set point is adjusted for the desired chlorine alarm level, , dependent on the product being produced. The dial reads 0-225 and has a multiplier of 100. The range represents 0 - 22,500 lbs, of chlorine. When the desired quantity of chlorine has entered the chlori nator, an alarm bell will ring and an annunciator light will flash indicating "Chlorinator, 807, Chlorinated". The totalizer can be used with automatic flow control above if the controller is not in "cascade". It must be reset by pushing the green set button. When the contfoiler is in "cascade", the Taylor Flexopulse Timer will, by predetermined program (See Appendix I) , change the chlorine flow rate to the chlorinator. The chlorine flow program is set by turning the knob on each flow profile set point. This program, once set up, should not be disturbed v/ithout consulting supervision. 4. Continuous Chlorinator Chlorine Flow Control - FRCS-558.01 The function of this loop is to control the chlorine flow to the continuous chlorinator system chlorinators and re gulate the chlorination rate. This is accomplished by measurement of the chlorine flow with an orifice and con trolling this flow with a control valve in the chlorine feed line. This system can be operated manually or automatically on chlorine feed control. Each of the chlorinators in the continuous system has the same controls. a. Manual Control The chlorine flow controller is positioned in "manual". The set point is regulated to give the desired chlorine flow to the chlorinator. The output pressure of the controller can be observed by looking at the top of the control instrument. DSW 334558 STLCOPCB4081028 Detailed Instructions Aroclors 96. b. Automatic Flow Control The chlorinator chlorine flow controller is in "auto". The chlorine feed desired is set on the feed controller which will maintain this chlorine feed by adjusting the control valve as required. 5. Biphenyl Mix Tank Level Indication - LIA-520.01 This loop measures the level of Biphenyl in the mix tank. This is accomplished by a bubbler differential pressure level indication instrument. A 0-100% dial indicates the tank level in the field and on the control panel. A low level alarm is set at 25% and a high level alarm at 75%. 6. Biphenyl Feed Tank Level Indication - FIA-520.01 This loop measures the level of Biphenyl in the feed tank for the continuous chlorinator system. This is accomplished by use of a bubbler differential pressure level indication instrument. A 0-100% dial indicates the tank level in the field and on the control panel. A low level alarm will sound at 25%. and a high level alarm at 80%. 7. Crude Aroclor Catch Tank Level Control - LICA-545.01 This loop measures the level of crude Aroclor in the catch tank for the continuous Aroclor chlorinator system and maintains a constant level of 50% in the tank. This is accomplished by measurement of the level in the tank by a bubbler differential pressure level indication instrument and throttling a control valve in the discharge of the crude Aroclor catch tank pump line. A high alarm will sound if the tank reaches 60% level. 8. Continuous Blow Tank Level Control - LICA-529.01 Function of this loop is to maintain a constant level in the continuous air blow tank. This is accomplished by measuring the level with a bubbler differential pressure level in dication instrument and throttling a control valve in the discharge line from the continuous blow tank pump to the roof tank or a blow tank. The level in the system is normally 50%. A low level alarm is set at 40% and a high level alarm at 60%. 9. HC1 Pressure Alarm - PKA-702.02 The purpose of this loop is to measure the HC1 header pressure to the EC1 absorber, record this pressure and give an alarm in case of excessive high pressure. This is accomplished by measurement: o f the pressure T:? *! f*V* pvapciivo f- y o T"* TT 1 T*! sounding an alarm at a high pressure of 5 psig. DSW 334559 STLCOPCB4081029 Detailed. Instructions Aroclors 97. 10. Continuous Cblorinator Biphenyl Feed Control . The function of this loop is to control the Biphenyl feed to the continuous chlorinator system. This is accomplished by measurement of the Biphenyl flow with an orifice and throttling a control valve in the Biphenyl line. This system can be operated by a controller on manual or auto matic operation. A flow range from 0-5 GPM of Biphenyl is possible with this controller-. A low flow alarm is set at 1 GPM and a high flow alarm at A GPM. The recorder read-out has a multiplier of 2. 11. Nos. 1, 3, and 4 Blow Tank Level Indication These loops measure the level of crude Aroclor in the Nos. 1, 3, and 4 blow tanks. This is accomplished by use of a bubbler differential pressure level indication instrument. A 0-100% dial indicates the tank level in the field. 12. Biphenyl Charge Tank Level Indication This loop measures the level of Biphenyl in the charge tank for the chlorinators. This is accomplished by use of a bubbler differential pressure level indication instrument. A 0-100% dial indicates the tank level in the field. 13. No, 1 and 2 Aroclor B.oof Tank Level Indication This loop measures the level of crude Aroclor in the No. 1 and 2 Aroclor roof tanks. This is accomplished by use of a bubbler differential pressure level indication instrument. A 0-100% dial indicates the tank level in the field. 14. Chlorine Vaporizer Control Loops There are several control loops on the chlorine vaporizer system to insure safe operation. The control loops consist of a steam pressure regulation valve, high liquid level control, and steam supply temperature control. These con trols are accomplished by the following: a. Steam Control A temperature indicating controller senses the liquid chlorine feed to the vaporizer and throttles a steam valve in the main steam feed line to the vaporizer. DS\N 334560 < STLCOPCB4081030 Detailed Instructions Aroclors 98 b. Liquid Level Control The liquid level control in the vaporizer is measured by a ball float level instrument which is actuated on high level and closes a control valve in the liquid chlorine feed line to the vaporizer. This high level also sounds an alarm in the control room. c Steam Supply Temperature Alarm The temperature of the steam supply to the vaporizer is measured by a Fenwall temperature element and sounds an alarm when the steam temperature drops below 100C. This failure indicates the vaporizer may fill with ' liquid chlorine. Normally, this indicates steam failure. . d. Chlorine Pressure Control A pressure control loop PIC-500.07 is installed for controlling the discharge pressure from the vaporizer. It is described under 3.5-A-2, Page 94. B. Interlocks - There are no interlocks in this system. C. Alarms - 1. Biphenyl Mix Tank A low level alarm sounds at 25% full and a high level alarm sounds at 75% full. These alarms are on the chlorinator annunciator panel. The high alarm horn indicates there is approximately 5 minutes before the tank will overflow. 2. Biphenyl Feed Tank A low level alarm will sound when the tank is 25% full and a high level alarm when the tank is 80% full. The low level alarm indicates there is approximately 30 mins. time before the tank will run empty. 3. Batch Chlorinators a. Chlorine Flow Alarm If the chlorine totalizer is being used, an alarm bell will ring when the batch is 80% chlorinated. The . chlorine set point for the totalizer depends on the crude Aroclor being produced. DSW 334561 STLCOPCB4081031 Detailed Instructions Aroclors 99. b. Temperature Alarm Abnormal temperature alarms are set for a low chlori nation temperature of 120C. and a high temperature of 190C. 4. Continuous Chlorinators Abnormal temperature alarms are set for a low chlorination temperature of 120C. and a high temperature of 190C. 5. Chlorine Header Pressure Alarm The chlorine header pressure will sound an alarm at a low pressure of 15 psig and a high pressure of 35 psig. This will actuate an annunciator on the chlorinator panel in dicating "high/low" chlorine header pressure. 6. Instrument Air Low Pressure Alarm An annunciator will sound in case the instrument air pressure drops to 70 psig. 7. Continuous Chlorinator Biphenyl Feed Alarm Biphenyl feed alarms are provided for a low flow of 1.0 GPM and a, high flow of 4,0 GPM. 8. Chlorine Vaporizer High Level A high level above 50% will sound an alarm for the chlorine vaporizer. IV. COMMENTS ON PROCESS 1. ' Problems with the chlorine vaporizer can occur which would allow liquid chlorine to be fed to the chlorinators. In case this should happen, slugs of liquid chlorine would be fed into the chlorinator possibly causing excessive reaction or excessive loss and venting of chlorine to the atmosphere. Chlorine in the HC1 off-gas pipe lines could cause extreme reactions which would generate excessive heat. The excessive heat will cause the chlorine to react and ignite with the steel pipe line. This would result in chlorine gas escaping to the atmosphere. Every effort possible should be made to operate the vaporizer with the control system provided. OS'N^456' STLCOPCB4081032 Detailed Instructions Aroclors 100. 2. Entrainment of Biphenyl or crude Aroclor into the HC1 lines can occur when excessive chlorine rates occur. This can be checked by observing the off-gas from the chlorinators in the sight glasses on top of the Brink Demister on each chlorinator. Normal operation of the chlorinator should be to minimize this carryover. Abnormally high or low chlorine header pressures can cause operating problems. Low chlorine pressure can cause operating problems within the Aroclor Department. In cases of extreme low pressure, the crude Aroclor could back up in the chlorine line and begin flow-back into the chlorine header. In small pipe lines where there is no heat removal from the reaction, problems can occur as stated in Item 1 above. 3. Free Chlorine in the off-gas from an individual chlorinator or from the vent at the HC1 absorber sewer box indicates problem operation in the Aroclor Department. It can be caused by inadequate reaction of the Biphenyl and might indicate formation of unstable Aroclor. If this situation occurs, it should be corrected immediately. Catch samples from the individual chlorinator off-gas and have them analyzed for free chlorine by the Lab. Check grab samples from each chlorinator of the crude Aroclor being produced and observe it for unusual appearances. Inadequate amounts of catalyst present as Ferric Chloride or iron turnings can cause free chlorine in the off gas 1ine. In case this situation occurs and cannot be re solved, remove the chlorinator from operation. Contact de Partment supervision immediately. A badly worn distributor can also cause free chlorine in the off-gas line. A. An agitator has been installed in the Biphenyl feed tank to keep Ferric Chloride in suspension. It is extremely important that the material be kept in suspension to allow production of stable A.roclors as well as eliminate production problems involving plugged lines with Ferric Chloride. 5. The continuous chlorinator catch tank has a high level alarm at 607o. This alarm indicates there is approximately 30 mins, before material will begin to back up in the continuous chlori nator system. Hold-up of material in the chlorinators can cause production of off-grade specification material. In case a high level alarm occurs, the problem should be solved im mediately or the system shut down rather than produce off-grade material. DSW 334563 STLCOPCB4081033 Detailed Instructions Aroclors 101. 6. A low pressure instrument air alarm sounds at 70 psig. This alarm indicates the large instrument air compressor did not come back on its normal 85 psig. In this case the small in strument air compressor will start up at 68 psig. The large compressor should be checked immediately to determine the problem since the small compr'essor will not normally handle the entire air requirements for this department. 7. Electricity to the two water supply pumps and the circulating fan, at the cooling tower north of the department, is provided through the motor control center at the Biphenyl Tubular Unit. DSW 334564 STLCOPCB4081034 APPENDIX I PROPOSED CHLORINE FLOW PROFILE FOR PROGRAMMED BATCH CHLORINATION CHLORINE INPUT ' First Hour . Second Hour . Third Hour Fourth Hour To End of .Batch End of Batch (Control Valve Closed) FLOW RECORDER CONTROLLER 400 lbs./Hour 600 lbs./Hour 800 lbs./Hour 1,000 lbs./Hour 300 lbs./Hour TEMPERATURE CONTROL Entire Batch RECORDER CONTROLLER 150C. III CHLORINE INTEGRATOR SETTINGS FOR 80% OF CALCULATED INPUT EASED ON 100% CHLORINE AND 90% CHLORINE Aroclor Product 100%. Chlorine 90% Chlorine 1121 1142 1148 1154 1160 1162 1280 2660 4450 5630 7220 7580 1420 3000 4940 6250 8020 8420 IV CHLORINE INTEGRATOR SETTINGS FOR 80% OF CALCULATED INPUT BASED ON USING 1142 TO CHARGE CKLORINATOR Aroclor Product 100%. Chlorine 90%. Chlorine 1148 1154 1160 1162 1790 2970 4560 4920 1990 3300 5070 5470 DSW 334565 STLCOPCB4081035 APPENDIX II CONTINUOUS CHLORINATOR SPECIFIC GRAVITY LEVELS FOR 1142 PRODUCTION I. FOUR STAGE PRODUCTION ' STAGE 1 2 3 A , CHLORINATOR 5 6 .7 8 SPECIFIC GRAVITY 1.078 - 1.104 @ 65C. 1.170 - 1.196 @ 65C. 1.254 - 1.280 (3 65C. 1.336 - 1.362 @ 65C. II. THREE STAGS PRODUCTION STAGE CHLORINATOR* 15 26 38 SPECIFIC GRAVITY 1.108 - 1.124 @ 65C. 1.224 - 1.240 Q 65C. 1.345 - 1.355 @ 65C. *NOTE: THIS INDICATES NO. 7 CHLORINATOR OUT OF SYSTEM. ANY ONE OF THE FOUR CAN BE BYPASSED. DSW 334566 STLCOPCB4081036  APPENDIX III FOUR CHLORINATOR BIPHENYL-CHIDRINH FEED RATE CHART: BIPHENYL FEED GPM i 2.1 2. 4 3.0 3.3 3.6 3.9 4.2 4.5 4.8 5.1 CM , CHLORINE RATE AT EACH CHLORINATOR 1007= CHLORINE 907= CHLORINE Total Chlor. Lbs/Hr. Each Chlor. Lbs/Hr. Total Chlor. Lbs/Hr. Each Chlor Lbs/Hr 1,400 350 1,560 390 1,600 400 1,760 440 1,800 450 2,000 500 2,000 500 2,200 550 2,200 550 2,440 610 2,400 600 2,680 670 2,600 650 2,880 720 2,800 700 3,120 780 3,000 750 3,320 830 3,200 800 3,560 890 3,400 850 3,760 940 DSVJ 4567 STLCOPCB4081037 APPENDIX IV OPERATION OF AUTOMATIC CONTROLLERS 1. Automatic Control This procedure starts with the,controller set at manual and gives set-wise changes to automatic and back to manual. This assumes a -flow recorder controller (FRC) is used. Example: Chlorine Flow Control Operation Manual to Automatic Switching FRC Manual Seal Automatic 1. FR.C on manual. Set point moved to give desired flow as indicated on recording sheet. X Flow indicated by recording pen. 2. Transfer FR.C to seal. Place set pointer (Red) opposite flow recording pen (Red). X 3. Transfer FRC from seal to automatic. Adjust FRC set pointer until flow j levels out if any fluctuations occur. X Leave instrument in this position for automatic control as the set point is adjusted. Return system to manual. A. Note FP.C output air signal. Transfer from automatic to seal. X Adjust FRC set pointer (Red) to the same output air. 5. Transfer from seal to manual. Adjust set point if fluctua tions occur. X DSW 334568 STLCOPCB4081038 APPENDIX IV (CONTINUED) 2. Cascade Control For a controller to operate in cascade, it must first be in automatic. The manual set position is overriding and will not let cascade signals control. Use the same procedure as above to transfer from manual to automatic. Operation "Automatic-Set" to "Automatic-Cascade Switching FRC Manual Seal Automatic Set Cascade 1. FRC on automatic. Set point (Red) moved for desired flow. XX 2. Adjust external set point (Orange) to line up with the (Red) set point. XX 3. Move the controller from "set" position to "Cascade". Adjust the FRC set pointer until flow levels out if fluctuations occur. XX Leave instrument in this position for "auto matic-cascade" control from the external set point. Return system to "Automatic-Set". A. Adjust the (Red) set point to line up with the (Orange) set point. XX 5. Transfer from "Cascade" to set. Adjust (Red) set pointer if fluctuations occur. XX DSW 334569 STLCOPCB4081039 APPENDIX V METHOD OF RUNNING SPECIFIC GRAVITIES Catch representative sample of material in metal cylinder provided for this* purpose. On the chlorinators, the sample point is at the discharge of the circulating pump. Excess material, and analyzed sample is sent to the charge (melt) tank by gravity through a system of pipe lines from each chlorinator. Take sample to the control room. Allow water to run down out side of the cylinder while stir ring sample vigorously until the sample is 10C. above the temperature at which the sample is run. See Table I, Page 68. Cut off the water when the sample is 10C, above the desired temperature. Keep stirring until the sample is 1C. above the temperature which the sample is to be run. Stop stirring. Allow the hydrometer which has been thoroughly cleaned to sink into the sample until it reaches equilibrium. Observe reading on the hydrometer. Record hydrometer reading on the operating data sheet, along with the time the sample was taken. . In case the temperature was off 1 or 2 when the reading was taken, a correction can be applied. It is 0.001 specific gravity units per C. If the sample was 2C, high, add 0.002 specific gravity units to the reading. If the sample was 2QC. low, subtract 0.002 specific gravity units from the reading. Carefully clean the hydrometer and thermometer. Place them in the rack provided for this purpose. Dump sample in the return line to the chlorinator pump. DS\N 334570 STLCOPCB4081040 APPENDIX VI INSTRUMENT AIR COMPRESSORS An instrument air compressor (No. 1) with a capacity of 105 cfm at 100 psig; has been "installed to. supply dry, oil-free air for instrumentation. A stand-by air compressor is available in the old Joy instrument air compressor with a capacity of 50 cfm at 85 psig. In case of failure of both of these compressors, an oil-type Ingersoll-Rand compressor is available. Capacity of this unit is 100 cfm at 100 psig. Operation of the compressor system is as follows: No. 1 compressor starts at low pressure of 85 psig. Compressor stops at 100 psig. No. 2 compressor (old) starts at 68 psig; stops at 78 psig. An instrument air failure alarm will sound at 70 psig. This will indicate failure of the No. 1 compressor to start up. The air compressor system should be checked immediately. The No. 1 instrument air compressor will be in "auto" position for operation. OSNN STLCOPCB4081041 APPENDIX VII / COOLING TOWER WATER SYSTEM The water supply system for the Aroclor Department is as follows. , At present, the cooling tower north of the department will supply the PNP Department, the old Biphenyl still system, the Aroclor Department, HB-40, and Santowax with cooling water. The supply pumps from the tower will feed water "into the departments and return it back to the cooling tower. The new pumps for the system are located in the basin east of the cooling tower. Two pumps are installed for supply of water to the departments. Electricity to these pumps is provided through the motor control center at the Biphenyl tubular unit. Operation of the pumps will be as follows: (1) Place the electrical switches on both pumps in the "off" position. (2) Open the valves in the discharge line from the pumps to the PNP Department and the Aroclor Department. (3) Within the using departments, open the valves to allow water to return to the cooling tower. (4) Turn on the circuit breakers for the cooling tower pumps and fan. (5) Start one of the cooling tower pumps by placing the switch in the "hand" position. (This is for manual.operation.) (6) Place the other pump switch in the "auto" position. (7) With the controls in this position, the pump in the manual or "hand" position will run unless failure occurs. In case of failure, the second pump in the "auto" control position will start up if the water discharge pressure drops below 60 psig. Normal operating pressure for the pump discharge is 70 psig. (8) The cooling tower temperature controls are set to start the circulating fan when the temperature drops to 75F. and stops the circulating fan when the .temperature rises to 85F. To start up, turn on circuit breaker and place switch to "auto". To operate the fan continuously, place the switch in "hand" or "manual". The fan is on same circuit as the water supply pumps at the Biphenyl tubular unit. DSW 334572 STLCOPCB4081042 NOS. 1, 3. & 4 BLOWING TANK CALIBRATIONS 1121 AROCLOR 7, Scale 0 Gallons 185 7, Scale 20 Gallons 1,196 % Scale 40 1 236 21 1,246 41 2 286 3 337. 4 388 22 1,297 23 1,347 24 1,398 42 43 44 5 438 6 489 7 539 25 1,448 26 1,499 27 1,549 45 46 47 8 590 9 640 28 1,600 29 1,650 48 10 691 30 1,701 11 741 31 1,751 12 792 32 1,802 13 842 33 1,852 14 893 34 1,903 15 943 35 1,953 16 994 36 2,004 17 1,044 37 2,054 18 1,095 38 2,105 19 1,145 39 2,155 Gallons 2,206 2,256 2,307 2,357 2,408 2,458 2,509 2,559 2,610 Aroclor 1121 Sp. Gr. - 1.070 @ 150C (1.155 @ 65C) Instrument Scale - Or100% Instrument Range - 0-200" 1^0 DSW 334573 STLCOPCB4081043 % Scale 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 Gallons 185 228 270 313 356 399 441 484 527 569 612 655 697 740 783 826 868 911 954 . 996 NOS. 1, 3, & 4 BLOW TANK CALIBRATIONS 1142 AROCLOR 7. Scale Gallons % Scale 20 1,039 39 H CM 1,082 40 22 1,124 41 23 1,167 42 24 1,210 43 25 ' 1,253 44 26 1,295 45 27 1,338 46 28 1,381 47 29 1,423 48 30 1,466 49 31 " 1,509 50 32 1,551 53, 33 1,594 52 34 1,637 53 35 1,680 54 36 1,722 55 37 1,765 56 38 1,808 57 Gallons 1,850 1,893 1,936 1,978 2,021 2,064 2,107 2,149 2,192 2,235 2,277 2,320 2,363 2,405 2,448 2,491 2,534 2,576 2,619 Aroclor 1142 Specific Gravity - 1.264 at 150C Instrument Scale - 0-100% Instrument Range - 0-200" H20 (1.389 @ 25C) 334574 DSNN STLCOPCB4081044 7, Scale Gallons 0 185 1 2 266 3 307 4 347 5 388 6 429 7 469 8 510 9 550 10 591 11 632 12 672 13 713 14 753 15 794 16 835 17 875 18 916 19 956 20 997 vO CM CM NOS. 1, 3, & 4 BLOWING TANK CALIBRATIONS 1148 AROCLOR 7. Scale Gallons % Scale 21 1,038 42 22 1,078 43 23 1,119 44 24 1,159 45 25 1,200 46 26 1,241 47 27 1,281 48 28 1,322 49 29 1,362 50 30 1,403 51 31 1,444 52 32 1,484 53 33 1,525 54 24 1,565 55 35 1,606 56 36 1,647 57 37 1,687 58 38 1,728 59 39 1,768 60 40 1,809 41 1,850 Gallons 1,890 1,931 1,971 2,012 2,053 2,093 2,134 2,174 2,215 2,256 2,296 2,337 2,377 2,418 2,459 2,499 2,540 2,580 2,621 Aroclor 1148 Sp Gr - 1.330 @ 150C (1.415 @ 65C) Instrument Scale - 0-100% Instrument Range - 0`-20Qu H20 ' OS'N^4515 STLCOPCB4081045 NOS. 1. 3, & 4 BLOWING TANK CALIBRATIONS S' 1154 AROCLOR % Scale r---- 0 1 2 Gallons 185 : 223 261 % Scale Gallons 21 22 ' 23 983 l,02i ' 1,059 % Scale C: "Gallons 42 1,781 43 1,819 44 1,857 3 299 24 . 1,097 45 1,895 4 337 25 1,135 46 1,933 5 375 26 1,173 47 1,971 6 413 27 1,211 48 2,009 7 451 28 1,249 49 2-047 8 489 29 1,287 50 2,085 9 527 30 1,325 51 2,123 10 565 31 1,363 52 2,161 11 603 32 1,401 53 2,199 12 641 33 1,439 54 2,237 13 679 34 1,477 55 2,275 14 717 35 1,515 56 2,313 15 755 36 1,553 57 2,351 16 793 37 1,591 58 2,389 17 831 38 1,629 59 2,427 18 869 39 1,667 60 2,465 19 907 40 1,705 61 2,503 20 945 r1 41 1,743 62 2,541 63 2,579 Aroclor 1154 Sp. Gr. - 1.420 @ 150C (1.505 <a 65C) Instrument Scale - 0-100% Instrument Range - 0-200" H2O . 64 2,617 DSW 334576 STLCOPCB4081046 7. Scale NOS. 1, 3, & 4 BLOWING TANK CALIBRATIONS Gallons 1160 AROCLOR % Scale Gallons 7, Scale , Gallons 0 185 23 1,011 47 1,872 1 221 24 1,047 48 1,908 m CM * 2 257 ' 1,083 49 1,944 3 293 26 1,118 50 1,980 4 329 27 1,154 51 2,016 5 365 28 1,190 52 2,052 6 400 29 1,226 53 2,088 7 436 30 1,262 54 2,124 8 472 31 1,298 55 2,160 9 508 32 1,334 56 2,195 10 544 33 1,370 57 2,231 11 580 34 1,406 58 2,267 12 616 35 1,442 59 2,303 13 652 36 1,477 60 2,339 14 688 37 1,513 61 2,375 15 724 38 1,549 62 2,411 16 759 39 1,585 63 2,. 447 17 795 40 1,621 64 2,483 18 831 41 1,657 65 2,519 19 867 42 1,693 66 2,554 20 903 43 1,729 67 2,590 21 939 44 1,765 68 2,626 22 975 45 1,801 46 Aroclor 1160 Sp.Gr. - 1.504 0. 150C (1.564 0 90C) Instrument Scale - 0-100% Instrument Range- 0-200" 1^0 1,836 DSW STLCOPCB4081047 NOS. 1, 3. & 4 BLOWING TANK CALIBRATIONS 1162 AROCLOR % Scale Gallons % Scale Gallons % Scale Q 185 23 1,002 45 1 221 24 1,037 46 2 256 25 1,073 47 31 292 4 327 26 1,108 27 1,144 48 49 5 363 28 1,179 50 6 398 29 1,215 51 7 434 30 1,250 52 8 I 469 9 505 31 1,286 32 1,321 53 54 10 540 11 576 ` 33 1,357 34 1,392 55 56 12 611 35 1,428 57 13 647 36 1,463 58 14 682 37 1,499 59 15 718 38 1,534 60 16 753 39 1,570 61 17 789 40 1,605 62 18 824 41 1,641 63 19 860 42 1,676 64 20 895 43 1,712 65 21 931 22 966 44 Aroclor 1162 Sp. Gr. - 1.522 <a 150C (1.582 @ 90C) Instrument Scale - 0-100% Instrument Range - 0-200" H2O 1,747 ' 66 67 68 69 Gallons 1,783 1,818 1,854 1,889 1,925 1,960 1,996 2,031 2,067 2,102 2,138 2,173 2,209 2,244 2,280 2,315 2,351 2,386 2,422 2,457 2,493 2,528 2,564 2,599 2,635 DSW 334578 STLCOPCB4081048 V O O O g O N U lJ M ^ tO H O V O O O N jO M n ^ C O Is )H O V O O O v |O N U lJ > U )|s 3 H O ^ O O M O ^ U l^ U )rs )H O % Scale Inches 6.0 7.6 9.2 10.8 12.3 13.9 15.5 17.1 18.7 20.2 21.8 23.4 25.0 26.6 28.2 29.7 31.3 32.9 34.5 36.1 37.6 39.2 40.8 42.4 44.0 45.6 47.1 48.7 50.3 51.9 53.5 55.1 56.6 58.2 59.8 61.4 63.0 64.6 66.1 67.7 NO. 1 ROOF TANK AROCLOR 1142 Gallons 296 420 553 107 856 1,015 1,183 1,352 1,548 1,738 1,944 2,125 2,354 2,572 2,758 2,993 3,221 3,446 3,675 3,905 4,118 4,361 4,604 4,839 5,080 5,307 5,523 5,839 6,077 6,307 6,548 6,781 6,928 7,148 7,482 7,711 7,940 8,166 8,377 8,626 . % Scale 40 41 - 43 44 45 . 46 47 48 49 50 51 52 53 54 55 56 Inches 69.3 70.9 72.5 74.0 75.6 77.2 78.8 80.4 82.0 83.5 85.1 86.7 88.3 89.9 91.4 93.0 94.6 Gallons 8,815 9,032 9,259 9,431 9,637 9,839 10,037 10,207 10,376 10,526 10,686 10,839 10,971 11,097 11,205 11,296 11,354 Aroclor 1142 Temperature 150C Sp. Gr. 1.264 @ 150C Sp. Gr. 1.389 @ 25C Inst. Range - 0-200" H20 Inst. Scale - 0-100% 90% full = 47% (10,219 gals.) DSW 334579 STLCOPCB4081049 % Scale 0 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 26 27 28 Inches Aroclor 3.0 4.9 6.7 8.6 10.5 12.3 14.2 16.0 18.0 19.8 21.7 23.6 25.4 27.3 29.2 31.0 32.9 34.8 36.6 38.5 40.4 42.3 44.1 46.0 47.9 49.7 51.6 53.5 55.3 #2 ROOF TANK AROCLOR 1121 Gallons 45 97 150 218 288 366 451 530 645 730 844 953 1,064 1,175 1,309 1,420 1,528 1,684 1,796 1,922 2,070 2,179 2,306 2,400 2,574 2,676 2,808 2,952 3,132 7o Scale 29 30 31 - 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 Inches Aroclor 57.2 59.0 60.9 62.8 64.7 66.6 68.4 70.3 72.2 74.0 75.9 77.8 79.6 81.5 83.4 85.2 87.1 89.0 90.9 92.7 94.6 96.5 98.3 100.2 102.0 103.9 105.8 107.4 Gallons 3,237 3,388 3,500 3,638 3,743 3,888 4,000 4,126 4,283 4,388 4,523 4,649 4,756 4,880 4,994 5,100 5,207 5,318 5,422 5,503 5,598 5,675 5,753 5,820 5,878 5,905 5,957 5,991 Aroclor 1121 Sp. Gr. @ 150C - 1.070 (1.155 Q 65C) Inst. Range - 0-200" H2O Inst. Scale - 0-100% 907. Full = 467. DSW 334580 STLCOPCB4081050 % Scale 0 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 26 27 28 29 30 31 32 Inches Aroclor 3.0 4.6 6.2 7.8 9.3 10.9 12.5 14.1 15.7 17.2 18.8 20.4 22.0 23.6 25.2 26.7 28.3 29.9 31.5 33.0 34.6 36.2 37.8 39.4 41.0 42.6 44.1 45.7 47.3 48.9 50.5 52.0 53.6 #2 ROOF TANK AROCLOR 1142 Gallons % Scale 45 90 134 .188 243 306 373 446 520 593 681 767 860 953 1,052 1,139 1,244 1,340 1,450 1,533 1,668 1,753 1,888 1,986 2,100 2,210 2,306 2,389 2,525 2,616 2,745 2,820 2,962 . 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 Inches Aroclor 55.2 56.8 58.4 60.0 61.5 63.1 64.7 66.3 67.9 69.5 71.0 72.6 74.2 75.8 77.4 79.0 80.5 82.1 83.7 85.3 86.9 88.4 90.0 91.6 93.2 94.8 96.4 98.0 99.5 101.1 102.7 104.3 105.8 107.4 Gallons 3,124 3,213 3,340 3,426 3,558 3,652 3,743 3,874 3,953 4,086 4,168 4,296 4,405 4,517 4,618 4,708 4,820 4,914 5,014 5,106 5,195 5,288 5,363 5,446 5,524 5,608 5,670 5,743 5,794 5,851 5,880 5,916 5,957 5,991 Aroclor 1142 Sp. Gr. 1.264 @ 150C (1.389 @ 25C) Inst. Range -0-200" H2O Inst. Scale - 0 - 100% 90% Full = 55% osV) STLCOPCB4081051 % Scale 0 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 26 27 28 29 30 31 32 33 34 35 Inches Aroclor 3.0 4.5 6.0 7.5 9.0 10.5 12.0 13.5 15.0 16.5 18.0 19.5 21.0 22.5 24.0 25.5 27.0 28.5 30.0 31.5 33.0 34.5 36.0 37.5 39.0 40.5 42.0 43.5 45.0 46.5 48.0 49.5 51.0 52.5 54.0 55.5 #2 ROOF TAMC AROCLOR 1148 Gallons % Scale 45 36 87 37 *27 38 178 . - 39 233 40 288 41 356 42 415 43 495 44 555 45 645 46 715 47 808 48 890 49 975 50 1,070 51 1,156 52 1,260 53 1,344 54 1,450 55 1,533 56 1,660 57 1,731 58 1,870 59 1,944 60 2,075 61 2,149 62 2,275 63 2,362 64 2,450 65 2,582 66 2,660 67 2,789 68 2,860 ' 69 3,004 3,148 Inches Aroclor 57.0 58.5 60.0 61.5 63.0 64.5 66.0 67.5 69.0 70.5 72.0 73.5 75.0 76.5 78.0 79.5 81.0 82.5 84.0 85.5 87.0 88.5 90.0 91.5 93.0 94.5 96.0 97.5 99.0 100.5 102.0 103.5 105.0 106.5 Gallons 3,219 3,348 3,426 3,558 3,646 3,733 3,859 3,933 4,064 4,138 4,277 4,348 4,475 4,558 4,664 4,748 4,852 4,938 5,033 5,118 5,200 5,303 5,363 5,453 5,513 5,593 5,652 5,721 5,775 5,831 5,878 5,895 5,934 5,973 Aroclor 1148 Sp. Gr. 1.330 @ 150C (1.415 @ 65C) Inst. Range - 0-200" H2O Inst. Scale - 0-1007o 90% Full = 58% 0S\N 334582 STLCOPCB4081052 % Scale 0 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 26 27 28 29 30 31 32 33 34 35 36 . Inches Aroclor 3.0 4.4 5.8 7.2 8.6 10.0 11.5 12.9 14.3 15.7 17.0 18.5 19.9 21.3 22.7 24.1 25.5 27.0 28.4 29.8 31.2 32.6 34.0 35.4 36.8 38.2 39.6 41.0 42.4 43.8 45.3 46.7 48.1 49.5 50.9 52.3 53.7 #2 ROOF TANK AROCLOR' 115 A Gallons % Scale Inches Aroclor 45 84 122 467 218 265 333 387 457 520 580 668 735 824 902 982 1,070 1,156 1,252 1,335 1,432 1,512 1,620 1,712 1,818 1,909 2,008 2,100 2,189 2,290 2,373 2,470 2,586 2,660 2,780 2,824 2,973 37 55.1 38 56.5 39 57.9 40 59.3 41 60.7 42 62.2 43 63.6 44 65.0 45 66.4 46 67.8 47 69.2 48 70.6 49 72.0 50 73.4 51 74.8 52 76.2 53 77.6 54 79.0 55 80.5 56 81.9 57 83.3 58 84.7 59 86.0 60 87.5 61 88.9 62 90.3 63 91.7 64 93.0 65 94.5 66 96.0 67 97.4 68 98.8 69 100.2 70 101.6 71 103.0 72 104.4 73 105.8 74 107.2 Gallons 3,116 3,204 3,299 3,399 3,483 3,616 3,683 3,758 3,879 3,948 4,073 4,144 4,277 4,340 4,458 4,540 4,634 4,708 4,820 4,902 4,988 5,072 5,148 5,234 5,313 5,383 5,463 5,513 5,593 5,652 5,716 5,769 5,820 5,866 5,881 5,918 5,957 5,987 Aroclor 1154 Sp. Gr. 1.420 @ 150C (1.505 @ 65C) Inst. Range - 0-200" H2O Inst. Scale - 0-100% 90% Full - 62% dS\N 334583 STLCOPCB4081053 7. Scale 0 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 26 27 28 29 30 31 32 33 34 35 36 37 38 Inches Aroclor 3.0 4.3 5.7 7.0 8.3 9.6 11.0 12.3 13.6 15.0 16.3 17.6 19.0 20.3 21.6 23.0 24.3 25.6 26.9 28.3 29.6 30.9 32.3 33.6 34.9 36.2 37.6 38.9 40.2 41.6 42.9 44.2 45.6 46.9 48.2 49.5 50.9 52.2 53.5 #2 ROOF TANK AROCLOR 1160 Gallons 45 82 119 160 206 252 310 366 420 495 545 619 690 760 839 920 995 1,076 1,150 1,244 1,326 1,412 1,496 1,585 1,692 1,753 1,876 1,940 2,060 2,129 2,240 2,312 2,385 2,490 2,590 2,660 2,780 2,836 2,952 % Scale 39 40 41 42 43 44 45 46 47 48 49 50 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 76 77 78 Inches Aroclor 54.9 56.2 57.5 58.9 60.2 61.5 62.8 64.2 65.5 66.8 68.2 69.5 70.8 72.1 73.5 74.8 76.1 77.5 78.8 80.1 81.5 82.8 84.1 85.4 86.8 88.1 89.4 90.8 92.1 93.4 94.8 96.1 97.4 98.7 100.1 101.4 102.7 104.1 105.4 106.7 Gallons 3,098 3,194 3,264 3,380 3,442 3,558 3,638 3,718 3,809 3,898 3,979 4,086 4,156 4,280 4,348 4,458 4,534 4,626 4,699 4,794 4,880 4,956 5,039 5,112 5,190 5,273 5,336 5,415 5,482 5,535 5,608 5,657 5,716 5,765 5,817 5,860 5,880 5,911 5,946 5,977 Aroclor Sp. Gr. <1a161_ 050_ nC - 1.504 (1.564 @ 90C) Inst. Range - 0-200" H0 Inst. Scale - 0-100% 907. Full = 657. ................................ ^ 334584 STLCOPCB4081054 % Scale 0 i 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Inches Aroclor 3.0 4.3 5.6 6.9 8.3 9.6 10.9 12.2 13.5 14.8 16.1 17.4 18.8 20.1 21.4 22.7 24.0 25.3 26.7 28.0 29.3 30.6 31.9 33.2 34.5 35.9 37.2 38.5 39.8 41.1 42.4 43.7 45.0 46.4 47.7 49.0 50.3 51.6 52.9 54.2. #2 ROOF TANK AROCLOR 1162 Gallons 45 82 116 157 206 252 306 363 415 484 535 606 681 747 829 902 975 1,058 1,139 1,220 1,313 1,390 1,474 1,550 1,660 1,728 1,852 1,922 2,029 2,105 2,189 2,285 2,362 2,440 2,557 2,620 2,727 2,808 2,892 3,025 , % Scale 40 41 42 43 44 45 ` 46 47 48 49 50 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 76 77 78 79 Inches Aroclor 55.6 56.9 58.2 59.5 60.8 62.1 63.4 64.8 66.0 67.4 68.7 70.0 71.3 72.6 74.0 75.3 76.6 78.0 79.2 80.5 81.8 83.2 84.5 85.8 87.0 88.4 89.7 91.0 92.4 93.7 95.0 96.3 97.6 .98.9 100.2 101.6 102.9 104.2 105.5 106.8 Gallons 3,156 3,216 3,324 3,407 3,492 3,612 3,671 3,748 3,859 3,928 4,032 4,108 4,201 4,296 4,388 4,491 4,564 4,664 4,724 4,820 4,897 4,981 5,061 5,136 5,200 5,288 5,350 5,428 5,492 5,552 5,618 5,666 5,725 5,772 5,820 5,866 5,881 5,913 5,949 5,979 Aroclor 1162 Sp. Gr. @ 150C - 1.522 (1.582 @ 90C) Inst. Range - 0-200" H2O Inst. Scale - 0-100% 90% Full = 66% ` DSW 334585 STLCOPCB4081055 ,fHg 0 0.1 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3.0 3.1 3.2 3.3 3.4 3.5 3.6 3.7 3.8 Gallons 380 421 463 504 546 587 629 670 712 753 795 836 878 919 960 1,002 1,043 1,085 1,126 1,168 1,209 1,251 1,292 1,334 1,375 1,417 1,458 1,499 1,541 1,582 1,624 1,665 1,707 1,748 1,790 1,831 1,873 1,914 1,956 LIQUIDS COLLECTION TANK CALIBRATIONS CRUDE AROCLOR TRAPPINGS "He Gallons 3.9 4.0 4.1 4.2 '4.3 4.4 4.5 4.6 4.7 4.8 4.9 5.0 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 6.0 6.i 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 7.0 7.1 7.2 7.3 7.4 7.5 7.6 7.7 1,997 2,038 2,080 2,121 2,163 2,204 2,246 2,287 2,329 2,370 2,412 2,453 2,495 2,536 2,578 2,619 2,660 2,702 2,743 2,785 2,826 2,868 2,909 2,951 2,992 3,034 3,075 3,117 3,158 3,199 3,241 3,282 3,324 3,365 3,407 3,448 3,490 3,531 3,573 7.8 7.9 8.0 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 9.0 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 10.0 10.1 10.2 10.3 10.4 10.5 10.6 10.7 10.8 10.9 11.0 11.1 11.2 11.3 Gallons 3,614 3,656 3,697 3,738 3,780 3,821 3,863 3,904 3,946 3,987 4,029 4,070 4,112 4,153 4,195 4,236 4,277 4,319 4,360 4,402 4,443 4,485 4,526 4,568 4,609 4,651 4,692 4,734 4,775 4,816 4,858 4,899 4,941 4,982 5,024 5,065 Tank 573 Sp. Gr. 1.160 @ 50C Trappings Sample 10/4/65 - Before start-iip of new clean-up system. DSW 334586 STLCOPCB4081056 STANDARD OPERATING INSTRUCTIONS FOR AROCLORS . 102. C. I. PROCESS FUNCTION OUTLINE LIQUID STILL SYSTEM 1.1 Scope This covers the charging, start-up, shutdown, and normal operation of the Liquid Aroclor Still System (Stills No. 1, 2, and 3). 1.2 Description of Process Aerated Crude Aroclor from a blowing tank or a roof tank is fed to the still tank. Hydrated lime is added to the Crude Aroclor. Vacuum is applied to the still and the Aroclor is circulated through the furnace coil and heated to the vaporization tem perature. Vapors pass up an open column to the condenser. Distilled Aroclor is collected in a receiver and then trans ferred into a blending tank. Distilled Aroclors are treated with Attapulgus Earth in the blending tank, filtered, analyzed, and packaged or held in storage. Part of the production is treated in a porocel column. Still residue or bottoms are sold as Montars or discarded. ' II. PROCESS DIAGRAM Attached ' III. DESCRIPTION OF PROCESS 3.1 Charging and Start-Up A. Charges for Various Aroclors 1. Under normal conditions Crude Liquid Aroclors are charged continuously to the still from a blowing tank or roof tank to a 55" outage. This level is maintained by an automatic level controller. Occasionally, Liquid Aroclors are charged batch-wise. When this is done, the crude is charged to a 25" outage. DSW 334587 STLCOPCB4081057 Detailed Instructions Aroclors 103. 2. ' Prepare blowing tank for transfer of charge: a. Check to be sure steam is on the pump and charging lines. Material to be pumped must be hot or it will damage the mechanical seals on #3 and #4 blowing tank'pumps. b. Check temperature of material in blowing tank to be sure it is hot enough to transfer (120-140C). c. Check with chlorinator operator to be sure Crude Aroclor has been blown with air for a minimum of one hour. 3. Prepare Still to receive Charge: a. Close valve in bottom line under the still. b. Open vent valve on the still. c. Remove vent cap on measuring nipple on the still. d. Open valve on charging line at the still. e. Set valves in charging line to pump from the desired blowing tank to the correct still. f. Close main valve in vacuum line to the still just above the receiver. Start steam to the vacuum jets. Adjust water to intercondenser on middle stage. The jets on stills should pull down to 20-30 mm Hg absolute on the receiver. 4. Charging the Still and Start-Up: a. Set valves in line to the still. . b. Start the blowing tank pump. ' c. Observe material entering the still. d. Insert rod in measuring nipple on the still and check amount of material in the still. As soon as 10-15 inches of material is in the still, start the cir culating pump. e. When complete charge is in the still stop the charging pump. Allow lines to drain and close valve in charging line at the still. f. Close valve under blowing tank. DSW 334588 STLCOPCB4081058 Detailed Instructions Aroclors 104 g. Add hydrated lime through the measuring nipple using funnel provided for this purpose. Add 250 pounds of lime for each five (5) still receiver batches of liquid . Aroclor. h. Replace cap on nipple over still. i. Light gas burners on furnace and set gas pressure at 5 psig on each burner. Accomplish this as follows: (1) Check all gas valves at furnace to be sure they are closed. . (2) Open valve in main gas supply line to furnace. (3) Put on face shield. (4) Open valve in pilot line. (5) Raise cover over peephole over pilot light and'insert torch to light pilot. (6) When pilot is burning, open valve to one main burner, the one directly in front of pilot light, to light this main burner. (7) When one main burner is on, open valves to other main burners, one at a time, until all burners have been lighted. j. Check temperature recording instrument to be sure it is operating correctly. k. In case temperature chart does not indicate a rise in temperature, check for plugged lines or instrument problems. l. Turn the pump off and on a couple of times. It may be necessary to pull a vacuum through the coil. Check the still pump ammeter to be sure the pump is pulling a load. Have the electrician check the instrument if the temperature does not rise. m. Adjust the gas burners to give maximum rate of tem perature rise without overheating. A spread of 10-15C. between the coil inlet and outlet is normal. Gas pressure is normally as follows on the stills when maximum rate is achieved. Still No. Gas Burner Pressure 1 20 psig. 2 20 psig. 3 30 psig. DS\N 334589 STLCOPCB4081059 Detailed Instructions Aroclors 104-A. n. Open valve in main vacuum line to the vacuum jets above the receiver. Vacuum should be 20-30 mm Hg absolute on receiver. o. Start water on condenser as material starts to come over. Adjust water to keep from plugging up the condenser. p. Gas pressure on the burners is adjusted until the coil temperatures reach a point about 20C. below the ex pected distillation temperature. Normally a 10C. temperature spread is obtained on the inlet and outlet of the coil. STLCOPCB4081060 Detailed Instructions Aroclors 105. q. Batch data sheets are filled out during each distillation. Information includes still lot number, material being distilled, start time, finish time, temperature spread on the still coils, end time for the distillation, etc.----(See distillation sheet. Page 106). 5. Operation of Still during Distillation: a. Regulate the gas pressure at the burners to give . maximum distillation rate consistent with a good color of the product. (See Item 4. m. Page 104) b. The lower the vacuum, the faster the distillation rate. (See Table I, Page 106) c. Coil Temperature Spread: . Coil inlet and outlet temperature must be watched closely at the end of the distillation. Still bottoms are very viscous; therefore, if the circulating pump is in poor condition, or the distillation is carried too far, circulation may stop and the coil will become plugged or be burned. Heat from the furnace actually burns the Aroclor to carbon. If the coil outlet temperature jumps suddenly and the inlet temperature stays the same or falls, circulation has nearly stopped. In this case, cut the burners off quickly and suck the coil. If the coil cannot be sucked, it is plugged and will have to be replaced. Observation of the ammeters on the still circulating pump motors will also indicate when the pump has stopped circulation. Normally, the pump motor will pull 20 to 40 amps during a distillation. A sudden increase in the amp load indicates the coil is probably plugging. A sudden decrease indicates the pump load has dropped off and the coil is plugged. d. Transfer of Receiver to Bland Tank: (1) Observe level of material in the still receiver. When material is 8" to 12" from the sightglass the receiver of material is transferred to a blend tank. (2) Check to be sure steam heat is on the transfer lines and the pump. DSW 334591 STLCOPCB4081061 Detailed Instructions Aroclors 106 TABLE I DISTILLATION OPERATING CONDITIONS Approximate Temperatures at which various Aroclors start distilling 35-40 mm Vac. Column Coil Inlet Coil Outlet Approximate Finishing temperature when bottoms are not to be drawn. Column Coil Inlet Coil Outlet Approximate Finishing temperature after which bottoms are to be drawn Column Coil Inlet Coil Outlet Finishing Specific Gravity ________ 1221 155C 165 170 LIQUID AROCLORS 1242 1248 1254 165C 170 175 170C 180 190 190C 200 220 1260 195 C 210 225 1262 235C 245 255 180 205 230 240 265 275 185 210 240 245 270 280 190 220 250 255 280 290 215 225 240 _ 1.1821.192 @ 25C 230 240 250 1.3811.392 <3 25C 250 255 265 1.4051.415 (3 65 oc 280 290 310 1.4951.505 @ 65 C 315 320 325 335 340 345 1.5551.566 @ 90C 1.5721.583 (a 90OC NOTE: Aroclor 1232 is a blend of Aroclors 1221 and 1242. 0* STLCOPCB4081062 Detailed Instructions Aroclors . 107. (3) Set valves in line to the blend tank desired. (4) Start transfer pump under the receiver. (5) Allow material to pump until the receiver is empty. - Do not let the still lose vacuum. This entire transfer can be made while the still is operating. (6) Check the blend tank to be sure the material is being transferred. (7) Close the valves and stop the pump when the transfer is complete. B. Stopping the Distillation 1. General Operation: a. Run down the stills. Stop feed to still and distill off material in the still tank until an outage of 82" to 84" is reached. b. Reduce gas pressure on the burners to 5 psig. c. Close valve in vacuum line above the receiver. d. Reduce water flow to the condenser as the distillation stops. 2. Operation Dependent on Aroclor being Distilled: Aroclors 1221, 1242, 1248, 1254, 1260, and 1262. a. Stop circulating pump after 15-20 minutes. b. Release vacuum through the vent valve on the coil. Suck the coil clean for one to three minutes. c. Remove cap from the measuring nipple on the still. d. Measure bottoms in the still and record in the log book. e. Prepare to draw bottoms and then recharge the still to ' start another distillation. C. Drawing Bottoms 1. Schedule for Drawing Bottoms: a. Aroclors 1221, 1242, 1248, 1254, 1260, and 1262: Draw bottoms after every 10th distillation on No. 1 and No. 2 stills and e\?ery 6th distillation on No. 3 St:Ll:L* DSW 334593 STLCOPCB4081063 Detailed Instructions Aroclors 108. 2. Operation for Drawing Bottoms into Drums: a. Check to be sure that Therminol heat is on the draw-out line. b. Place necessary drum near draw-out station. c. Set valves in line to draw-out station. d. Check to be sure the exhaust fan is running. e. Obtain assistance to draw bottoms. NOTE: Fumes from this operation are toxic. If the exhaust fan should stop, discontinue drawing out and notify the Chief Operator. The material to be drawn into drums is hot. Have the person filling the drums to put on face shield. f. Place drum under valve at draw-out station. Open valve under still. Close draw-out valve. g. If the bottoms being drawn out are to be packaged for shipment, open the valve at draw-out station and allow approximately 25 to 30 gallons of material to flow through the line into the drum to flush out the line. h. If the bottoms being drawn out are not to be packaged for shipment, flush out of line is not necessary. i. Continue drawing out until the still is empty. Fill drums to within 6"-8" of top and place cover on drum. As the drums are filled move them on conveyor to east platform. j. Close the valve under the still. Leave the valve at draw-out station open. . NOTE: If bottoms are packaged for shipment, take a one pint sample of the material and send to the laboratory for analysis. . Stencil Montar number and lot number on each drum. (See Appendix I for identification.) k. Allow drums to set on conveyor until they have cooled 6-10 hours, then palletize the drums to be transferred to warehouse. Drums to be discarded will be trans ferred to the dump by plant stake truck. oSXN 33*59* STLCOPCB4081064 Detailed Instructions Aroclors 109. D. Earth-Treatment of Aroclors Liquid Aroclors 1221, 1242, 1248, 1254, 1260, and 1262 are treated with Attapulgus Earth for three hours per the following procedure: 1. Collect two receiver distillations from Ho. 1 and 2 stills in a blend tank. Collect one receiver dis tillation from No. 3 still in a blend tank. 2. Prepare Attapulgus earth which is to be added to the blend tank. This earth must be dried in an oven for a minimum of four hours at a temperature of 210-250C. 3. Start the agitator in the blending tank and add 40 lbs. of dried earth for two receiver distillation batches from No. 1 or 2 stills. Add 40 lbs, to one receiver distillation batch from No. 3 still. 4. Agitate the mixture of earth and Aroclor for 3 hours at the following temperatures: Aroclor 1221 1242 1248 1254 1260 1262 60 - 70C 70 - 80 C 80 - 90C 90 - 100C 100 - 110C 110 - 120C E. Filtration of Aroclors 1. Prepare filter for filtration of Aroclor by cleaning the earth from the previous filtrations from the press and installing new filter paper. a. Run tightening screw back to permit removal of papers. b. Separate and clean frames and remove used papers. Be sure no earth is left on the surfaces of the plates and frames. Discard earth and paper in a 55 gallon trash drum. c. Install new papers and tighten the press. Use two papers between each plate. 334595 STLCOPCB4081065 Detailed Instructions Aroclors 110. 2. Starting Filtration: a. After the Aroclor has been earth treated for three hours, start filtration. b. Set valves in the system to pump the treated Aroclor from the blend tank, through the filter press, and back to the blend tank. Recycle this material until no earth is visible in a sample from the filter. c. Set valves to direct material to the Filtrate Receiver when the material has cleaned up. d. Catch a sample of the filtrate. Check specific gravity and observe color. Record data in log book. F. Transfer to Storage Tank 1. Measure outage of material in the filtrate tank and record in the log book. 2. Set valves in the line so the Aroclor will be pumped to the desired storage tank. 3. Check to be sure steam is on the transfer pump and the transfer lines. 4. Start the pump under the filtrate receiver. 5. Close the valve under the filtrate receiver and stop the transfer pump-when the Aroclor has been pumped out. 6. Measure innage in the storage tank and record in the log book. G. Aroclor Treatment Columns 1. Start-Up from Complete Shutdown a. Charging Column(s) with Porocel a-1) Check bottom nozzle valves to insure that they are closed. a-2) Remove manhole on top of column. Insure that bauxite discharge manhole at bottom of column is securely bolted closed. ' a-3) Inspect inside of column through top to insure that bottom support is not damaged and that interior of column is not dirty or rusted. oSnN STLCOPCB4081066 Detailed Instructions . Aroclors 111. 1 cd Obtain about 12 drums of porocel from storage (400 lb. drums - 20-60 mesh). a-5) Place one drum in drum hoist and lift to top of column. a-6) Leave drum in hoist, remove cover lid and pour porocel into the column. a-7) Lower empty drum to ground and repeat a-5, a-6, and a-7 until column is filled. a-8) Actuate the column vibrators to pack the porocel bed a-9) Have manhole cover reinstalled on top of column. b. Aroclor Porocel Columns Therminol System b-1) Check out lines from Therminol header to column jacket to Therminol tank. b-2) Close all manual valves on column jackets except the valves on column jacket inlet and outlet of column which is to be dried and the Therminol tank fill valve after exiting the column jacket. b-3) Open the by-pass valve around the Therminol tempera ture control valve (TCV-691.1) to allow Therminol to fill the Therminol tank. b-4) Close by-pass valve when Therminol tank is 75% full. b-5) Open the Therminol valves to and from the plate coil jacket of the Therminol tank. b-6) The Therminol heating system is now ready to use to dry the porocel bed in the specific column in question. c. Drying the Aroclor Treating Column Porocel Bed c-1) Close all inlet and outlet product valves on Aroclor column to be dried. c-2) Line up nitrogen supply line leaving the valve nearest the column closed. c-3) Close column vent valve on top of column. c-4) Slowly open nitrogen purge valve. Do not bump porocel bed. Leave valve wide open. DSW 334597 STLCOPCB4081067 Detailed Instructions Aroclors 112. c-5) Open slowly vent valve on top of column. Nitrogen is now flowing through porocel bed. c-6) Line up valves to allow Therminol to flow from Therminol tank, through pump, through column jacket, and back to Therminol tank. c-7) Start Therminol circulating pump. c-8) Set Therminol temperature controller (TIC-691.2) at top of scale. c-9) Open block valves around Therminol temperature control valve (TCV 691.1). Close by-pass valve. c-10) Hot therminol should now be circulating through the column jacket and nitrogen should be blowing through the porocel bed. After four (A) hours of drying, close nitrogen supply valve. c-11) Sample the porocel by dipping glass rod through the vent valve on top of column. c-12) Send porocel sample to Lab for moisture analysis. Resume nitrogen purging while waiting for analysis. c-13) Sample the porocel bed every four (4) hours as above until the moisture analysis is 1,000 ppm or below. c-14) When the moisture is in spec, close the nitrogen supply valve and column vent valve in that order. Do not leave nitrogen pressure on the column. c-15) Therminol is left circulating on column after dry ing. If it is going through the jacket of a 1242 column, reset Therminol temperature control to 65C. If going through a 1254 or 1260 column, reset temperature to 100C. When it becomes necessary to dry a different column, divert the Therminol flow to the fresh column by opening inlet and then outlet Therminol valves on the fresh column and then clos ing inlet and outlet Therminol valves on the previous column. d. Initial Aroclor Conditioning: of New Porocel Column Beds d-1) After one still batch of 1242, 1254, or 1260 has been pumped to the blend tank, line up to flow from the blend tank to the Viking pump, to the appropriate product heat exchanger, to the appropriate column, on through the filter and then to the No. 3 filtrate receiver. Close vent valve on top of column. DSW 334598 STLCOPCB4081068 Detailed Instructions Aroclors d-2) Set the flow controller at the blend tank (FIC 913.2, 914.2, or 915.2) at 3 gpm. 112-A d-3) Set the product temperature controller(s) at the column(s) to control as follows: 1242 1254 1260 65 C 100C 125 C If the blend tank temperature is above this temperature, manually set cooling water to go through the heat exchanger. If the temperature of blend tank is below the desired temperature, set up valves to put steam into the exchanger. d-4) Start the positive displacement Viking pump under the appropriate blend tank and pump the blend tank dry through the column. d-5) When the batch of Aroclor has all been put through the column to the No. 3 receiver, sample the re ceiver and have checked for resistivity. d-6) If the resistivity is within spec, pump out receiver to appropriate storage tank. d-7) If resistivity is below spec, pump back to blend tank and rework through column until resistivity spec is met. 2. Routine Operations of Aroclor Treating Columns Following are pertinent comments on conditions which will exist on the porocel treatment systems during normal opera tions. a. Therminol Heating System a-1) Therminol tank will be 75% full. a-2) Therminol temperature controller (TIC 691.2) will be set at 65C. if the Therminol is going through a 1242 column jacket. If it is going through a 1254 or a 1260 column jacket, set-point of control ler should be at 100C. a-3) Temperature of Therminol entering and leaving the jacket of a column can be read on the temperature recorder in the control room (L&N). oSVM 334599 STLCOPCB4081069 Detailed Instructions Aroclors 113 b. Porocel Column b-1) ^ The Viking feed pumps under each blend tank will be pumping Aroclor from the blend tanks through the appropriate heat exchanger located near each column on the second level, through the individual columns, polishing filters, and on to storage. b-2) The flow recorder controllers at each blend tank can be set from 0-10 gpm of Aroclor going to the columns. Object is to adjust flow such that there will be a continuous feed to each column when stills are running normally. Flows of around 3 gpm should be normal. In practice, adjust flow rate so that blend tanks are almost empty in time to re ceive another batch from still receivers. This will involve close watching of still receiver and blend tank levels. b-3) Each column has a heat exchanger to bring tempera ture of product going to the columns to desired temperatures. These temperatures are as follows: Aroclor 1242 Aroclor 1254 Aroclor 1260 65C 100C 125 C These temperatures are automatically controlled with one manual stipulation. If the temperature of product from the blend tank is above these tempera tures, cooling water is put on the exchanger manually to bring the temperature down. If the temperature from the blend tank is below the desired temperature, steam is put on the exchanger to bring temperature up. Once the inlet temperature is determined to be above or below the desired tempera ture and the temperature control medium is manually selected, the temperature recorder controller will maintain desired temperature to column. b-4) A selector valve and timer makes it possible to put a side stream from any one of the columns through the power factor instrument at the old column. This power factor reading is remoted into the control room. When selecting a stream - allow about one-half hour before taking reading. b-5) Tempei'atures into and out of each column are read on temperature recorder in control room (L&N). This same temperature recorder also records temperature of product stream out of power factor instrument. DSW 334600 STLCOPCB4081070 Detailed Instructions Aroclors 113-A. c. Data Collection Data to be taken and recorded on data sheet at indicated times is as follows: c-1) Flow rate through column. c-2} Blend tank level. c-3) Still receiver level. c-4) Temperature of Aroclor entering column. c-5) Temperature of Aroclor out of column. c-6) Power factor. c-7) Therminol temperature. d. Sampling During routine operations, quality will be monitored mainly by in-line power factor measurements of product from the columns. On start-ups of the column, initial production will be sampled and lab tested for resistivity to determine whether rework is necessary. Operator will measure and record specific gravity of each batch. 3. Dumping Porocel Beds a. Porocel in individual columns will be dumped when: a-1) Resistivity of treated Aroclor drops below 10,000. a-2) When pressure drop through column becomes so great as to restrict flow to such an extent that it is bottlenecking stills. a-3) If it becomes necessary to treat a different Aroclor other than the one for which the column is earmarked. b. Stop column feed pump. c. Close inlet and outlet valves to column. d. Position Dempster-Dumpster under manhole near bottom of column. e. Have top of column opened. f. Have manhole near bottom of column opened. DSW 334601 STLCOPCB4081071 Detailed Instructions Aroclors 114. g. Rake out porocel - Aroclor mixture from bottom manhole into Dumpster. h. Have bottom manhole cover replaced when column is empty and refill column as per instructions above. 4. Shutdowns . a. Temporary Shutdown a-1) Stop column feed pump under blend tank. a-2) Close inlet valve to pump. a-3) Leave Therminol system as is. a-4) Start-up when ready as per above instructions. b. Complete Shutdown b-1) Stop column feed pump. b-2) Close inlet valve to pump. b-3) Stop Therminol circulating pump. b-4) Close inlet and outlet valves of Therminol circulatinh pump. . b-5) Close inlet block valve to TCV 691.1 - Therminol temperature control valve. b-6) Slowly blow out lines and column with nitrogen at blend tank connection. b-7) Close block valve on column product outlet valve. b-8) Shut off steam or cooling water valves to product heat exchanger. b-9) Open vent valve on top of column. 5. Control Loops a. Aroclor Flow Control FIC 913.2, 914.2, and 915.2 The function of these instrument loops is to control the flow of Aroclor from each blend tank to each porocel column. This is done by setting the desired flow on the flow indicator controller located at the blend tank, measuring the flow stream to a column with an orifice and regulating this forward stream by automatically throt tling of a control valve on a recycle line which recycles the excess Aroclor back to the blend ta^1' nere of these instruments are 0-10 gpm. DSW334602 STLCOPCB4081072 Detailed Instructions Aroclors b. Therminol Temperature Controller TIC 691.2 115 The function of this loop is to maintain a constant Therminol temperature to dry out a fresh porocel charge in any one of the four Aroclor treatment columns. It does this by regulating the flow of hot Therminol from the main header to the plate coil jacket on the Therminol tanlc. Control .valve TCV 691.1 is throttled by TIC 691.2 as needed to maintain the Therminol temperature at the desired set point in the surge tank. c. Aroclor Product Temperature Controller TIC 913.1, 914.1, and 915.1 The function of these loops is to control the temperature of Aroclor going into each column. The TIC's throttle either a cooling water control valve or a steam control valve to maintain a set temperature. The choice of water or steam is made and set up by the operator depending on if temperature of Aroclor from blend tank is above or below desired temperature. Range of instruments are 50-150C. 6. Comments on Process . a. Column Feed Pumps (Items 910, 911, 912) The-column feed pumps are Viking positive displacement pumps with internal relief valves to prevent over pressurizing the system. The relief valves are set for 80 psi. b. Column Pressure Relief Each column is equipped with a 2-inch rupture disc to prevent damage from over-pressurizing columns. The discs are rated at a bursting pressure of 95 psig and a bursting temperature of 205C. c. Product Changeover In normal operations, each column will be earmarked for a specific Aroclor. If it should become necessary to put a different Aroclor through a particular column other than its normal product, this column will have to be dumped and recharged with fresh bauxite to avoid con tamination of the Aroclors. Only electrical grade Aroclors (1242, 1254, 1260) will be column treated. DSW 334603 STLCOPCB4081073 Detailed Instructions Aroclors 116. G-a. TCB AND TTC3 TREATMENT COLUMNS' 1. Start-up From Complete Shutdown a. Charging columns with Porocel Follow instructions as for charging the Aroclor columns except you will only need nine (9) drums or porocel rather than twelve (12). b. Drying the Porocel Beds b-1) Follow instructions c-1 through c-5 of section dealing with drying of Aroclor column Porocel beds. b-2) There is no Therminol system servicing these two columns. Instead, introduce steam flow into the jackets of these columns for heating by manipulating appropriate valves. b-3) Follow instructions c-10 through c-15 of section dealing with drying of Aroclor column porocel beds. b-4) When porocel is dried, discontinue steam flow to column jackets. c. Routine Operation of Columns The TCB or TTCB will be unloaded directly from the tank cars or trucks through the porocel columns, through the polishing filter, and then to storage. The flow from the unloading pump will be split to go through both columns in order to unload in a reasonable length of time. c-1) Set up car, pump and unloading line for unloading material. c-2) Open inlet product valves to both columns. Insure that the by-pass valve enabling by-passing of material around columns is closed. c-3) Open discharge valves on product lines out of column. c-4) Open valve to either TCB or TTCB storage tanks depending on which product is to be unloaded. Be sure correct valve to correct tank is opened. DSW 334604 STLCOPCB4081074 Detailed Instructions Aroclors 117. c-5) Start unloading pump and pump all material out of car to storage tank. c-6) When all material is unloaded, stop pump and dis connect and secure car. c-7) Blow out line from unloading dock, through columns and to storage tank to rid the lines and treatment system of material. c-8) Close valves on storage tank and on porocel columns. c-9) There are no automatic flow or temperature control loops on these columns. Local pressure and temperature gauges allow for trouble-shooting and monitoring the unloading procedures. d. Dumping Porocel Beds Follow procedure c through f of instructions for dumping Aroclor column beds. H. Trouble Shooting Aroclor Stills, Earth Treatment, and Storage Operation Problem Possible Cause & Action 1. Still Vacuum Problems a. Jet not operating properly. Action: Close valve on receiver and be sure the jet will pull down. Check steam pressure to the jet, check vacuum lines for leaks, or , plugs, and check the jet for pluggage. Notify chief operator repairs are necessary. b. Plugged condenser. Action: Put steam or flame heat on the condenser to unplug. c. Leaks in the system. Action: Apply full vacuum to the jet. Check out the piping system, the still, still pump, and the receiver for leaks. DSW 334605 STLCOPCB4081075 Detailed Instructions Aroclors Problem 1. Still Vacuum (Contd.) 2. Holes or plugs of still coils 3. Plugged Lines 118. Possible Cause & Action d. Minor jet problems Action: Water to the intercondenser must be adjusted properly. Steam to the jet must be constant. Nozzles in the jet must be in good condition. a. Coils occasionally wear until a hole comes in the coil from heat ing and age. Black smoke in the furnace, or out the furnace stack indicates Aroclor is burning. Action: If the leak is minor continue operation until the still is finished. Notify the chief operator repairs are necessary. b. Running down in the still at the end of a distillation, failure of the pump, or excess heating of a coil can cause a coil to plug. Action: Check the pump ammeter to see how many amps are required. (Normal 25-30 amps). A higher reading would indicate the coil is plugging. Cut the fire off of the furnace immediately, check the inlet and outlet coil temperature to determine if coil has overheated. Notify the chief operator if the coil must be changed out. a. The still residue will plug lines, still coils, and pumps when it is not kept hot. Action: Check to be sure steam or hot Aroclor is on the pipe line. If not put steam on and give it time to heat up the line. Check pipe lines and valves for exposed areas not steam traced or insulated. Use CO2 and try to blow the line out. Use a gas torch flame to heat the valve or pipe line. DSW 334606 STLCOPCB4081076 Detailed Instructions Aroclors Problem 4. Off-Color Aroclor on a Still 5. High Moisture in Aroclor 6. Bad Electrical Property Problem in Aroclor Possible Cause & Action 119. a. Rapid or too fast a heat-up on a still. Action: Decrease fire and stop dis tillate, then increase temperature slowly to give good color Aroclor (normally 10 on 1242). b. Rapid surges in the vacuum system can cause material to burp over. Action: Check vacuum control - adjust to give good control. Notify chief operator if repairs are necessary. c. Rundown on a still can cause carry over of high color material at end of a distillation. Action: Watch temperature spread on rundown. Do not exceed final tem perature on a distillation. Do not let temperature spread exceed 15 C. a. Moisture above 50 ppm is too high in finished Aroclors. Normally material must be 20 to 25 ppm to be loaded in specification, since moisture is picked up during loading. Action: Start sampling to determine where the moisture is being obtained. It may be necessary to run a pressure test on tank coils to determine the problem. Notify the chief operator as soon as material out of specifi cation is found. a. Resistivity and stability of the Aroclors are very critical in this quality product. Material must be loaded at a 500 resistivity minimum to be in specification. Since the electrical property drops during loading, it should be 700-800 when loaded. If material is low in the storage tank it is transferred back to the blending tank for earth treat ment, laboratory check, and then loaded to a car. qS'N M`607 STLCOPCB4081077 Detailed Instructions Aroclors 120. Problem 7. Still Receiver Transfer Pump Problems Possible Cause & Action a. Transfer pump will not pump the receiver out under vacuum. Action: Check the lines to be sure the valves are set correctly. Check lines at bottom of the receiver to be sure they are not plugged. If necessary to pump out, shut off vacuum on the still and transfer the receiver. Notify the chief operator that the pump, relief valve, or the pipe lines need work. IV. COMMENTS ON PROCESS Vacuum problems on the stills are usually due to flashing of product over, plugged vacuum lines, leaks in the still system, leaks at pump packing, water adjustment on intercondenser on jets, changes in steam pressure to the jets, or problems in the jet nozzles. Flashing can be stopped by adjusting the cooling water on the condenser or operation of the still at a slower rate. Vacuum trouble must be traced systemati cally from the jet, to the receiver, and then to the still. Export Quality & Quantity At present. Export grade 1242 and 1254 have tighter specs resistivity and Biphenyl content. The resistivity target is 10,000 giga ohm cms in drums which means a department spec of at least 15,000 will be needed to assure this spec. Although demand for export grade 1242 and 1254 has increased over 1966, it is still a small portion of the overall sales. This means the Porocel column, will be operated on a part time basis to meet the demand. Interference with Normal Still Operation The necessity of using No. 3 Filtrate tank as an intermediate storage tank will cause problems with the normal operation of the No. 2 still. Export grade Aroclor will be drummed from the No. 3 Filtrate tank when ever No. 5 storage tank contains regular electrical grade 1242 (No. 6 storage tank applies to 1254). With two Filtrate Receivers servicing three stills the Filtrate Receivers will be the bottleneck and will cause downtime on the three stills. DSW 334608 STLCOPCB4081078 Detailed Instructions Aroclors - 121. Column Feed Pump - Item 693 The column feed pump is a Viking positive displacement pump. To prevent over-pressurizing the lines and equipment, the pump is equipped with an internal pressure relief system. It is set at psig. * Porocel Column Pressure Relief The Porocel column is provided with a rupture disc to prevent damage from over-pressurization. The disc rating is psig, at F. Changing Product Whenever a product change from 1242 to 1254 or vice versa is needed, the Porocel bed must be dumped to prevent product contamination. DSW 334609 STLCOPCB4081079 APPENDIX I Montar No. 1 - Aroclor 1242 Still Bottoms Montar No. 2 - Aroclor 1248 Still Bottoms Montar No. 3 - Aroclor 1254 Still Bottoms Montar No. A - Aroclor 1260 Still Bottoms Montar No. 5 - Aroclor 5460 Still Bottoms Montar No. 6 - Aroclor 4465 Still Bottoms Montar No. 7 - Aroclor 1268 Still Bottoms Montar No. 9 - Santowax Still Bottoms Montar No. 10 - 50% Montar 5, 50% Montar 9 There is no Montar numbered 8 dSnN 3346^0 STLCOPCB4081080 NO* 1, 2 & 3 AROCLOR STILLS AROCLOR 1121 % Scale 0 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 26 27 28 29 30 31 Gallons 202 219 235 251 268 284 * 301 317 334 350 367 383 400 416 432 449 465 482 498 515 531 548 564 581 597 614 630 646 663 679 696 712 Outage (Ins.) 78.0 77.1 76.1 75.2 74.3 73.3 72.4 71.5 70.5 69.6 68.7 67.7 66.8 65.8 64.9 64.0 63.0 62.1 61.2 60.2 59.3 58.4 57.4 56.5 55.6 54.6 53.7 52.8 51.8 50.9 50.0 49.0 * ' % Scale 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 Gallons 729 745 762 778 795 811 827 844 860 877 893 910 926 943 959 976 992 1,008 1,025 1,041 1,058 1,074 1,091 1,107 1,124 1,140 1,157 1,173 1,190 1,206 1,223 1,239 Outage (Ins.) 48.1 47.1 46.2 45.3 44.3 43.4 42.5 41.5 40.6 39.7 38.7 37.8 36.9 35.9 35.0 34.1 33.1 32.2 31.3 30.3 29.4 28.4 27.5 26.6 25.6 24.7 23.8 22.8 21.9 21.0 20.0 19.1 Aroclor 1121 Sp. Gr. 1.070 @ 150C (1.155 @ 65C) Inst. Range - 0-100" H2O Inst. Scale - 0-100% STLCOPCB4081081 7. Scale 0 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 26 27 28 29 30 31. 32 33 34 35 36 37 Gallons 202'. 216 230 244 258 272 285 299 313 327 341 355 369 383 397 411 424 438 452 466 480 494 508 522 536 550 563 577 591 605 619 633 647 661 ' 675 689 702 716 NO. 1, 2 & 3 AROCLOR STILLS AROCLOR 1142 Outage (Inches) 7o Scale 78.0 77.2 76.4 75.6 74.8 74.0 73.2 72.4 71.6 70.8 70.0 69.2 68.4 67.6 66.8 66.0 65.2 64.4 63.6 62.8 62.0 61.2 60.4 59.6 58.8 58.0 57.2 56.4 55.6 54.8 54.0 53.2 52.4 51.6 50.8 50.0 49.2 48.4 ' 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 Aroclor 11421 Sp.Gr. 1.264i @ 150C (1 .389 Q 25C) Inst. Range 0-100" H20 Inst. Scale 0-1007. Gallons 730 744 758 772 786 800 814 828 841 855 869 883 897 911 925 939 953 967 980 994 1,008 1,022 1,036 1,050 1,064 1,078 1,092 1,106 1,119 1,133 1,147 1,161 1,175 1,189 1,203 1,217 1,231 Outage (Inches) 47.6 46.8 46.0 45.2 44.4 43.6 42.8 42.0 41.2 40.4 39.6 38.8 38.0 37.2 36.4 35.6 34.8 34.0 33.2 32,4 31.6 30.8 30.0 29.2 28.4 27.6 26.8 26.0 25.2 24.4 23.6 22.8 22.0 21.2 20.4 19.6 19.0 DSW 334612 STLCOPCB4081082 NO. 1, 2 & 3 AROCLOR STILLS % Scale Gallons Outage (Inches) AROCLOR 1148 . % Scale Gallons 0 202 78.0 1 215 77.3 2 228 76.5 3 242 75.8' 4 255 75.0 5 268 74.3 6 281 73.5 7 294 72.8 8 308 72.0 9 321 71.3 10 334 70.5 11 347 69.8 12 360 69.0 13 374 68.3 14 387 67.5 15 400 66.8 16 413 66.0 17 426 65.3 18 440 64.5 19 453 63.8 20 466 63.0 21 479 62.3 22 492 61.5 23 506 60.8 24 519 60.0 25 532 59.3 26 545 58.5 27 558 57.8 28 572 . 57.0 29 585 56.3 30 598 55.5 31 611 54.8 32 624 54.0 33 638 53.3 34 651 52.5 35 664 51.8 36 672 51.0 37 690 50.3 38 704 49.5 39 717 48.8 40 41 42 43 44 45 46 47 48 49 50 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 76 77 78 730 743 756 770 783 796 809 822 836 849 862 875 888 902 915 928 941 954 968 981 994 1,007 1,020 1,034 1,047 1,060 1,073 1,086 1,100 1,113 1,126 1,139 1,152 1,166 1,179 1,192 1,205 1,218 1,232 Outage (Inches) 48.0 47.3 46.5 45.8 45.0 44.3 43.5 42.8 42.0 41.3 40.5 39.8 39.0 38.3 37.5 36.8 36.0 35.3 34.5 33.8 33.0 32.3 31.5 30.8 30.0 29.3 28.5 27.8 27.0 26.3 25.5 24.8 24.0 23.3 22.5 21.8 21.0 20.3 19.5 Aroclor 1148 Sp.Gr. 1.330 <a 150C (1.415 @ 65C) Inst. Range 0-100" H2O Inst. Scale 0-100% DSW 334613 STLCOPCB4081083 % Scale 0 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 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Gallons 202 214 227 239 252 264 276 289 301 314 326 338 351 363 376 388 400 413 425 438 450 462 475 487 500 512 524 537 549 562 574 586 599 611 624 636 648 661 673 686 698 710 723 NO. 1, 2 & 3 AROCLOR STILLS Outage (Inches) AROCLOR 1154 % Scale Gallons 78.0 77.3 76.6 75.9 75.2 74.5 73.8 73.1 72.4 71.7 71.0 70.3 69.6 68.9 68.2 67.5 66.8 66.1 65.4 64.7 64.0 63.3 62.6 61.9 61.2 60.5 59.8 59.1 58.4 57.7 57.0 56.3 55.6 54.9 54.2 53.5 52.8 52.1 51.4 50.7 50.0 49.3 48.6 43 44 45 46 47 48 49 50 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 76 77 78 79 80 81 82 . 83 ' 735 748 760 772 785 797 810 822 834 847 859 872 884 896 909 921 934 946 958 971 983 996 1,008 1,020 1,033 1,045 1,058 1,070 1,082 1,095 1,107 1,120 1,132 1,144 1,157 1,169 1,182 1,194 1,206 1,219 1,231 Outage (Inches) 47.9 47.2 46.5 45.8 45.1 44.4 43.7 43.0 42.3 41.6 40.9 40.2 39.5 38.8 38.1 37.4 36.7 36.0 35.3 34.6 33.9 33.2 32.5 31.8 31.1 30.4 29.7 29.0 28.3 27.6 26.9 26.2 25.5 24.8 24.1 23.4 22.7 22.0 21.3 20.6 19.9 Aroclor 1154 Sp. Gr. 1.415 @ 150C (1.505 @ 65C) Inst. Range - 0-100" H2O Inst. Scale - 0-100% ' DSW 334614 STLCOPCB4081084 NO. 1, 2 & 3 AROCLOR STILL % Scale Gallons Outage finches) AROCLOR 1160 % Scale 0 202 78.0 1 213 ' 77.4 2 224 76.8 3 235 76.1 4 246 75.5 5 257 74.9 6 268 74.3 ' 7 279 73.6 8 290 73.0 9 301 72.4 10 312 71.8 11 323 71.4 12 334 70.5 13 345 69.9 14 356 69.3 15 367 68.7 16 378 68.0 17 389 67.4 18 400 66.8 19 411 66.2 20 422 65.5 21 433 64.9 22 444 64.3 23 . 455 63.7 24 466 63.0 25 477 62.4 26 488 61.8 27 499 61.2 28 510 60.6 29 521 59.9 30 532 59.3 31 543 58.7 32 554 58.1 33 565 57.4 34 576 56.8 35 587 56.2 36 598 55.6 37 609 54.9 38 620 54.3 39 631 53.7 40 642 53.1 41 653 52.5 42 664 51.8 43 675 51.2 44 686 50.6 45 697 50.0 46 708 49.3 Aroclor 1160 Sp.Gr. 1.504 @ 150C (1.564 @ 90C) Inst. Range - 0-100" h2o Inst. Scale - 0-100% 47 : J48 49 50 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 76 77 78 79 80 81 ' 82 83 84 85 86 87 88 89 90 91 92 93 94 Gallons 719 730 741 752 763 774 785 796 807 818 829 840 851 862 873 884 895 906 917 928 939 950 961 972 983 994 1,005 1,016 1,027 1,038 1,049 1,060 1,071 1,082 1,093 1,104 1,115 1,126 1,137 1,148 1,159 1,170 1,181 1,192 1,203 1,214 1,225 1,236 Outage (Inches) 48.7 48.1 47.5 46.9 46.2 45.6 45.0 44.4 43.7 43.1 42.5 41.9 42.2 40.6 40.0 39.4 38.8 38.1 37.5 36.9 36.3 35.6 35.0 34.4 33.8 33.1 32.5 31.9 31.3 30.7 30.0 29.4 28.8 28.2 27.5 26.9 26.3 25.7 25.0 24.4 23.8 23.2 22.6 21.9 21.3 20.7 20.1 19.4 STLCOPCB4081085 % Scale 0 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 26 27 28 29 30 Gallons 202 214 225 237 248 260 271 283 294 306 318 329 341 352 364 375 387 398 410 422 433 445 456 468 479 491 503 514 526 537 549 Outage Inches 78.0 77.3 76.7 76.0 75.4 74.7 74.1 73.4 72.7 72.1 71.4 70.8 70.1 69.5 68.8 68.1 67.5 66.8 66.2 65.5 64.9 54.2 63.5 62.9 62.2 61.6 60.9 60.3 59.6 59.0 58.3 NO. 1, 2 & 3 AROCLOR STILLS AROCLOR 1162 % Scale Gallons Outage Inches 31 32 33 34" 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 560 572 584 595607 618 630 641 653 664 676 688 699 711 722 734 745 757 768, 780 792 803 815 826 838 849 861 872 884 896 907 57.6 57.0 56.3 55.7 55.0 54.3 53.7 53.0 52.4 51.7 51.1 50.4 49.7 49.1 48.4 47.8 47.1 46.5 45.8 45.2 44.5 43.8 43.2 42.5 41.9 41.2 40.6 39.9 39.2 38.6 37.9 % Scale 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 Gallons 919 930 942 953 965 976 988 1,000 1,011 1,023 1,034 1,046 1,057 1,069 1,081 1,092 1,104 1,115 1,127 1,138 1,150 1,161 1,173 1,185 1,196 1,208 1,219 1,231 Outage Inches 37.3 36.6 36.0 35.3 34.6 34.0 33.3 32.7 32.0 31.4 30.7 30.0 29.4 28.7 28.1 27.4 26.8 26.1 25.4 24.8 24.1 23.5 22.8 22.2 21.5 20.8 20.2 19.5 Aroclor 1162 Sp. Gr. 1.522 @ 150C (1.582 @ 90C) Inst. Range - 0-100" 1^0 Inst. Scale - 0-100% DSW 334616 STLCOPCB4081086 BLENDING TANK & FILTRATE RECEIVER AROCLOR 1221 % Scale 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Gallons 189 234 279 325 370 415 460 505 551 596 641 686 731 777 822 867 912 957 1,003 1,048 1,093 1,138 Outage (Ins.) % Scale 94.0 92.1 90.2 88.4 86.5 84.6 82.7 80.8 78.9 77.1 75.2 73.3 71.4 69.5 67.6 65.8 6j3.9 62.0 60.1 58.2 56.3 54.5 ` 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 Gallons 1,183 1,229 1,274 1,319 1,364 1,409 1,455 1,500 1,545 1,590 1,635 1,680 1,726 1,771 1,816 1,861 1,906 1,952 1,997 2,042 2,087 2,132 Outage (Ins.) 52.6 50.7 48.8 46.9 45.0 43.2 41.3 39.4 37.5 35.6 33.7 31.9 30.0 28.1 26.2 24.3 22.4 20.6 18.7 16.8 14.9 13.0 Aroclor 1221 Sp. Gr. 1.062 <a 150C (1.187 @ 25oc) Inst. Range - 0-200" H2O Inst. Scale - 0-100% DSW 334617 STLCOPCB4081087 BLENDING TANK & FILTRATE RECEIVER AROCLOR 1242 % Scale 0 1 2 3 A 5 6 7 8 9 10 11 12 13 1A 15 16 17 18 19 20 21 22 23 2A Gallons 189 227 265 303 3A1 379 A17, A55 A93 531 569 607 6A5 68A 722 760 798 836 87A 912 950 988 1,026 1,06A 1,102 Outage (Ins.) 94.0 92.4 90.8 89.2 87.7 86.1 8A.5 82.9 81.3 79.7 78.2 76.6 75.0 73.A 71.8 70.2 68.6 67.1 65.5 63.9 62.3 60.7 59.1 57.5 56.0 % Scale 25 26 27 28 29 30 31 32 33 3A 35 36 37 38 39 A0 A1 A2 A3 AA A5 46 A7 A8 A9 50 51 Gallons 1,1A0 1,178 1,216 1,254 1,292 1,330 1,368 1,406 1,AAA 1,482 1,520 1,558 1,596 1,634 1,672 1,710 1,748 1,786 1,825 1,863 1,901 1,939 1,977 2,015 2,053 2,091 2,129 Outage (Ins.) 54.4 52.8 51.2 49.6 48,0 46.5 44.9 43.3 41.7 40.1 38.5 36.9 35.4 33.8 32.2 30.6 29.0 27.4 25.9 24.3 22.7 21.1 19.5 17.9 16.3 14.8 13.2 Aroclor 1242 Sp. Gr. 1.262 @ 150C (1.387 @ 25C) Inst. Range - 0-200" H2O Inst. Scale - 0-100% DSW 334618 STLCOPCB4081088 % Scale 0 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 26 27 BLENDING TANK & FILTRATE RECEIVER Gallons 189 225 262 298 334 370 406 443 479 515 551 587 624 660 696 732 769 805 841 877 914 950 986 1,022 1,058 1,095 1,131 1,167 AROCLOR 1248 Outage (Ins.) Jo Scale 94.0 92.5 91.0 89.5 88.0 86.5 84.9 83.4 81.9 80.4 78.9 77.4 75.9 74.4 72.9 71.4 69.8 68.3 66.8 65.3 63.8 62.3 60.8 59.3 57.8 56.3 54.8 53.3 28 29 30 ' 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 . 46 47 48 49 50 51 52 53 54 Gallons 1,203 1,240 1,276 1,312 1,348 1,384 1,421 1,457 1,493 1,529 1,566 1,602 1,638 1,674 1,710 1,747 1,783 1,819 1,855 1,892 1,928 1,964 2,000 2,037 2,073 2,109 2,145 Outage (Ins.) 51.7 50.2 48.7 47.2 45.7 44.2 42.7 41.2 39.7 38.2 36.6 35.1 33.6 32.1 30.6 29.1 27.6 26.1 24.6 23.1 21.6 20.0 18.5 17.0 15.5 14.0 12.5 Aroclor 1248 Sp. Gr. 1.325 <a 150C (1.410 @ 65C) Inst. Range - 0-200" H2O Inst. Range - 0-100% DSW 334619 STLCOPCB4081089 BLENDING TANK & FILTRATE RECEIVER AROCLOR 1254 7. Scale 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 is 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 Gallons 189 223 257 291 325 359 393 427 460 494 528 562 596 630 664 698 732 766 800 834 867 901 935 969 1,003 1,037 1,071 1,105 1,139 1,173 1,207 . Outage (Ins.) 94.0 92.6 91.'2 89.8 88.3 86.9 85.5 84.1 82.7 81.3 79.9 78.5 77.0 75.6 74.2 72.8 71.4 70.0 68.6 67.1 65.7 64.3 62.9 61.5 60.1 58.7 57.3 55.8 54.4 53.0 51.6 _ 7o Scale 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 Gallons 1,241 1,275 1,308 1,342 1,376 .1,410 1,444 1,478 1,512 1,546 1,580 1,614 1,648 1,682 1,716 1,749 1,783 1,817 1,851 1,885 1,919 1,953 1,987 2,021 2,055 2,089 2,122 2,156 Outage (Ins.) 50.2 48.8 47.4 45.9 44.5 43.1 41.7 40.3 38.9 37.5 36.1 34.6 33.2 31.8 30.4 29.0 27.6 26.2 24.7 23.3 21.9 20.5 19.1 17.7 16.3 14.8 13.4 12.0 Aroclor 1254 Sp. Gr. 1.415 @ 150C (1.500 <a 65C) Inst. Range - 0-200" H2O Inst. Scale - 0-1007. DSW 334620 STLCOPCB4081090 BLENDING TANK & FILTRATE RECEIVER AROCLOR 1260 % Scale 0 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 26 27 28 29 30 31 Gallons 189 221 253 285 317 349 381 413 445 477 509 541 573 605 637 669 701 733 765 797 829 861 893 925 957 989 1,020 1,052 1,084 1,116 1,148 1,180 Outage (Ins.) 94.0 92.7 91.'3 90.0 88.7 87.3 86.0 84.7 83.3 82.0 80.7 79.3 78.0 76.7 75.3 74.0 72.7 71.3 70.0 68.7 67.4 66.0 64.7 63.4 62.0 60.7 59.4 58.0 56.7 55.4 54.0 52.7 . * % Scale 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 Gallons Outage (Ins.) 1,212 1,244 1,276 1,308 1,340 1,372 1,404 1,436 1,468 1,500 1,532 1,564 1,596 1,628 1,660 1,692 1,724 1,756 1,788 1,820 1,852 1,884 1,916 1,948 1,980 2,012 2,044 2,076 2,108 2,140 51.4 50.0 48.7 47.4 46.0 44.7 43.4 42.0 40.7 39.4 38.0 36.7 35.4 34.0 32.7 31.4 30.0 28.7 27.4 ' 26.0 24.7 23.4 22.1 20.7 19.4 18.1 16.7 15.4 14.1 12.7 Aroclor 1260 Sp Gr 1.501 @ 150C (1.561 <a 90C) Inst. Range - 0-200" 1^0 Inst. Scale - 0-100% - DS 3*1621 STLCOPCB4081091 BLENDING TANK & FILTRATE RECEIVERS AROCLOR 1262 % Scale 0 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 26 27 28 29 30 31 32 Gallons 189 221 252 284 316 347 379 410 442 474 505 537 568 601 632 663 695 727 758 790 821 853 885 916 948 980 1,011 1,042 1,074 1,106 1,138 1,169 1,201 Outage (Ins.) 94.0 92,7 91.4 90.0 88.7 87.4 86.1 84.8 83.5 82.1 80.8 79.5 78.2 76.8 75.6 74.2 72.9 71.6 70.3 69.0 67.7 66.3 65.0 63.7 62.4 61.1 59.7 58.4 57.1 55.8 54.5 53.2 51.8 ` . % Scale 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 Gallons 1,233 1,264 1,296 1,327 1,359 1,391 1,422 1,454 1,485 1,517 1,549 1,580 1,612 1,644 1,675 1,707 1,738 1,770 1,802 1,833 1,865 1,896 1,928 1,960 1,991 2,023 2,055 2,086 2,118 2,149 . Outage (Ins.) 50.5 49.2 47.9 46.6 45.3 43.9 42.6 41.3 40.0 38.7 37.4 36.0 34.7 33.4 32.1 30.8 29.4 28.1 26.8 25.5 24.2 22.9 21.5 20.2 18.9 17.6 16.3 15.0 13.6 12.3 Aroclor 1262 Sp.Gr. 1.518 @ 150C (1.578 @ 90C) Inst. Range - 0-200" H2O Inst. Scale - 0-100% SW 334622 STLCOPCB4081092 STANDARD OPERATING INSTRUCTIONS FOR AROCLORS 122 PROCESS FUNCTION OUTLINE C. I. SOLID KC1 OFF-GAS CLEAN-UP 1.1 Scope This covers the start-up, shutdown, and normal operation of the Solid HC1 Off-Gas Clean-Up System involving No. 9 Chlorinator. 1.2 Description of Process HC1 gas produced on the No. 9 chlorinator system passes through a Solids off-gas condenser which cools the gas to knock out the Santowax and Solid Aroclor vapors. The gas then flows through a catch tank, combines with the gas from the Liquid system and flows to the Muriatic Acid absorber. A Therminol (1248 Aroclor) cooling system is circulated through the tube side of the off-gas condenser to cool the HC1 gases. Material collected in the catch tank is returned to the weigh tank for other chlorinator charges. II. PROCESS DIAGRAM Attached. III. OPERATION OF PROCESS 3.1 Start-Up ' 1. Open valves in heated air purge system and the pressure indicating instruments on the Solids knock-out tank and the HC1 gas line to the Muriatic Acid absorber. 2. Open the valves in the heated air purge for the level instrument in the Solids knock-out tank. 3. Set the therminol temperature recording controller in automatic with the set point at 80C. 4. Set the Solids knock-out tank temperature indicating controller in automatic with the set point at 110C. DSW 334623 STLCOPCB4081093 Detailed Instructions Aroclors 123. . 5. Set valves to allow circulation of the therminol system from the therminol surge tank to the circulating pump through the tube side of the Solids off-gas condenser, through the air cooled off-gas condenser, and back to the therminol surge tank. 6. Open manual valves to*allow circulation of therminol heat through the jacket on the Solids knock-out tank. 7. Check to be sure the valves on bottom of the Solids knock out tank are closed. 8. Set manual valves to allow HC1 gas to flow through the Solids off-gas condenser, through the Solids knock-out tank, and to the Muriatic Acid absorber. 9. This system should now be in automatic control. Checking of the pressure across the condenser will indicate plugging if it should occur. 10. When approximately 3" is showing on level gauge, open manual valves at the bottom of the Solids knock-out tank before pumping a charge to weigh tank, to allow collected material to drain into the weigh tank. Material accumulated in the Solids knock-out tank will be recycled through the chlorinator system for re-use. (The knock-out tank should be drained when approximately 3" is showing on the level gauge.) 3.2 Shutdown 1. Open manual valve to direct HC1 gas to the drowning jet at the Muriatic Acid Department. . 2. Close the manual valve to isolate the HC1 gas clean-up system. It is possible to by-pass the off-gas condenser in the HC1 clean-up system and still have the HC1 gas pass through the Solids knock-out tank. 3. The therminol heat system on the tube side of the off-gas condenser can be shut down by stopping the circulating pump. A. The system is now shut down and can be worked on if necessary. It may be necessary to shut down No. 9 chlorinator, dependent upon repairs to be made. DsW 334624 STLCOPCB4081094 Detailed Instructions Aroclors .124 3.3 Instruments 1. Therminol Circulating System Temperature Control - TRC 577.01 The temperature in the therminol circulating system for the off-gas condenser in the Solids clean-up system is controlled by sensing the temperature in the surge tank and controlling the louvers on the air cooled off-gas condenser and the con trol valve in the line from the coil in the surge tank. The instrument will be in automatic with the set point at 80C. 2. Solids Knock-Out Tank Temperature Controller - TIC 581.01 The temperature in the Solids knock-out tank is controlled by sensing the temperature of the material in the tank and throttling the control valve on the discharge line from the tank jacket. The controller is in automatic with the set point at 110 C. 3. Solids Knock-Out Tank Level Indicator - LI 581.06 . The Solids knock-out tank has a level indicator with a range of 0-30" Hg indicating the level in the tank. IV. COMMENTS 1. Plugging of the Solids off-gas condenser in the Solids clean-up system can occur. To unplug the off-gas condenser the temperature of the therminol system will be elevated as required. It will probably require a temperature of 160 - 170C. During this time, the off-gas condenser will be by-passed. 2. The Solids knock-out tank is provided with a drain system to empty the tank completely when products are to be changed on the No. 9 chlorinator. This will eliminate contamination in the weigh tank, 3. Any material collected in the Solids knock-out tank from Aroclor produced while using Biphenyl is discarded. DSW 334625 STLCOPCB4081095 STANDARD OPERATING INSTRUCTIONS . FOR AROCLORS PROCESS FUNCTION OUTLINE 125. C. I. LIQUID HC1 OFF-GAS CLEAN-UP . . 1.1 Scone ' This covers the start-up, shutdown, and normal operation of the Liquid HC1 Off-Gas Clean-Up System. 1.2 Description of Process HC1 gas from the Liquid chlorinators is directed through the off-gas condenser into the Liquids collection tank, out the demister, combines with gas from the Solids system, and flows . to the Muriatic Acid absorber. The gas is cooled to knock out Aroclor and Biphenyl vapors. It passes through the Liquids collection tank and a demister which returns collected liquid to the Liquids collection tank as the gas flows on to the . Muriatic Acid absorber. The HC1 gas can also be turned into the drowning jet in the Muriatic Acid area without passing through the clean-up system. II. PROCESS DIAGRAM Attached. III. OPERATION OF PROCESS . ' 3.1 Start-Up 1. Start air purges flowing on the pressure recording alarm to the off-gas condenser, the level indicator on the Liquids collection tank, and the pressure recording instruments across the demister. 2. Open the steam valves to the coil in the Liquids collection tank and set the temperature indicating controller TIC-573.01 in automatic with the set point at 50C. 3. Set the tempered water controller in automatic with the set point at 40C. 4. Open all tower water valves to flood the circulating water system on the tube side of the off-gas condenser. DSW 334626 STLCOPCB4081096 Detailed Instructions Aroclors 126. 5. Start the tempered water circulating pump. 6. Open the manual steam valve to the water mixer. 7. Open all plug valves to permit water circulation through the off-gas condenser* and to the water return system. 8. Open manual valves to direct HC1 gas from the chlorinator headers into the off-gas condenser, to the Liquids collection tank, and out the demister to the Muriatic Acid absorber. The HC1 gas leaving the clean-up system should be 99% free of Biphenyl and Aroclor vapors. 9. Trappings accumulated in the Liquids collection tank will be used in the batch chlorinators frl through #4 to make Aroclor 1148 or 1162 only. The material can be pumped from the Liquid collection tank to the existing Biphenyl charge tank (melt tank) by setting the manual valves and starting the pump. Material collected in the Liquids collection tank can also be pumped to drums or a Dempster-Dumpster skip for dis carding if the tank should become too full. This will only be done as a last resort. 3.2 Shutdown 1. Open manual valves to direct HC1 gas to the drowning jet system. 2. Close manual valves to isolate HG1 clean-up system from routine flow. 3. Stop the tempered water circulating pump. 4. If necessary for a complete shutdown, close the manual valves for water arid steam to the off-gas condenser. 5. Drain the water out of the off-gas condenser to prevent freezing during cold weather. 3.3 Instruments 1. Tempered Mater System - TRC 549.01 This control loop maintains the temperature of the water circulating through the HC1 off-gas condenser at 40C. This is accomplished by sensing the temperature in the tempered water circulating pump discharge line and regulating the con trol valves in the steam and water supply lines to the pump suction. DSW 334627 STLCOPCB4081097 Detailed Instructions Aroclors 127. 2. Liquid Collection Tank Level Instrument - LI 573.04 The level in the Liquids collection tank is indicated by a bubbler differential pressure indicator. Range of the in strument is 0-30" Hg indicating the level in the tank. This system has a heated air purge to keep the dip lines open. 3. Demister Differential Pressure - PR 376.01 Pressure recorders indicate the pressure drop across the demister. This is a recording pressure instrument to indicate plugging of the demister. 4. Liquids Collection Tank Temperature Control - TIC 373.01 Temperature in the Liquids collection tank is controlled by a sensing element in the tank operating the control valve in the steam line to the coil in the tank. 5. Liquids Collection Tank Relief System - RD 573.05 An emergency relief system is provided on the Liquids collection tank to relieve excessive pressure through a rupture disc at 20 psig. 6. HC1 High Pressure Alarm - PRA 549.05 HC1 gas pressure to-the off-gas condenser is sensed by a purged dp cell. It will record the KC1 feed pressure to the off-gas condenser and sound an alarm at 5 psig. IV. COMMENTS A. It is extremely important that the tempered water system be drained during excessive cold weather if it is shut down. The bottom head on the KC1 off-gas condenser has drain valves at two locations. Both of these drain valves must be open to remove water from the off-gas condenser when the system is shut down. B. The demister on top of the Liquids collection tank is used as a final knock-out for Aroclor and Biphenyl entrained droplets in the KC1 gas system. Usually this system will be operating with the steam tracing around the outer shell shut off. When the steam tracing is turned on it will allow vapors to be carried through the demister to the Muriatic Acid absorber. The sight glass on the discharge of the demister can be checked to determine if en trained droplets are being carried over. The steam is installed for use to unplug the demister in case this should occur. DSW 334628 STLCOPCB4081098 Detailed Instructions Aroclors 128. C. At the present, the trappings from this clean-up system will be used to produce Aroclor 1148 and 1162 only. The reason for this is to be sure that we do not produce any unstable electrical grade Aroclors. The Liquids collection tank will hold 5,000 gallons of trappings which should last 15-30 days. D. In case the problems with the clean-up system, HC1 gas must be directed to the drowning tower. This can be done in case the off-gas condenser or demister should become plugged. The pressure recording instruments across the demister should in dicate an increase in HC1 gas pressure if this occurs. The HC1 gas pressure to the off-gas condenser will sound an alarm at 5 psig to indicate an excessive pressure in the system. DSW 334629 STLCOPCB4081099 STANDARD OPERATING INSTRUCTIONS FOR ' AROCLORS 129. PROCESS FUNCTION OUTLINE C. I. LOADING OF REFUTED AROCLORS - 1.1 Scope This covers loading of Refined Aroclors into tank cars and trucks and packaging of cans, drums, and bags. 1.2 Description of Process Refined Liquid Aroclors are collected in storage tanks or filtrate tanks. A representative sample of all Aroclors from storage tank or filtrate tank is analyzed by the lab oratory prior to packaging. A final sample of the packaged material is analyzed by the laboratory prior to shipment or storage. . Refined Solid Aroclors are collected in the flaker hold tank for packaging or they may be drawn directly from the still receiver or a blow tank into appropriate drums. All Solid Aroclors are also analyzed by the laboratory prior to shipment. Some Solid Aroclors and Montars (Aroclor Still Residue) are crushed, screened, or milled prior to packing for shipment. II. PROCESS DIAGRAM Does not apply. III. DESCRIPTION OF PROCESS 3.1 Loading of Liquid Aroclor Cars or Trucks Aroclors are shipped in 4,000, 7,000, and 8,000 gallon tank cars; and 3,000 or 4,000 gallon tank trucks to customers. A. Spotting Tank Cars Normally the railroad switch crew will spot cars at the Aroclor loading dock. Occasionally, it will be necessary to move a car. When this is necessary, use the track mobile to put the car into position. DSW 334630 STLCOPCB4081100 i Detailed Instructions Aroclors 130. 1. Obtain help to move car. 2. Get track mobile from storage area, normally old hydrogen compressor room and place on railroad track near car to be spotted. ' 3. Move chocks from car wheels. 4. Release the brakes on the car. 5. Connect track mobile to car to be moved. 6. Move car to desired location. 7. Put brakes on car. 8. Put wheel chocks in place. 9. Disconnect track mobile from car. 10. Remove track mobile to storage area. B. Filling Tank Cars or Trucks Aroclors are shipped in lined vessels to protect the electrical properties from contamination. Most vessels are lined with aluminum or a zinc-tin lining. 1. -Inspection of car or truck for loading: a. Enter each car or truck for inspection prior to loading. If necessary clean out the vessel. All material in the tank should be removed. Car should be wiped out using lint-free rags. Damaged lining areas should be cleaned of any rust particles. Report damaged areas or comments on inspection form. b. Use an approved tank entering and fire permit when entering a car or truck. Observe safety rules for each permit, c. A fellow worker must be on top of the car or truck holding the rope harness. Uear the safety belt harness, an air mask, gas test the car, and use a low voltage, explosion-proof light when entering a tank car or truck. DSW 334631 STLCOPCB4081101 Detailed Instructions Aroclors 131. C. Preparation for Loading of Car or Truck 1. Fill out tank inspection form. 2. Put steam on the car or truck after it is clean. 3. Check to be sure there is enough material in storage tank to load a car or truck as required. (See Appendix III for storage tank calibrations) 4. Circulate the material in the storage tank for two (2) hours, sample the tank, and have the sample checked for loading by the laboratory. If material is in speci fication, proceed with loading of the tank. 5. Install diaper cloth sock in the filter in the loading line and place a sock over the end of the loading line extension. 6. Attach extension to the loading line at the dock and place sock end into the dome of the car. 7. Connect ground wire to the car. 8. Set valves in the loading line from the storage tank to the loading dock. Do not open valve in the line at the car. NOTE: Care should be taken to see that the correct valves are set so only the desired Aroclor enters the loading line. D. Loading of Car or Truck 1. Start pump at the storage tank. 2. Open valve in drain line at the loading dock and allow one drum of Aroclor to flow through the line to flush out the loading line. 3. Close valve in the drain line and open valve in the line to the car or truck. Approximately 2-1/2 hours is re quired to load a car. (1-1/2 hours to load a truck.) 4. When the car or truck is loaded, stop the pump and close the valve to the loading line. Fill car or truck one to two feet into the dome. 5. Remove loading line from the car or truck. DSW 334632 STLCOPCB4081102 Detailed Instructions Aroclors 132. 6. Take samples from the car or truck and send to the laboratory for final analysis. (See Appendix II for samples required.) 7. Close and tighten lid on car or truck. 8. Seal car or truck and record seal number and car or truck number in the Aroclor still log book. 3.2 Filling Drums A. Preparation for Filling Liquid Aroclor Drums Liquid Aroclor can be drummed from the storage tank or a filtrate receiver. 1. Send a representative sample (1/2 gallon) of the material to the laboratory to be checked for drumming. If the material to be drummed is in a storage tank it should be circulated for two (2) hours prior to sampling. Material in a filtrate tank need not be circulated, since it is mixed in the blend tank. If the material is in specification proceed with drumming preparation. 2. Check the scales to be used. Set the scales for the weight specified for each drum (See Appendix I). 3. Inspect each drum to be filled for rust and water. A. Install diaper cloth sock on end of the drum-out line. B. Filling Liquid Aroclor Drums 1. Start the pump. 2. Open the valve in the drum-out line and allow approxi mately 5 to 30 gallons of material to flow through the line into a drum to flush out the line. Drumming from a filtrate tank should take 5 gallons of material to flush the line. Drumming from a storage tank should take 30 gallons to flush the line. 3. Fill 5 or 6 drums of material to the specified weight; stencil each drum showing the name of product, lot number, net weight of drum, and the initials of the person doing the drumming. (See Appendix I for drum weights) DSW 334633 STLCOPCB4081103 Detailed Instructions Aroclors 133. 4. Sample these drums with a thief for final lot samples. (See Appendix II for samples required.) 5. Continue drumming the Aroclor when the laboratory gives the final OK that material is in specifications. 6. Be sure to tighten bungs on all drums. 7. Drum material until you have the required quantity of drums. Filled drums are palletized and moved to the loading platform for transfer to the warehouse. C. Preparation For Filling Solid Aroclor Drums Solid Aroclor (5442) is drawn from the..Aroclor' .............' flaker hold tank into steel drums. Solid Aroclor 2565 (undistilled) is drawn from blow tank into steel drums. 1. Send a representative sample (1 pt. can) of the material to the laboratory to be checked for drumming. If the material to be drummed is in the receiver it should be circulated for 10 to 15 minutes prior to sampling. If the material is in the blow tank it should be air blown for.30 minutes prior to sampling. If the material is in specification the sample will be given a lot number. Proceed with drumming preparations. 2. Check the scales to be used. Set the scales for the weight specified for each drum (See Appendix I). 3. Inspect each drum to be filled for rust and water. 4. Install screen on end of the drum-out line. D. Filling Solid Aroclor Drums 1. Open valve on bottom of tank. 2. Open valve in the drum-out line and allow approximately 20 gallons of material to flow through the line into a drum to flush out the line. 3. Stencil each drum showing the name of product, lot number, net weight of drum, and initials of the person doing the drumming. (See Appendix I for drum weights.) 4. Be sure to tighten lids on all drums. 5. Drum material until tank is empty. Filled drums are palletized and moved to the loading platform for transfer to the warehouse. DSW 334634 STLCOPCB4081104 Detailed Instructions Ar odors 134. 3.3 Flaking; Aroclors (Bldg. 27 Flaker - 5060 and 1268) Aroclor 5060 is flaked on a drum flaker and bagged in 50 lbs. or 100 lbs. bags. Aroclor 1268 is flaked and packaged in fibre drums at 200 lbs. net. A representative sample of Aroclor 1268 is taken from .............. the receiver and sent to the laboratory to be checked for flaking. A representative sample of Aroclor 5060 is taken from theblow tank and sent to the laboratory to be checked for flaking. NOTE: Aroclor 5060 must be free of acid before bagging. A. Preparation For Flaking 1. Place Therminol heat on the pipe lines, valves, and flaker hold tank. Observe temperature of the Therminol heater system on the recorder controller on the still control panel - should be 250C. When producing 1268, this temperature is increased to 280C. 2. Pump Aroclor to be flaked into the flaker hold tank. Aroclor 5060 is pumped from the No. 2 Blow Tank to the flaker. Aroclor 1268 and 5460 are flaked from the Flaker Hold Tank. 3. Check level indicator after transfer. 4. Start agitator and continue to agitate until the temperature of the hold tank reaches 220-230C. B. Start-Up of Flaker System 1. Turn on electrical heat in the flaker pan about 20 to 30 minutes before start-up. ' 2. Open valve in water line feed to the flaker drum. 3. Start the flaker drum. Start breaker at discharge of flaker. 4. Open valve at sight glass to start Aroclor feed into the flaker pan. Observe flow in sight glass. Adjust valve to maintain the level in the flaker pan about one inch from the top of the pan. DSW 334635 STLCOPCB4081105 Detailed Instructions Aroclors 135. 5. Observe operation to be sure the drum is picking up the material. 6. After the flaker has run 15 to 20 minutes, notify the chief operator material is in the hopper to be bagged. 7. Continue to flake until the flaker hold tank is empty. C. Shutdown of Flaker 1. Normally the flaker will be run until the hold tank is empty or below 27o on level instrument. 2. Allow the drum to pick up material from the pan until it will no longer contact the hot liquid product. 3. Stop the flaker drum and the breakers. 4. Turn off the electrical heat to the flaker pan. 5. Close the valve in the water line to the flaker drum. 6. Close the valve at the sight glass feed to the pan. D. Bagging Solid Aroclors 1. Check to be sure flaked material is in the hopper under the flaker. 2. Get bags ready for use and stack near the bagging machine. 3. Get a stencil for the bags with name of the product, lot number, net weight of each bag, and the initials of the person doing the bagging. 4. Set up an empty pallet at the bagger for stacking filled bags. . 5. Check the scales to be used. Set the scales for the weight specified for each bag. 6. Open the slide gate valve above the bagger. 7. Stencil each bag per (3) above. Insert the bag on the bagger nozzle. Clamp the bag in position. Be sure the bag support is at the right height. 8. Start the bagger. Fill the bag until is is nearly full. Stop the bagger. 9. Start collecting a l-^qt. composite sample of the flaked material. DSW 334636 STLCOPCB4081106 Detailed Instructions Aroclors 136. 10. Check the weight of each bag to be sure it is correct. Add material or take out as is necessary to get correct weight. Place bags on the' pallet and move to the load ing platform for transfer to the warehouse. 11. Continue to operate the bagger until all the material in the hopper is iri bags. When complete, stop the bagger and put up all items left. 12. Send the composite sample of the flaked material to the laboratory for inspection. . 13. Flaked material may hang up in the hopper. Turn on the electric vibrator for about one minute if this occurs. It may be necessary to remove the plate over the chute from the hopper to the bagger and poke the material into the bagging machine. 14. Occasionally flaked material hangs up in the screw in the bagger and becomes molten. When this occurs stop the bagger and let it cool for 10 minutes and try again. At times the screw must be removed from the bagger and cleaned as follows: a. Tag out the electrical switch. b. Close the slide gate valve above the bagger. c. Remove the back cover on the bagger. d. Remove the bolts on the screw drive pulley. e. Pull the screw out. Clean all molten material off the screw and out of the screw chamber. f. Replace the screw in the bagger. Put the bolts on the drive pulley and replace the back cover on the machine. g. Throw the switch on the electrical starter box and remove the tag-out card. h. Open the slide gate valve above the bagger. i. Start the bagger into operation. 3346^ OS'N STLCOPCB4081107 Detailed Instructions Aroclors 137. 3.4 Crushing; Aroclors Several of the Montars (Aroclor still bottoms or residue) are crushed and repackaged in drums for shipment. A. Preparation For Crushing ' 1. Select drums of material to be crushed. 2. Break the material in the drum by hitting the side of the drum with a hammer. 3. Place new empty drum under the crusher to collect the crushed material. 4. Check scales to be used. B. Operation of Crusher 1. Start the crusher. 2. Feed the material from the drum into the crusher by use of a hand scoop. 3. Start collecting a 1-quart composite sample. 4. Fill the drum to the desired weight (See Appendix I). 5. Stencil the drum with the name of the product, lot number, net weight of each drum, and the initials of the person doing the work. 6. Continue this operation until the required number of drums have been filled. 7. Stop the crusher and clean up the scales, crusher, and surrounding area. 8. Send the composite sample to the laboratory for lot number. 9. All drums filled are palletized and moved to the loading platform for transfer to the warehouse. dS\N 334638 STLCOPCB4081108 Detailed Instructions Aroclors 138. 3.5 Milling Aroclors Aroclor 1268 is the only Aroclor which is sold as a milled product. The material must first be flaked. A. Preparation For Milling 1. Select the drums or bags of material to be milled. 2. Check the scales to be used. . 3. Place a new drum under the milling machine to collect the ground material. 4. Crush the dry ice to be used during milling. This keeps the machine cool and the Aroclor 1268 from clogging up the machine. B. Operation of Mill 1. Start the mill and auger. 2. Fill the bucket with flaked 1268. 3. Blend dry ice with the 1268 and feed it into the hopper over the mill. Use approximately five pounds of dry ice to each 100 pounds of Aroclor 1268 that is milled. 4. Start collectings composite sample of the ground material. 5. Fill the drums to the specified weight (normally 200 lbs. net) . 6. Stencil the drums with the name of the product, lot number, net weight of each drum, and the initials of the person doing the work. 7. Continue this operation until the required number of drums are filled. 8. Stop the milling machine and clean up the scales, the milling machine and the milling area. 9. Send the composite sample to the laboratory for screen test. 10. All drums filled are palletized and moved to the loading platform for transfer to the warehouse. DSW 334639 STLCOPCB4081109 Detailed Instructions Aroclors 139. IV. COMMENTS ON PROCESS . A. All P.efined Liquid Aroclors are stored in aluminum, zinc, or tin lined tanks. B. Tank cars, trucks, and all cans and drums used for Aroclors must be carefully inspected for rust, water, and foreign particles prior to filling. C. Every precaution must be taken when collecting Aroclor samples to prevent any contamination of the material. D. To keep lot numbers correct for the products , be sure to note the date and lot number in the book for this purpose. DSW 334640 STLCOPCB4081110 APPENDIX I AROCIOR FINISHED GOODS CONTAINER WEIGHTS Material Weight Lbs. 1221 50 or 520 1232 50 or 550 1242 55 or 600 1248 55 or 600 1254 60 or 600 1260 60 or 600 1262 60 or 600 Inerteen 54201-A6 600 Therrainol FR-0 60, 600, or 635 Therminol FR-Lo Temp. 55 or 600 Santicizer 794 600 Aroclor 1242-1248 55 or 600 Pyranol A13B3B 65, 360, or 675 Inerteen PPO 65 , , 360 , or 674 Inerteen 54201-KA 674 Inerteen 70-30 674 Inerteen 54201-CM 600 Aroclor 1254 - 4465 650 Aroclor 1260-5% Toluene 60 or 600 Aroclor 1260-10%, Toluene 60 or 600 Aroclor 1254-107= Toluene 600 Aroclor 1262-10%, Toluene 60 or 600 Aroclor 1262-10% Xylene 60 or 600 Container 5 Gal. - 55 Gal. Steel Drum II If II tl II 11 If ft It II ft It It ft 11 It ft II II II 11 II If 11 55 Gal. Steel drum 5 Gal. - 55 Gal. steel drum II II ft II 55 Gal. Steel Drum 5 Gal. - 55 Gal. steel drum 5 Gal. - 30 Gal. -55 Gal. steel drum !1 II II 11 It ft 11 If 55 Gal. steel drum II 11 It It II 11 It It 11 It 11 11 5 Gal. - 55 Gal. steel drum 11 11 II 1! II II 55 Gal. steel drum 5 Gal. - 55 Gal. steel drum If ft II If tl II DSW 334641 STLCOPCB4081 111 Material Aroclor 5442 Aroclor 4465 Aroclor 2565 MCS 295 Aroclor 5060 Aroclor 5460 Aroclor 1268 APPENDIX I AROCLOR FINISHED GOODS CONTAINER WEIGHTS PG. 2 Weight Lbs. 50 or 450 50,500 , or 535 50 or 500 635 50 or 100 50 or 100 200 Container 5 Gal. - 40 Gal. Galv. drum 5 Gal. - 40 Gal. Galv. drum 55 Gal. Steel drum 5 Gal. - 40 Gal. Galv. drum 55 Gal. steel drum Paper Bags. Paper Bags 41 Gal. Fiber drums DSW 334642 STLCOPCB4081112 APPENDIX II ARQCLQR AND PYRANOL LOT S/MPLE3 Aroclor 1221 ' 1232 1242 1248 1254 1260 1262 1262 - 10% Toluene 1262 - 10% Xylene 1260 - 10% Toluene A13B3B ' Inerteen PPO Inerteen 54201-KA \ Tank Cars - Trucks or Drums 2 'X 1/2 Gallon 2 X 1/2 Gallon 3 X 1/3 Gallon & 1 x 5 pint 2 X 1/2 Gallon 3 X 1/3 Gallon 6= 1 x 5 pint 3 X 1/3 Gallon 2 X 1/2 Gallon 1 X 1/2 Gallon - From Mix Tank 1 X 1/2 Gallon - From Mix Tank 1 X 1/2 Gallon - From Mix Tank 3 X 1/2 Gallon 3 X 1/2 Gallon *1 X 1/2 Gallon - From Mix Tank DSW 334643 STLCOPCB4081113 Galloi 493 765 1036 1308 1579 2122 2393 2665 2937 3208 3480 3751 4023 4294 4566 4837 5109 5380 5652 5923 6195 6466 6738 7009 7281 7552 7824 8095 8367 8638 8910 9181 9453 1242 STORAGE TANKS ITEMS 704, 705, & 707 Ins.Aroclor Ins.Aroclor Ins.Aroclor (Innage) % Scale Gallons (Innage) 7a Scale Gallons (Innage) 6 9 13 16. 19 22 26 29 32 36 39 42 46 49 52 56 59 62 65 69 72 75 79 82 85 88 92 95 98 102 105 108 112 115 34 9724 " 35 9996 36 10,267 37 10,537 38 10,810 39 11,082 40 11,353 41 11,625 42 11,896 43 12,168 44 12,439' 45 12, 711 46 12,982 47 13, 254 48 13,525 49 13,797 50 14,068 51 14,340 52 14,611 53 14,883 54 15,154 55 15,426 56 15,697 57 15,969 58 16,240 59 16,512 60 16,783 61 17,055 62 17,326 63 17,598 64 17,869 65 18,141 66 18, 412 67 18,684 118 122 125 128 131 135 138 141 145 148 151 154 158 161 164 168 171 174 178 181 184 188 191 194 197 201 204 207 211 214 217 220 224 227 68 18,955 69 19,227 70 19,498 71 19, 770 72 20,041 73 20,313 74 20,584 75 20,856 76 21,127 77 21,399 78 21,670 79 21,942 80 22,213 81 22,485 82 22, 756 83 23,028 84 23,299 85 23,571 86 23,842 87 24,114 88 24,385 89 24,657 90 24,928 91 25,200 92 25,471 93 25, 743 94 26,014 95 26, 286 96 26,557 97 26,829 98 27,100 99 27,372 100 27,643 230 234 237 240 244 247 250 254 257 260 263 267 270 273 277 280 283 286 290 293 296 300 303 306 310 313 316 320 323 326 329 333 336 Aroclor 1242 Temperature - 140C. Sp. Gr. - 1.272 @ 140C. Inst. Range - 0-425" H2O Inst. Scale - 0-100% DSW 334644 STLCOPCB4081114 AROCLOR 1254 ITEMS 707. 708 % Scale Gallons Ins.Aroclor % Scale Gallons Ins.Aroclor % Scale Gallons Ins.Aroclor 0 493 1 732 2 971 3 1210 4 1449 5 1688 6 1927 7 2166 8 2405 9 2644 10 2883 11 3122 12 3361 13 3600 14 3839 15 4078 16 4317 17 4556 18 4795 19 5034 20 5273 21 5512 22 5751 23 5990 24 6229 25 6468 26 6707 27 6946 28 7185 29 7424 30 7663 31 7902 32 8141 33 8380 6 34 8619 106 9 35 8858 109 12 36 9097 112 15 37 9336 115 18 38 9575 118 21 39 9814 121 24 40 10,053 124 27 41 10,292 127 30 42 10,531 129 32 43 10,770 132 35 44 11,009 135 38 45 11,248 138 41 46 11,487 141 44 47 11, 726 144 47 48 11,965 147 50 49 12, 204 150 53 50 12,443 153 56 51 12,682 156 59 52 12,921 159 62 53 13,160 162 65 54 13,399 165 68 55 13,638 - 168 71 56 13,877 171 74 ' 57 14,116 174 ' 77 58 14,355 177 80 59 14,594 180 82 60 14, 833 182 85 61 15,072 185 88 62 15,311 188 91 63 15,550 191 94 64 15,789 194 97 65 16,028 197 101 66 16,267 200 103 67 16,506 203 68 16, 745 69 16,984 70 17,223 71 17,462 72 17, 701 73 17,940 74 18,179 75 18,418 76 18,657 77 18,896 78 19,135 79 19,374 80 19,613 81 19,852 82 20,091 83 20,330 84 20,569 85 20,808 86 21,047 87 21,286 88 21,525 89 21,764 90 22,003 91 22,242 92 22,481 93 22,720 94 22,959 95 23,198 96 23,437 97 23,676 98 23,915 99 24,154 100 24,393 206 209 212 215 218 221 224 226 229 232 235 238 241 244 247 250 253 256 259 262 265 268 271 274 276 279 282 285 288 291 294 29 7 300 Aroclor 1254 Temperature - 140C. Sp. Gr. 1.425 @ 140C. Inst. Range - 0-428" H2O Inst. Scale - 0-100% DSW 334645 STLCOPCB4081115 1248 STORAGE TANK ITEM 709 Ins.Aroclor Ins.Aroclor Ins.Aroclor % Scale Gallons (Innage) 7, Scale Gallons (Innage) 7, Scale Gallons (Innase) 0 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 26 27 28 29 30 31 32 33 420 601 782 963 1144 1325 1506 1687 1868 2049 2230 2411 2592 2773 2954 3135 3316 3497 3678 3859 4040 4221 4402 4583 4764 4945 5126 5307 5488 5669 5850 6031 6212 6393 . 6 9 11 14 16 19 21 24 27 29 32 34 37 40 42 45 47 50 52 55 58 60 63 65 .68 70 73 76 78 81 83 86 89 91 ' 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 6574 94 6755 96 6936 ' 99 7117 101 7298 104 7479 107 7660 109 7841 112 8022 114 8203 117 8384 120 8565 122 8746 125 8927 127 9108 130 9289 132 9470 135 9651 138 9832 140 10,013 143 10,194 145 10,375 148 10,556 150 10,737 153 10,918 156 11,099 158 11,280 161 11,461 163 11,642 166 11,823 169 12,004 171 12,185 174 12,366 176 12,547 179 - 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 12,728 12,909 13,090 13,271 13,452 13,633 13,814 13,995 14,176 14,357 14,538 14, 719 14,900 15,081 15,262 15,443 15,624 15,805 15,986 16,167 16,348 16,529 16,710 16,891 17,072 17, 253 17,434 17,615 17,796 17,977 18,158 18,339 18,520 181 184 187 189 192 194 197 199 202 205 207 210 212 215 218 220 223 225 228 230 233 236 238 241 243 246 249 251 254 256 259 261 264 Aroclor 1248 Temperature - 140C. Sp. Gr. - 1.335 @ 140C. Inst. Range - 0-352" 1^0 Inst. Scale - 0-1007, SW 334646 STLCOPCB4081116 AROCLOR 1221 STORAGE TANK ITEM 710 Ins.Aroclor Ins.Aroclor Ins.Aroclor Scale Gallons (Innage) % Scale Gallons (Innage) % Scale Gallons (Innage) 0 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 26 27 28 29 30 31 32 33 420 601 782 963 1144 1325 1506 1687 1868 2049 2230 2411 2592 2773 2954 3135 3316 3497 3678 3859 4040 4221 4402 4583 4764 4945 5126 5307 5488 5669 5850 6031 6212 6393 6 9 11 14 16 19 21 24 27 29 32 34 37 40 42 45 47 50 52 55 58 60 63 65 68 70 73 76 78 81 83 86 89 91 34 6574 35 6755 36 6936 37 7117 38 7298 39 7479 40 7660 41 7841 42 8022 43 8203 44 8384 45 8565 46 8746 47 8927 48 9108 49 9289 50 9470 51 9651 52 9832 53 10,013 54 10,194 55 10,375 56 10,556 57 10,737 58 10,918 59 11,099 60 11,280 61 11,461 62 11,642 63 11,823 64 12,004 65 12,185 66 12,366 67 12,547 94 96 99 101 104 107 109 112 114 117 120 122 125 127 130 132 135 138 140 14i3 145 148 150 153 156 158 161 163 166 169 171 174 176 179 - 68 12, 728 69 12,909 70 13,090 71 13,271 72 13,452 73 13,633 74 13,814 75 13,995 76 14,176 77 14,357 78 14,538 79 14, 719 80 14, 900 81 15,081 82 15,262 83 15,443 84 15,624 85 15,805 86 15,986 87 16,167 88 16,348 89 16,529 90 16, 710 91 16,891 92 17,072 93 17, 253 94 17,434 95 17,615 96 17, 796 97 17,977 98 18,158 99 18,339 100 18,520 181 184 187 189 192 194 197 199 . 202 205 207 210 212 215 218 220 223 225 228 230 233 236 238 241 243 246 249 251 254 256 259 261 264 Aroclor 1221 Temperature 140C. Sp. Gr. - 1.072 Q 140C. Inst. Range - 0-273" H^O Inst. Scale - 0-100% DSW 334647 STLCOPCB4081117 AR0CL0R 1232 ITEM 710 lions Ins.Aroclor % Scale Gallons Ins.Aroclor % S ca 1 e Gallons Ins .Aroc! 420 582 744 906 1068 1230 1392 1554 1716 1878 2040 2202 2364 2526 2688 2850 3012 3174 3336 3498 3660 3822 3984 4146 4308 4470 4632 4794 4956 5118 5280 5442 5604 5766 6 ' 34 -5928 85 8 35 6090 87 11 36 6252 89 13 37 6414 91 15 38 6576 94 18 39 6738 96 20 40 6900 98 22 41 7062 101 24 42 7224 103 27 43 7386 105 30 44 7548 108 31 45 7710 110 34 46 7872 112 36 47 8034 115 38 48 8196 117 41 49 8358 119 43 50 8520 121 45 51 8682 124 48 52 8844 126 50 53 9006 128 52 54 9168 131 55 55 . 9330 133 57 56 9492 135 59 57 " 9654 138 61 58 9816 140 64 59 9978 142 65 60 10,140 145 68 61 10,302 147 71 62 10,464 149 73 63 10,626 152 75 64 10,788 154 78 65 10,950 156 80 66 11,112 158 82 67 11,274 161 68 11,436 69 11,598 70 11,760 71 11,922 72 12,084 73 12,246 74 12,408 75 12,570 76 12, 732 77 12,894 78 13,056 79 13,218 80 13,380 81 13,542 82 13, 704 83 13,566 84 14,028 85 14,190 86 14,352 87 14,514 88 14,676 89 14,838 90 15,000 91 15,162 92 15,324 '93 15,486 94 15,648 95 15,810 96 15,972 97 16,134 98 16, 296 99 16,458 100 16,620 163 165 168 170 172 175 177 179 182 184 186 188 191 193 194 198 200 202 205 207 209 212 214 216 219 221 223 225 228 230 232 235 237 Aroclor 1232 Temperature 140 C. Sp. Gr. - 1.160 @ 140 C. Inst. Range - 0-278" HO Inst. Scale - 0-100% DSW 334648 STLCOPCB4081118 AROCLOR 1260 STORAGE TANK ITEM 711 Ins.Aroclor Ins.Aroclor Ins.Aroclor % Scale Gallons (Innage) % Scale Gallons (Innage) % Scale Gallons (Innage) 0 420 1 601 2 782 3 963 4 1144 5 1325 6 1506 7 1687 8 1868 9 2049 10 2230 11 2411 12 2592 13 2773 14 2954 15 3135 16 3316 17 3497 18 3678 19 3859 20 4040 21 4221 22 4402 23 4583 24 4764 25 4945 26 5126 27 5307 28 5488 29 5669 30 5850 31 6031 32 6212 33 6393 6 34 6574 9 35 6755 11 36 6936 14 37 7117 16 38 7298 19 39 7479 21 40 7660 24 41 7841 27 42 8022 29 43 8203 32 44 8384 34 45 8565 37 46 8746 40 47 8927 42 48 9108 45 49 9289 47 50 9470 50 51 9651 52 52 9832 55 53 10,013 58 54 10,194 60 55 10,375 63 56 10,556 65 ' 57 10,737 68 58 10,918 70 59 11,099 73 60 11,280 76 61 11,461 78 62 11,642 81 63 11,823 83 64 12,004 86 65 12,185 89 66 12,366 91 67 12,547 94 96 99 101 104 107 109 112 114 117 120 122 125 127 130 132 135 138 140 143 145 148 150 153 156 158 161 163 166 169 171 174 176 179 68 12,728 181 69 12,909 184 70 13,090 187 71 13,271 189 72 13, 452 192 73 13,633 194 74 13,814 197 75 13,995 199 76 14,176 202 77 14,357 205 78 14,538 207 79 14, 719 . 210 80 14,900 212 81 15,081 215 82 15,262 218 83 . 15,443 220 84 15,624 223 85 15,805 225 86 15,986 228 87 16,167 230 88 16,348 233 89 16,529 236 90 .16,710 238 91 16,891 241 92 17,072 243 93 17,253 246 94 17,434 249 95 17,615 251 96 17,796 254 97 17,977 256 98 18,158 259 99 18,339 261 100 18,520 264 Aroclor 1260 Temperature - 140 C. Sp. Gr. - 1.511 @ 140C. Inst. Range - 0-394" 1^0 Inst. Scale - 0-100% DSW 334649 STLCOPCB4081119 I AROCLOR 1262 STORAGE TANK ITEM 712 Ins.Aroclor Ins.Aroclor Ins.Aroclor % Scale Gallons (Innage) 5o Scale Gallons (Innage) % Scale Gallons (Innage) 0 420 1 601 2 782 3 963 4 1144 5 1325 6 1506 7 1687 8 1868 9 2049 10 2230 11 2411 12 2592 13 2773 14 2954 15 3135 16 3316 17 3497 18 3678 19 3859 20 4040 21 4221 22 4402 23 4583 24 4764 25 4945 26 5126 27 5307 28 5488 29 5669 30 5850 31 6031 32 6212 33 6393 6 9 11 14 16 19 21 24 27 29 32 34 37 40 42 45 47 50 52 55 58 60 63 65. 68 70 73 76 78 81 83 86 89 91 34 6574 35 6755 36 6936 37 7117 38 7298 39 7479 40 7660 41 7841 42 8022 43 8203 44 8384 45 8565 46 8746 47 8927 48 9108 49 9289 50 9470 51 9651 52 9832 53 10,013 54 10,194 55 10,375 56 10,556 57 10,737 58 10,918 59 11,099 60 11,280 61 11,461 62 11,642 63 11,823 64 12,004 65 12,185 66 12,366 67 12. 547 94 96 99 101 104 107 109 112 114 117 . 120 122 125 127 130 132 135 138 140 143 145 148 150 153 156 158 161 163 166 169 171 174 176 179 68 12,728 69 12,909 70 13,090 71 13,271 72 13,452 73 13,633 74 13,814 75 13,995 76 14,176 77 14,357 78 14,538 79 14, 719 80 14,900 81 15,081 82 15,262 83 15,443 84 15,624 85 15,805 86 15,986 87 16,167 88 16,348 89 16,529 90 16,710 91 16,891 92 17,072 93 17, 253 94 17,434 95 17,615 96 17,796 97 17,977 98 18,158 99 18,339 100 18,520 181 184 187 189 192 194 197 199 202 205 207 210 212 215 218 220 223 225 228 230 233 236 238 241 243 246 249 251 254 256 259 261 264 Aroclor 1262 Temperature - 140C. Sp. Gr. - 1.528 @ 140C. Inst. Range - 0-402 " HO Inst. Scale - 0-100% DSW 334650 STLCOPCB4081120 MIX TANK ITEM 725 (15 SLOPE BOTTOM) lions Ins. Blends %, Scale Gallons Ins. Blends % Scale Gallons Ins. Blend; 15 34 60 94 136 184 250 320 400 500 600 700 800 925 1050 1174 1298 1422 1546 1670 1794 1918 2042 2169 2290 2414 2538 2662 2786 2910 3034 3158 3286 3406 6 8 10 12 14 16 18 20 23 25 27 29 31 33 35 37 40 42 44 46 48 50 52 54 56 58 61 63 65 67 69 71 73 75 34 35 ,, 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 3530 3654 3778 3902 4026 4150 4274 4398 4522 4646 4770 4894 5018 5142 5266 5390 5514 5638 5762 5886 6010 6134 6258 6382 6506 6630 6754 6878 7002 7126 7250 7374 7498 7622 77 80 82 84 86 88 90 92 94 96 98 100 103 105 107 110 111 113 115 117 119 121 124 126 128 131 132 134 136 138 140 142 145 147 68 69 70 71 72 73 74 . 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 7746 7870 7994 8118 8242 8366 8490 8614 8738 8862 8986 9110 9234 9358 9482 9606 9730 9854 9978 10102 10226 10350 10474 10598 10722 10846 10970 11094 11218 11342 11466 11590 11714 149 151 153 155 157 159 161 163 166 168 170 173 174 176 178 180 182 184 187 189 191 194 195 197 199 201 203 205 208 210 212 214 216 . Mix Tank Temperature - 140C Sp. Gr. - 1.375 @ 140C Inst. Range - 0-297" 1^0 Inst. Scale - 0-100% DSW 334651 STLCOPCB4081121 CM BLEND STORAGE TANK ITEM 726 Ins. Aroclor Ins. Aroclor Ins. Arocloi 7o Scale Gallons (Innage) % Scale Gallons (Innage) . % Scale Gallons (Innage) 0 420 1 601 2 782 3 963 4 1144 5 1325 6 1506 7 1687 8 1868 9 2049 10 2230 11 2411 12 2592 13 2773 14 2954 15 3135 16 3316 17 3497 18 3678 19 3859 20 4040 21 4221 22 4402 23 4583 24 4764 25 4945 26 5126 27 5307 28 5488 29 5669 30 5850 31 6031 32 6212 33 6393 6 34 6574 9 35 6755 11 36 6936 14 37 7117 16 38 7298 19 39 7479 21 40 7660 24 41 7841 27 42 8022 29 43 8203 32 44 8384 34 45 8565 37 46 8746 40 47 8927 42 48 9108 45 49 9289 47 50 9470 50 51 9651 52 52 9832 55 . 53 10013 58 54 10194 60 55 10375 63 56 10556 65 57 10737 68 58 10918 70 ' 59 '11099 73 60 11280 76 61 11461 78 62 11642 81 63 11823 83 64 12004 86 65 12185 89 66 12366 91 67 12547 94 96 99 101 104 107 109 112 114 117 120 122 125 127 130 132 135 138 140 143 145 148 150 153 156 158 161 163 166 169 171 174 176 179 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 . 95 96 97 98 99 100 12728 12909 13090 13271 13452 13633 13814 13995 14176 14357 14538 14719 14900 15081 15262 15443 15624 15805 15986 16167 16348 16529 16710 16891 17072 17253 17434 17615 17796 17977 18158 18339 18520 181 184 187 : 189 192 194 197 199 202 205 207 210 212 215 218 220 223 225 228 230 233 236 238 241 243 246 249 251 254 256 259 261 264 . CM Blend Temperature - 140C Sp. Gr. - 1.265 @ 140C Inst. Range - 0-334" 1^0 Inst. Scale - 0-1007 DSW 334652 STLCOPCB4081122 TCB STORAGE TANK ITEM 733 cal Gallons Inches TCB % Scale Gallons Inches TCB % Scale Gallons Inches TCB 0 354 1 478 2 602 3 726 4 850 5 974 6 1098 7 1222 8 1346 9 1470 10 1594 11 1718 12 1842 13 1966 14 2090 15 2214 16 2338 17 2462 18 2586 19 2710 20 2834 21 2958 22 3082 23 3206 24 3330 25 3454 26 3578 27 3702 28 3826 29 3950 30 4074 31 4198 32 4322 4446 6 34 4570 8 35 4694 10 , 36 4818 12 37 4942 14 38 5066 16 39 5190 19 40 5314 21 41 5430 23 42 5562 25 43 5686 27 44 5810 29 45 5934 31 46 6058 33 47 6182 35 48 6306 37 49 6430 40 50 6554 42 51 6678 44 52 6802 46 53 6926 48 54 7050 50 55 7174 52 56 7298 54 57 7422 56 58 7546 58 59 7670 61 60 7794 63 61 7918 65 62 8042 67 63 8166 70 64 8290 71 65 8414 73 66 8538 75 67 8662 77 80 82 84 86 88 90 92 94 96 98 100 102 105 107 109 111 113 115 117 119 121 124 126 128 130 132 134 136 138 140 142 145 147 68 8786 149 69 8910 151 70 9034 153 71 9158 155 72 9282 157 73 9406 159 74 9530 161 75 9654 163 76 9778 166 77 9902 168 78 10026 170 79 10150 172 80 10274 174 81 10398 176 82 10522 178 83 10646 180 84 10770 182 85 10894 184 86 11018 187 87 11142 189 88 11266 191 89 11390 193 90 11514 195 91 11638 197 92 11762 199 93 11886 201 94 12070 203 95 12134 205 96 12258 208 97 12382 210 98 12506 212 99 12630 214 100 12754 216 TCB Temperature - 140C Sp. Gr. - 1.303 <3 140C Inst. Range - 0-281" l^O Inst. Scale - 0-100% DSW 334653 STLCOPCB4081123 TTCB STORAGE TANK ITEM 734 Inches TTCB % Scale Gallons Inches TTCB % Scale Gallons Inches TTCB 354 478 602 726 850 974 1098 1222 1346 1470 1594 1718 1842 1966 2090 2214 2338 2462 2586 2710 2834 2958 3082 3206 3330 3454 3578 3702 3826 3950 4074 4198 4322 4446 6 34 4570 8 ' 35 4694 10 36 4818 12 37 4942 14 38 5066 16 39 5190 19 40 5314 21 41 5430 23 42 5562 25 43 5686 27 44 5810 29 45 5934 31 46 6058 33 47 6182 35 48 6306 37 49 6430 40 50 6554 42 51 6678 44 52 6802 46 53 6926 48 54 7050 50 55 7174 52 56 7298 54 57 7422 56 58 7546 58 59 7670 61 60 7794 63 61 7918 65 62 8042 67 63 8166 70 64 8290 71 65 8414 73 66 8538 75 67 8662 77 80 82 84 86 88 90 92 94 96 98 100 102 105 107 109 111 113 115 117 119 121 124 126 128 130 132 134 136 138 140 142 145 147 68 8786 149 69 8910 151 70 9034 153 71 9158 155 72 9282 157 73 9406 159 74 9530 161 75 9654 163 76 9778 166 77 9902 168 78 10026 170 79 10150 172 80 10274 174 81 10398 176 82 10522 178 83 10646 180 84 10770 182 85 10894 184 86 11018 187 87 11142 189 88 11266 191 89 11390 193 90 11514 195 91 11638 197 92 11762 199 93 11886 201 94 12070 203 95 12134 205 96 12258 208 97 12382 210 98 12506 212 99 12630 214 100 12754 216 TTCB Temperature - 140C Sp. Gr. - 1.357 @ 140C Inst. Range - 0-293" lUO Inst. Scale - 0-1007o DSW 334654 STLCOPCB4081124 % Scale Gallons 0 538 1 708 2 .878 3 1,048 4 1,218 5 1,388 6 1,558 7 1,728 8 1,898 9 2,068 10 2,238 11 2,408 12 2,578 13 2,748 14 2,918 15 3,088 16 3,258 17 3,428 18 -3,598 19 3,768 20 3,938 21 4,108 22 4,278 23 4,448 Aroclor 1232 Sp.Gr. 1.150 @ 150C Sp.Gr. 1.275 Q 25C Inst. Range - 0-400" H20 Inst. Scale - 0-1007. NOS. 5 & 6 STORAGE TANKS 1232 AROCLOR 7. Scale Gallons 24 4,618 . 25 4,788 26" 4,958 27 5,128 28 5,298 29 5,468 30 5,638 31 5,808 32 5,978 33 6,148 34 6,318 35 6,488 36 6,658 37 6,828 38 6,998 39 ' 7,168 40 7,338 41 7,508 42 7,678 43 7,848 44 8,018 45 8,188 46 8,358 47 8,528 7. Scale 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 Gallons 8,698 8,868 9,038 9,208 9,378 9,548 9,718 9,888 10,058 10,228 10,398 10,568 10,738 10,908 11,078 11,248 11,418 11,588 DSW 334655 STLCOPCB4081125 NOS. 5 & 6 STORAGE TANKS 1242 AROCLOR % Scale Gallons % Scale Gallons 0 538 24 4,258 1 693 25 4y413 2 848 26 4,568 3 1,003 27 4,723 4 1,158 .28 4,878 5 1,313 6 1,468 29 i 30 5,033 5,188 7 1,623 31 5,343 8 1,778 32 5,498 9 1,933 33 5,653 10 2,088 11 2,243 34 5,808 i 35 5,963 12 2,398 36 6,118 13 2,553 37 ` 6,273 14 2,708 38 ' 6,428 15 2,863 39 6,583 16 3,018 40 6,738 17 3,173 41 6,893 18 3,328 42 7,048 19 3,483 43 7,203 20 3,638 44 7,358 21 3,793 45 7,513 22 3,948 46 7,668 23 4,103 47 Aroclor 1242 48 Sp. Gr. 1.262 @ 150C (1.387 @ 25C) Inst Range - 0-400** H2O Tn^ Scale - 0-100% . 7,823 7,978 % Scale Gallons 49 8,133 50 8,288 51 8,443 52 8,598 53 8,753 54 8,908 55 9,063 56 9,218 57 9,373 58 9,528 59 9,683 60 9,838 61 9,993 62 10,148 63 10,303 64 10,458 65 10,613 66 10,768 67 10,923 68 11,078 69 11,233 70 11,388 71 11,543 72 11,698 73 11,853 DSW 334656 STLCOPCB4081126 % Scale Gallons 0 538 1 686 2 834 3 982 4 1^ 130 5 1,278 6 1,426 7 1,574 8 1,722 9 1,870 10 2,018 11 2,166 12 2,314 13 2,462 14 2,610 15 2,758 16 2,906 17 3,054 18 3,202 19 3,350 20 3,498 21 3,646 22 3,794 23 3,942 Aroclor 1248 Sp.Gr. 1.325 @ 150C (1.410 (p 65C) Inst. Range - 0-400" h2o Inst. Scale - 0-100% NOS. 5 & 6 STORAGE TANKS 1248 AROCLOR 7o Scale Gallons 24 4,090 25 4,238 26^ 4,386 27 4,534 28 4,682 29 4,830 30 4,978 31 5,126 32 5,274 33 5,422 34 5,570 35 5,718 36 5,866 37 6,014 38 6,162 39 ' 6,310 40 6,458 41 6,606 42 6,754 43 6,902 44 7,050 45 7,198 46 7,346 47 7,494 48 7,642. 49 7,790 % Scale Galloi 50 7,938 51 8,086 52 8,234 53 8,382 54 . 8,530 55 8,678 56 8,826 57 8,974 58 9,122 59 9,270 60 9,418 61 9,566 62 9,714 63 9,862 64 10,010 65 10,158 66 10,306 67 10,454 68 10,602 69 10,750 70 10,898 71 11,046 72 11,194 73 11,342 74 11,490 75 11,638 DS\W 334657 STLCOPCB4081127 % Scale . Gallons --iV 0 538 1 676 2 814 3 952 4 1,090 5 1,228 6 1,366 7 1,504 8 1,642 9 1,780 10 1,918 11 2,056 12 2,194 13 2,332 14 ' 2,470 15 2,608 16 2,746 17 2,884 18 3,022 19 3,160 20 3,298 21 3,436 22 3,574 23 3,712 24 3,850 Arocior 1n n / Sp. Gr. 1.415 <? 150C Sp. Gr. 1.500 @ 65C Inst, Range 0-400" H2O NOS. 5 & 6 STORAGE TANKS 1254 AR0CL0R % Scale Gallons % Scale Gallons 25 3,988 52 7,714 26 4,126 53 7,852 27 . 4,264 54 7,990 28 4,402 55 8,128 29 4,540 56 8,266 30 4,678 57 8,404 31 4,816 32 4,954 58 59 ' 8,542 8,680 33 5,092 60 8,818 34 5,230 61 8,956 35 5,368 62 9,094 36 5,5.qe 63 9,232 37 5,644 64 9,370 38 5,782 65 9,508 39 ` 5,920 66 9,646 40 6,058 67 9,784 41 6,196 68 9,922 42 6,334 69 10,060 43 6,472 70 10,198 44 6,610 71 10,336 45 6,748 72 10,474 46 6,886 73 10,612 47 7,024 74 10,750 48 7,162 75 10,888 DSW 334658 49 7,300 50 7,438 51 7,576 76 11,026 77 11,164 78 11,302 79 11,440 80 11,578 81 11,716 STLCOPCB4081128 NOS. 5 & 6 STORAGE TANKS 1260 AROCLOR % Scale 0 Gallons 538 % Scale 26 Gallons 3,918 1 668 27 4,048 .2 798 28 . 4,178 3 928 ' 29 *. 4,308 4 1,058 30 4,438 5 1,188 31 4,568 6 1,318 32 4,698 7 1,448 33 4,828 8 1,578 34 4,958 - ' 9 1,708 35 5,088 10 1,838 36 5,218 11 1,968 37 5,348 12 2,098 38 5,478 13 2,228 39 5,608 14 2,358 40 5,738 15 2,488 41 5,868 16 2,618 42 5,998 17 2,748 43 6,128 18 2,878 44 6,258 19 3,008 45 6,388 20 3,138 46 6,518 21 3,268 47 6,648 22 3,398 48 6,778 23 3,528 49 6,908 24 3,658 50 7,038 25 3,788 51 7,168 Sp.Gr . 1.501 @ 150C 1.561 <a 90C Inst. Range - 0-400" H2O Inst. Scale - 0-100% 52 53 7,298 7,428 % Scale 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 Gallons 7,558 7,688 7,818 7,948 8,078 8,208 8,338 8,468 8,598 8,728 8,858 8,988 9,118 9,248 9,378 9,508 9,638 9,768 9 ,898 10,028 10,158 10,288 10,418 10,548 10,678 10,808 10,938 11,068 11,198 11,328 11,458 11,588 11,718 DSW 334659 STLCOPCB4081129 7, Scale Gallons NOS. 5 & 6 STORAGE TANKS 1262 AROCLOR % Scale Gallons % Scale - Gallons 0 538 23 3,505 46 6,472 1 667 24 3,634 47 6,601 2 796 25 3,763 48 6,730 3 925 26 3,892 49 6,859 4 1,054 27 4,021 50 6,988 5 1,183 28 4,150 51 7,117 6 1,312 29 4,279 52 7,246 7 1,441 30 4,408 53 7,375 8 1,570 31 4,537 54 ' 7,504 9 1,699 32 4,666 55 7,633 10 1,828 33 4,795 56 7,762 11 1,957 34 4,924 57 7,891 12 2,086 35 5,053 58 8,020 13 2,215 36 5,182 59 8,149 14 2,344 37 5,311 60 8,278 15 2,473 38 5,440, 61 8,407 16 2,602 39 5,569 62 8,536 17 2,731 40 5,698 63 8,665 18 2,860 41 5,827 64 8,794 19 2,989 42 5,956 65 8,923 20 3,118 43 6,085 66 9,052 21 3,247 44 6,214 67 9,181 22 3,376 45 6,343 68 9,310 Aroclor 1262 Sp.Gr. 1.518 <a 150C (1.578 @ 90C) Inst. Range - 0-400" H2O Inst. Scale - 0-100% % Scale Gallons 69 9,439 70 9,568 71 9,697 72 9,826 73 9,955 74 10,084 75 10,213 76 10,342 77 10,471 78 10,600 79 10,729 80 10,858 81 10,987 82 11,116 83 11,245 84 11,374 85 11,503 86 11,632 DSW 334660 STLCOPCB4081130 STANDARD OPERATING INSTRUCTIONS . FOR SOLID AROCLORS - (1970 EXPANSION) Synopsis of Process --- The Solid Aro.clor' equipment" ins tailed "in 1970 wa's designed for A ' nominal 20 M pounds per year production rate. These facilities are intended for the production of Santowax based Solid Aroclors (Aroclors 5060, 5460, 5442) exclusively while the old facilities are retained to produce Biphenyl bas'ed Aroclor 1268 and also the Santowax based Solid Aroclors as total product demand dictates. Total production capability of the combined systems is a nominal 30 M pounds per year. General operation of the newer system is as follows: Santowax R from the Biphenyl-Santowax department is pumped into a terphenyl feed tank (weigh tank) until a pre-determined weight is collected in the tank. Ferric chloride is introduced into the Santowax and the mixture is agitated. From the weigh tank, the charge is pumped into one of two identical chlorinators. The Santowax in the chlorinator is circulated through a twopass, therminol cooled shell and tube heat exchanger through the tube side and back to the chlorinator. Chlorine is fed into the circulating mass at a controlled rate over approxi mately an 11 hour period. The heat of reaction is removed in the therminol cooled exchanger under programmed temperature conditions. .Both the chlorine : feed and temperature of the mass are controlled and stepped up at predetermined-intervals during the length of - the chlorination period. The control for determining when the .- reaction is complete is softening point. HC1 gas is liberated throughout the chlorination and is sent to the muriatic acid ............ plant for processing into acid. .................. After the chlorination is completed, the crude A.roclor is pumped to a. blow tank where residual HC1 is removed by air sparging. A slight vacuum is drawn on the tank by a water scrubber to remove the KC1 fumes. The blow tank will hold material from both chlorinators (2 chlorinator batches). ................... From the blow tank, the material's transferred to a still pot. Again, two chorinator batches constitute a still charge. Lime is added to the still and the still buttoned up. Vacuum is then drawn on the system by a four-stage steam ejector. The mass is circulated through a gas fired furnace which provides the heat for distillation. DSW 334661 STLCOPCB4081131 Synopsis of Process (Cont'd) The vapors from the still pass upward through a cyclone separator to remove entrainment and then on through a therminol cooled con denser where they are liquefied. From the condenser the molten Aroclor is collected'in the still receiver. The distillation takes place over approximately an 11 hour period. After distillation is completed (as determined by the softening point of the Aroclor), the material in the receiver is pumped out to a hold tank and then on to the flaking area to be pack aged in 50 pound bags. In the case of Aroclor 5442, it is either drummed from the receiver or pumped to storage for tank car shipments. The Montar (still bottoms) is drawn out in drums from the still pot after every second run. DSW 334662 STLCOPCB4081132 STANDARD OPERATING INSTRUCTIONS FOR SOLID AROCLOR 5460 PROCESS FUNCTION OUTLINE III. C. I. MAIN THERMINOL HEATER SYSTEM 1.1 Scope This covers the charging, start-up, shutdown, normal operation, and emergency situations involving the Therminol heater in the Aroclor Department. 1.2 Description of Process Therminol FR-2 (.Aroclor 1248) or FR-1 (Aroclor 1242) is circulated through a pipe system in the Aroclor Department. This heating system is used to heat up tanks, transfer lines, and material involved in producing solid A.roclors. There are three separate circulating systems drawing off the same surge tank (Item 149). They should not be confused with the Therminol cooling systems other places in the process. The first system circulates 400 GFM through the furnace to heat the A*roclor to 250C. The second system can circulate 1,000 GPM through the old system (existing users). The third system can circulate 300 GPM through the new Solid Aroclor Expansion area (CEA 2080 users). The pumps are equipped with a seal guard system. II. PROCESS DIAGRAM Attached. III. OPERATION OF PROCESS ' 3.1 a. Charge System with Therminol FR-2 (Aroclor 1248) . 1. Use temporarily relocated Pyranol pump to charge Therminol surge tank. 2. Position 55 gallon drum next to pump. Remove drum bung and vent cap. 3. Connect flexible hose to pump suction and the stainless steel pipe to be inserted into the drum. 4. Position discharge line from the pump into the tank. 5. Open valve on pump suction. Insert pipe into drum and start pump. . 6. Adjust the suction valve on the pump until flow is steady. 7. Continue to fill the tank until 72 drums or approximately 3,950 gallons total are in the. surge tank (Item 149). DSW 334663 STLCOPCB4081133 Aroclor PFO 2. C. III. 3.1 b. Therminol 1242 can be charged directly to the surge tank (Item 149) by the following procedure: 1. Align valves from storage tank No. 5 to surge tank - (Item 149). Care must be taken to ensure that all valves to the other surge tanks are closed. They are also filled from this storage tank line. 2. Check level gauge at surge tank. 3. Start storage tank pump. 4. Observe the level gauge at surge tank and shut off pump when you have 3,950 Gals. 5. Close valves in line from storage tank to surge tank. 3.2 Start-Up A. Initial Start-Up 1. Turn on circuit No. 5 at the still panel and the switch at the field control box. 2. Place TRCA-629.12 in "Manual" with the output pressure at 15 psie. Blower air control valve is air to open. 3. Check to be sure Therminol is in the surge tank (Item 149). Temperature should be 100C. minimum. 4. There is no flow control through the heater. The old FIC instrument will be used as a flow indicator, FIA-159-1. An alarm will sound if the pump stops and furnace shutdown will occur below 200 GPH. . 5. Open natural gas valves in line to furnace. 6. Open blower air valves in pilot and main air lines. 7. Actuate red inset safety lever inside the Honeywell Pro tectoglo unit (lower right cover of case). You must wait 10 seconds between settings of this lever in case it has to be redone. 8. Set the temperature shutdown control point on Honeywell coil outlet temperature Indicator at 325C. (617F.). 9. Start Therminol circulating pump (Item 159). DSW 334664 STLCOPCB4081134 Aroclor PFO 3. C. III. 3.2 A. 10. Start air blower. Use pushbutton at side of field panel. ' ' Red light on Protectoglo unit should light up. Air - pressure at the blower discharge should be above 1 psig. 11. Check pressure gauge at main air inlet to burner. It must"be above 15-o.s.i. 12. Wait 6 minutes. Green light on Protectoglo unit lights up indicating purge period is over. 13. Press ignition "Start" pushbutton on side of control box and hold in until white light on Protectoglo unit lights up. Red and green lights should go out. Pilot lights up indicated by 0-7 reading on micro amp meter. 14. Adjust manual valve in air line to burner until pressure is below 1-1/2 o.s.i. 15. Reset the two North American safety valves in the main gas line. Handle on both valves must be in UP position prior to opening either valve. 16. Adjust manual valve in air line to burner until pressure is between 15 and 22 o.s.i. It must be above 15 o.s.i. 17. Adjust TRCA-629.12 to temperature at outlet of coil and transfer instrument to "Auto". This is for low fire start-up. Use care to make this change, since you can cause shutdown of the furnace. 18. Shut steam valve to coil in the surge tank. Vent coil line to atmosphere. 19. The furnace has been dried out and is ready for use. . 20. Observe the furnace temperature at the coil outlet. Do not exceed 50C. increase for first two hours. Set TRCA-629.12 in automatic and raise the temperature 50C. .per hour until you reach 280C. Open the manual air valve slowly to raise the temperature. Place TRCA-629.12 in "Aulo" position and put set point at 280C. System will circulate until needed. Check stack temperature and do not exceed 400C. on the multipoint temperature recorder. DSW 334665 STLCOPCB4081135 Aroclor PFO 4. C. III. 3. A. 21. The therminol will continue to circulate from surge tank to heater and back to surge tank until the pumps for the other two systems are turned on. (Items 150 (existing users) and 158 (CEA 2080 users)). 22. To put the therminol through these two systems, fill the lines one at`a time. Open each branch valve at feed and discharge to drive out air. B. Start-Up Following Temporary Shutdown Assume circulating pump is running (FIA-159-1) and the pilot light is burning. 1. Check to be sure Therminol is in the surge tank (Item 149). 2. Check temperature in surge tank (Item 149), TI-149-2. It should be 100C. Turn on steam to tank coil if necessary. 3. Adjust set point TR.CA-629.12 at 126 - 150C. and controller in "Auto" position. 4. White light on the Honeywell Protectoglo unit will be on indicating the pilot is on. 5. Adjust manual valve in air line to burner until pressure is below 1-1/2 o.s.i. 6. Reset the two North American safety valves in the main gas line. 7. Adjust manual valve in air line to burner until pressure is between 20-22 o.s.i. 8. Adjust TRCA-629.12 to temperature at outlet of coil and transfer instrument to "Auto". Gradually raise the set point to 280C. 9. Start circulating pumps to both areas (existing old system and 2080 system). Fill lines one at a time, opening dis charge and feed line at each feeder. DSW 334666 STLCOPCB4081136 Aroclor PFO 5. C. III. 3.3 Routine Operations When the Therminol heater system is operating normally, the following conditions will exist in the process. A. FIA-159-1 will indicate A15 GPM. . B. PI-159 pump discharge pressure 44 psig. C. PI-150 (existing users) pump discharge pressure 43 psig. D. PI-158 (CEA 2080 users) pump discharge pressure 44 psig. E. PI-629.16 heater coil outlet pressure 5-10 psig . F. TRCA-629.12 heater coil outlet temperature set at 280C. G. Honeywell coil outlet temperature indicator at 280C. Shutdown alarm set at 325 C. H. TI-149-2 surge tank temperature is around 250aG. I. Air blower reduced discharge pressure - above 15 o.s.i. less than 22 o.s.i. J. Main natural gas pressure 40 psig. K. Natural gas reduced pressure 3-5 o.s.i. L. Natural gas feed to burner atmospheric pressure (0 o.s.i.). 3.4 Safety Features A. Honeywell Protectoglo unit has the following safety features: 1. Ignition period 10 second delay between actuation periods for warp switch to cool. 2. Blower reduced air pressure must be above 15 o.s.i. and less than 22 o.s.i. 3. Heater coil high temperature outlet shutdown set at 325C. (617F.). . 4. Main natural gas low pressure shutdown set at 20 psig, and at 10 psig. 5. Natural gas high reduced pressure shutdown set at 5.0 psig. 6. Circulating pump low flow rate shutdown set at 200 GPM. 7. Air blower start-up sets up automatic 6 minute timed purge before next step of start-up can proceed. DSW 334667 STLCOPCB4081137 Aroclor PFO 6. C. III. 3 .A A. 8. Minimum 15 o.s.i. air pressure is necessary at the main burner for the purge period. 9. A low air pressure ignition for lighting main burner is necessary. Set for air pressure to be below 1-1/2 o.s.i. to-main burner. 10. Pilot flame must be burning to start up unit, indicated by 0-7 microamperes on current meter. Meter gives an alternating off-on reading. B. Check surge tank. Item 149, to be sure therminol level is adequate. There should be 24 inches in the bottom sight glass during normal operation. .5 Shutdown A. Temporary Shutdown Main gas burner off with pilot light on and circulating pump running. 1. Adjust TRCA-629.12 set point to zero (instrument in "Auto"), or 2. If instrument is in "Manual", adjust controller for output pressure to zero, or 3. Close the 6" manual valve in the main air line to the furnace burner. In case it is necessary to cool the furnace quickly, leave the air valve open. 4. Normally, the circulating pump is left on to cool the heater coil and prevent overheating. 5. Close one or both of the North American safety valves in the gas line to the main burner. B. Complete Shutdown - Main gas burner pilot light and circulating pump off. 1.. Push ignition "Stop" button on side of field control panel. 2. Push "Stop" button for air blower. 3. Close manual valve in the main air line. 4. Close manual valves in main gas supply line. DSW 334668 STLCOPCB4081138 Aroclor PFO 7. C. III. 3.5 B. 5. Allow circulating pump to continue pumping until furnace coil outlet has cooled to 150C. then shut off the circulating pump. 6. Check surge tank level (Item 149) to be sure the tank does not overflow. 7. If a temperature of 100C. is to be maintained in the surge tank, it may be necessary to open the valve in the steam line to the tank coil. 8. Set points on TRCA-629.12, heater coil outlet, and the Honeywell Protectoglo unit set point can be left in position when shut off. 9. Shut off circuit No. 5 behind the still panel if the shutdown is to be an extended one. C. Emergency Shutdown In case it becomes necessary to shut down fast, the following methods can normally be used. 1. From the Field a. Push ignition "Stop" button on side of field control panel to shut off pilot and main burner. b. Turn temperature shutdown set point on Honeywell Protectoglo unit below the furnace coil outlet temperature. c. Close manual valve in air blower discharge line or stop the air blower. d. Push "Stop" button for the circulating pump located near the surge tank (Item 149)-beside the pump (Item 159). Main and pilot gas burner will be shut off, while air is being blown through the furnace. Item d. is the least preferred of the above methods. Normally, the circulating pump will continue to be operated. SVV 334669 STLCOPCB4081139 Aroclor PFO 8. C. III. 3.5 C. 2. At the Still Fsnel a, Turn off circuit No. 5 behind still panel. 3. At Motor Control Center a. Shut off circulating pump circuit breaker. This ' method is least preferred. b. Shut off blower circuit breaker. D. Emergency Shutdown with Alarm Pilot and main gas burner off. Circulating pump still on. 1. High coil outlet temperature - above 325C.(617F.) 2. Low natural gas supply pressure - below 20 psig or below 10 psig 3. Low blower outlet pressure - below 1 psig A. High reduced natural gas pressure- above 5 psig 5. Low coil flow - below 200 GPM 6. Failure of circuit 5 behind still panel. 7. Failure of "on-off" switch at side of field control panel or blowing 115 volt fuse in panel. 3.6 Control Loons, Interlocks, and Alarms A. Control Loops There are three major loops in this system. 1 Circulating Pump Flow Indication - FIA-159-1 Low circulation rate (below 200 GPM) will shut off natural gas to the furnace and sound an alarm horn. 2. Therminol Heater Outlet Coil Temperature Control TRCA-629.12 Function of this loop is to maintain a constant tempera ture of 280C. at the furnace coil outlet. This is ac complished by measurement of the temperature with a thermocouple and controlling the heat input to the furnace with a control valve in the main combustion air line. A low temperature alarm a.t 220C, and a high temperature alarm at 325cC. will be actuated at too low or too high a temperature. DSW 334670 STLCOPCB4081140 Aroclor PFO 9. C. III. 3.6 A. 3. Therminol Heater Furnace Control - 629A The function of this loop is to provide a source of heat for the Therminol. circulating ` system. This is obtained with a North American burner and air blower'which is used to heat the Therminol circulating through a direct fired coil. Control of this heating system is obtained by TRCA-629.12. There are four safety features in the furnace controls to shut the system down. a. High coil outlet temperature - above 325C. b. Low natural gas supply pressure-below 20 psig or -below 10 psig c. Low blower outlet pressure -below 1 psig d. High reduced natural gas pressure-above 5 psig B. Interlocks Interlocks in this system are as follows. Each, except Items l.a. and b., have alarms. 1. Start-Up of Furnace a. Actuation of pilot ignition lever on Honeywell Protectoglo unit has a 10 second delay before second try can be made. b. Ignition "Start" button at the Protectoglo unit has a 6 minute purge delay after the air blower has been started before the furnace will light up. c. During purge period a minimum of 15 o.s.i, air pressure is necessary prior to completion of purge. d. To light the main burner the air discharge pressure to the main burner must be below 1-1/2 o.s.i. for low fire start-up. 2. Automatic Furnace Shutdown with Alarms (Pilot and Main Gas Burner Off) a. High coil outlet temperature - above 325C. (617F.) b. Low natural gas supply pressure - below 20 nsig or below 10 psig DSW 334671 STLCOPCB4081141 Aroclor PFO 10. C. III. 3.6 B. 2. c. Low blower outlet pressure - below 1 psig do High reduced natural gas pressure - above 5 psig Low coil flow - below 200 GPM f. Failure of circuit No. 5 behind still panel. g. Failure of switch at side of field control panel or blowing 115 volt fuse in panel. C. Alarms 1. All shutdown items under Interlocks B.2. above. 2. Therminol heater coil outlet low temperature below 220C. 3. Therminol heater coil outlet high temperature above 325C. 3.7 Abnormal Conditions A. Unusual high or low temperature readings can occur if the thermocouple extension wire for the Honeywell Protectoglo unit and TRCA-629.12 are mixed up. See note, Section IV-C., ' below. IV. COMMENTS ON PROCESS A. It is very important to be sure the coil in the surge tank (Item 149) is covered when the system is in operation. This assures the circulating pump has a positive suction and pre vents surging in the heater coil. Surges in flow can cause coil hot spots and shorten the coil life. B. FIA-159-1 flow indicator will shut the system down if the flow is less than 200 GPM. " C. At TRCA-629.12, be sure the iron constantan thermocouple extension lead wire (type J) is used to transmit to the control room and the instrument. The conduit run also contains a type K extension lead wire which is chrome1 alumel. If the type J wire is used, the indicator will read correctly. If the type K wire is used by mistake, the therminol will overheat by about 100C. The high temperature switch should shut the furnace down at 325C. DSW 334672 STLCOPCB4081142 Aroclor PFO 11. C. IV. D. The Therminol furnace is rated at 8,000,000 Btu/hour heat input. This corresponds to 22 o.s.i. air pressure at the air inlet of the burner. The manual valve in the air line should be set for 22 o.s.i. when the automatic valve is wide open. This will assure the heat input will not exceed the design rate' if the automatic valve should open wide. E. Care must be taken not to fill the surge tank (Item 149) too full during normal operation. This can cause the tank to run over when the circulating pump is stopped. Normal level will be about 24 inches in the sight glass. The level in the tank will vary, dependent on the operating temperature of the system and the Therminol usage. F. The control valve formally controlled by FIC-159-1 must be kept closed at all times. This is accomplished by setting the red arrow at zero flow. If this valve is open the hot Therminol does not go through the branch lines to return to the surge tank, since the large supply and return lines are connected at this point. G. To get natural gas to the main burner the North Americal safety valves must be reset. Prior to opening the valves the handle of each valve must be in the UP position. This sets the safety shutdown pressure switches. H. Use care when opening the inner door to the field control panel at the furnace. The high temperature shutdown instrument pointer is free floating and can go above the shutdown pointer. The door must be opened slowly. I. Gas to the venturi mixing chamber for the pilot light on the furnace should be at atmospheric pressure. Air pressure will be the blower discharge pressure (22 o.s.i.). The pilot light will not burn unless this pressure ratio is maintained to give the proper gas-air mixture. J. In case of a power failure at the field panel for the Therminol heater the reset button on the high temperature shutdown in strument must be pushed to restart the system. There is no apparent indication that this button has been pushed. The red no flame light will not light up and furnace can not be started. DSW 334673 STLCOPCB4081143 APPENDIX I Item 149, Main Therminol Surge Tank 90" OD X 134" Long Dished Heads iep Contents In (Gal.) 00 1 7.4 2 21.7 3 39.4 4 60.4 5 84.1 6 111.1 7 139.7 8 170.7 9 203.1 10 248.1 11 273.9 12 312.0 13 348.0 14 385.1 15 433.3 16 472.5 17 512.7 18 568.6 19 610.8 20 652.4 21 712.0 22 763.3 23 815.2 24 865.7 25 922.9 26 970.7 27 1024.8 28 1079.6 29 1135.9 30 1191.4 31 1248.5 32 1306.0 33 1363.9 34 1422.0 35 1480.5 36 1541.0 37 1600.1 38 1659.2 39 1719.5 40 1709.9 41 1840.5 42 1901.2 43 1962.9 44 2024.7 45 2086.5 Depth (In.) Content (Gal.) 46 2148.3 47 2210.0 48 2271.7 49 2332.3 50 { 2392.8 51 2452.1 52 2512.3 53 2572.3 54 2631.0 55 2689.5 56 2747.8 57 2805.7 58 2862.3 59 2918.5 60 2975.4 61 2030.8 62 2085.7 63 3141.2 64 3195.1 65 3248.5 66 3300.3 67 3340.5 68 3397.9 69 3445.5 70 3494.7 71 3530.9 72 3592.3 73 3637.8 74 3682.3 75 3724.8 76 3765.2 77 3804.5 78 3843.5 79 3880.3 80 3915.6 81 3948.4 82 3979.7 83 4010.1 84 4036.6 85 4059.9 86 4081.7 87 4100.7 88 4115.1 89 4125.6 DSW 334674 STLCOPCB4081144 STANDARD OPERATING INSTRUCTIONS . FOR SOLID AROGLOR 5460 PROCESS FUNCTION OUTLINE III. ' C. I. NO. 2 WEIGH TANK, NO. 10 & 11 CHLORINATORS, AND NO. 5 BLOW TANK 1.1 Scope This covers the charging, start-up, shutdown, normal operation, and emergency situations involving the No. 2 Neigh (charge) Tank, No. 10 & 11 Chlorinators, and the No. 5 Blow Tank for production of 5460 Solid Aroclor. To avoid confusion, the instructions for the chlorinators will be written for No. 10 with the corresponding item number, controller number, etc., for No. 11 appearing in . parenthesis. 1.2 Description of Process Crude 5460 (5060 A.roclor) is produced by the batch chlorination of a i-jeighed quantity of Santowax R in a vertical reaction vessel with Ferric Chloride as a catalyst. Chlorine gas is added at the bottom of the vessel. By-product HC1 gas vented at the top of the chlorinator is recovered in the Muriatic Acid Department. The 5060 produced in batch chlori nation is transferred to a blowing tank when the chlorination is completed. Chlorine gas is fed to the chlorinator from tank cars. 11 PROCESS DIAGRAM Attached. III. DESCRIPTION OF PROCESS ' 3.1 Start-Up A. Charge Therminol Cooling System for the No. 10 (11) Chlorinator Both chlorinator cooling systems use the same surge tank (Item 114). Therminol 1242 can be charged directly to the surge tank by the following procedure: 1. Align valves in line from storage tank No. 5 to surge tank (Item 114). Care must be taken to ensure that all valves to the other surge tanks are closed. They are also filled from this storage tank line. 2. Check level gauge at surge tank.and start the storage tank pump. .. DSW 334675 STLCOPCB4081145 Aroclor PFO 2. C. III. 3.1 A. 3. Observe the level gauge at surge tank and shut off pump when you have 700 Gals, or 3-1/2 ft. in the sight glass. Once circulation is established Therminol should be added to bring the sight glass level to 12" (approximately 150 gallons more). A. Close valves in line from storage tank to surge tank. B. Charge Therminol Cooling System for No. 10 (11) Chlorinator Charge Therminol (1248 Aroclor) into the surge tank (Item 114) by the following procedure: 1. Use temporarily relocated Pyranol pump to charge the tank. 2. Position 55 gal. drum next to the pump. Remove drum bung and vent cap. 3. Connect flexible hose to pump suction and the stainless steel pipe to be placed in the drum. 4. Position discharge line from the pump into the surge tank (item 114). 5. Open valve on pump suction. Insert pipe into the drum and start pump. 6. Adjust the suction valve on the pump until flow is steady. 7. Continue to fill the tank until 16 drums or 850 gallons are in the'surge tank. C. Start-Up Therminol Cooling System for No. 10 (11) Chlorinator 1. Set valves in the system to flow through the No. 10 (11) chlorinator heat exchanger (Item 106 (119)) and through the tube side of the therminol cooler (Item 116 (123)). 2. Close drain valve on the suction of the circulating pump (Item 115 (122)). 3. Close valves to put Therminol from the. furnace system on the No. 10 (11) Aroclor chlorinator heat exchanger (Item 106 (119). Tag lines closed. 4. Open steam valve to coil rn the surge tank (Item 114). Both chlorinator cooling systems use the same surge tank (Item 114). There is no temperature controller on this tank. The steam valve should be set to bring the tem perature in this tank to 45C. Once in operation, the valve can be closed. It will be reopened upon shutdown of both cblor-in??tors or if required to maintain an adeou.ate temperature. DSW 334676 STLCOPCB4081146 Aroclor PFO 3. C. III. 3. 1 C. 5. Check level in the surge tank (Item 114). Should have an adequate level in the tank. 6. Set TRCA-106-1 (119-1) in "Auto" with set point at 190C. Low temperature alarm set at 120C. - high temperature alarm set at 275?C. 7. Set FICA-115-1 (122-1) in "Auto" with set point at 300 GPH. Low flow alarm should sound at 250 GPH. 8. When the material in the surge tank is at 45C.. start the circulating pump (Item 115 (122). 9. Check flow through the Therminol cooling system by observ ing the following items: a. Pump discharge pressure should be 45 psig on the local gauge. b. Flow through Therminol system should be 300 GPM. Check FICA-115-1 (122-1). c. Check action of control valve to the No. 10 (11) Aroclor heat exchanger. See TRCA-106-1 (119-1). Valve should be closed. 10. Set TICA-116-1 (123-1) on the Therminol cooler to 70C. Low temperature alarm is set at 50C. - high temperature alarm is set at 90C. 11. Check the following temperature points in the Therminol cooling system: a. Pump discharge temperature, No. 10 (11) chlorinator heat exchanger outlet temperature, and the outlet tem perature of the water-cooled heat exchanger for the therminol system (See TRCA-116-1 (123-1)). 12. If there are no problems with the system, let it continue to circulate until needed. D. Initial Equipment Check for Start-Up Open valves on steam lines to the Santowax supply to the weigh tank (Item 101). Open valves in the steam lines to the coil on the weigh tank. 1. Set temperature controller on the No. 2 weigh tank, TIC- 101-1, at 150C. The controller has no provision for . manual operation. . DSW 334677 STLCOPCB4081147 Aroclor PFO 4. C. III. 3.1 D. 2, Check Therminol cooling system. a. Therminol cooler controller TICA-116-1 (123-1) is set in "Auto." with a set point at 70C. b. Flow controller FICA-115-1 (122-1) in "Auto." with the set point at 300 GPM. c. Pump pressure 45 psig. 3. The No. 5 blow tank temperature controller TIC-125-1 should be in "Auto." with the set point at 24CC. 4. Make sure the main Aroclor therminol heater system is in operation and is circulating at 25QC. This system provides the heat for high temperature li.ne tracing and for the No. 5 blow tank coil. 5. Open therminol feeder lines to heat the following equipment: a. Transfer lines from weigh tank (Item 101) to the transfer pump and to No. 10 (11) chlorinator (Item 104 (117). b. Circulating line on No. 10 (11) chlorinator. c. Sample line on No. 10 (11) chlorinator. d. Transfer line at No. 10 (11) chlorinator to the No. 5 blow tank (Item 12j). e. Plate coils on No. 5 blow tank (Item 125). f. Transfer line from No. 5 blow tank to the pump (Item 126). Observe temperature to be sure the therminol system stays at 250C. . or returns to this temperature after the various feed lines have been started up. 6. Open steam valve on mist eliminator (Item 107 (120)) tracing. 7. Open water valve to S&K jet (Item 127) - 20 psig water pressure. This unit stays in continuous operation. DSW 334678 STLCOPCB4081148 Aroclor PFO 5. C. III. 3. D. 8. Start the air blower (Item 124). Open the valve at the No. 3 blow tank two turns. 9. Check the suction on the No. 5 blow tank (Item 125) to be sure it is adequate for operation. 10. Open the manual valves in the water system to the Aroclor . cooler (Item 116 (123)). E. Charge and Operating Temperatures for Crude 5460 Solid Aroclor The charge and operating temperatures for the chlorinators are shown in Table I. F. Charge No. 2 Weigh Tank (Charge Tank) 1. Charge 11,200 lbs. of Santowax R in the following manner: a. Set the valves to receive the charge from the Santowax Department. Santowax R is obtained from the Santowax storage tank. b. Open the manual valve in the Santowax R line. c. Depress the pushbutton near the scale to open the auto matic valve. This will put the annunciator window light out which is marked "Charge Complete Terphenyl Feed Tank". d. Start the pump to charge the weigh tank. Santowax R is now entering the weigh tank. e. When the measured weight reaches the set point, the automatic Santowax R control valve will close and annunciator window marked "Charge Complete Terphenyl Feed Tank" will be actuated. f. If the charge valve does not close at 11,200 lbs. another switch will attempt to close it at 15,000 lbs. and also sound an alarm. g. Close the manual valve in the Santowax R line. Turn off pump. h. Open the automatic valve and allow the line to drain, then reclose the automatic valve. i. Obtain a Santowax R sample before adding catalyst. j. Open wing nut lid on top of the weigh tank (Item 101) and add 5 pounds of Ferric Chlorine. Close the lid after adding the Ferric Chloride. DSW 334679 STLCOPCB4081149 Aroclor PFO TABLE I 6 BATCH CHLORINATOR OPERATING CONDITIONS - 5060 AROCLOR Chlorinator Charge:(Lbs.) . Santcwax R 11,200 Approximate Pounds 1007=, Chlorine Required to Produce Batch: 30,500 Totalizer Chlorine Settings Lbs. Cl2:@ 80% Chlorinator Temperature: Beginning Ending 24,400 190C 250C. Softening Point 105 - 115C Weight of Crude Batch'- Lbs.: Gallons 24,200 2,000 NOTE: ADD 15 POUNDS OF FERRIC CHLORIDE TO EACH BATCH CHLORINATOR CHARGE. DSW 334680 STLCOPCB4081150 Aroclor PFO 7. C. III. 3.1 F. 1. k. Start the agitator in the weigh tank. Allow agitation to take place for a minimum of one hour. Stop the agitator just before material in the weigh tank is to be charged to the chlorinator. 1. The-material is now ready for the next chlorinator charge when needed. 6. Charge No. 10 (11) Chlorinator and Start Chlorination 1. Programmed Chlorinator Operation a. Close manual chlorine valves at distributors on No. 10 (11) chlorinator. b. Close vent valve on chlorinator. c. Open HC1 valve to off-gas condenser and on the Muriatic Acid area. d. Set the chlorine flow' controller FRC-104-1 (117-1) in "Manual-Cas'cade". :The controller set point is auto . matically altered in three steps - 1,500 lbs/hr. for first hour; 2,000 lbs/hr. for the second hour; and 3,000 Ibs/hr. for each of nine subsequent hours. The last set point on the flow controller will stay on until the programmer is jogged back to step 0. e. Set the temperature controller TRCA 106-1 (119-1) in "Manua1-Cascade" with the manual set point at zero. The last set point on the temperature controller will stay on until the programmer is jogged back to step 0. The cascade set points are as follows: 1st Hour 2nd Hour 3rd Hour 4th Hour 5th Hour 6 - 7th Hour 8 - 9th Hour 10 - 11th Hour 190C 200 210 220 230 240 250 250 f. Check the following control instruments: (1) #2 weigh tank temperature - TIC-101-1 set at 150C. (2) Therminol cooling temperature - TICA-116-1 (123-1) . set at 70C. (3) Therminol cooling flow - FICA-115-1 (122-1) at 300 0PM j c on r c 11 g t in 11 Au q* 1 # (4) No. 5 blow tank temperature - TIC-125-1 set at 240r.. DSW 334681 STLCOPCB4081151 Aroclor PFO 8 C. III. 3.1 G. 1. g. Set valves to transfer charge from #2 weigh tank to the No. 10 (11) chlorinator. Special care must be taken to close the charge valve to the other chlori nator, since it is possible to pump to the wrong one. Be sure transfer line to blow tank is closed off. h. Staft transfer pump (Item 103). The pump discharge valve and the valve at the bottom of the weigh tank have been left open. This is to allow for the thermal expansion of the 150C Santowax R remaining in the transfer line that is being heated to 250C by the hot therminol. In this way the pump's seal and the valve's packing are protected from a build up in pressure. i. As pump-out proceeds and weight falls to 100#, a switch actuates to close down the pump (Item 103). An alarm sounds and the pump "Run Light" will go out. j. The transfer pump (Item 103) cannot be started if the charge valve is open and vice versa. k. Close the charge valve on top of the chlorinator. Set valves to circulate the No. 10 (11) chlorinator batch through the heat exchanger (Item 106 (119)) and back to the chlorinator. Once again check line to blow tank. l. Start the circulating pump (Item 105 (118)) when about one-third of the batch is transferred. m. After circulation has been established the chlorination is started by pressing the start button on programmer XC1-CP1 (XC1-CP2). This injects both a flow and temperature set point into the respective controllers. Change the temperature controller TRCA-106-1 (119-1)' from manual to automatic. The chlorine flow is started in Manual. . Set the instrument output pressure at 6 psig then open the manual valves on the distributor. Manually raise the chlorine flow rate until it matches the yellow arrow of the programmer set point. Then change the controller FRC-104-1 (117-1) from manual to automatic. The batch chlorine flow and temperature will now be controlled according to the preset program. Now a flow integrator with two dials is used to read out 80% and total pounds of chlorine. When integrated flow equals the preset 80% mark, one dial stops counting, an alarm bell rings and "Chlorinator #10 (11) 80% Chlorination" lights up. The second dial continues indicating total flow until chlorine flow is shut off. DSW 334682 STLCOPCB4081152 Aroclor PFO 9. C. III. 3.1 G. 1. n. Chlorine header pressure control PIC-500-07 will control the pressure to 20-25 psig. A low pressure alarm is set at 15 psig - high pressure alarm at 35 psig. o. After four hours, take a sample of the Aroclor and . check for softening point. Samples are taken off . the circulating line. This sample is a check to be sure a short charge was not transferred into the chlorinator. The next sample after that will be taken when the 807. alarm bell rings. p. Check the following items during operation: (1) Circulation temperature on TRCA-106-1 (119-1). (2) Chlorine flow on FRC-104-1 (117-1). (3) Therminol cooling system flow through FICA-115-1 (122-1) - 300 GPM. (4) Therminol temperature on TICA-116-1 (123-1) - 70C. (5) Chloriiiator body temperature on the multipoint #1 (7). q. Kigh chlorinator temperature or failure of the circulating pump will sound an alarm. This high chlorinator body temperature alarm set at 275C. is in addition to the high alarm of TRCA-106-1 (119-1). r. The alarm bell will ring when 80% of the chlorine has been fed to the chlorinator. Immediately take-a sample at the circulation line to determine the point which the chlorination has reached and the additional chlorine to add. s. Continue the chlorination until complete. It may be necessary to run the softening point more often during the last one or two hours of the chlorination. A density measurement system DRC-104-4 (117-4) is installed to determine the correlation between density and final soften ing point. This might in the future eliminate the time consuming softening point determination. For the present it will just record the density. t. Upon completion of the chlorination (softening point 105112C.), shut off the manual chlorine feed valves on the distributors, circulate for 10 min., take a final sample and pump to the NoA5 blow tank. DSW 334683 STLCOPCB4081153 Aroclor PFO 10. C. III. 3.1 G. 1. u. As previously stated the final set points will remain on the controllers until the programmer is advanced to Step 0. If there is any delay in transferring, TRCA-106-1 (119-1) may remain in "Automatic-Cascade" as long as Step 0 does not appear on the programmer. At Step 0 the temperature controller must be put in manual with a set point of zero; otherwise, cooling will start and will continue until the circulation cooler is plugged. 2. Manual Operation Complete manual operation is possible but is not recommended because the function of the programmer is to relieve the operator of the duty of keeping time and manually dialing in set points. The operation is very similar to the auto matic programmed operation except for the following: a. Place the chlorine flow controller FRC-104-1 (117-1) in "Automatic-Set1.1 Then place the arrow at 1,500 lbs/hr. After one hour move it to 2,000 Ibs/hr. and then one hour later to 3,000 lbs/hr. The controller can also be placed in "Manual" and the control valve positioned manually. The integrator digit counters will continue to totalize and will sound at the 807, point. b. Place the circulating temperature controller TIC-106-1 (119-1) in "Automatic-Set" and increase the set point in a number of steps which will simulate the programmer action. If the process is to be operated in "Manual" then this can also be done by manually positioning the control valve and observing the temperature on the con troller. ' c. Samples should be taken more often towards the end to ensure against over chlorination. H. Transfer to No. 5 Blow Tank and Air Blow 1. Set transfer lines to pump to the No. 5 blow tank (Item 125). Be sure Therminol heat is on jacketed lines and that the temperature controller TIC-125-1 is set at 240C. The chlorinator is still vented to the off-gas storage tank. DSW 334684 STLCOPCB4081154 Aroclor PFO 11. C. III. 3.1 H. 2, Check the level indication instrument, LIA-125-2.1 to be sure there is enough room to transfer into the blow tank (Item 125). The tank is sized to hold two chlorinator batches. There is a high level alarm - LIA-125-2. 3. Change final valve in the transfer line and allow material to pump from the No. 10 (11) chlorinator to the No. 5 bio;? ' tank. Observe transfer and note level increase in the No. 5 blow tank by LIA-125-2.1. Make sure the complete batch has been transferred. At the completion of the transfer, close the valve in the circulating system and shut off the circulating pump (Item 105 (118)) on the No. 10 (11) chlorinator, A. The chlorinator is now ready to charge back for the next chlorination. 5. Record transfer information on the chlorinator data sheet and in the log book. 3.2 Routine Operations During normal operations of the #2 weigh tank. No. 10 (11) chlori nator, and No. 5 blow tank system, the following conditions will exist in the process. A. Mai.n Therminol Heater 1. Flow through the main therminol heater system will be indicated on FIC-628.1, A15 GPU normal. 2. TRCA-629.12 controls the temperature of the main therminol heating system. Set point normally at 280C. Low tem perature alarm set at 220C. - high temperature alarm set at 325% B. No. 2 Neigh Tank 1. Assuming a batch is charged into the weigh tank ready for the chlorinator, the following conditions will exist in the control room. The annunciator panel will indicate "charge complete terphenyl feed tank". 2. The control valve in the Santowax R charge line will be closed. 3. TIC-101-1 will be controlling the temperature in the weigh tank at 150C. 4. Temoerature on the Multipoint Indicator will indicate 150C. DSW 334685 STLCOPCB4081155 Aroclor PFO 12. C. III. 3.2 B. 5. The agitator will be running to keep the Ferric Chloride in suspension. 6. The transfer pump will be shut off. C. No. 10 til.) Chlorinator 1. Chlorine flow will be indicated on FRC-104-1 (117-1). If in "cascade-auto" control, the Taylor Timer will be controlling the flow by program system. 2. Temperature will be controlled by TRCA-106-1 (119-1). With the system in "cascade-auto", the temperature will be controlled by a preset program. Initial starting temperature set point of 190C. , completion temperature 250C. 3. No. 10 (11) chlorinator circulating pump will be in operation. 4. The Therminol chlorinator cooling system should have the following checks: a. Flow will be indicated by FICA-115-1 (122-1). Normal set point 300 GPM. Low flow alarm set at 250 GPH. b. Temperature in the circulating system is indicated by TIC-116-1 (123-1). Normal indication is 70C. Low temperature alarm set at 50C. - high temperature alarm set at 90C. c. Surge tank Therminol level (Item 114) is 12 inches in the sight glass, " d. The Therminol cooling system pump discharge pressure should be 45 psig. 5. Temperature of the No. 10 (11) chlorinator can also be observed on the Multipoint temperature recorder point 1(7). There should be no more than a 10C temp, spread between the body temp, and the circulating temperature. D. No. 5 Blow Tank . 1. Temperature will be indicated by TIC-125-1. Normal set point 240C. 2. Level in the No. 5 blow tank will be indicated by LIA125-2.1. 3. Water valve should be open to the S&K let providing suction on the No. 5 blow tank - pressure : 2(3 psig. 4. The air blower (Item 124) should be operating with a discharge pressure of 8-10 psig. DSW 334686 STLCOPCB4081156 Aroclor PFO 13 C. III. 3.2 E. Data Sheets A Solid Aroclor system data sheet is available for the #2 weigh tank, No. 10 (11) chlorinator, and the #5 blow tank. Filling out this sheet is a normal portion of the operator's duties during the shift. 3.3 Safety Features A. The weigh tank (Item 101) has an interlock .system which will not allow starting the transfer pump (Item 103) when Santowax R is being charged into the weigh tank. This interlock is to assure that an overcharge of Santowax cannot be made to the No. 10 (11) chlorinator. A high weigh alarm set at 15.000 pounds will sound for an overcharge. B. A high temperature alarm is set at 275C. on the body of No. 10 (11) chlorinator (Item 104 (117)). A low temperature alarm is provided at 120C. to prevent production of unstable Aroclors. C. The main tlierminol heating circulation system has several safety features which can be found in the PFO for this heater system. D. Check the level in the therminol cooling system surge tank (Item 114) to be sure the therminol level is 12 inches in the sight glass. E. The valves in the main therminol heating system used to put heat on the No. 10 (11) chlorinator heat exchanger (Item 106 (11S)) will normally be tagged out since this heat exchanger is used for cooling. The Therminol heating system is available only for cases of unplugging the heat exchanger. . F. When the chlorine and temperature programmed control system is in operation, the preset program should not be disturbed since this can cause excessive chlorine flow or temperature problems to result. G. Normally, when the programmed flow control system is in operation, a sample of the material being chlorinated will be taken after four hours of operation. This sample is taken to assure a short charge has not been made to the No. 10 (11) chlorinator. The sample should be checked for softening point. If this sample indicates a normal batch, the next sample would be taken when the 80% bell rings as preset by the chlorine flow totalizer. This sample is to assure a batch is not over-chlorinated and does not set up in the chlorinator preventing its transfer to the #5 blow tank. DSW 334687 STLCOPCB4081157 Aroclor PFO . 14. C. III. 3.4 Shutdown Operations of the No. 2 weigh tank, the No. 10 (11) chlorinator, and the No. 5 blow tank can occur which will cause temporary or prolonged shutdowns. The following detailed information concerns individual shutdowns of each of the above items. If the entire system is to be shut down, the various sections can be combined to achieve this objective. Dependent on the reason for the shut down, it may be necessary to isolate the system from the main therminol heating system to make the system safe. This must be considered, depending on the situation. A. No. 3 Neigh Tank (Item 101) ' 1 Temporary Shutdown . a. Close the manual valves in the Santowax supply line to the weigh tank. b. Close automatic valve in Santowax line to weigh tank. c. Leave TIC-101-1 in "Auto" with set point at 130C. d. Leave therminol heat on the transfer lines to the No. 10 (11) chlorinator. e. The agitator and pump will normally be shut down unless in use. 2. Prolonged Shutdown a. Close the manual valve in the Santowax supply lines to the weigh tank. ' b. Close automatic valve in Santowax line to weigh tank. c. Close the valve at the bottom of the weight tank if necessary. - d. Leave the discharge valve on transfer pump open. e. Move the weigh tank temperature control TIC-101-1 set point to 0C. Close the manual valve in the steam supply line. DSW 334688 STLCOPCB4081158 Aroclor PFO 15. C. III. 3.4 A. 2. f. The agitator and transfer pump will be shut off. g. Close the valves in the main therminol heating system lines for the weigh tank transfer lines. Clo'se valves in. steam supply to Biphenyl lines. ' h. The tank may or may not be empty, dependent on the work to be done or the cause for shutdown. Under normal conditions the tank will be empty. i. Note shutdown information on data sheet. j. Drain the weigh tank if necessary for repair work. k. Leave the system in this condition until needed. B. No. 10 (11) Chlorinator (Item 104 (117)) Operations can occur which will require a chlorinator to be cut back or temporarily shut down. Some of these items are failure of chlorine feed, or a tank car emptying. Normally, if a partial reduction in the chlorine feed occurs, the batch liquid chlorinators will be shut off and the No. 10 (11) chlorinator will continue to be operated. 1. Temporary Shutdown a. The circulating pump (Item 105 (118) will normally be left in operation. b. Close the chlorine valves at the distributor on the No. 10 (11) chlorinator. ` c. Check the chlorine header pressure and chlorine feed to the other chlorinators. Pressure should be 20-25 ESi. d. Check to see that liquid chlorine is being fed to the vaporizer and that steam is on the vaporizer. Steam pressure should be 15 psig. Discharge pressure on the vaporizer should be 70-100 psig. Chlorine header pressure normally 20-25 psig. e. Shutdowns should be minimized. If the cause of the cut back can easily be remedied, start the chlorinator back immediately. . f. Leave the therminol cooling system circulating. DSW 334689 STLCOPCB4081159 Aroclor PFO 16. C. III. 3.4 B. 1. g. Ensure the cooling therminol does not flow through the circulation cooler. As long as the programmer _ is in a step other than 0, it is taken care of automatically. If the programmer is in Step 0 then TPvCA-106-1 (119*-.l) should be placed in manual with the set point at zero. ' h. Leave the main therminol heating system circulating on the jacketed lines. i. Notify your chief operator or department supervision immediately in case of a problem. . 2. Prolonged Shutdown a. Normally, when a chlorinator will be left down for a period longer than a few hours, the chlorination will be completed and the batch pumped out prior to shutdown. If Maintenance personnel are to work on the chlorinator, it may be necessary to vent the - vessel and purge the chlorine lines and the chlorinator tank with CC>2. NOTE: In case of a complete shutdown for maintenance work, the chlorine valves on the main header to the chlorinator, and the transfer lines into the vessel, will be tagged. The circulating pump circuit breaker box switch will also be tagged out. b. Empty chlorinator by pumping it out. Then shut off the circulating pump. Drain the chlorinator and pump suction line. c. Close chlorine valves at distributor on No. 10 (11) chlorinator. d. Check chlorine header pressure as in Item l.c. above. e. Close the 1IC1 vent valve on the chlorinator to the . off-gas storage tank. f. Notify your chief operator or department supervision the vessel is shut doTM. DSW 334690 STLCOPCB4081160 Aroclor PFO 17. C. III. 3.4 B. 2. g. Shut down the therminol cooling system by: (1) Shutting off circulating pump (Item 115 (122)j. (2) Leave FICA 115-1 (122-1) in ''Auto" with set - pointat 300 GPM. . (3) TICA-116-1 (123-1) will be in "Auto" with the set point at 70C. (4)Turn on the steam to the surge tank (Item 114). This will keep the system ready for use. (5) In case the therminol cooling system must be worked on, it may be necessary to drain the system. If this should occur: (a) Shut off the steam to the surge tank. (b) Shut off %-7ater to the cooler (Item 116 (123$, if necessary. (c) Tag out the circulating pump (Item 115 (122)) circuit breaker; and . (d) Tag out the therminol heating valves to the No. 10 (11) chlorinator heat exchanger system. h. Note shutdown information on the data sheet. C. No. 5 Blow Tank (Item 125) 1. Temporary Shutdown a. Close the valve at the bottom of the No. 5 blow tank (Item 125). b. Vent pump discharge line into the blow tank. c. Transfer pump will be shut off. d. Leave TIC-125-1 set point at 240C. Leave in "Auto". e. The air blower will continue to run. f. Water will remain on the S&K jet (Item 127) , 20 . fig i. g. The system will be left in this condition until need to start back up. . DSW 334691 STLCOPCB4081161 Aroclor PFO 18. C. III. 3.k C. 2. Prolonged Shutdown a. Normally if this vessel is to be shut down for any length of time, the material in the tank will be emptied. b.' Close the yalve at the bottom of the blow tank. c. Shut off the transfer pump (Item 126). d. Adjust TIC-125-1 controller to 0C. Close the manual valve in the therminol heating system to the coils on the No. 5 blow tank and tag out valves. e. Shut off the air blower (Item 124). f. Shut off water to the S&K jet (Item 127). g. Leave the system in this condition until necessary to start back up. D. Emergency Shutdown Normally, an emergency shutdown does not occur concerning the weigh tank (Item 101) or the No. 5 blow tank (Item 125). However, emergencies can occur which make it necessary to shut down the No. 10 (11) chlorinator as fast as possible. The following methods can be used. 1. From the Field a. Close the manual chlorine valves to the distributor, or the manual valve from the chlorine header feeding the No. 10 (11) chlorinator. ' . b. Shut valve in HC1 pipe line to the Muriatic Acid Dept, if necessary. c. Stop circulating pump (Item 105 (118)) if necessary. d. Dependent on the emergency situation which has occurred, continue to shut this system down ' systematically by normal procedure. 2. At the Panel a. Stop chlorine feed to the No. 10 (11) chlorinator. This will be done as follows, dependent on operation: DSW 334692 STLCOPCB4081162 Aroclor PFO 19 C. III. 3.4 D. 2. a. (1) Manual Operation Controller FRC-104-1 (117-1) in "Manual". Adjust chlorine flow controller set point to zero. Immediately shut off manual valves feeding this chlorinator in the field. (2) Programmed Operation Move chlorine controller FRC-104-1 (117-1) from "automatic": to "Manual"1 and adjust set point on chlorine feed controller to zero. Proceed as in Item (1) above, b. Shut valve in KC1 pipe line to the Muriatic Acid Department if necessary. c. Stop the circulating pump (Item 105 (118) if necessary. d. Continue shutdown of this unit as is necessary to handle the emergency which has occurred. 3. Emergency Shutdown Therminol Cooling System for No. 10 (11) Chlorinator a. Stop therminol cooling system circulating pump. b. Close manual valves as necessary in the system. c. The pump can be shut off in Item a. above at the pump itself or at the motor control center circuit breaker. 3.5 Control Loops, Interlocks, and Alarms A. Control Loops There are nine (9) major control loops in this system. i No. 2 Weigh Tank Scale loop - 101 The function of this loop is to allow setting the scale by the adjustable set point for Santowax R charges. When the material reaches the desired weight, it automatically closes the control valve in the feed line to the weigh tank and rings an alarm bell indicating "charge complete terphenyl feed tank". During charging of the weigh tank, the transfer pump (Item 103) cannot be started. In case the weigh tank is overcharged, an alarm horn will sound at 15,000 lbs, and will again attempt to close the charg ing valve. DSW 334693 STLCOPCB4081163 Aroclor PFO 20. C. III. 3.5 A. 1. As pump-out proceeds and weight falls to 100 lbs., the pump (Item 103) is shut down. An alarm sounds and "terphenyl feed pump shutdown" is indicated. The pump running light will also go out. 2. Weigh Tank Temperature Control - TIC-101-1 The function of this loop is to maintain a constant temperature of 150^. in the weigh tank. This is accomplished by measurement of the temperature and controlling the heat input by throttling a control valve in the steam line to the coil in the weigh tank. 3 No. 9 Chlorinator Chlorine Flow Control - FRC-104-1 (117-1) The function of this loop is to control the chlorine flow to the No. 10 (11) chlorinator to regulate the chlori nation rate. This is accomplished by measurement of the chlorine flow with an orifice and controlling this flow with a control valve in the chlorine feed line. This system can be operated manually, automatically, or by a preset programmed chlorine feed control. a. Manual Control . . The chlorine flow controller FRC-104-1 (117-1) is positioned in "Manual". The instrument'pressure is regulated to give the desired chlorine flow to the No. 10 (11) 1 chlorinator. . b. Automatic Flow Control The No. 10 (11) chlorinator chlorine flow controller FRC-104-1 (117-1) is positioned in "Auto-Set". The chlorine feed desired is set on the controller which will maintain this chlorine feed by adjusting the control valve as required. c. Programmed Flow Control The chlorine flow controller has the set points in "Auto-Cascade". The first chlorine integrator set point is adjusted on a digit counter for the desired chlorine alarm level. When the desired quantity of chlorine has entered the chlorinator, an alarm bell will ring and an annunciator light will flash in dicating "No. 10 (11) chlorinator, 80% chlorination". A second digit counter will continue to totalize the flow. The integrator readout (X2) is total pounds of chlorine. The totalizer settings can be used with the automatic flow control above if the controller , , ,, it. , ~ ^ ,, A ~ 11 1 1 s mf*V>rs ' r\r> f- t* oi r* y* to t 1 A cascade", the predetermined prograTM will change the DSW 334694 STLCOPCB4081164 Aroclor PFO 21. C. III. 3.5 A. 3. c. chlorine flow rate to the No. 10 (11) chlorinator. The chlorine flow program is set by turning the knob or( each flow profile set point. This program, once set up, should not be disturbed without con .. suiting supervision. It is: 1,500 #/hr. for one . hour; 2,000 #/hr. for one hour; and 3,000 #/hr. for the remaining time. 4. No. 10 (11) Chlorinator Temperature Control - TRCA-106-1 m?.-U The function of this loop is to provide temperature control of the chlorination batch in the No. 10 (11) chlorinator. This is accomplished by measurement of the temperature in the crude Aroclor circulating line at the heat exchanger and controlling the therminol cooling system to the shell of this heat exchanger (Item 106 (119). The temperature controls can be operated manually, automatically, or by a predetermined program temperature profile. The temperature system has a low temperature alarm at 120C. - a high temperature . alarm at 275C. Range of the instrument is 0-300C. a. Manual Control The temperature controller TRCA-106-1 (119-1) will be in "manual". Circulating of the therminol cooling system across the No. 10 (11) chlorinator heat ex changer cai be controlled manually by adjusting the control valve with TRCA-106-1 (119-1). . . Adjust until the desired temperature is acquired. b. Automatic Control The temperature controller TRCA-106-1 (119-1) is in "Auto-Seti" The controller set point is adjusted to the desired temperature. It will automatically adjust the control valve to maintain the temperature. . c. Programmed Temperature Control . The temperature controller is placed in "auto-cascade". The chlorination temperature time profile is adjusted to the desired temperature by turning the knob on each temperature profile set point. A predetermined Drogram is set up on the Taylor Timer. After start of the program, the Timer will automatically advance through the temperature profile as set up by the pro gram. These set points will be directed by the pro grammer only if TRCA-106-1 (119-1) is in "auto-cascade". This program, once set up, should not be disturbed without consulting supervision. DSW 334695 STLCOPCB4081165 Arocl or PFO 22. C. III. 3.5 A. 5. Chlorine Header Pressure Control - PIC-500.07 ' The function of this loop is to maintain the chlorine header pressure to the Aroclor chlorinators within a . range of 20-25 psig. This is accomplished by measuring the chlorine header pressure and throttling a control valve in the discharge from the chlorine vaporizer to maintain the chlorine header pressure within * 1 psig of the set point. A low pressure alarm is set at 15 psig and a high pressure alarm at 35 psig. 6. Therminol Cooling System Flow Control-FICA-115-1 (122-1) The function of this loop is to maintain a constant flow of 300 GPH in the Therminol cooling system. This is accomplished by measurement of flow with an orifice flow meter and adjusting a control valve to by-pass the No. 10 (11) chlorinator heat exchanger (Item 106 (119). Flow through the No. 10 (11) heat exchanger is regulated by the temperature control TRCA-106-1 (119-1). As the chlorinator heat exchanger needs more cooling fluid the control valve reduces the by-pass quantity. Normal operation of the system is with the controller in "Auto" and the set point at 300 GPM. A low flow alarm will sound at 250 GPH. 7. Therminol Cooling System Temperature Control - TICA-116-1 (123-1) ` The function of this loop is to control the temperature of the cooling therminol system at 70C. This is ac complished by measurement of the discharge temperature from the therminol water cooler (Item 116 (123) and automatically throttling the water flow on the shell side of the cooler. The low temperature alarm on this system is set at 50C. - the high temperature alarm is set at 90C. Experience has shown that a temperature controller is not needed on the surge tank (Item 114). 8. No. 5 Blow Tank Temperature Control - TIC-541.01 The function of this loop is to maintain a constant temperature of 240C. in the No. 5 blow tank.. This is accomplished by measuring the temperature in the blow tank and throttling the control valve in the Therminol heating system to the coils in the No. 5 blow tank. There are no alarms in this system. DSW 334696 STLCOPCB4081166 Aroclor PFO 23. C. III. 3.5 A. 9. No. 2 Blow Tank Level Indication - IIA-125-2.1 ' This loop measures the level of crude Aroclor in the No. 5 blow tank. This is accomplished by use of a bubbler differential pressure level indication in strument. A 0-1007. dial indicates the tank level. B. Interlocks There is one interlock in this system. 1. Weigh Tank System The Santovax transfer pump (Item 103) cannot be started while Santovax R is being filled into the weigh tank. This interlock is energized when the control valve in the feed line is open. Conversely the charge valve cannot be opened if the pump is running. C. Alarms The following alarms exist through this system. 1. Weigh Tank (Item 101) a. When the measured or preset weight approaches the set point on the scales, an alarm bell will sound indicating "charge complete terphenyl feed tank". b. A high weight alarm will sound if the weigh tank is filled above 15.000 lbs. Immediate action should be taken to stop the filling by stopping the charge pump and/or closing the manual valve. . c. An alarm will sound upon completion of pump-out. The pump is shut off automatically. 2. No. 10 (11) Chlorinator System (Item 106 (117)) a. Chlorine Flow Alarm (1) When the chlorine totalizer is being used, an alarm bell will ring when the batch is 807. chlorinated. b. Temperature Alarms Abnormal temperature alarms are set on the cooler for a low circulation temperature of 120C. and a high tem perature of 275C. In addition to the high-low temperature alarm of the circulation, .high-low alarms will sound at 275C. and 120C. for the chlorinator body temperature. . DSW 334697 STLCOPCB4081167 Aroclor PFO 24. C. III. 3.5 C. 2. c. Chlorine Header Pressure Alarm The chlorine header pressure will sound an alarm at a low pressure of 15 psig and a high pressure of 35 psig. This will actuate an annunciator on the chlorinator panel indicating "High-Low Chlorine Header Pressure." d. Low Flov? Alarm A low flow alarm will sound for the Therminol cooling system if the flow falls below 250 GPM. e. Abnormal exit temperatures on the therminol cooling system from the cooler (Item 116 (123)) will sound an alarm. The low temperature alarm is set at 50C. and the high temperature alarm at 90C. f. An alarm will sound upon circulation pump shutdown (Item 105 (118)). C. IV. COMMENTS ON PROCESS A. Special flexible piping joints have been made to the weigh tank (Item 101) since this tank is placed on scales,. These flexible piping joints should be carefully inspected to be sure there are no leaks since the material contained in them is extremely hot. During weighting of the raw material charge, the operator should be careful to eliminate problems with excessive movement of the scale. B. Steam is provided on the incoming transfer lines and the coil to the weigh tank. From the bottom piping on the weigh tank, all the transfer lines and coils in process vessels have therminol heat up to the No. 5 still. Then steam is used in the transfer lines to the flaker hold tank. C. The transfer pump (Item 103) for the weigh tank has steam on the casing of the pump. - D. The therminol heating system has been provided for this Solid Aroclor facility to eliminate use of gas torches on vessels and pipe lines. E. Care must be taken not to fill the therminol cooling system surge tank (Item 114) too full during normal operation. This can cause the tank to run over when the circulating pump is stopped. F. The programmer has been set up to hold the last temperature and chlorine flow set points for a total chlorination cycle time of 20 hrs. This is to prevent the chlorine flow from automatically being shut off at the end of a batch before the manual distributor valves can be closed. It also allows for the chlorination cycle to be increased from the designed 11 hrs. without changing the programmer itself. DSW 334698 STLCOPCB4081168 Aroclor PFO 1. J 2. APPENDIX I ` SOLID AKOCLORS PROGRAMMED CHLORINATION TEMPERATURE & CHLORINE FLOW PROFILE CHLORINE FLOW - FLOW RECORDER CONTROLLER (FRC-104-1 (117-1) Time Aroclor 5060 1st hour @ 1,500 Lbs/hr. 2nd Hour @ 2,000 Lbs/hr. 3rd & subsequent hours to end of batch @ 3,000 Lbs/hr. 25 TEMPERATURE CONTROL - TEMPERATURE RECORDER CONTROLLER (TRCA-106-1 (119-1) Time Aroclor 5060 1st hour @ 190 2nd hour @ 200 3rd hour @ 210 4th hour @ 220 5th hour @ 230 6 - 7th hour @ 240 8 - 9th hour @ 250 10 -11th hour 0 250 Total Batch Time - Approximate hours - 10 - 12 STLCOPCB4081169 Aroclor - PFO APPENDIX II 26 METHOD OF RUNNING SOFTENING POINTS 1. Obtain representative sample of material from sampleline at discharge - of circulating pump. Catch the sample in can lid or Pyrex beaker. 2. Heat ring and sample. ' - 3. Place ring on can lid or metal plate and fill with sample until material stands slightly higher than edge of ring. Fill the ring from the large diameter side. 4. Cool the ring and lid from bottom of the side until sample sets up, being careful not to get any water on top of the sample. 5. Finish cooling by running water on top of the sample after it sets up. 6. Remove filled ring from lid and trim off any material that is on the outside. 7. Make slight indentation on top of the sample in the center of the ring with a heated wire to hold the ball in place. 8. Fill beaker with water or glycerin. a. Use water when expected softening point is under 80C. b. Use glycerin when expected softening point is over 80C. 9. Place the ring in the sample holder, place ball on sample, and put holder in the beaker. , . 10. Adjust the thermometer in the holder so that the tip of bulb protrudes 1/4" through the hole in the crossbar that holds sample. ' 11. Place the beaker on a stand with screen under it and set burner under the stand. 12. Light burner and adjust to give a temperature rise as shown on the thermometer of 5C, per minute. 13. Bring temperature up 5C. per minute until ball falls through the sample. 14. Record temperature at time ball falls to lower crossbar as the softening point. dS\N 334700 STLCOPCB4081170 Aroclor PFO 27 APPENDIX III ITEM 114: THEEMINOL SURGE TANK. 5 ' -0" OD X 5'-3" HIGH - DISHED ENDS Level Gallons Level Gallons Level Gallons Q" 78 (Dish) 1 90 2 102 3 114 4 127 5 139 6 151 7 163 8 176 9 188 10 200 11 212 1'- 0" 225 - 1 ` 237 -2 249 -3 261 -4 274 -5 286 -6 298 -7 310 - -8 323 -9 335 - 10 347 - 11 359 2'- 0" 372 -1 384 -2 396 -3 408 -4 421 2 * -5" -6 -7 -8 -9 -10 -11 3* - 0" -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 4'- 0" -1 -2 -3 - 4' 1 -5 -6 -7 -8 -9 433 445 457 470 482 494 506 519 531 543 555 568 580 592 604 617 629 641 653 666 678 690 702 715 727 739 751 764 776 4'-10" -11" 5' - .0" - 1" - 2" - 3" ' 788 800 813 825 837 849 DSW 334701 STLCOPCB4081171 % Scale 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 ITEM 125: BLOWING TANK 10'-0" OD X 10*-0" HIGH DISHED HEADS Gallons Innage(") 611 (d ish) 0 728 2.4 844 4.8 961 7.2 1,078 9.6 1,194 12.0 1,311 14.4 1,427 16.8 1,544 19.2 1,661 21.6 1,777 24.0 1,894 26.4 2,011 28.8 2,127 31.2 2,244 33.6 2,361 36.0 2,477 38.4 2,594 40.8 2,711 43.2 2,827 45.6 2,944 48.0 3,060 50.4 3,177 52.8 3,294 55.2 3,410 57.6 3,527 60.0 (16.3") * % Scale 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 *90 92 94 96 98 100 Gallons 3,644 3,760 3,877 3,994 4,110 4,227 4,343 4,460 4,577 4,693 4,810 4,927 5,043 5,160 5,277 5,393 5,511 5,627 5,743 5,860 5,976 6,093 6,210 6,326 6,443 Inna; 62.4' 64.8 67.2 69.6 72.0 74.4 76.8 79.2 81.6 84.0 86.4 88.8 91.2 93.6 96.0 98.4 100.8 103.2 105.6 108.0 110.4 112.8 115.2 117.6 120.0 Sp.Gr.: 1.5 Inst. Range: 0-180" H2O Inst. Scale: 0-100% Linear *Alarm Point % SW 334702 STLCOPCB4081172 vSTANDARD OPERATING INSTRUCTIONS FOR SOLID AROCLOR 5460 \ PROCESS FUNCTION OUTLINE III. C. I. NO. 5 STILL SYSTEM 1.1 Scope This covers the charging, `start-up, shutdown, normal operation, and emergency situations involving the No. 5 Aroclor Still System. 1.2 Description of Process Aerated crude Aroclor from a blowing tank is fed to the still tank. Hydrated lime is added to the crude Aroclor. Vacuum is applied to the still and the Aroclor is circulated through the furnace coil and heated to the vaporization tem perature. Vapors pass up an open column through a cyclone . separator to the condenser. Distilled Aroclor is collected in a receiver. Quality of the distilled solid Aroclors is analyzed by the Lab, and if in specification, it is transferred to the flaker hold tank for flaking or drumming into suitable containers. Still residue or bottoms from two distillations (four chlorinator batches) are drawn into containers and sold as Montars, or it is . discarded in trash drums. II. PROCESS DIAGRAM - Attached. III. OPERATION OF PROCESS 3.1 Start-Up A. Initial Start-Up 1. Therminol Cooling System for No. 5 Still Condenser a. Charge system with Therminol FR-2 (Aroclor 1248); (1) Use temporarily relocated Pyranol pump to charge Therminol surge tank (Item 139). (2) Position 55 gallon drum next to the pump. Remove drum bung and vent cap. (3) Connect flexible hose to pump suction and the stainless steel pipe to be inserted into the drum. SVV 334703 STLCOPCB4081173 Aroclor PFO 2 C. III. 3.1 A. 1. a. (4) Position discharge line from the pump into the tank. (5) Open valve on pump suction; insert pipe into drum ~ and start pump. (6) Adjust the suction valve on the pump until the flow is steady. (7) Continue to fill the surge tank until six drums . or approximately 325 gallons total are in the surge tank (Item 139). b. Therminol 1242 can be charged directly to the surge tank (Item 139) by the following procedure: (1) Align valves in line from storage tank to surge tank (Item 139). Care must be taken to ensure that all valves to the other surge tanks are closed. They are also filled from this storage tank line. (2) Check level gauge at surge tank. (3) Start storage tank pump. (4) Observe this level gauge at the surge tank and shut off pump when you have 275 gallons or 32 inches in the sight glass. Once circulation is established add therminol to bring the sight glass level to 12". (5) Close valves in line from storage tank to surge tank. 2. Still and Furnace Start-Up a. Charge to the No, 5 Still Under normal conditions, crude Aroclor is charged to the No. 5 still with the charge measured by the level in dication (LIA-125-2) on the No. 5 blow tank. The blow tank (Item 125) holds two chlorinator batches of 2,160 gals/batch. Two chlorinator batches are charged to the No. 5 still to make up one still batch. b. Prepare No. 5 Blow Tank (Item 125) for transfer of charge: (1) Check to be sure the steam heating system is on :;he transfer pump (Item 126) and the therminol on the charging lines. Material to be pumped must be hot. Cold lines can also cause plug-ups and failure to transfer material. 0siv STLCOPCB4081174 Aroclor PFO 3 C. III. 3.1 A. 2. b. (2) Check temperature of material in blowing tank ' to be sure it is hot enough to transfer - above 200C. See TIC-125-1. (3) Check with the chlorinator operator to be sure crude Aroclor has been air-blown for one hour. c. Prepare still to receive charge: (1) Close valve at the bottom line under the still (Item 129). (2) Set valves from the No. 5 blow tank to the No. 5 still. Be sure the therminol heating system is on all transfer lines. (3) Close the main valve in the vacuum line to the still just above the receiver. Start steam to the vacuum jets. Put steam on stage 4, stage 3, - stage 2, and stage 1, in that order. Stage 1 is the closest to the receiver. Adjust water to the after condensers on the last three stages. The jet on the No. 5 still should pull down to 2-3 mm Hg absolute on the receiver (Item 132). The steam to. the jet on the No.5 still should have a minimum of 90 psig supply pressure - operate at 110 psig. Normally, this unit will stay in continuous operation. (4) Open vent valve on the still receiver. d. Start up the Therminol Cooling System for the No. 5 Still Condenser (Item 131): (1) Set TICA-141-1 at 60C. (2) The set points for the therminol hjgh and low tem perature alarms are at 70 C and 30 C.respectively. (3) Set the valves in the therminol cooling system for the No. 5 still condenser (Item 131) to allow cir- culation from the surge tank through the condenser and back into the surge tank. Therminol only goes through the tower water cooler on demand. When needed, the small stream of 60F therminol is mixed with the hot circulating therminol to maintain the desired 145C. (4) Open the steam heating valve to the surge tank (Item 139). Wait until the temperature of the therminol cooling system is 70C. , then start the circulating pump (Item 140). DSW 334705 STLCOPCB4081175 Aroclor PFO 4 C. III. 3.1 A. 2. d. (5) Check the level in the surge tank (Item 139). There should be 12 inches in the sight glass. . (6) Set the temperature controller TRC-131-1 for the therminol going to the condenser at 145C. . (7) Check the following items on the therminol cooling system circulation: (a) Therminol cooling system circulating pump (Item 140) discharge pressure should be 45 psig. Flow rate should be 200 GPM. (b) TICA-131-1 (circulating therminol temperature) should be set at 145C. (c) TIC-141-1 (cooled therm, from therm, cooler) should be set at 60C. e. Charging the No. 5 Still and Start-up: (1) Set valves in transfer line from No. 5 blow tank to the still. (2) Start the blowing tank pump (Item 126) and transfer a full charge into the still tank. This is done by observing the before and after level in the blow tank (Item 125). (3) Stop the No. 5 blow tank transfer pump when the charge is complete as noted on the No. 5 blow tank level gauge. (4) Close the valve on the transfer line located on top of the blow tank. (5) Set valves in the No. 5 still circulating line through the heater coil (Item 128) and back into the still"tank. These valves stay in the correct position during normal operation. (6) Start up preheat of the No. 5 still furnace (Item 128). (See the following page) (7) Start the circulating pump (Item 134) after the furnace stack temperature has reached 200C. DSW 334706 STLCOPCB4081176 Aroclor PFO 5. C. III. 3.1 A. 2. e. (8) Add hydrated lime through the chute provided for this purpose on the No. 5 still. Add 400 pounds (8 bags) of lime for each still batch. (9) Swing the chute away and button down the wing nuts, f. Furnace Start-Up for the First Time: (1) Preliminary Procedure' (a) Open manual valves in the natural gas line . to the furnace main and pilot gas lines. (b) Open damper on the furnace stack. (c) Turn on circuit No. 9 at the still panel and . the breaker switch on the outside of the field control box to "ON". The, "RED" light at the Honeywell Protectoglo unit will light up. (d) Put fuel gas flow controller FRCA-128-1 in manual with output at 1 psig. (e) Set high temperature switch at 425C.(800F). (f) At this stage the "RED" light on the "Protectoglo Relay" is on. The heater shutdown alarm is sounding and must be acknowledged. (2) Start-Up Procedure (a) Move red safety switch inside the"Protectoglo" unit in the field control box to the right to reset. You must wait 10 seconds before the switch can be reset in case it has to be redone. (b) At end of purge period (there is no air blower and hence no purge but purge timer introduces a time delay and natural convection will cause an upward draught) the green "pre-purge complete" light will light. (c) Carry out a "sniff" test through the small side door of;the.furnace.. If the test shows dangerous, stop and correct the cause of trouble before lighting the burner. When the heater is cold, there is no natural draft to carry away gas or fumes. After the unit gets hot, there will always be a natural draft provided the flue damper -is open. If satisfactory, proceed. DSW 334707 STLCOPCB4081177 Aroclor PFO 6. C. III. 3.1 A. 2. f. (2) (d) Depress the ignition start button inside the field control box to actuate the pilot flame. Hold the button depressed for no more - than 10 seconds. If all is well, the "white" ^ light on the Protectoglo unit will come on and the "^reen" and "red" lights will go out. When this occurs, pull your finger away. The pilot is now properly lit. Pilot flame is detected by "purple peeper" and a steady audible clicking of checking relay will be heard. (e) Manually open the two reset safety valves in the main gas~line prior to the flow valve. The heater is now ready for operation. These safety valves will not stay open if the signal to the gas flow control valve is above 3 psig. (f) The main burner will not yet be lit because the fuel gas flow control valve FV-128-1 is closed. See f.(l)(d) previous page. (g) The still furnace coil can be preheated by using the pushbutton on the still control panel. This will allow by-passing the furnace no flow inter lock to start gas into the furnace without start ing the still pump. . It is desirable to fire the furnace for the purpose of either drying out the brickwork or to temper the coils before circulation begins when the unit is cold. Preheating is necessary to prevent plugging. For this reason, a tem pering button is installed on the burner control panel which is mounted in the field. This button energizes a relay for ten (10) minutes only. It may be necessary to use this temper button several times. (h) When preheating is required the tempering button is pushed and with the gas flow controller FRCA128-1 in "manual", slowly open the control valve and monitor stack temperature when the main burner has lit. Observe the temperature at point #8 on the multipoint recorder. Do not exceed 200C. but this temperature should be maintained until circulation :'s established. If preheating is not necessary, skip this step. DSW 334708 STLCOPCB4081178 Aroclor PFO 7. C. III. 3.1 A. 2. f. (2) (i) Start up .the solid still circulating pump (Item 134). The circulating flow meter FIA-128-2 will now indicate a flow around 290 GPM. Flow below 125 GPM will cause the main burner to be shut off. (j) Leave the gas flow controller, FRCA-128-1 on manual. If there was no preheat the gas flow will be a zero. Gradually increase the set point to 3,000 SCFH. Press the "acknowledge" button on main control panel. Alarm "Still #5 Fuel Gas Low Flow" should go out. If the stack outlet temperature is higher than 550C. the ' set point should be lowered. Switch the con troller to automatic operation. Observe the coil outlet temperature on the multipoint temperature recorder. The dis tillation or "boiling" is considered to be started when the vapor temperature makes a sudden increase. Observe point #14 on the digital indicator for this indication. After the initial heat up to around 290C. the fuel gas must be cut back to 2,300 SCFH to maintain vacuum around 12-15 mm Hg in the still. (k) Check the following items in the system to be sure operations are normal. 1) Natural gas flow to the furnace on FRCA-128-1. 2) No. 5 still circulating pump flow FIA-128-2. 3) Therminol cooling system temperature on TRCA 131-1. 4) Check the coil temperature differential on the inlet and outlet of the furnace (Item 128). ' There should be an 8C. spread. . g. Start-Up of Furnace after Temporary Shutdown; (1) Prior to start-up, the still coil can be preheated before starting the circulating pump, if necessary. See Section f.(2)(g). (2) Adjust natural gas flow controller in "manual" to a set point of 1 psig output pressure. This is FRCA-128-1. DSW 334709 STLCOPCB4081179 Aroclor PFO 8. C.:: III. 3.1 A. 2. g. (3) Start up the solid still circulating pump (Item 134). The Aroclor circulating flow meter FIA128-2 should now indicate a flow in excess of 290 GPM. Shutdown will occur at a flow below - 125 GPM. - (4) Check that the vacuum is 1 mm Hg on the line above the catch tank (Item 135). Open the main valve in the vacuum line from the jets to the receiver. Vacuum at the still receiver should be approximately . 2-3 mm Hg. The vacuum on the still will be 12-15 mm Hg. during operation. (5) Gradually raise the set point of the natural gas flow controller FRCA-128-1 to 3,000 SCFH for the initial heat up. (See (j) previous page) 3. Operation of the Still During Distillation a. Check the multipoint temperature recording instrument for the temperature rise across the coil in the heater furnace points #8 and #9. In case this temperature chart is not indicating correctly, check for plugged lines or instrument problems. Check to be sure the pump . flow is being measured correctly. If necessary, shut off the pump while at a low temperature to be sure the system is operating. Have the electrician check the temperature instruments if you do not get a rise. b. A spread of 8C. between the coil inlet and outlet is normal. A 12C. temperature spread is the maximum difference allowable. c. Be sure the steam heating system is off the vacuum line to the jets during operation. d. Check the therminol cooling system on the No. 5 still condenser (Item 131) to be sure the condenser does not plug up. If plugging begins to occur, raise the tem perature in the therminol cooling circulation system. Use TRC -131-1 to accomplish this. There is no alarm on this controller, so it must be watched closely. e. Vacuum problems on the stills are usually due to flashing of product over plugging vacuum lines, leaks in the still system, leaks at pump packing, or therminol flow problems on the condenser, water adjustment on the jets, changes in the steam pressure to the jets, or problems in the nozzles for the jet. Flashing can be stopped by lowering the temperature of the therminol cooling system for the No. 5 still condenser. Vacuum trouble must be traced systematically from the jet to the receiver and then to the still. To accomplish this, manometer pressure in dicators have been placed in the system as follows: DSW 334710 STLCOPCB4081180 Aroclor PFO 9. C. III. 3.1 A. 3. e (1) On top of the trap in front of the jet (Item 135). (2) On the cyclone separator off-gas line (Item 130). (3) On the still (Item 129). (A) On the receiver (Item 132). f The still receiver temperature indicating controller TIC-132-1 is set at 150C. g. A level indication gauge has been installed in the still receiver (Item 132) to allow indication of the level of material being distilled over. The level instrument is LI-132-2.1. This level indication can be used to help determine when the distillation is near completion. Normally the receiver gauge will be indicating 80-90% at the end. h. As the distillation nears completion, the vacuum will start to come down lower and the flow through the coil will start to drop. If the flow drops below 125 GPH, an alarm will sound and the main gas burner to the furnace will shut off. Normally the flow will not drop below 2AO GPM. i. The distillation temperature should normally be carried no higher than 370C. on the coil outlet. At this point the batch is checked for color and softening point. Be sure the receiver has been circulating for at least 30 minutes,before a sample is taken. If it is in specifi cation, cut the fuel gas flow to zero, transfer the receiver to the day tank (Item 810), and prepare to charge the still again. For the second run, the fuel gas should be cut back to 1A00-1500 SCFH to maintain the circulating Montar 5 around 360C. This is to prevent it from cooling down before they are drawn. Be careful to shut off the furnace before the coil is sucked. j. Close the main valve in the vacuum line on top of the receiver (Item 132). This is to isolate the jet from the still system and eliminate plugging of the jet. k. Vent the furnace coil and allow it to suck dry after the second run. l. Coil inlet and outlet temperature must be watched closely at the end of the distillation. Still bottoms are very viscous; therefore, if the circulating pump is in poor condition, or the.distillation is carried too far, cir culation may stop and the coil will .become plugged or be burned. SW 334711 STLCOPCB4081181 Aroclor PFO 10. C. HI. 3.1 A. 3. 1. Heat from the furnace actually burns the Aroclor to carbon when overheated. If the coil outlet temperature jumps suddenly and the inlet temperature stays the same or falls, circulation is nearly stopped. In this case, shut off the furnace gas supply and suck the coil. If the coil cannot be sucked, it is plugged and will have to "be replaced* m. Batch data sheets are filled out during each distillation. Information includes the still lot number, materials being distilled, start time, finish time, the temperature spread on the still coils, the vacuum, the end time for the dis tillation, etc. n. The distillation operating conditions are show in Table II. 4. Pump Out Still Receiver a. Transfer material from the still receiver (Item 132) to the day hold tank (Item 810) or the flaker hold tank (Item 811). b. Observe level of material in the still receiver by use of LI-132-2.1. c. Check to be sure the heating system is on the jackets of the transfer lines. d. Set valves in the line to transfer to the desired hold tank. e. When material is to be transferred, start the transfer pump (Item 133) under the receiver. Allow material to pump until the receiver is empty. f. Close the valves and stop the transfer pump when the receiver is empty. This can be observed by checking level gauge LI-132-2.1. 5. Operation for Drawing Bottoms into Drums: a. Check to be sure that Therminol heat is on the draw-out line. b. Place necessary drum near draw-out station approximately 30-35 drums. . c. Set valves in line to draw-out station. DSW 334712 STLCOPCB4081182 Aroclor PFO TABLE II DISTILLATION OPERATING CONDITIONS-SOLID 5460 AROCLOR Approximate Temperature at which 5460 Aroclor starts distilling @ 10 mm Vacuum. At Still: Coil Inlet Coil Outlet 280C 290C Approximate Finishing Temperature: Still Pot Coil Inlet Coil Outlet Finrshing Softening Point 360C 360C 370C 98-105C 11 STLCOPCB4081183 Aroclor PFO 12. C. III. 3.1 A. 5. d. Check to be sure the exhaust fan is running. e. Obtain assistance to draw bottoms. NOTE: Fumes from this operation are toxic. If the exhaust fan should stop, discontinue drawing out and notify the Chief Operator. The material to be drawn into drums is hot. Have the person filling the drums to put on face shield and gloves. f. Place drum under valve at draw-out station. Open valve under still. Close draw-out valve. g. If the bottoms being drawn out are for shipment, open thevalve at draw-out station and allow ap proximately 25 to 30 gallons of material to flow . through the line into the drum to flush out the line. h. If the bottoms being drawn out are not for shipment, flush out of line is not necessary. i. Continue drawing out until thestill is empty. Fill drums to within 6" - 8" of top and place cover on drum. As the drums are filled move them on conveyor to east platform. j. Close the valve under the still. Leave the valve at draw-out station open. k. Allow drums to set on conveyor and labor will palletize the drums. Drums to be discarded will be transferred to the dump by plant stake truck. 334714 STLCOPCB4081184 Aroclor PFO 13. C. III. 3.1 B. Start-Up Following Temporary Shutdown This start-up phase would normally be a situation where a previous distillation is complete and the still has been shut down for charging with a new batch. 1. Prepare No. 5 Blow Tank for Transfer Charge a. Check to be sure that the therminol heating system is on the transfer lines from the blow tank to the still pot. b. Check the temperature of the material in the blow tank. It should be at least 200C. c. Check with the chlorinator operator to be sure that the crude Aroclor has been air-blown one hour. d. The No. 5 still vacuum system should be operating with the valve just above the No. 5 still receiver closed. Water should be on the condensers and steam on the jet stages. Vacuum on the trap (Item 135) in the vacuum pipe line should be indicating 1-3 mm Hg. 2. The No. 5 still receiver temperature controller TIC-132-1 should have the set point at 150C. 3. The therminol cooling system should be circulating through the No. 5 still condenser and back to the surge tank. The - temperature controller ' XRC-131-1 should be in "auto" with the set point at 145C. Tower water should be on the therminol water cooled heat exchanger. A. The natural gas flow controller FRCA-128-1 will be in "manual" with the set point below 2.5 psig output pressure. 5. The pilot flame for the No. 5 still furnace (Item 128) will be on as indicated by the Honeywell Protectoglo unit in the field panel. The "white" light on the Protectoglo unit will be on. 6. Set valves in the transfer line from the No. 5 blow tank to the No. 5 still. 7. Open the vent valve on the No. 5 receiver. 8. Start the No. 5 blow tank transfer pump and charge the No. 5 still. Observe level indication gauge in the No. 5 blow tank to measure the still charge. OS***"1 STLCOPCB4081185 Aroclor PFO 14. C. III. 3.1 B. 9. The solid still circulating pump will already be circulating. 10. Stop the No. 5 blow tank transfer pump as soon as the blow tank is empty. Close the valve on the transfer line. 11. Add 400 lbs. of lime to the still charge. 12. Close the vent valve on the No. 5 receiver. Open the vacuum valve on the No. 5 still receiver and start the vacuum on the system. 13. Gradually raise the set point of the natural gas flow controller FRCA-128-1 to 3,000 SCFH. Watch the tem perature rise across the furnace coil inlet and outlet as the temperature is raised. Normally, an 8C. spread will be obtained across the furnace coil. 14. During normal operation of the still system, the following items will be observed. a. Temperature spread across the still furnace. b. Flow of the Aroclor through the furnace coil. See FIA-128-2. c. Level indication in the No. 5 still receiver. See LI-132-2.1. d. Natural gas flow control to the No. 5 still furnace. See FRCA-128-1. e. Temperature control on the No. 5 still condenser therminol circulating system. See TRC-131-1. f. Temperature control in the No. 5 still receiver. See TIC-132-1. 15. At the end of the distillation the batch is checked for color and softening point. ' DSW 334716 STLCOPCB4081186 Aroclor PFO 15. C. III. 3 .1 B. 16. Shut off the natural gas when the distillation is finished, and bottoms are ready to be drawn. Clear the coil by doing the following: a. Close the vacuum valve on top of the No. 5 still receiver in the line to the jet. b. Vent the still heater coil and suck the coil dry. 17. Set lines to transfer material to the desired hold tank. Set the valves in the transfer line and start transfer pump to the hold tank. When the No. 5 still receiver is empty, stop the circulating pump and close the valves in the transfer lines. .2 Routine Operations When the No. 5 still system is operating normally, the following conditions will exist in the process: A. No. 5 still pressure will be around 12-15 mm Hg. B. No. 5 still circulatin pump flow indicated on FIA-128-2 with flow above 125 GFM. C. No. 5 still condenser temperature control TRC-131-1 set at 1A5C. D. Natural gas feed to the still furnace controller FkCA-128-1 set to give desired coil outlet temperature (about 2300 scfh). E. Furnace high temperature alarm instrument set at A25C. F. Therminol cooling system temperature controller TICA-1A1-1 set at 60C. G. No. 5 still receiver temperature control TIC-132-1 set at 150C. " H. No. 5 still receiver level indication gauge LI-132-2.1 will indicate level. I. Main natural gas pressure AO psig. J. Natural gas reduced pressure A psig. DSW 334717 STLCOPCB4081187 Aroclor PFO 16. C. III. 3.3 Safety Features ' A. The Honeywell Prote'ctoglo unit has the following safety features for the No. 5 still furnace (Item 128): 1. Ignition period-TO second delay between actuation periods for the warp switch to cool. 2. Heater coil high temperature outlet shutdown set at A25C. 3. Natural gas high reduced pressure shutdown set at .25 psig. 4. Circulating pump low flow rate shutdown and alarm set at 125 GPM. 5. Pilot flame must be burning to start up the unit. This is indicated by 4 microamperes on the field control panel. 3.A Shutdown A. Temporary Shutdown Main gas burner is off with the pilot light on. The No. 5 still circulating pump running and the vacuum system on. 1. Adjust FRCA-128-1. Set point to . Instrument in "manual" . 2. The vacuum may be cut off by closing the manual valve ` above the No. 5 still receiver. The still would then be vented and shut down systematically, if necessary. B. Complete Shutdown Main gas burner and pilot light shut off. Still circulating pump off. The vacuum shut down and the Therminol cooling system shut off. 1. . Push ignition stop button inside the field control panel for the furnace control system. Hold it until the red lamp comes on. DSW 334718 STLCOPCB4081188 Aroclor PFO 17. C. III. 3 .4 B. 2. After the furnace has cooled slightly, push the stop button for the No. 5 still circulating pump (Item 134). 3. Close manual valve above the No. 5 still receiver in the vacuum line. 4. Shut off steam to the vacuum jet by closing main valve in the steam supply line. 5. Close valve in the water line to the condensers on the No. 5 still jet. 6. Stop the Therminol cooling system circulating pump (Item 140). An alarm will sound. 7. Check the surge tank level to be sure the tank does not overflow after this pump is shut off. 8. Adjust .. . . - . TRC-131-1, and TIC-132-2 controller set point to 0. 9. Turn off the tower cooling water to the Therminol cooler (Item 141). .5 Control Loops, Interlocks, and Alarms A. Control Loops There are nine (9) major control loops in this system. 1. No, 5 Still Circulating Pump Low Flow Shutdown-FIA-128-2 The function of this loop is to measure the flow through the furnace heater coil on the No. 5 still. This is ac complished by measurement with a Ramapo Mark 5 Flow Meter that indicates the flow to a panel. Normal flow will be 290 GPM. A low flow alarm shutdown for the furnace (Item 128) main gas system will be actuated if the flow drops below 125 GPM. Complete shutdown Of fuel gas to the main burner occurs. . 2. Heater Fuel Gas Flow Control - FRCA-128-1 The function of this loop is to control the gas input to the No. 5 still furnace. This is accomplished by measure ment of the natural gas th'-ough an orifice flow meter and throttling the control valve in the reduced gas line until the desired setting is obtained. '; DSW 334719 STLCOPCB4081189 Aroclor PFO 18 C. III. 3.5 A. 3. No. 5 Still Furnace Controls - Item 128 The function of this control system is to control the natural gas feed pressure to the still furnace and assure a pilot light is always burning when natural gas is being fed to the furnace. This is accomplished with a Minneapolis-Koneywell Protectoglo pilot light control mechanism. There are six safety features in the furnace controls to shut the system down: a. High furnace coil outlet temperature will shut down the furnace above 425C. b. Low reduced natural gas pressure 2-1/2 psig. c. High reduced natural gas pressure 25 psig. d. Failure of circuit No. 9 at the rear of the still panelboard, or electrical failure. e. Failure of any component in the Honeywell pilot flame mechanism. . f. Low circulating of crude Aroclor flow below 125 GPH. When any one of the six conditions occurs an alarm sounds in the main control room indicating furnace shutdown. If the shutdown is caused by a. or f. separate alarms also sound. If neither of these alarms sound then the cause of shutdown must be eliminated between b. , c. , d. , or e. A. No. 5 Still Receiver Temperature Control - TIC-132-1 The function of this loop is to control the temperature in the No. 5 still receiver to 150C. This is accomplished by measuring the temperature in the receiver and throttling a control valve on the 200# steam inlet line to the heating coil. 5. No. 5 Still Receiver Level Indication - LI-132-2.1 The function of this loop is to indicate the level of distilled product in the No. 5 still receiver. This is accomplished by a float level instrument which indicates the Aroclor level in the control room and in the field. 6. No. 5 Still Condensate Temperature - TRC-131-1 The function of this loop is to control the temperature of the cooling therminol going into the No. 5 still con denser. It does this by mixing therminol cooled to 60C. in the tower water cooler (Item 141) with the hot cir culating therminol to maintain a temperature of 145C. DSW 334720 STLCOPCB4081190 Aroclor PFO 19. C. III. 3.5 A. 7. Therminol Cooling System Floy? Control - FICA-140-1 The function of this loop is to maintain a constant flow of 200 GPI1. through the still condenser. This is ac complished by measurement of flow with an orifice flow meter and adjusting a control valve. When TRC-131-1 calls for cooled therminol to maintain 145C. in the circulating system, FICA-140-1 closed down in proportion to maintain a 200 GPM total flow. Normal operation of the system is with the controller in "Auto" and the set point at 200 GPM. A low flow alarm will sound at 160 GPM. 8. Therminol Cooling System Temperature Control-TICA-141-1 The function of this loop is to control the temperature of the therminol going through the cooler at 60C. This therminol is needed by TRC-131-1 to maintain 145C in the condenser during distillation. This is accomplished by measurement of the discharge temperature from the therminol water cooler (Item 141) and automatically throttling the water flow on the shell side of the cooler. The low tem perature alarm on this system is set at 30C. The tower water valve TV-141-1 has a stop to ensure water is always flowing through the cooler thus preventing boiling. The high temperature alarm is set at 70C. There is no tem perature controller on the surge tank (Item 139). 9. Still No. 5 Level System - LS-129-3 & 4 The function of this loop is to only give visual and audible indication of low level. High level will shut down the blow tank pump (Item 126). These will prevent over charging the still pot and alert operators that batch distillation has continued to a point that endangers the N.P.S.H. requirements of the still circulating pump. The level switches are both gamma type radiation detectors. The high level actuates when radiation is decreased- and the low level when radiation increases sufficiently. B. Interlocks Interlocks in this system are as follows: 1. Start-Up of No. 5 Still Furnace (Item 128) a. Actuation of the pilot ignition lever on the Honeywell Protectoglo unit has a 10 second delay before a second try can be made. b. Before the ignition "start" button at the Protectoglo unit is pushed the red safety switch is moved to reset, It has a 3 minute purge delay. This is to allow for surf bet; i - f. J- up DSW 334721 STLCOPCB4081191 Aroclor PFO 20. C. III. 3.5 B. 1. c. The two safety valves in the main fuel gas line will not stay on unless the signal to the gas control valve is below 3 psig. d. Complete shutdown of fuel gas to the main burner occurs if the ^circulating flow through the furnace drops below 125 GPM. e. As stated in "A" Section (Control Loops), the furnace will shut down from six safety features. See Section "A". 2. Automatic No. 5 Still Furnace Shutdown with Alarms (Pilot and Main Gas Burner Off) a. High furnace coil outlet temperature above 425C. b. Low reduced natural gas pressure 2-1/2 psig. c. High reduced natural gas pressure 25 psig. d. Low coil flow below 125 GPM. (Pilot light stays on) e. Failure of circuit No. 9 at the rear of the still panel. f. Failure of the switch inside the field control panel, or blowing the 115 volt fuse in the panel. C. Alarms 1. All shutdown items under "Interlocks" (B.2. above) have alarms. 2. No. 5 still circulating pump low flow alarm below 125 GPM. 3. Therminol cooling system TICA-141-1 has a low temperature alarm at 30C. and a high temperature alarm at 70C. A. There is a high-low temperature alarm on the No. 5 still pot that is detected by the multipoint recorder. It is set at 430C. for the high alarm and at 200C. for the low alarm. IV. COMMENTS ON THE PROCESS A. It is very important to be sure there is adequate fluid in the Therminol cooling system surge tank (Item 139). This assures the circulating pump has a positive suction. This will allow more uniform control of the temperature in the Therminol cooling system. DSW 334722 STLCOPCB4081192 Aroclor PFO 21. C. IV. B. Care must be taken not to fill the surge tank (Item 139) too full during normal operation. This can cause the tank to run over when the circulating pump is stopped. - C. . After the first two or three still batches have been run so the natural gas heat input rate is known, adjust the linkage on the reduced gas pressure control valve so a 3-15 psig in strument signal will fully stroke the valve. Make the adjust- ment so that only 10-15% above the maximum needed gas pressure can be obtained. This will reduce charring of the coils in the still furnace (Item 128). D. . During distillation of Solid Aroclors, vacuum problems occur in the pipe line to the jet system and plugging of the jet nozzles occur due to flashing and normal vapor pressure carry over. The vacuum line from the No. 5 still receiver (Item 132) has steam heat on the tracers of the pipe line up to the suction line on the jet (Item 136). The trap tank (Item 135) in the vacuum line has steam heat on the coils in the tank. It is very important that the steam heating system be cut off the tracer lines and the coils in the trap -tank during normal operation. If these lines are kept hot during normal operation, it will cause carry-over into the jet nozzles and cause more rapid plug ging than in the past. When using the steam heating system to clean out the lines or drain the trap tank, the jet should be isolated from the No. 5 still system. This can be done by either shutting the steam off to the jets or closing the block valve in the pipe line at the suction of the jet. E. The still pot No. 5 level system LS-129-3 &. A requires special attention. There is a lock that maintains a safety shutter on the radiation source holder which must be unlocked to operate. The law requires the source holder will be periodically wipe tested by an approved representative to ensure that leakage of the radioactive source has occurred. DSW 334723 STLCOPCB4081193 Aroclor PFO APPENDIX ITEM 111 and 139: Therminol Surge Tank 3'-6" OD X 4'-3" High Dished Ends Level 0" 1" 2" 3" 4" 5" 6" 7" 8" 9" 10" 11" l'-0" l'-l" 1* -2" l'-3" 1' -4" l'-s" l'-6" 1' -7" l'-s" l'-9" l'-10" l'-ll" 2* -0" 2* -1" 2'-2" 2'-3" 2'-4" 2'-5" Gallons 24 (Dish) 30 36 42 48 54 60 66 72 78 84 90 96 102 108 114 120 126 132 138 144 150 156 162 168 174 180 186 192 198 Level 2*-6" 2'-7" 2*-8" 2'-9" 2'-10" 21-11" 31_0" 3' -1" 3'-2" 3' -3" 3'-4" 3'-5" 3'-6" 3'-7" 3'-8" 3'-9" 3'-10" 3'-11" 4 *-0" 4'-l" 4'-2" 4'-3" Gall 204 210 216 222 228 234 240 246 252 258 264 270 276 282 288 294 300 306 312 318 324 330 DSW 334724 STLCOPCB4081194 % Scale 0 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 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 Gallons 310 347 385 422 459 496 534 571 608 646 683 720 757 795 832 869 907 943 981 1,018 1,056 1,093 1,131 1,168 1,205 1,243 1,280 1,317 1,354 1,391 1,428 1,466 1,503 1,540 1,578 1,615 1,652 1,689 1,727 1,763 1,801 1,838 1,877 1,913 1,950 1,988 2,027 2,062 2,100 2,137 2,173 Aroclor 5460 Sp.Gr.: 1.5 Q 150C Temperature: 150C ITEM 132: APPENDIX No. 5 STILL BATCH RECEIVER 8'-0" OD x 10'-0" HIGH - DISHED HEADS InnageT.) 0 (13") 1.2 2.4 3.6 4.8 6.0 ' 7.2 8.4 9.6 10.8 12.0" (1 ft.) 13.2 14.4 15.6 16.8 18.0 19.2 20.4 21.6 22.8 24.0 (2 ft.) 25.2 26.4 27.6 28.8 30.0 31.2 32.4 33.6 34.8 36.0 (3 ft.) 37.2 38.4 39.6 40.8 42.0 43.2 44.4 45.6 46.8 48.0 (4 ft.) 49.2 50.4 51.6 52.8 54.0 55.2 56.4 57.6 58.8 60.0 (5 ft.) % Scale 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 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 Gallons 2,212 2,250 2,287 2,325 2,362 2,399 2,435 2,472 2,510 2,547 2,584 2,522 2,660 2,698 2,732 2,770 2,808 2,847 2,883 2,920 2,957 2,995 3,031 3,070 3,108 3,145 3,182 3,218 3,256 3,292 3,330 3,368 3,405 3,442 3,480 3,517 3,553 3,590 3,628 3,667 3,702 3,740 3,777 3,815 3,853 3,890 3,928 3,964 4,000 4,040 Innage(") 61.2 62.4 63.6 64.8 66.0 67.2 68.4 69.6 70.8 72.0 (6 ft.) 73.2 74.4 75.6 76.8 78.0 79.2 80.4 81.6 82.8 84.0 (7 ft.) 85.2 86.4 87.6 88.8 90.0 91.2 92.4 93.6 94.8 96.0 (8 ft.) 97.2 98.4 99.6 100.8 102.0 103.2 104.4 105.6 106.8 108.0 (9 ft.) 109.2 110.4 111.6 112.8 114.0 115.2 116.4 117.6 118.8 120.0 (10 ft.) Inst. Range: 0-10 ft. Inst. Scale: 0-1007o Linear nS\N 334725 STLCOPCB4081195 % Scale 0 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 26 27 28 29 30 31 32 33 34 Ga1 . * 480 520 561 601 641 681 722 762 802 842 883 923 963 1003 1044 1084 1124 1164 1205 1245 1285 1325 1366 1406 1446 1486 1527 1567 1607 1647 1688 1728 1768 1808 1849 AROCLOR 5460 ITEM 810 Inch. 7o Scale Gal. 9 35 1889 10 36 1929 11 37 1969 12 - 38- 2010 14 39 * 2050 15 40 2090 16 41 2130 17 42 2171 18 43 2211 19 44 2251 21 45 2291 22 46 2332 23 47 2372 24 48 2412 25 49 2452 26 50 2493 27 51 2533 29 52 2573 30 53 2613 31 54 2654 32 55 2694 33 - 56 2734 34 57 2774 35 58 2815 37 59 2855 38 60 2895 39 61 2935 40 62 2976 41 63 3016 42 ' 64 3056 44 65 3096 45 66 3137 46 67 3177 47 68 3217 48 69 3257 Inch. 49 50 52 53 54 55 56 57 58 60 61 62 63 64 65 67 68 69 70 71 72 73 75 76 77 78 79 80 81 83 84 85 86 87 88 % Scale 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 Gal. 3298 3338 3378 3418 3459 3499 3539 3579 3620 3660 3700 3740 3781 3821 3861 3901 3942 3982 4022 4062 4103 4143 4183 4223 4264 4304 4344 4384 4425 4465 4505 Inch 90 91 92 93 94 95 96 98 99 100 101 102 103 104 106 107 108 109 110 111 113 114 115 116 117 118 119 121 122 123 124 Range - 0-172" W.C. Sp.Gr. 1.49 For 5460 <a 240C DSW 334726 STLCOPCB4081196 Inches 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 26 27 28 29 30 31 32 33 34 35 Gallons 8 23 40 64 90 119 152 187 223 262 302 345 389 433 480 528 578 629 682 735 790 846 904 961 1022 1080 1139 1201 1264 1328 1386 1454 1521 1586 1650 SOLID AROCLOIl FLAKER FEED TANK ITEM 811 Inches 36 37 -38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 , 64 65 66 67 68 69 70 Gallons 1715 1783 1853 1928 1994 2060 2128 2198 2266 2342 2408 2478 2545 2621 2695 2762 2829 2903 2979 3046 3116 3182 3258 3326 3396 3464 3530 3596 3671 3741 3809 3874 3938 4003 4070 Inches 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 Gallons 4138 4196 4260 4323 4385 4444 4502 4563 4620 4678 4734 4789 4841 4894 4945 4995 5043 5090 5134 5178 5221 5261 5300 Sp. Gr. 1.49 For 5460 @ 240C DSW 334727 STLCOPCB4081197 STANDARD OPERATING INSTRUCTIONS FOR SOLID ARQCLOR 5460 PROCESS FUNCTION OUTLINE III. C. I. SOLID HC1 OFF-GAS CLEAN-UP 1.1 Scope This covers the start-up, shutdown, and normal operation of the HC1 Off-Gas Clean-Up System involving No. 10 (11) Chlorinator. 1.2 Description of Process HC1 gas produced on the No. 10 (11) chlorinator system passes through an off-gas condenser which cools the gas to knock out the Santowax and Aroclor vapors. The gas then flows through a catch tank, combines with the gas from the Liquid system and flows to the Muriatic Acid absorber. A Therminol (1242 Aroclor) cooling system is circulated through the tube side of the off-gas condenser to cool the HC1 gases. Material, collected in the catch tank is returned to the weigh tank for other chlorinator charges. II. PROCESS DIAGRAM Attached. ::.Ill. OPERATION OF PROCESS 3.1 Charge Therminol Cooling System Surge Tank (Item 111) A. Therminol 1242 can be charged directly to the surge tank by the following procedure: 1. Align valves in line from storage tank to surge tank. Care must be taken to ensure that all valves to the other surge tanks are closed. They are also filled from this storage tank line. - 2. Check level gauge at surge tank. 3. Start storage tank pump. 4. Observe the level gauge at surge tank and shut off pump when you have 275 gals, or 32 inches in the level gauge. 5. Close valves in line from storage tank to surge tank. DSW 334728 STLCOPCB4081198 Aroclor PFO 2 C. III. 3.1 B. Charge System with Therminol FR-2 (Aroclor 1248) 1. Use temporary relocated Pyranol pump to charge surge tank (Item 139). 2. Positiofi 55 gal. drum next to the pump. Remove drum bung and vent cap. 3. Connect flexible hose to pump suction and the stainless steel pipe to be inserted into the drum. A. Position discharge line from pump into the tank. 5. Open valve on pump suction; insert pipe into drum and start pump. . 6. Adjust suction valve on pump until flow is steady. 7. Continue to fill the surge tank until five (5) drums or approximately 275 gallons total are in the surge tank (Item 111).' 3.2 Start-Up 1. Set the panel mounted therminol temperature controller TIC-111-1 in automatic with the set point at 120C. . 2. Set the off-gas storage tank (Item 109) locally mounted temperature indicating controller TIC 109-1, in automatic with the set point at 120c. 3. Set valves to allow circulation of the therminol system from the therminol surge tank (Item 111) to the circulating pump (Item 112), through the tube side of the off-gas condenser (Item 108), through the air therminol cooler (Item 113), and back to the therminol surge tank. ' A. Open manual valves to allow circulation of steam heat through the jacket on the off-gas storage tank (Item 109). 5. Check to be sure the valve on bottom of the off-gas storage tank is closed. 6. Set manual valves to allow HCl gas to flow through the off-gas condenser (Item 108) through the off-gas storage tank (Item 109) and to the Muriatic Acid absorber. DSW 334729 STLCOPCB4081199 Aroclor PFO 3. C. III. 3.2 7. This system should now be in automatic control. Checking of the pressure across the condenser will indicate plugging if if should occur. 8. Material accumulated in the off-gas storage tank will be re cycled through the chlorinator system for reuse. A locally mounted gauge indicates the tank level. 3.3 Shutdown 1. It is necessary to shut down the No. 10 (11) chlorinator if work is to be done on the condenser (Item 108) or the off-gas storage tank (Item 109). 2. Close manual valve from the chlorinator and on the exit line . after the storage tank. 3. The therminol heat system on the tube side of the off-gas condenser can be shut down by stopping the circulating pump (Item 112). 4. The system is now shut down and can be worked on if necessary. 3.4 Instruments 1. Therminol Circulating System Temperature Control-TIC-111-1 The temperature in the therminol circulating system for the off-gas condenser in the clean-up system is controlled by sensing the temperature in the surge tank and controlling the louvers on the air cooled therminol cooler and the control valve on the line to the coil in the surge tank. At 3 psig, the louvers are open giving maximum cooling; at 9 psig, the louvers are closed and the second positioner (which has been inoperative up to 9 psig) applies a 3 psig signal to the steam control valve on the coils causing it to open. At 15 psig., input into this positioner will cause a 15 psig signal to the valve to open it fully. The instrument will be in automatic with the set point at 120C.. 2. Off-Gas Storage Tank Temperature Controller - TIC-109-1 The temperature in the off-gas storage tank (Item 109) is con trolled by sensing the temperature of the material in the tank and throttling the control valve on the input line on the tank's jacket. The controller is in automatic with the set point at 120C. DSW 334730 STLCOPCB4081200 Aroclor PFO b C. III. 3.4 3. Solids Knock-Out Tank Level Indicator - LI-109-2 The off-gas storage tank has a sight feed bubbler system sensed by a D/P cell and is transmitted to a gauge graduated 0-100%. The signal is-directly proportional to tank level. It is field mounted. IV. COMMENTS 1. Plugging of the off-gas condenser in the clean-up system can occur. To unplug the off-gas condenser the temperature of the therminol system will be elevated as required. It will probably require a temperature of 160 - 170C. ' 2. Even with the louvers shut the steam coil does not transfer enough heat to the Therminol to overcome the cooling effect of the fan in cold weather. During winter months it will be necessary to operate with the fan off and only turning it on as needed to keep the off gas condenser temperature below 130C. DSW 334731 STLCOPCB4081201 ITEM 109r OFF-GAS SURGE TANK 6'-6" OD X 7'-9" HIGH DISHED HEADS % Scale 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44 46 48 50 Gallons Innage (") . 170(Dish) 208 246 282 320 356 394 432 470 506 544 580 618 654 692 730 766 804 842 878 916 954 990 1,028 1,066 1,102 0 (14") .1.9 3.8 5.6 7.5 9.3 11.2 13.1 15.0 16.8 18.7 20.5 22.4 24.2 26.1 28.0 29.8 31.7 33.6 35.4 37.3 39.2 41.0 42.9 44.8 46.6 *. % Scale 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84 86 88 90 92 94 96 98 100 Gallons 1,140 1,176 1,214 1,252 1,290 1,326 1,364 1,400 1,438 1,474 1,512 1,550 1,586 1,624 1,662 1,698 1,736 1,774 1,810 1,848 1,886 1,924 1,960 1,996 2,034 InnageC") 48.5' 50.3 52.2 54.1 56.0 57.8 59.7 61.5 63.4 65.2 67.1 69.0 70.8 72.7 74.6 76.4 78.3 80.2 82.0 83.9 85.8 87.7 89.5 91.3 93.2 Sp.Gr .: 1.2 Inst. Range: Inst. Scale: 0-112" 0-100% h2o Linear DSW 334732 STLCOPCB4081202 Aroclor PFO APPENDIX ITEM 111 and 139: Therminol Surge Tank 3'-6" OD X 4'-3" High Dished Ends Level 0" 1" 2" 3" 4" 5" 6" 7" 8" 9" 10" 11" l'-O" l'-l" l'-2" l'-3M 1* -A" l'-5" l'-6" 1* -7" i'-8" l'-9" l'-lO" 1'-11" 2` -0" 2* -1" 2' -2" 2' -3" 2' -4" 2'-5" . Gallons 24 (Dish) 30 36 42 48 54 60 . 66 72 78 84 90 96 102 108 114 120 126 132 138 144 150 156 . 162 168 174 180 186 192 198 Level Gallons 2'-6" 2* -7" 2' -8" 2'-9" 2'-10" 2'-11" 3'-0" 3' -1" 3'-2" 3'-3" 3'-4" 3'-5" ------ ~ 3*-6" 3'-7" 3'-8" 3'-9" 3'-10" S'-ll" 4* -0" 4' -1" 4'-2" 4'-3" 204 210 216 222 228 234 240 246 252 258 264 270 276 282 288 294 300 306 312 318 324 330 DSW 334733 STLCOPCB4081203 DSW 334734 STLCOPCB4081204 AROCLOR DEPARTMENT OPERATING INSTRUCTIONS EMERGENCY PROCEDURES This is the plan for departmental action in the event a hazardous situation or injuries warrant emergency action either in the Aroclor Department or within the Anniston Plant* 1. Hazardous Situations which might occur are: a. Operational Accidents or difficulties, such as explosions, fires, release of toxic fumes, etc. b. Forces of Nature - hurricanes, tornadoes, floods, lightning, etc. c. Deliberate Damage - malicious actions, sabotage, direct enemy action. 2. The Primary considerations in the event of a disaster are: a. The care of injured individuals and evacuation of personnel to safe areas. b. Measures to prevent any, or further, property or equipment damage. c. Measures to provide accurate and thorough information so that other plant personnel and the community can be informed, if necessary. d. Prompt restoration of affected facilities and resumption of uninter rupted operations. 3. Responsibility The areas of responsibility and overall department organization for disaster control are as follows: a. Chief Operator: Responsible for continuing or closing down production facilities as conditions permit; for directing fire fighting and damage control activities in the department area; keeping department supervision fully informed of conditions within the department. b. Operators: Responsible for evacuation of all personnel from danger area; for directing and assisting in first aid and rescue missions; reporting to and keeping Chief Operator informed of conditions within his area of responsibility. NOTE: All actions of the Fire Brigade are coordinated with the Chief Operator. .. DsW 334735 STLCOPCB4081205 Aroclor Dept. Emergency Procedure . 2. 4. Detail of Plan: a. In the event of an emergency, personnel must be accounted for. The first assembly area for the department is the open area south of the HB-40 plant near the ladder rack, the second or alternate assembly area is east of the Aroclor-Biphenyl building in the road. It is very important to know where people are in an emergency or before action is taken to correct an emergency. If the alternate area has to be used, take whatever safety equipment you can from the department to the assembly area. b If assistance is needed, pertinent phone numbers of plant personnel to be contacted are as follows: T. E. Lackey M. J. Williams R. A. Haydel H. L. Williams G. L. Jessee H. Schulte J. C. Landwehr J. G. Thorne T. D. Tucker P. K. Ward Dr. J. C. Francis 358-4284 Munford 237-1952 831-4924 236-3835 237-5328 238-1222 237-0546 237-7652 237-3927 831-4189 237-5612 (Home) Main Gate 236-2961 (308 or 317) c. In the event of a plant disaster, the Main Conference Room is the Control Center. The alternate Control Center is the Guard Room at the Service Building. The Medical Center is the Plant Dispensary. The alternate Medical Center is the Service Building. d. If the emergency or disaster occurs before or after the day shift, or on a weekend, the department Chief Operator shall notify the Guard on duty and the Guard will be responsible for notifying plant supervision. e. Immediately upon discovering a fire, or a current or imminent disaster condition, turn in an alarm. Dial 7-111 and leave the phone off the hook until the alarm has sounded five times. Use another phone to call operator. f. On day shift, Monday through Friday, Dial operator - state location and type emergency and need for outside help. g. On "off-shifts", contact Guard (317). DSW 334736 STLCOPCB4081206 Aroclor Dept. Emergency Procedure 3. 4. Detail of Plan (Continued) h. If the Guard cannot be contacted and the local Fire Department is needed, call them at 237-3541, giving them location, material burning, size of area involved, etc. .Then call the department supervision. NOTE: Chief Operator may designate this job to one of the operators. i. The Plant Primary Assembly Area, should the emergency be so widespread that the major portion of the plant is affected, is West of HC1 Neutralization Pit (Secondary is Guard Gate No. 4 West of Niran). j. The Off-Side Primary Assembly Area, should complete plant evacuation be necessary, is REA Terminal, Highway 202 (Secondary is Rescue Squad Headquarters, 1313 Walnut Avenue, South side of Building). To signify complete evacuation, the plant fire alarm will be activated and the sound repeated two-second blasts at one-second intervals for several minutes. At this signal, leave the plant by the most expedious means and route available and reassemble at the off-site assembly point and report to the Personnel Superintendent for head count. 5. Emergency Situations: The following emergencies are possible at the Aroclor Department: Emergency Action a. Fire Handling Biphenyl a. Turn in alarm - Dial 7-111. b. Remove injured from fire area take care of them. c. Proceed under Chief Operator to extinguish the fire: (1) Dry powder extinguisher. (2) Fire truck, dry powder, and water. - (3) Water. d. Pull power on all motors. e. Cut off gas to Aroclor and Biphenyl stills at main cut-off at northwest corner of blowing tank area. f. Shut down Department. DSW 334737 STLCOPCB4081207 Aroclor Department Emergency Procedure Emergency Situations (Continued) Emergency b. Chlorine Release Tank Car * c. HC1 Release d. Fire or explosion at HB-40, Santowax, or Biphenyl Depts. - e. Emergency in the Plant f. Equipment failure creating hazard. . ' 4. Action a. Obtain help and turn in alarm if necessary- Notify Chief Operator. b. Obtain gas mask or Scott Air Pak. c. Shut off source of Chlorine. d. Disconnect CI2 connection at car if necessary. e. If vaporizer is full of liquid chlorine, vent to the chlorine car, then shut off car. f. Notify Department Supervision as soon as possible. a. Obtain help and turn in alarm if necessary-Notify Chief Operator. b. Obtain gas mask or Scott Air Pak. c. Shut off source of HCl gas. d. Notify Department Supervision as soon as possible. ' a. Turn in alarm, shut down Aroclor Department. Obtain gas mask, go to an assembly point, be prepared to assist in stopping the ' fire as directed by Chief Operator. a. Prepare to shut down on orders. ' a. Notify Chief Operator or Department Supervision. b. Take appropriate action. SW 334738 STLCOPCB4081208 Aroclor Department Emergency Procedure Emergency Situations (Contd.) f. Injuries and Treatment 5. a. Obtain help. b. Prevent further injuries to person involved. c. Make comfortable. d. Know your first aid: (1) Mouth-to-mouth resuscitation. (2) How to use a resuscitator. (3) How to remove from electrical contact. (4) Action for a heat stroke. (5) Chest massage for heart failure. (6) Emergency action in case of burns. (7) Location of stretcher, blanket, oxygen. (8) Know equipment available from the dispensary. e. Contact Plant Physician as soon as possible, if necessary. Make contact through Plant Guard or Department Supervision. DSW 334739 STLCOPCB4081209 AROCLOR DEPARTMENT EMERGENCY PROCEDURE ALARM METHODS To Activate Plant Disaster System 1. Dial 7-111 - This alarms only and the phone must be left off the hook. Use another phone j:or contacting personnel. 2. On-Shifts - Dial *'0" - State location and type emergency and need for outside aid. Off-Shifts - Dial 317 - State location and type emergency and need for outside aid. 3. If 317 does not answer - get outside aid directly. Signal for Complete Plant Evacuation of "Off-Site" Assembly Airea Dial 7-555 - Evacuation will sound automatically ASSEMBLY AREAS 1. Department a. Primary - Open area South of HB-40 Plant. b. Secondary - Road East of Biphenyl-Aroclor Building. 2. Plant a. Primary - West of KC1 Neutralization Pit. b. Secondary - Guard Gate No. 4 (West of Niran). 3. Off-Site a. Primary - REA Terminal - Highway 202. b. Secondary - Rescue Squad Hdq. , 1313 Walnut Avenue (South side of Bldg.). PRIORITY OF ACTIONS 1. Care for injured. 2. Account for all personnel. 3. Property Safety. dSMM 334740 STLCOPCB4081210 Aroclor Department Emergency Procedure 2. LOCATION OF EMERGENCY EQUIPMENT; 1. Stretcher - In Biphenyl-Aroclor Building North of old Biphenyl Control Room. 2. Blankets - In Tubular Unit Control Room. 3. Burn Treatment Equipment - Box north of old Santovax R Plant. 4. Gas Masks - East and West vail outside Aroclor Control P^oom. 5. Scott Air Paks - South of Air Blox?ers in Aroclor and old Biphenyl Control Room. 6. Emerson Resuscitator - In Dispensary. . 7. Emergency Oxygen - In old Biphenyl Control Room. SW 334741 STLCOPCB4081211 APPENDIX A EMERGENCY PROCEDURE COLD WATER TREATMENT OF BURNS (Thermal & Chemical) . Thermal Burn - The type of burn you would get by: 1. Direct exposure to flame. - 2. Skin-make contact 'with hot surface. 3. Hot materials, such as molten Santowax, solidify when it touches the skin, thereby holding the heat in the skin. Chemical Burn - The type of burn you would get by: 1. Contact with Muriatic or Sulfuric Acid. 2. Contact with Potassium or Sodium Hydroxide. 3. Contact with any acid or strong alkali material. Treatment - Thermal Burns ' If possible, submerge burn area in container of cold water (50F). The container may be a drum, water pail, wash basin - anything that will hold the water. Follow these steps: 1. Put water in container to desired depth. 2. Try to obtain a water temperature of 50F. by adding ice cubes. 3. Submerge burn area below the surface of.the water. 4. Transport injured person to the doctor, keeping burned surface submerged in water. , If burn is in area that cannot be submerged in water, it is a good practice to take the cleanest cloth or toweling that you can obtain, soak it in cold water (wringing out excess water), and place on the burned area. This would be an area such as the back, shoulders, or stomach. UNDER NO CIRCUMSTANCES SHOULD A PERSON SUFFERING FROM THERMAL BURNS BE PLACED UNDER RUNNING WATER. There is a danger of the small droplets of water striking the burned area, causing pain to such an extent as to result in shock. Treatment - Chemical Burns 1. Place injured person under safety shower or some other method of washing with large amounts of water. 2. Remove contaminated clothing while under the shower. . 3. If goggles are worn, keep in place until all the chemical has been washed from the body. General In our dispensary, we have an ointment labeled Sulfathizole. This material is used in the treatment of burns, both thermal and chemical. It allows an injury to heal from the inside out, which is usually the situation with a burn injury. SW 334742 STLCOPCB4081212