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ABD00209918 COMPLIANCE PLAN CAPITAL ITEMS REACTOR VALVE LIMIT SWITCH REPLACEMENT ABERDEEN CHEMICAL PLANT September 9, 1985 WORK BY: y'WTx vVQ . Frank G. Jeanson Process Engineer 1 REVIEWED AND APPROVED BY: j; <S Velaon E. Messick Chief Process Engineer ABD00209919 COMPLIANCE PLAN CAPITAL ITEMS REACTOR VALVE LIMIT SWITCH REPLACEMENT ABERDEEN CHEMICAL PLANT TABLE OF CONTENTS I.PURPOSE AND PROCESS DESCRIPTION II. INSTRUMENT SPECIFICATIONS III. DRAWINGS ABD00209920 COMPLIANCE PLAN CAPITAL ITEMS REACTOR VALVE LIMIT SWITCH REPLACEMENT ABERDEEN CHEMICAL PLANT I. Purpose and Process Description The purpose of this design is to provide the valves on the reactors with accurate indication in the control room of the valve position. The existing limit switches do not provide this accuracy, since they are operated by the position of the actuator and not the actual valve stem. This type of operation does not take into account the possibility of shearing between the valve stem and actuator, which has occurred here in the plant. This poses a potentially hazardous situation for a VCM release. This design will provide each of the designated valves on the reactors with a new limit switch that operates on the position of the valve stem. These new limit switches will provide accurate indication in the control room and eliminate the hazard of a valve being open when it's actuator position is showing closed. A total of 70 valves will be equipped with this new type of limit switch. These limit switches will be mounted on the bracket between the valve and the actuator. Drawings of several different types of valves with the new limit switches are attached. Table I lists the valve location and manufacturer. Table II lists the different types of valves, quantity of each and actuator type. ABD00209921 i Reactor 745 + 700 600 + 500 600 500 400 300 TABLE I Valve Location Size Chem Wash Rtrn. Hot H2O Charge Sewer Dump 6" 6" 6" 6" Evacuation Recovery Vent 8" 6" 4" Chem Wash Rtrn. Hot ^0 Charge Sewer Dump 6" 6" 6" 6" Evacuation Recovery Vent 6" 6" 3" Vent 3" Chem Wash Rtrn. 6" Hot H2O Charge Sewer Dump 6" 6" 6" Evacuation Recovery Vent 6" 6" 3" Chem Wash Return Hot H-0 Charge 6" Sewer 6" Dump 6" Manufacturer Jamesbury (Ball) TuFline (Plug) 150 Jamesbury (Ball) Jamesbury (Ball) TuFline (Plug) 150 TuFline (Plug) 150 TuFline (Plug) 300 KTM E0106 (Ball) TuFline (Plug) 150 TuFline (Plug) 150 WKM 6FB112 (Ball) TuFline (Plug) 150 TuFline (Plug) 150 WKM (Ball) 3RB100 TuFline (Plug) 300 WKM (Ball) 6FB123 Module 310C TuFline (Plug) 150 Durco (Plug) 6411 WKM (Ball) 310 TuFline (Plug) 150 TuFline (Plug) 150 WKM (Ball) 3RB100 310C KTM (Ball) E0106 TuFline (Plug) 150 TuFline (Plug) 150 WKM (Ball) 6FBI 12 310 B ABD00209922 Reactor 744 743 742 + 741 Valve Location Evacuation Recovery Vent Size 6" 6" 3" Manufacturer TuFline (Plug) 150 TuFline (Plug) 150 TuFline (Plug) 300 Chem Wash Rtm. 6 Hot H~0 Charge 6" Sewer 6" Dump 6" Evacuation Recovery Vent 6" 6" 3" WKM (Ball) 6F-B130 310B WKM (Ball) 6X4-B102 WKM (Ball) 6X4-B102 WKM (Ball) 6F-B112 310B TuFilne (Plug) 150 TuFline (Plug) 150 WKM (Ball) 3KB150 ABD00209923 I h is *8 2 I I I I I II I I CM I I I I 1 I I -X I I I I CM I I I I I J I 1-- I I I I I I I VO | I I I -m I I I I I I I V4O CM P CJ 43S 4-> r-. 4-t m3 r- II I CM II i i l i ii i I-- I l l i I sr I i - I I I V I I III I I CO I 1I I III I II a w a<0 r- | CM I i Ii i mt I I II 44HJJ COD mi I l l Cr-M. l1 i l I II iil i i oo i l I I I I r-*.CMCMCMi00 CM 00*3''3'CM CO or- 6H0 -^cOi 0CQ o o 8 s s ,-s ---v q m5 <0 co wwl--^ Q t*s I CM i--i .w* r-.r-.Qcc cm <_n --ro --roi O--CQ--rOojinO_ o_O i cc --* CO g 3 = 8 2si 8 8 'cOO'soS3 -o isvD asO.g" s 4) _ 43 ^0 00 CO vO \ >0 V CO X"S /-v /-s CO V< CL, cl CL CL, s-^ cu N-> CQ CO oa CO CQ CQ CO CM CO n in vO oo OV o 8 CM CO ABD00209924 COMPLIANCE PLAN CAPITAL ITEMS REACTOR VALVE LIMIT SWITCH REPLACEMENT ABERDEEN CHEMICAL PLANT III. Instrument Specification Item PLS-101 through 170 Description Promimity Limit Switches ABD00209925 i (conoco) Conoco Inc. Engineering Center Ponca City. Oklahoma SttCiriCATIOM SMUT Mv rdec '\ CU-AVtc <*1 PLANT PROJECT . f^C<3cioi SPCClHCAffON sutf r project no - A t l 1411 -------- OAir imi nii VAiif h*-a2T mo no - ITEM NO SERVICE p\_^ -- \O \ -MrsrvA 1 TO Pro^j^i^-y : /S5 SeJcS- ( ^rkere. c=j-e -Koo (-^n4-3LAji-f-cK.ei per ^ S<?r-/\c,e ` yp[\/V. J-yvcXt C-CoW LocaW^A ' 0^ ce'k^eer^ ^ u-e. ^^pL fAp <\ WWo-V^r- eJ- : (oO tfr- COfwo^w ^POm^ck l' Mfljpi '- 7/377V Oe^s. Or i p Vvovv OoW-e-A. ^ s We! W AJ PT conJui^- i aj i vU iaaitp 1 . -M/trie pX2& .S"W,i la/Wk --^ -- 1R AJF y ' 1 3> //f . 4 441 S SHEET. Of. REV. --r ABD00209927 End Cap: .050" Stainless Steel (304) End Cap. available with thicker End Caps for higher pressure. Pressure Options: Normally the standard 5/8" diameter will withstand 2000 PSI. Larger cases with thicker walls and front End Caps will allow the switch to function at much higher pressures (up to 10.000 PSI). Certification available as factory option. Case: 300 Series Stainless Steel case, plain or threaded body (5/8-18 NF). Different body lengths available, SEE options on MODELS AVAILABLE. Magnets: Made with a high energy product magnet. An excellent coercive force which converts into grams of Contact Pressure for reliable operation. Meets MMPA Specifications. External Threads: Machines to meet SAE 5/8-18 UNF Specifications. Units available with or without threads. r Contacts: Type Silver. Cadmium Oxide, resists welding and is some of the most widely used Contact Material in the industry. Sized to withstand approved ratings. Hermetically Sealed Contact Chamber. Bearing: Consists of a finely around Stainless Steel Pin and durable plastic housing. Sized to withstand a wide temperature range. Resists seizing and gives millions of free operations. Potting: Terminal cavity filled with epoxy resin com pound for sealing and mechanical support of wire/ cable connections. Body Tube: Made of Free Mechanical Stainless Steel. Resists most all harsh environments and withstands high working pressures. Impervious to water, oils and gases. Internal Threads:1/2-14 NPT. complies with CSA requirements for Explosion Proof Applications. Wire or cable leads available to meet Customer's r Specifications. ABD00209928 When time, accuracy, and dependability count... you can count on the 70 Series GO Switch. ' Maintenance free; engineered for precision, performance and reliability. The standard 70 Series GO Proximity Limit Switch has been designed and built to rugged specifications for use in most industrial and environmental applica tions. Each switch is totally enclosed, hermetically sealed and capable of operating in hostile environments. The standard stainless steel housing is impervious to oils, caustic acids, water laden areas and most Standard Models atmospheric conditions, with a broad operating temperature range. (See specification) Many different models of the switch are available for your design needs. (See ordering information for specifications, detail and options.) Hazardous Location approved models for Class I, Division 1, All Groups ^ ........ Model 713360 No conduit connection. 18" 3 conductor cable with water resistant squeeze connection, tyoe 300 stainless steel housing with H-18 NF x 1.5" threads with 2 lock nuts. Model 713570 'A NPT conduit outlet. 18!' 3 conductor cable, type 300 stainless steel housing with H-18 NF x 2.813" threads with 2 lock nuts. Model 713524 Z NPT conduit outlet with 18" potted. 3 conductor cable, type 300 stainless steel housing, no threads. Model 713420 No conduit outlet. 18" potted. 3 conductor cable, type 300 stainless steel housing; no threads. Model 713660 No conduit outlet, 18" potted, 3 wire leads, type 300 stainless steel housing with H-18 NF x 1.5" threads with 2 lock nuts. Model 713564 Z NPT conduit outlet with 18" potted, 3 conductor cable, type 300 stainless steel housing with H-18 NF x 1.5" threads with 2 lock nuts. uhommuubmiiummm* Model 713460 No conduit outlet, 18" potted, 3 conductor cable, type 300 stainless steel housing with H-18 NF x 1.5" threads with 2 lock nuts. Model 713720 'Z NPT conduit outlet with 18" potted, 3 wire leads, type 300 stainless steel housing, no threads. Model 713574 Z NPT conduit outlet with 18" potted. 3 conductor cable, type 300 stainless steel housing with H-18 NF x 2.813" threads with 2 lock nuts. Model 713520 Z NPT conduit outlet, 18" 3 conductor cable, type 300 stainless steel housing, no threads. Model 713760 Z NPT conduit outlet with 18" potted. 3 wire leads, type 300 stainless steel housing with H-18 NF x 1,5" threads with 2 lock nuts. Model 713724 Z NPT conduit outlet with 18" potted. 3 wire leads, type 300 stainless steel housing, no threads. Model 713560 Z NPT conduit outlet with 18!' 3 conductor cable, type 300 stainless steel housing with H-18 NF x 1.5" threads with 2 lock nuts. Model 713770 Z NPT conduit outlet, 18" potted 3 wire leads, tyoe 300 stainless steel housing with H-18 NF x 2.813" threads with 2 lock nuts. Model 713764 Z NPT conduit outlet with 18" potted, 3 wire leads, type 300 stainless steel housing with H-18 NF x 1.5" threads with 2 lock nuts. Approved switches are in compliance with current bulletins 1243, 1273 and 1308. Model 713774 Z NPT conduit outlet with 18" potted, 3 wire leads, type 300 stainless steel housing with H-18NF These switches are U/L and CSA approved for industrial control, general purpose use. See hazardous location approved models in Column 3, this page. ABD00209929 TOLERANCES Untoa* otftarwiM K*cHt*d Anglw 1*. Fractions: 1/3T. .XX 01*. XXX 005' Surtaoas must ba Conoantrtc. Parana). Flat A Squara (as apptieatts) to aacti otter within T I P. NO. REVISION OATE 8Y APPO. MATERIAL LIST Item Qty. Description Dwg. No. 9witch Activator V126411-1943 Mounting Bracket V126411-1944 1/4-20 x 1/2 Hex Hd. Screw 1/4 L.W. 5/8 Shakeproof L.W. 5/8 F.W. (1-5/16" O.D.) DRILL 8 TAP I/4-20UNC L 13/16 00 Switch ACTUATOR ,MTG. BRK T. EBJj FIG. 2 GO Switch COUPLING : i VT/ 2-1/4 lkS_L INSTALLATION INSTRUCTIONS 1. Disassemble Actuator and Coupling from Valve and remove existinq pointer. 2. Slide 9witch Activator (item 1) onto drive shaft. 3. Drill and Tap Actuator Mtg. Brk't. for 1/4-20UNC screws and attach Mount ing Bracket (item 2) with items 3 & 4. 4. Mount GO Switches in Mounting Bracket (item 2) with two jam nuts supplied with switch and washers items 5 & 6. 5. Adjust Switches in slots on Mounting BRacket (item 2) to sense Switch Activator (item 1) in full open and full closed positions. Note: 1. GO Switches are not included in V.I.P. (Valve Indication Package) and should be orderec separately. 2. Use Model 713774 GO Switches, OWN. BY RON 8. CHK. BY APPO. OATE 9-26-83 5?C5m?S5>5i2E>* S5ifE*5yP3J *. m. * 76^ Qzc 70 SERIES GO SWITCH V.I.P. ON DURCO 6" 150# G411 Valve WITH BETTIS ACTUATOR FOR CONOCO GQGENERAL EQUIPMENT 4 MANUFACTURING CO.. INC. MOO FERN VALLEY ROAO P.O.BOXS7MO . ________ lOUMVIUE. KENTUCKY. USA. 40233 SYSTEMS (80ft Ml ?W. TWX I104M47M --------- DWG- n6. V126411-1942 REV. ABD00209930 TOLERANCES UnlMS otherwise spodfled Angks: 1*. Fractions; 1/32". .XX .01". .XXX .005" Surfaces must be Concantrtc, Parallel. Flat A Square (as applicable) to each other within T.I.R. ACTUATOR MOUNTING BRACKET NO. REVISION OATE BY APPO. Item Qty. 11 21 31 44 54 62 72 MATERIAL LIST Description CWg. No. Switch Activator V907310-1951 Mounting Bracket V907310-1952 Set Screw #12-24 x 1/4 1/4-20 x 1/2 Hex Hd. Screw 1/4- L.W. 5/8 Ext. Tooth L.W 5/8 F.W. GOB SWITCH ACTUATOR MTG. BRKT ORILLB TAP 1/4-20 UNC (4) HOLES GO SWITCH ORIVE SHAFT INSTALLATION INSTRUCTIONS 1. Remove. Actuator, Coupling and Existing position indication plate. 2. Slide Switch Activator )item 1) onto drive shaft and secure with set screw (item 3). 3. Assemble 00 Switches to Mounting Bracket (item 2) with Jam Nuts supplied with switches and washers items 6 & 7. 4. Place Switch mounted on bracket on sides of Actuator mounting bracket and align switch with Activator (item 1) then natch drill Actuator mounting bracket with holes in Mounting Bracket (item 2) Secure with items 4 & 5. 5. Switches should sense Switch Activator when Valve is in full open and full closed positions. FIG. 2 NOTE: GO Switches are not included in V.I.P. (Valve Indication Package) and should be ordered as a Separate item. DWN. BY RON S. CHK. BY APPO. OATE 10*5-63 & i/ ?$ 70 SERIES GO SWITCH V.I.P ON W-K-M 310 BALL VALVE *' FOR CONOCO GQGENERAL EQUIPMENT & MANUFACTURING CO.. INC. 3300 FERN VALLEY ROAD P.0. SOX 97290 LOUISVILLE. KENTUCKY, USA. 40239 SYSTEMS (502) 909-2306, TWX110496-2799 HMIH DWG. NO. REV. V 907310-1950 ABD00209931 Angle*: 1 1*. Friction*: 1/32". .XX .01". .XXX 005" Surface* must be Concentric. Parallel. Flat & Square (at applicable) 10 each other within T lR NO REVISION OAfE BY APPD ACTUATOR MOUNTING Item Qty. 11 2I 31 44 54 62 72 material LIST Description CWg. No. Switch Activator V907310-1955 Mounting Bracket V90731Q-1954 Set Screw 112-24 x 1/4 1/4-2C x 1/2 Hex Hd. Screw 1/4- L.W. 5/8 Ext. Tboth L.W. 5/8 F.W. FIG. 1 INSTALLATION INSTRUCTIONS Remove Actuator, Coupling and Existing position indication plate. .2 Slide Switch Activator (item 1) onto drive shaft and secure with set screw (i tern 3). i 3. Place Mounting Bracket (item 2)onto Actuator Mtg. Brk't. and mark position of two holes. Drill and tap for 1/4-20 UNC holes. Secure Mounting Bracket (iter (item 2) with items 4 & 5. 2) 4. Screw GO Switches into Mounting Brk't. (item 2) till Gap between end of switch & Switch Activator (item 1) is approx. 1/16". Secure with Jam Nuts that are included with Switches and with washers (items 6 & 7). 5. Switches should sense Switch Activator when Valve is in full open and full closed positions. NOTE: GO Switches are not included in V.I.P. (Valve Indication Package) and should be ordered as a Separate.item. OWN. 0Y (f RON S. CHK. BY APPO. DATE 10- ,, 4* it 76 0_____________ 70 SERIES GO SWITCH V.3.P ON W-K-M 310 BALL VALVE 6" FOR CONOCO GOGENERAL EQUIPMENT & MANUFACTURING CO . INC 1100 firm VAUCV AOAO A O. BOX 17290 _______ LOUISVIUE. KENTUCKY. USA. 40331 SYSTEMS (902) 900-33*6. TWX 110416*3710 aMfSl OWQ. NO. r2v? V 907310-1953 ABD00209932 TOLERANCES Unleaa otherwise tpecifiad Anglo* 1*. Frictions: 1/32". XX .01". XXX .005" Surfaces must be Concentric. Parallel. Flat A Square (as applicable) to each other within _____ T.l.R. NO. REVISION MATERIAL LIST Item Qty. Description OATE 8Y APPO. Dwa. `lo. 1 1 Switch Activator V402800-1948 2 1 Mounting plate V402800-1949 3 3 #10-24 x 1/2 Rd. Hd. Screw 4 3 #10 Ext. Tooth L W. FIG. 1 MATCH DRILL FOR THREE 10-24 UNC-28 THREADED INSTALLATION INSTRUCTIONS 1. With Valve Actuator removed slide Switch Activator (item 1) onto drive shaft as shown in figure 1. 2. To Mount Mountinn Bracket (item 2) match drill and tap for three #10-24 UHC screws and attach item 2 to Actuator mountinn bracket with items 4 & 5. 3. Screw GO Switches into threaded holes on Mounting Bracket (item 2) and secure with jam nuts included with Switches. 4. Adjust Switches to sense triangular bars on Switch Activator when Valve is in full open or full closed positions. FIG. 2 FIG. 3 DWN. BY RON S. CHK. BY /OATE 10*3* 83 APPD. word a--iw-- MII--ftIMW y // ZiQ. 70 SERIES GOSWITCH V.I.P. ON KTM 6" VALVE E0800 WITH JAMESBURY ACTUAf&tf FOR CONOCO GQGENERAL EQUIPMENT A MANUFACTURING CO.. INC. 3300 FERN VALLEY ROAD P.O.BOX 37290 . LOUISVILLE. KENTUCKY. USA. 40233 SYSTEMS (902) S69-23M. TWX 810-435*2786 SMBMII DWG. NO. REV. V402800-I947 ABD00209933 TOLERANCES UntoM ottorwtM iptcrtM Angtoc 1*. Fraction*: 1/32". .XX .01". .XXX .005" Burteew must b# Conoantrte, ParmM. FM A Squara (m appttoatta) to mch othar wttNn T.I.R. MATCH DRILL SHAFT J29 TO .129 DIA X 3/8 OCEP ORILL ft TAP SHAFT FOR \ 1/4-20 UNC NO. REVISION DATE BY APPO. MATERIAL LIST Item Qty. Description Dwg. NO. 1 1 Mounting Bracket V782067-1935 2 1 Switch Activator V782067-1936 3 1 Rollpin 1/8 x l/2Hlong 4 1 1/4-20 x 5/8 Flat Hd. Screw 5 4 1/4-20 x 3/4 Hex Hd . Screw 6 4 1/4 L.W. 7 2 5/8 Ext. Ttooth L.W. 8 4 5/8 F.W. (1-5/16 O.D.) 5 )DRILL & TAP (4)HOLES 1/4-20 UNC i 9/16 DEEP GO SWITCH ACTUATOR MTG. PLATE (2 FIG. 1 GO SWITCH ACTUATOR COUPLING INSTALLATION INSTRUCTIONS 1. Remove Valve Actuator and Coupling from Valve. 2. ftochine notch in coupling to 7/8" depth as indicated in view A-A. 3. Drill & tap top of shaft for 1/4-20UNC x 1/2** deep hole. 4. Place Switch Activator (item 2) on shaft and secure with flat head screw (item 4) Then orient Switch Activator as shown in figure 1. Match drill shaft with hole in Switch Activator and drive rollpin (item 3) into hole to prevent rotation. 5. Fit Mounting Bracket (item 1) to sides of"Actuator mounting plate support and nark location of four mounnting holes, dril^ and tap four 1/4-20UNC x 9/16- dp Then secure Mounting bracket (item 1) with items 5 & 6. 6. Insert GO Switches into slots on Mtg. Bracket (item 1) and secure with two jam nuts that ocme with switches and washers items 7 & 8. 7. Mjust Switches to sense Activator (item 2) in full open and full closed positions. FIG, 2 / x /^Vk7 OWN. BY T)aa m GENERAL EQUIPMENT RON S. 9-12-63 70 SERIES GO SWITCH V.I.P. A MANUFACTURE*) CO.. MC. 0MLBV Mi PMN VM4JY *0*0 ON TUrLINE 067 6" PLUG VALVE p.o. sor m jM.1 VALVE SHAFT ^ ILAMWUI. KMTUCKV. MBA. stwannacin-a-.-T-W-M--u-M-i-r-a- sssssS^i INDICATION V782067-1934 m ABD00209934 TOLERANCES Unless oiiieiwise spcC'tivU Anglos l fractions 1/3?'. XX Of XXX j 005' Surfaces must t'e Concentric. Parallel. Flat & Square (as applicate*) lo each other within TIR NO REVISION DATE BY APPD MATERIAL LI"T Item Qty . Description Owo . "o . 1 * Switch c t i va : ^- V40280Q-1948 2 1 Mounting plate V402800-1949 3 sj #10-24 x 1/2 Rd. Hd. Screw 4 3 #10 Ext. Tooth L.W. FIG. 1 MATCH DRILL FOR THREE 10-24 UNC-2B THREADED HOLES INSTALLATION INSTRUCTIONS 1. With Valve Actuator removed slide Switch Activator (item l) onto drive shaft as shown in figure 1. 2. To Mount Mount inn Bracket (item 2) match drill and tap for three #10-24 U-iC screws. Attach Mount inq Plate to Actuator mounting bracket with items 4 b 5. 3. Screw GO Switches into threaded holes on Mounting Bracket (item 2) and secure with jam nuts included with $witches . 4. Adjust Switches to sense triangular bars on Switch Activator when Valve is in full open or full closed positions. FIG. 2 OWN. BY RON CHK. BY APPO. DATE 10-3- 8 5 V* --< * : - 70 SERIES GO SWITCH V.I.P. ON 6600 JAMASBURY VALVE WITH BETTIS ACTUATOR FOR VISTA POLYMER GENERAL EQUIPMENT 4 MANUFACTURING CO.. INC. 3300 FERN VALLEY OOAO GO p O BOX 37290 _________ SYSTEMSLOUISVILLE. KENTUCKY. USA. 40233 (502) 969-2386. TWX BIO-S36-2788 DWG. NO. V402800 -1947 B REV.