Document wr63Y4n1q6Z56z68BbR3OVg5o

To: Distribution Interoffic 5 Copra munt cation From: Date: Subject: F. G. Jeanson/K. W. Birck February 6, 1986 REMOTE OPERATING VALVES/VCM PUMP PRESSURE RELIEF Attached is a letter defining the Remote Operating Valves Status and a Class "A" design for VCM Pump Pressure Relief. A review meeting of these projects will be held on Wednesday, February 12 at 10:00 a.m. in the conference room. Both projects will be reviewed at the same time since they are related. Please bring any comments on these projects to the review meeting. 1 Frank G. Jeanson Prroocess Engineer ATTACHMENT / aeb Process Engineer >. VAB.0001104953 To: J. Friend Interoffice Communit otion From: Date: Subject: F. G. Jeanson January 31, 1986 REMOTE OPERATING VALVES - STATUS Presently, the Remote Operating Valves project is in the mechan ical design stage. Several changes have been made to this design since the class "A" was issued in September of 1983. A design addendum was issued in December of 1983 that provided for position switches on seven additional valves. A letter was issued in October of 1985 that described additional changes to the design. These changes include: (1) additional interlocks to protect equipment affected when the remote operated valves are shut; (2) four additional remote operated valves for the equalization lines in both modules; (3) limit switches and panel indication for the five remote operated valves located at the sphere. In addition, for safety considerations, new valves that accommo date flange mounted actuators must be purchased to replace the valves that accommodate bonnet mounted actuators. The original design called for reuse of existing valves that accommodate bonnet mounted actuators. These changes and additions were estimated by the Mechanical Department to overrun the initial AFE amount of $130M by $40M. A review meeting was held to discuss these changces in November of 1985. Since the review meeting. three issues have been looked into and include: (1) Providing the remote operated valves that did not have panel pushbuttons with local handswitches so that they could be cycled periodically for testing purposes. This has been added to the design. (2) Providing all the remote operated valves with panel in dication of OPEN/CLOSED position. This is addressed in this letter. (3) Providing the valves that are specified to have limit switch es with the new type of GO limit switch. This is addressed in this letter. VAB.0001104954 Remote Operating Valves - Status Paee 2 Three options are outlined below for the Remote Operating Valves design (costs are only approximate for Options 2 & 3; estimates have not been done). OPTION 1 Total Cost $170M Complete the design as proposed in the letter of October 21, 1985. OPTION 2 Total Cost $190M Option I and provide GO limit switches on all valves that have limit switches specified. Currently, the plant is changing to GO limit switches that indicate the position of the valve ste on critical, VCM service valves. Twenty-two valves, all in VCM vice, have limit switches specified. Wesco type limit switches have been purchased or are currently installed, on twelve valves. The remaining ten valves were estimated using Wesco type limit switches. GO type limit switches for these twenty--two valves would increase the overrun approximately $20M. With the overrun of $40M for Option 1, the total overrun would then be $60M over the initial AFE amount of $130M. OPTION 3 Total Cost $230M Option 1 and provide all thirty-two valves in this design with limit switches (GO type) and panel indication. This option would increase the overrun approximately $60M. With the overrun of $40M for Option 1, the total overrun would then be $100M over the initial AFE amount of $130M. Tables 1 and 2 list each valve in this design, whether it has panel indication, and if it doesnTt have panel indication, why panel indication is not required. Option 2 is recommended because: (1) Since the new plant standard for VCM service is the GO type limit switch, these will eventually be installed on all valves in VCM service. If we change to the GO type limit switch now while we will be working on the valves and actuators, we will save installation cost, the cost and installation of ten Wesco switches, and production downtime. More importantly, we will be providing these valves with positive open/close indication. (2) The benefits don't justify the extra money that would have to be spent to install panel indication for each of the remote operated valves. Listed below are several reasons. (a) Remote operated valves will only be used in an emer gency. They will stay in one position most of the time and therefore will not by cycled like most of the other valves with panel indication. Remote Operating Valves - Status A (b) If a valve closes by itself, the valves that would affect other equipment are interlocked. (c) Limited panel space is available, especially with BASF improvements. (3) A procedure to cycle these valves regularly could be set up and would provide a high confidence level in the operation of these valves in an emergency. A review meeting will be held to discuss these options. F. G. Jeanson Process Engineer ATTACHMENTS aeb cc: JWW, DWH, CWT, MLN, SCH, VEM, JGC, AHS, REP, KSA, SKG, RBN, RAF VAB.0001104956 NEW MODULE (See P & I Diagram No. GP-D5M3-42- 3-D) TABLE I Valve No. CV-701 CV-818 CV-892 CV-893 CV-899 Size 8,,-150 4"-150 2"-150 2"-150 2"-150 Limit Switch Exist. Exist. Exist. Exist. New Panel Indication Exist. Exist. Exist. Exist. CV-900 2"-150 CV-901 CV-902 6M-150 2"-150 New ---- CV-903 CV-904 6M-150 2"-150 New ---- CV-905 2"-150 New CV-906 1M-150 4* -- ^-- CV-909 1"-150 SPHERE (See P & I D agram No. GP-D5M3-42-1-D) CV-601 6"-150 New New CV-602 6"-150 *New New CV-603 4"-150 *New New CV-604 3"-150 New New CV-606 1V-150 New New * Wesco Limit Switch Already Bought, Reason for Not Having Panel Indication Limit Switch signal will be tied into the Modicon to shut-off the VCM transfer pumps at the sphere and the RVCM charge pumps if CV-899 closes. Also, the equipment listed will not start if CV-899 is closed. If CV-900 located in west RVCM receiver recovery line closes simultaneously with CV-902, pressure will build in the receivers and will then cause pressure to build on the discharge of the compressors resulting in slow recovery. There is also a high pressure alarm and shut-down on discharge of compressors. Limit Switch signal will be tied into the Modicon to shut-off the RVCM charge pumps if CV-901 closes. Also, the pumps will not start if CV-901 is closed. If CV-902 closes simultaneously with CV-900, pressure will build in the receivers and will then cause pressure to build on the discharge of the compressors resulting in slow recovery. There is also a high pressure alarm and shut-down on discharge of compressors. Limit Switch signal will be tied into the Modicon to shut-off the RVCM charge pumps if CV-903 closes. Also, the pumps will not start if CV-903 is closed. If CV-904 located on vent line for both receivers closes, pressure will build in the receivers and will then cause pressure to build on the discharge of the compressors resulting in slow recovery. There is also a high pressure alarm and shut-down on discharge of compressors. Limit switch signal will be tied into the Modicon to shut-off the recovery compressors and vacuum pumps if CV-905 closes. Also, the equipment listed will not start if CV-905 is closed. If CV-906 located in equalization line from FVCM pumps and FVCM filters closes, equipment will not be affected. Equipment listed is protected by relief valves or will be by VCM PPR design. If CV-909 located in equalization line from RVCM pumps and filter closes, equipment will not be affected. Equipment listed is protected by relief valves or will be by VCM PPR design. VAB.0001104957 OLD MODULE (See P & I Diagram No. GP-D5M3-42- 9-Dl TABLE II Valve No. CV-301 Size 8"-150 CV-418 CV-492 CV-493 CV- 5 01 3"-150 2M-150 2"-150 3M-150 Limit Switch New Exist. Exist. Exist. New CV-502 CV-503 CV-504 CV-505 CV-506 CV-507 CV-508 CV-509 CV-510 1"-150 2"-300 2M-150 4"-300 2"-150 2"-150 3M-150 1V-150 1M-150 New -- New -- New New -- --- Panel Indication -- Exist. Exist. Exist. -- -- ---- -- -- -- Reason for Not Having Panel Indication Limit switch signal to be tied into Modicon will shut-off FVCM and RVCM pumps if CV-301 closes. Also, the equipment listed will not start if CV-301 is closed. Limit switch signal to be tied into Modicon will shut-off VCM transfer pumps at sphere and the RVCM charge pump if CV-501 closes. Also, the equipment listed will not start if CV-501 is closed. If CV-502 located in incinerator feed line closes, flow to the incinerator will be shut off and pressure will build in the receivers. Have both flow and pressure indication on control panel. Limit switch signal to be tied into Modicon will shut-off VCM collect tank pumps if CV-503 closes. Also, the equipment listed will not start if CV-503 is closed. If CV-504 closes, it will not affect the emission recovery system since the collect tank also provides back-pressure for this system. Limit Switch signal will be tied into the Modicon to shut-off the RVCM charge pumps if CV-505 closes. Also, the pumps will not start if CV-505 Is closed. If CV-506 closes, it will not affect the emission recovery system since the collect tank also provides back-pressure for this system. Limit switch signal to be tied into Modicon will shut-off VCM collect tank pumps If CV-507 closes. Also, the equipment listed will not start if CV-507 is closed. Limit Switch signal will be tied into the Modicon to shut-off the RVCM charge pumps if CV-508 closes. Also, the pumps will not start if CV-508 is closed. If CV-509 located in equalization line from FVCM charge pumps and filters closes, equipment will not be affected since it is protected by relief valves or will be by VCM PPR design. If CV-510 located in equalization line from RVCM filter closes, RVCM filter will not be affected since it is protected by a relief valve. * Wesco Limit Switch Already Bought. VAB.0001104958