Document xz7J0RDDg29VrGb4wnMKrkmay

HQHSAHTQ CHEMICAL COMPAHY ORGAHIC CHEMICALS DIVISIOS ASHISTOK, ALABAMA DEFENDANT'S EXHIBIT , (0 XmLmSLm3mlA REVISION OF PHOSPHATE DIVXSIOH EHGIWEERIHG DEPARTMENT REPORT HO. 117 OS 12 PHIT BIPHESYL PLABT AT ANHISTOH, ALABAMA Dated: December 23, 1948 by G. W. Jordan Audi Eon Technical Service* Department Report Ho. 729-68-9 by R. L. Hedworth Dls trlbutlon: M. Patrick - Mala Office ^A. M. Elleabarg - Kiln Office R. K. Morris - Roberta Bldg. H. Li Minckler - Roberta Bldg. R. S. Wobu* - Roberta Bldg. F. J. Holsapfel - Roberts Bldg. L. Li Felllager - Roberta Bldg. J. W. Graves - WGR (2) J. F. Stickley-Robta, Bldg. D. B. Honaer C. M. Edeiblut J.H. Gould Jack Clegorm R, L. Hedworth Extra (3) DEFENDANT'S , EXHIBIT a, nrf/Huj O DSW 462477 WATER PCB-SD0000045278 ( INDEX SUMMARY DESCRIPTION OF PROCESS........................................................ 1 - 5 EQUIPMENT DESCRIPTIONS........................................................... Series 100: Geaeral Process........................ 6 - 40 Series 200: Bipheayl Usits........... .......... 41 - 65 Series 300: Bipheayl Stills.................. 66 - 81 Series 400: I&stromeatatioa......................82 - 89 Series 500: Utilities................................. 90 - 98. (. FLOW SREETS DRAWING NUMBERS...................................................................... 99 "107 EQUIPMENT NUMBER LIST (DEFT.20)............................ 108 -117 MAINTENANCE SURVEY.......................... ,............................... Series 100: Gemercl Pleat......................... 118 -124 Series 200: Bipheayl Ualts....................... 125 -128 Series 300: Bipheayl Stills.....................129 -131 Series 400: Iaatrrsaeatatiom.....................132 -134 Series 500: Utilities................................135 -139 ( DSW 462478 WATER PCB-SD0000045279 c SUMMARY Future Bipheayl-Santovax requirements have aeceseitated an increase la Bipheayl productloa while maintaining approximately the same Santowax productloa. This productloa balaace caa be achieved oaly by increasing the bemeeae feed rate. Numerous altermativea caa be coacelved oa how this might be accomplished, but before aay evaluatioa can be made, it was accessary to determine what must be dome to the existlag plant to obtala continued production. Consequently, a Maintenance Survey was needed to determine the extent of the necessary repairs. In addition, the Phosphate Division Final Design Data Report for the existing Bipheayl plant, prepared in 1948, was out-dated and needed revising. To minimise the work load, these jobs were combined. This report describes in detail the equipment used' for the production of Biphenyl at Anniston. The equipment description is based on equipment inspection, firsthand knowledge, and on Information supplied in Phosphate Division Engineering Depart ment Report No. 117, titled "Final Design Data dm 12 Unit ' Diphenyl Plant at Anniston, Alabama,11 dated December 23, 1948, by 6. V. Jordan. The Maintenance Survey presented in this report'is based on visual inspection of each item and includes only those repairs needed to put the plant in good operating condition. Revisions to*the process, equipment improvements,piping alterations, etc., are beyond the scope of this report.* These alterations and/or additions will be presented in tubsequent reports and will be evaluated and Justified oa their own merits. The words "Bipheayl" and "Diphenyl" are synonymous and are interchangeable in this report. RtH/fb 9/27/57 WATER PCB-SD0000045280 DESCRIPTION OF PROCESS 1. INTRODUCTION Diphenyl if produced by a. pyrolysis reaction between two molecules of benzol in which one molecule of diphenyl and one molecule of;hydrogen are formed. The pyrolysis is brought about in this particular case by stepwise vaporising and super-heating benzol by bubbling the vapor through a series of pots filled with molten lead. The temperature to which the final lead pot or "converter" is heated determines the percentage of the benzol converted, which increases with higher temperatures. Several other pyrolysis reactions also occur producing mainly terpheayl and also some more highly polymerized compounds. In addition, some free carbon is formed which deposits la the units causing considerable maintenance difficulties because of plug-ups. The percentage of terphenyl in the crude Biphenyl is rough ly the same as the conver*ioa percentage of the benzol. SYNOPSIS OF PROCESS Liquid benzol is shipped in tank car lota to the plant site and unloaded through the top dome by a siphon type pumping arrangement delivering the benzol to storage tanks. The benzol delivery pipe is steam traced'and the storage tanks have steam coils to prevent the benzol from freezing in the winter. Each of the five storage tanks has a sump pump for delivering benzol to the feed tank. These feed tanks are automatically refilled by a continuous "let-down" control. Only one of the storage tanks is allowed to feed the feed tank at a time. This choice of storage tank is manually determined by an operator. The single feed tank services all of the diphenyl units by neans of a centrifugal pump fed from a bottom outlet in the tank. The benzol feeds a header where the individual feeds are metered through orifices to the different units. Isopropyl alcohol is added to the benzene feed in concentrations of 0 to 0.5Z by weight, usually 0.15Z is added. This isopropyl alcohol is pumped to the suction of the benzene feed pump where it is mixed and pumped to the units. This material catalyses the conversion, that is, a 40-60C. lower operating tempera ture, can be maintained when this material is added to the feed benzene. There are twelve diphenyl units of equal capacity, each consisting of a pipe coil vaporizer located la the flue gas exhaust stack, two preheater pots and a converter pot filled with molten lead and suspended in a firebrick setting for burning natural gas, and a fractionating column with a condenser and split flow box. Ia two of the units. Nos. 4 and 5, one of the preheater pots la replaced with a heat exchanger. The units are numbered 2 through 13, there having been a No. 1 unit at oaa time. The present number of units were erected in five installments. Nos. 2 and 3 having been erected at dCEfemat tiads, Nos. 4 and 5 together, Nos. 6, 7, 8, 9, and 10 together, and Not. 11, 12, and 13 together so that these groups are all DSW 462480 WATER PCB-SD0000045281 2. lightly different la ions details. Hovever, there are only actually two fundamen tally different types of units, Hos. 4 and 5 differing from the rest In that oae of the preheater pots la replaced by a heat exchanger. Although the heat exchanger effected a gas sawings as predicted. It proved impractical due to carbon formatloa foul lag the tubes and the idea was abandoned on the subsequent units. After the benrol feed has been netered through an orifice, It passes through the vaporizer pipe coll in the flue gas exhaust stack where the liquid benzol is vaporized and at the sane tine recovers sone of the heat from the exhaust flue gases. The benzol vapor Is then bubbled through noltes lead in the two preheater pots la series sad the temperature stepped up to the pyrolysis reaction tempera ture. The hot vapors are converted to 10-305 diphenyl si they leave the converter pot, which is similar to the preheater pots except that the nolten lead is very carefully controlled at the desired reaction temperature, usually between 750 and 810C. The temperature Is adjusted to give the percent conversion needed to maintain the balance between Biphenyl and Saatowax needed to meet sales demands. After leaving the converter, the benzol and conversion products pass first through a lead trap (which is essentially a wide place la the line) for removing __ entrained lead and then eater the bottom plate of a fractionating column. A '--~i | considerable amount of carbon" adheres to the pipes between the converter and the I l lead trap, and the lead trap and the fractionating column, necessitating the re- j I nova! and cleaning of the pipes every one to six months. J The super-heat in the vapors from the converter is utilized in a fractionating column to effect a partial separation of the benzol from the conversion products. The conversion products are later completely separated la a batch distillation. The column top is maintained at<100 C. by refluxing the condensed benzol vapors back to the top plate. The conversion product and some benzol la condensed la the column and allowed to overflow from a carbon trap on the bottom of the column to a crude diphenyl catch tank for storage prior to batch distillation. The overhead vapora from the column are cooled by a partial condenser and the liquid benzol drained to a rotaweir for spitting the flow into reflux and benzol overhead which is "run back" to the benzol feed tank by gravity. The rotaweir ia used to adjust the ratio between reflux and overhead. There are five differently aired and designed groups of condensers, a new design having been made for each lastallsent of units as mentioned earlier, and a different design used to replace some bad condensers. In addition, these condensers have been shifted from oae unit to another to facilitate cleaning and repairing condensers. The conversion product hydrogen, saturated with benzol vapor, la bled off from the condenser and rotaweir, collected la a common header, and passed through six coolers, connected in parallel, where some of the benzol la condensed and allowed to run by gravity back to the auxiliary feed tank. From the coolers the saturated hydrogen gas la passed to a collecting tank in which more of the benzol condenses out and ia drained to the benzol pump tank la the compressor room. The hydrogen from the collecting tank is compressed ia two stages to 250-300#/ia. An intercooler end aftercooler condenses the benzol vapor after each stage. This benzol is collected ia pressure receivers after each stage and periodically . DSW 462481 WATER PCB-SD0000045282 3. V. blown by the hydrogea pressure over imto the puap teak for retura to the benzol feed tank. The hydrogea is Teated to the atmosphere or else aged la the aeaafactare of HB-40, HB-20, etc. Ia the secoad type of aait (Hog. 4 aad 5) the flow of material is essentially the .sane as that described above except the vaporized benzol feed emerging from the vaporizer coll passes through a heat exchaagar ia lieu of one of the preheaters. The conversion products sad benzol from the converter pot are also passed through the heat exchaagar, countercurrent to the benzol feed, thus transferring sensible heat from the converted gases to preheat the feed. The conversion products and vapors from the converter pot then pass on to a column as is the case with the other units. Some of the units have been altered since their installation. Unit Ho. 4 is being equipped with a 4 foot extension on the converter. This exten sion to the converter will act as a sojourn section. This addition reaction space will provide additional reaction time aad penalt a temperature reduction of 30-60C. in che converter while maintaining the sane percent conversion. This reduced temperature will minimize carbon formation aad reduce the heat exchanger fouling and unit clean-outs. The lead traps will be eliminated. Unit Ho. 11 has a large coil in the lower section of the column which acts as a vaporizer. The flow ia through the large coil, the standard vaporizer coil ia , the stack, the three pots, and to the column. The hot gases from the converter ( pot heat the benzene la the large coil and vaporize the benzene. The recovery of heat from the converted gas stream has permitted an increased benzene feed rate of about 100 gallons per hour. The Increase is due to better utilization of the heat input and the reduced heat load on the colinen and condenser. Room for this large coil was made available by removing the two lower babble cap plates from the column. Units Hos. 12 and 13 are equipped with this large coil but the coil la being by passed because the units surged and caused excessive pressures throughout the unit, thus blowing the gaskets around the top of the preheater and converter pots. Ho. 11 unit also surges occasionally but since Ho. 11 unit ia equipped with a sojourn pot (the sane as will be installed on Ho. 4 unit), the added space provides a cushion to absorb the sudden expansion caused by rapid vaporization of benzene in the large coil. Ho. 11 unit is being equipped with an automatic reflux control which will control the reflux rate to maintain a constant vapor temperature on the third plate from the top of the colma. Each unit is equipped with two orifice plates between the converter and column. These orifice plates are sized to give a pressure drop of about 40 pslg and thereby permit an increased pot operating pressure, increased soujoum time, and a reduced operating temperature aad minimize lead carryover from both entrainment and lead vaporization. The diameter of these orifices are 1.031 and 1.014 inches, the larger orifice being upstream from the smaller one. r DSW 462482 WATER PCB-SD0000045283 The cusp prodact from all the columns li collected by gravity la two exude dlphaayl catch tasks. The piping to thetaaka Is stem jacketed to prevent the dlpheayl fro* freezing amd has a liquid trap to prevent vapors fro entering the catch task front Che column. The tasks are vested into the hydrogen header to equalize the pressure. The two hatch stills each consist ef a horizontal, cylindrical tank surmounted by a fractionating column, a submerged Runs ay pump, and a gas fired coil heater. The pump circulates the still charge from the tank, through the coil heater and back to the tank. The rate of distillation of the crude diphenyl is con trolled by the combustion rate of natural gas in the gas fired heater, which is controlled by an adjustable automatic temperature recorder and controller so as to give a temperature rise of 20-25C. between inlet and exit temperatures of the still charge through the heater coil. If an attempt is made to increase the temperature rise above 25C., the coil becomes plugged with carbon. The vapors from the still are separated in a fractionating column. The first cut from the column at 80C. is benzol which is returned by gravity to a catch tank for subsequent return to the benzol feed tank for recycling through the diphenyl units. The benzol cut is not run directly back to the feed tank because of the possibility of not cutting the column at the proper time and allowing some con tamination to run back with the benzol. The next fraction, distilling between 80 and a distillate crystallizing point of 68.6C. is called "heads" and consists of light oils with boiling points nearing that of diphenyl. The diphenyl fraction is collected until the temperature in the still pot reaches 340-350C. The tail cut is collected until the distillate vappr temperature in the top of the column reaches 300C. The various distillation cuts are made with these reflux ratios: Benzol Cut Heads Cut Biphenyl Cut Tails Cut 20% 501 201 15% The high boiler, remaining in the still as residue, is pumped to the high boiler catch task from which it is run into 55 gallon dross for storage or pumped to the Santowax still or Snntowax storage tank. In order to prevent freezing of diphenyl in the condenser at the top of the fractionating column, the conaenser cooling water must be at a temperature near the nelting point of diphenyl (1587.). The flow of pond water ia adjusted to prevent freezing of the prodact. It is generally necessary only to cut back the flow of pond water at the end of a distillation. The diphenyl production is neasured in a catch tank amd pumped to storage tanks ot tank cars by a 2" Roaaey vertical sump pump. Tbe heads and tails are collected and charged back to the next still batch. qS\N WATER PCB-SD0000045284 5. GENERAL DISCUSSION The carboa formed is the dlphemyl units partly deposits la the pipe after the converter units, through the lead trap, la the pipe after the lead trap, aad la the fractionating column. These pipes become plugged vith carboa aad must be disaaatled Aad cleaned every one to six moatha. The lead trap aad frac tionating column are cleaaed out at more infrequent iatervala. This so called "carbon" deposit analyzes as follows: Lead ........................................... Insoluble in HHO-.............. (carbon included).... Insoluble, ignited............ Iron oxide. Insoluble... Carbon, combustion............ 56.5% 42.7% 18.5% 0.7% 28.9% As much of this piping aad equipment is above the melting point of lead, It is evident that the adhering carboa prevents coalescence of the molten lead drop lets. The amount of reflux returned to the fractionating column is controlled by the operator to maintain a temperature of about 100C. at the column top. The cooling water to the condenser is operated at full capacity and as the heat duty of each unit is approximately the same, it is apparent that the amount of reflux required will vary according to the effectiveness of each condenser at a particular time. When the temperature of the effluent water exceeds 70C., the condensers are cleaned. The diphenyl units produce crude diphenyl by a continuous process with a 24hour day operation. The number of units operated depends upon the diphenyl market or the maintenance required on the equipment. The crude diphenyl is collected and batch distilled at interval a depending upcm the rate of collection. The batch distilling requires 10-12 hours. DSW 462484 WATER PCB-SD0000045285 BQPTPMEHT DESCRIPTION SERIES 100 - GEHERAL PROCESS EQUIPMENT Item Ho. 101; Benzol Unloading Pump (1-Requlred) 6. August 1957 Function: Operation: Materials Handled: Controls: Services: To unload benrol from railway tank cars to the benrol storage tanks. Intermittent. About 5 hours is required for unloading one car. Prior to unloading, the car must be chocked to prevent movement, and grounded to the pump to prevent formation of a static electrical charge. The pump inlet pipe is inserted through the tank car dome, the valve, nearest the pump auction Is opened, and the pomp is started. A small stream of water is adjusted to pour over the pimp bearings for cooling. After the tank car is unloaded, the pump is shut off, benzene is allowed to drain back into the pump suction line, and the valve nearest the pump suction is closed. This benzene is left in the line to prime the pump when the next car is unloaded. Air pressure is cut into the line which blows the benzol remaining in the line on to the storage tank. With the diphenyl plant operating at peak capacity and all 12 units producing, it is estimated that the pump will be required to unload an average of one car par day. Benzol at about 30 GPH at the existing head which is estimated to be about 80' TDR. Manually controlled by a motor starting switch located at the puap. Approximately 10 KWH per day average. A negligible amount of priming and cooling water. A negligible amount of compressed air. OS\N 462485 WATER PCB-SD0000045286 Item 101 Continued: Size and Type: Inlet Pipe: Strainers: Kanufsctarer: Materials of Construction: Kotor: Drive: Location: r 7. Westco turbine pump with removable Users and impellers. The inlet pipe forms am arch with swivel joints so that it may be passed down through the tank car dome. A platform is provided for the operator to manipulate the pipe. Am Acme pomp straimer is installed la both the pomp Inlet and outlet. Westco Pxaip Company, Bettendorf, Iowa Liners sad Impellers are mi-resist and shaft is stainless steel. 3 HP, 1740 RPH, 3 phase, 60 cycle, 220/440 v. TEFC Allis-Chalmers motor vith #225 frame. Direct drive with flexible coupling. Located along aide of railroad spur about 200 ft vest of the diphenyl building. ( DSW 462486 WATER PCB-SD0000045287 Item 102; Benzol Storage Tanks (5-Raqulrad) 8. August 1957 Function: Operation: Materials Handled: Controls: Services: Site sad Type: Openings: Manufacturer: Capacity: Materials of Coastructiom: Steaa Coil: To provide benzol raw material buffer storage betveem receipt aad use. Benxol is periodically fed into the storage tasks asd Intermittently withdraws as seeded to the bemzol feed task. The storage tanks provide about 5 days operatiag storage at maximum plaat capacity. Materials is: Bemzol at approximately 30 GPM while oaloading. Materials out: Bemzol at approximately 500 GPM while operating plant at maximum capacity. See Item 104 Steam is furnished to steam colls as seeded os cold days depending os judgment of operator. The three newer tasks are 181 lomg x 10' I.D. horizontal tasks with dished heads. The two original tasks are slightly smaller(as shows below)is capacity. Top: 2'0n dia. asshole 6" dia. atd. pipe suction 3 dia. atd. pipe standpipe and feed 3" dia. thief hatch 1%" dia. condensate and steam pipe 2" dia. vent aad flame arrestor Adamson Company Three 10,800 gal. tank* and two 9,800 gal. tanka 5/16" steel plate tank with 3/8" steel plate dished heads. Flat hairpin type steam coil of 1" pipe installed in bottom of tank. DSW 462487 WATER PCB-SD0000045288 ^ It** 102 Continued: Location: ' References: 9. Located about 200* south of the diphenyl building. The five tasks are 31' apart and each located la a moat with a cycline fence surrounding the group. Drawings Moasaato Details of Storage Tasks Layout of Storage Tasks Location of Present Storage Tanks Foundation and Fence Details Detail of Hev Benrol Storage Tanks 1 9C-7961 9C-7960 9C-6668 9C-6685 9C-7961 ( ( 0SVM 462488 WATER PCB-SD0000045289 Itw 103; Benzol Transfer Pomps (5-Requlred) 10. August 1957 Function: Operation: Materials Handled: Controls: Services: Size and Type: Manufacturer: Capacity: Materials of Construction: Kotor: Reducer: Strainer: Location: To transfer benzol from the benzol storage tasks to the benzol feed tank. Each benzol storage tank has a separate benzol transfer pump and benzol is let down from one tank at a tine. The pump operates intermittent ly for about 6 hours per day when the plant is operating at maximum capacity. Benzol - Approximately 500 GPH (average) Tho operator mamually sets a five point motor starting svitch to select the storage tank from which he desire* the automatic let-down system to feed. (See Item 104) Approximately 9 KWH per day (max.) Steam is supplies to copper coils surrounding the pumps or is blown directly into the pump from a hose connection to prevent the benzol from freezing in the pump on cold days. Positive displacement pumps, model S0 100, non sparking construction with flanged connec tions . Pump integral with reducer shown below. The pumps are self-priming by means of a stand pipe and prising tank integral with the pump. Blackaer Pump Company Viking Prnap Company 75 to 100 GPH of benzol vs. 25' TDH with a suction lift of about 11'. Bronze fitted. 2 HP, 1800 RPM, 3 phase, 60 cycle, 220/440 v., TEFC explosion proof motor. Gear reduction unit furnished with pump to give 525 RPM when using 1800 RPM motor. A pump strainer is installed oa the pump outlet. Mounted on benzol storage tanks. DSW 462489 WATER PCB-SD0000045290 I team 104: Isopropyl Alcohol Storage Tank (1-Required) 11. August 1957 Function: Operation: Materials Handled: Controls: Sice & Type: Materials of Construction: Location: Maintenance Required: To provide 'buffer storage for isopropyl alcohol. Isopropyl alcohol la periodically fed into the storage tank and intermittently withdrawn aa needed to the isopropyl alcohol feed tank. The storage tank provides about 3 months opera ting storage at maximum plant capacity. Material in: Isopropyl alcohol at approximately 30 GPM while unloading. (This material la unloaded at the benzol unloading dock. The benzol umloading pump is used for this purpose.) Material out: Isopropyl alcohol at approximately 4 gallons per hour while operating plant at maximum capacity.(Average) Hone provided. Tank 10'6" dia. x 15'6" long equipped with standard mnnhead and nozzle for flame arrestor vent, top inlet and top discharge. 5/16" steel plate with 3/8" steel plate dished heads. Located about 200 feet South of the biphenyl building and due east of the benzol storage tanks. None. DSW 462490 WATER PCB-SD0000045291 12. August 1957 Item 105: Isopropyl Alcohol Transfer Pump Function: To transfer isopropyl alcohol to the isopropyl alcohol feed tank. ' Operation: Isopropyl alcohol is pusped from the isopropyl alcohol storage tank to the isopropyl alcohol feed tank about once each shift. Materials Handled: Isopropyl alcohol Controls: The Operator manually starts and stops this pump as required. The snitch is located near the isopropyl alcohol feed tank. Size & Type: Positive displacement, self-priming by means of a stand pipe and priming tank integral with the pump. Manufacturer: Blackmer Pump Company Capacity: Approximately 10 GPK at a 25 TDH with a maximum suction of 11 feet. Materials of Construction: Bronse fitted Location: Mounted on isopropyl alcohol storage tank. DSW 462491 WATER PCB-SD0000045292 Item 106: Bcarol Feed Task (2-Requlred) 13. August 1957 Function: Operation: Materials Handled: 1: To provide a source of benzol for feeding to the diphenyl omits. 2: To provide a catch tank for the benzol re turned from the diphenyl process. Let-down from benzol storage tanks is intermittent. Run-back from diphenyl units is continuous. Return from benzol recovery system ia batchvise. Return from hydrogen coolers is continuous. This benzol returns to the auxiliary benzol feed tank aad is periodically pumped back to the primary benzol feed tank. When returning recovered benzol to the primary benzol feed tank from the benzol recovery system (hydrogen compressors), the distilled benzol catch tank or the auxiliary benzol feed tank, the operator must first cut off the automatic let-down from the benzol storage tank and let the level of the benzol in the feed tank drop enough to provide for the additional benzol returned. In addition, the distilled benzol must be checked for clear color before returning it to the feed tank. The operator must manually once or twice per shift drain off the water ia the feed tank which comes from the water priming during un loading and from condensed moisture from Che atmosphere. Benzol: Out: 240 GPH per unit 2900 GPH (max.) 12 unit operating . Ia: 500 GPH from storage tanks 2000 GPH (avg.) returned from process Part of the benzol returned from the process is returned batchwige so that the above figure* are only average. DSW 462492 WATER PCB-SD0000045293 Item 106 Continued: Controls: Services: i4. Water: Same water condenses from the atmosphere la the storage tank. Generally the amount of water is significant when the let-down control Is switched to a new task and diminishes to a negligible amount after the storage tank has been used awhile. The recycled benzol also contains traces of water and finally divided carbon. The water is slightly corrosive as it contains 0.031 sulfates, 0,031 chlorides, and some undetermined reducing compounds which will react with oxygen. It is necessary to return the recycled benzol to the feed tank rather than the storage tanks at it has been determined that the' recycled benzol contains some undetermined catalyst which upsets the operation of the diphenyl units. There fore, an effort is made to blend the recycled benzol in. with the fresh feed in a more or less constant ratio to maintain smooth operation of the units. An automatic level (let-down) control is provided for maintaining the supply of benzol in the feed tank. When the level of benzol in the feed tank recedes to 15" below the top, the automatic con trol starts one of the transfer pumps. The transfer pump is automatically shut off when the benzol level Is 9" below the top of the feed tank. Another similar level control to that controlling the transfer paap is provided for sounding a high and a low level alarm should the level exceed 3" beyond the control level. A manually operated five-point selector switch is provided at the feed tank for selecting the benzol storage tank to furnish the benzol feed. Steam Is provided to the steam coil during cold weather depending upon the judgment of the opera tor who merely feels the aide of the tank to determine if it feels war. A negligible amount of electricity is necessary to operate the control system. DSW 462433 WATER PCB-SD0000045294 Item 106 Continued: Sizn & Type: Openings: Manufacturer: Capacity: Materials of Construction: Steam Coils: Locatioa: References: 15. 7*6" I.D. z 15'6" long, dished head horizontal tasks lastailed la a concrete vailed emclosure about 4' high to catch the benzol la the event of a task rupture. The feed tanks are located oa a concrete slab surrounded by a cyclone fence. Top: ' 2'0" I.D. manhole centrally located for installation of the steam coils (2) 8" flanged pipe nozzles for the automatic let-dovn controls. 2%" foam nozzle 2" vent to hydrogen coolers (Item 110) 4" benzol runback nozzle 4" benzol inlet nozzle (from storage) 2" redding nozzle 2" thermal veil Bottom: 2" outlet nozzle extending 6" above bottom of feed tank. 1" drain nozzle in dished veil (for draining water). Chattanooga Boiler and Tank Works 5,000 Gallons. 3/8" steel plate Flat hairpin coils made from 1" XH seamless steel pipe forming three loops 5* long and with 1'0" pitch. The coils are supported on the bottom of the tank with one coil in each end. Located about 30' vest of diphenyl building Drawings Monsanto Layout of Feed Tank Feed Tank Details Bill of Materials 9C-8205 9C-8206 9BM-54 DSW 462494 WATER PCB-SD0000045295 Item 107: Benzol Peed Pump (2-Rcquired) 16. August 1957 Function: Operation: Materials Saadi ed: Controls: Servicea: Sire & Type: Manufacturer: Materials of Construction: Motor: Drive: Location: To deliver the benzol feed from the benzol feed tank to the benzol vaporizer coil of each diphenyl trait. One pump Is operated continuously while the other pumps are held as spares. Benzol - Maximize rate required is 55 GPM with all 12 units operating at full capacity. The pump is manually controlled by motor starting switch. The rate to each diphenyl unit is automatically controlled and recorded by an orifice and flow recorder and controller. The approximate head required at the orifice is around 17 0 psig. Approximately 175 KWH per day electricity required. Two-stage Westco pump with removable liners. Micro-Westco, Incorporated . Impellers of Ri-Resist and shafts of stainless steel. 15 HP, 3740 RFM, TEFC, explosion proof Howell Electric Company motor. Direct drive with flexible coupling. Located on concrete pad next to feed tank. DSW 462495 WATER PCB-SD0000045296 (. Item 108: Isopropyl Alcohol Feed Task 17. August 1957 Function: Operaticm: Material* Handled: Controls: Capacity: Location: To provide a source of isopropyl alcohol for feeding to the benzene feed. Let-down from the isopropyl alcohol inter mittently. Isopropyl alcohol Out: 4 gal./hour Float to indicate liquid level. 100 gallons Southwest corner of benzene feed tank area. c ( DSW 462496 WATER PCB-SD0000045297 August 1957 Item 109; Isopropyl Alcohol Feed Ptmp Fuactioa: Oper&tlom: Rat erial's Haadled: Coatrols: Locatioa: To tramsfer isopropyl alcohol to the suctloa of the beaxol feed pumps. Coatlmuoua Isopropyl alcohol The ptaap is maaually coatrolled by a motor startlag svitch. Hear isopropyl alcohol feed task. SIV 462497 WATER PCB-SD0000045298 19. August 1957 Item 110: Hydrogen Coolers (6-R.equired) Fuactioa: Operatloa: Materials Handled: Size & Type: Maaufacturer: Locatloa: Conaaat: 1. To cool the gas aad vapors froa the beazol coadeaser la order to decrease the vapor load oa the hydrogea compressors. 2. To condease some of the beazol vapor froa the hydrogea gas. Coatiauous. The coadeased beazol la coatlauously dralaed by gravity to the beazol auxiliary feed taak. Hydrogea gas aad beazol vapors from the dipheayl Halts. Beazol vapors vested from the crude dipheayl snap tasks. Beazol vapors vested froa the primary beazol feed taak. Twia 6-fia sectida coolers BSS-248 6-12 "B" type modified with am external water Jacket. The cooTera are conaected la parallel aad iastalled horizoatally. Griscom-Ruasel Company Iastalled oa the hydrogea compressor room roof. The coolers were modified im the field by the addition of aa external water cooled jacket. A62a98 WATER PCB-SD0000045299 1. Item 111; Benzol Catch Tank (1-Raqulred) 20. August 1957 Function: 1. To trap condensed benzol from the hydrogea gas to insure its mot reachimg the hydrogea compressors. 2, To provide a surge tank for hydrogea gas prior to compress lorn. Operation: Coatlmuous. The coadeased beazol trapped la the tank Is coatlauoualy dralaed to the pump task for return to the beazol feed tank. Materials handled: Hydrogea gas saturated with benzol vapor. Condensed beazol. Size & Type: 4'-0" O.D. x 4 *-0" long vertical tank with dished heads. Top - (4) 1" threaded outlets ( (1) 4" flanged nipples Side - (2) 4" flanged nipples (1) threaded outlet Bottom - (1) ln threaded outlet Manufacturer: Chattanooga Boiler Works Capacity: 56 ft.3 50 psig pressure Materials of Construction: 3/16" steel plate fabricated is accordance with ASMS code for unfired pressure vessels. Location: Suspended from the ceiling in the compressor room. References: Drawing* Monsanto Hydrogea Compressor Tanks 9C-7367 DSW 462499 WATER PCB-SD0000045300 (. ' Iten 112: Hydrogen Compressors (3-Requlred) 21. August 1957 Function: To provide a means of recovering benzol from the by-product hydrogen gas. Operation: Continuous. The benzol is recovered by compres sing and cooling the hydrogen gas in tvo stages to 300 psig. The compressors automatically load at 3 psig and unload at \ psig inlet pressures. Materials Handled: Maximum volume operating at maximum rating, (Conditions 2500 gal/hr. feed (3 217, conv.) 10,900 CFH hydrogen @ 30C. and 7 60 mm 13,000 CFH hydrogen plus benzol vapors <3 30C. and 760 mm 7.2# benzol/# hydrogen @ 15 psig, 30C. 0.8# benzol/# hydrogen @ 300 psig, 52C. 6.4# benzol recovered/# hydrogen compressed e 0.0179# hydrogen produced/# diphenyl Controls: Pressure controller controls intake. Pressure controller controls pressure of first and second stages. Services: Pressures are all indicated. Estimated electrical coaiuaptloa Is 700 EHH par day. Size & Type: Motor: (2) Class 11 AT serial 6965, size 9 and 4^ x 9 Pennsylvania compressors. Max. rpm 275; working pressure 350#-Rated Capacity 110 CFM ea. (1) Two-stage Worthington Compressor. Rated Capacity 75 CFM (2) 40 HP, 1175 rpm, type K6 motor with frame, #504 (1) 30 HP, 1175 rpm, type K motor with frame, #444 - Drive: (2) 8 V-belt sheaves (1) 3 V-belt sheaves ( References: Bill of Material 9BM-47 DSW 462500 WATER PCB-SD0000045301 22. August 1957 Item 113: Iater-Coolar (3-Requlred) . Fuactioa: Operation: Heat Duty: Services: Size & Type: Kaaufacturer: Capacity: To coademse beazol from the hydrogea gas after the first stage compression Coatiauoua. The hydrogea from the first stage compressioa of each of the three compressors stay be delivered to either of the two coolers. 80,000 BTU/hr. approximate (Roper's report). Cooliag water. Wt. 160#, overall leagth 62-5/8" Aadale Eagiaeeriag Compaay, Philadelphia, Pa. For 100# pressure DSW 462501 WATER PCB-SD0000045302 23. August 1957 Item 114: Lw Pressure Receiver (3-Requirad) Function: Operation: Materials Handled: Controls: Site A Type: Opening: Manufacturer: Capacity: Material of Construction: Hota: To provide a trap tad collecting task for the benzol condensed from the hydrogen gas after the first stage compression. The receivers are provided with piping connec tions so that either of the three compressors can be connected to either of the two receivers. The benzol is periodically blown from the re ceivers to the pump tank. Hydrogen gas saturated with benzol vapor and condensed benzol. Pressure - 65 psig A manually operated valve la provided in the pipe out of the bottom of the receiver. When this valve is opened the hydrogen pressure forces the benzol up into the pump tank. 3'-0" I.D. x 6'-0" high vertical tank with dished heads. Top: 2%" standard pipe'extending through center of top down to the middle of the tank. Two 3/4" threaded outlets. Side: 6" handhole 2" flanged nipple 3/4" threaded outlet Bottom - 3/4" threaded outlet Chattanooga Boiler Works 100 psig pressure 45 ft,3 * 5/16" steel pla.te Fabricated in accordance with ASME Code for unfired pressure vessels. WATER PCB-SD0000045303 Itea 114 Coatlaued*. Locstie*: . References: Located lm compressor room. Drawiags Moasaato Hydrogea Compressor Teaks 9C-7367-3 24. A6l53 OS^ WATER PCB-SD0000045304 V Item 115: After-Cooler (3-Requlred) . 2S* August 1957 - Function: Operation: Pressure: Heat Duty; Services: Site & Type; Manufacturer: Capacity: To condense benzol from the hydrogen gas after the second stage compression. Continuous 300 psig operating pressure 42,000 BTU/hr. approx. (Roper's report) Cooling water Wt. 160# - overall length 62-5/8" Andale Engineering Company, Philadelphia, Pa. For 350# pressure ( DSW 462504 WATER PCB-SD0000045305 26. August 1957 Item 116: High Pressure Receiver (3-Requlrad) Function: To provide a trap and collecting taaik for benrol condensed from the hydrogen gas after the second stage compression. Operation: The receivers are provided with piping connec tions so that either of the three compressors can be connected to either of the two receivers. The benzol is periodically blows from the re ceivers to the pimp tank. Materials Handled: Hydrogen gas saturated with benzol vapor and condensed benzol @ 300 palg 52C- Controls: A manually operated valve is provided in the bottom outlet pipe connection to the pump tank. Sire A Type: 2'-0" I.D. x 6'-0" long vertical tank with dished heads. All flanges are Crane #856E. Openings; Top: 2^" standard pipe extending through center down to the middle of the tank, two 3/4" threaded outlets. Side: 6" handhole 2" flanged nipple 3/4" threaded outlet Manufacturer: Capacity: Bottom: 3/4n threaded outlet Chattanooga Boiler Works 20 ft.3 350 psig pressure Material* of Construetion: 11/16" steel plate Iota: Fabricated in accordance with ASHE code for omflred pressure vessels. Location: Located in compressor room. Referases*: Drawings Monsanto Hydrogen Compressor Tanks C-7367-3 DSW 462505 WATER PCB-SD0000045306 It-- 117: Bemzol Return Pwp Tamk (1-Requlred) 27. August 1957 Faactiom: Operation: Materials Handled: Size & Type: Openings: Manufacturer: Capacity: Material of Comstruction: Hota: Locatiom: References: To "collect the condensed Benzol iron the receivers amd the benzol trap. . TBebenzol from the collecting tank is continuously rum back to the pump tank amd the benzol fro* the receivers is periodically blovm back lmto the pomp tamk. The collected bemzol is periodically pusped back to the bemzol feed tamk. Approx. 4600# or 620 gal. of bemzol recovered per day (max.). 3'-0" I.D. x 6'-0" high vertical tamk with dished heads. Top: 1%" threaded outlet Two 3/4" threaded outlets Side: Five 3/4" threaded outlets Ome 6" hamdhole Bottom: 1\;" threaded outlet Chattamooga Boiler Works 45 ft.3 50 psig pressure 3/16" steel plate Fabricated im accordance with ASME code for umfired pressure vessels. Located im hydrogem compressor room. Drawings Momsamto Hydrogem Compressor Tamk* C-7367-3 DS\N 462506 WATER PCB-SD0000045307 Item. 118: Recovered Benzol Return Pump (2-Required) . Function: > Operation: Control*: Services: Size & Type: To return the recovered benzol La the pimp teak to the benzol feed tank. Periodic. Manually controlled by motor starting switch. Estimated 15 KWH per day (max.) One Kicro-Westco and one Worthington pump connected in parallel. These are old pimps repossessed from another process and the identification narks are illegible. DSW 462507 WATER PCB-SD0000045308 ( Ifgm 119: Crude Diphenyl Catch Tasks (2-Raquirad) 29. August 1957 Function: To catch the crude diphenyl fro the dipheayl ualta and store It prior to batch distilling or delivery to crude dipheayl storage task. Operation: The catch tasks receive the suzap product, crude dipheayl, frm the coluams as a continu ous overflow fros the carbon trap, The crude dipheayl is periodically withdrawn from the catch tasks for batch distilling. No definite schedule is followed as the catch tanks become filled at indefinite Intervals depending upon the number of units in operation.. Materials Handled: Crude diphenyl of the following approximate cooposition; Diphenyl 60.87% Hl-boiler 14.011 c Benrol 22.49% Head & Tails Oil 0.10% Fraction eventually lost 2.53% 100.00% Oper. Temp. 120-130C. Oper. Pressure 2-5 psig Control*: Provisions are made for indicating the temperature of the crude diphenyl. An enclosed tape is provided for indicating the level la the tank. An explosion disk (Protectoseal) is provided to prevent excessive pressure la the tank. Services: Steam coils are provided in the bottom of the task. teats: Considerable benrol flasks out of these tanks through a vast line connect to the hydrogen vapor system. ( 4e^og WATER PCB-SD0000045309 Item 119 Continued: Size & Type: . Openings: Manufacturer: Capacity: Material Construction: Insulation: Steam Coils: 30. 8'-0" I.D. x 16'-0" loag horizontal task with dished heads. Top: Ome 3'-0" aaahole cemtrally located amd containing three openings; oae for the lastallatloa of the samp pomp, <rse for the pump discharge amd ome for the Protectoaeal connection amd Teat lime. Four steam coil mozzles are im the vertical side of the 3 mamhole mozzles. Ome 2'-0" mamhole cemtered fi'-O" from the middle of the taak with the oarer drilled for the imstallstiom of the "Varec" gage for measuring the level im the tamk. Three 3" slip om welding flanges are provided l'-0" apart 4'-6" from the middle of the tamk. The outside mozzle is for filling the task, the cemter for a vest (which is mow sealed), amd the lmside ome for the thermowell connection. Bottom: A. 2" plugged pipe coupling drain is pro vided in the pump well. - Chattanooga B. & T. Company (tank) Crane (steam coils) 6,000 gal. ea. - tank, tested for 25 psig 3/8" steel plate The eatire tamk is covered by a 2" blanket insulation, followed by a V' layer of Eagle 66, and a Insulseal, and with a metal jacket protective sheeting. Two 2" (iron pipe size) extra heavy seamless steel pipe ceils approximately 64' and 56' long are provided in the bottom of the tank with inlets nmd outlets through the side of the center nozzle for the sump pump. Each coil consists of four hairpin turns 6'-0" long, 4" pitch and installed flat. The two inside coils for the "Varec" gage end of the tank are 2' short to clear the gage. DSW 462509 WATER PCB-SD0000045310 Item 119 Continued: Location: Auxiliary Equipment: References: 31. Located i a reimforced concrete pit, 4*-6" deep, with a 3'-6" wall between tasks with a drain under the wall which can be closed off with a stopper from either side. The pit is located east of the diphenyl building and has a high brick wall shield to protect the tanks against fire from the building. The H.W. comer of the pit contains a sump pump annually controlled. The pump is a Taber Ho. 2 - Fig. B-148 sump pump with ^ HP,' 1750 RPH motor. The pit also contains a 1500 gal. catch tank for benzol. The pit is surrounded by a handrail and provided with handrailing and walkways over the tanks. Drawings Monsanto Layout of Crude Diphenyl Catch Tanka Layout of Pit and Foundations Crude Diphenyl Catch. Tank Pit-Details 6000 Gal. Catch Tank , Pit Handrail Platform (Sheet 1) Piping Walkway and Stairs (Platform Sh.2) Bill of Material 9C-8193 9C-8196 9C-8197 9C-8192 9C-8197 9C-8198 9C-8194 9C-8199 9BM-54 DSVV 462510 WATER PCB-SD0000045311 32. August 1957 Item 120; Still Charging Pumps.(2-Requirad) Function: Operatic: Materials S&adled: Controls: Services: Sire & Type: Manufacturer: Capacity: Materials of Construction: Drive: Location: Refereace: To deliver the crude dipheayl from the catch tasks to the still. Periodically operated whenever the catch tank becomes almost filled. Crude dipheayl - sp.gr. approx. 1.041 Controlled manually by a motor starting switch. Approximately 20 KWH per day (max.) Vertical submerged type sump pump. Taber Pump Company 100 GFM vs. 50' TDH 5 HP, 1750 RPH, 3 phase, 60 cycle, 220/440 v. vertical explosion proof motor with ring base. Direct connected with flexible coupling. Installed on crude diphenyl catch tank. Bill of Material 9BM-54 qSVY 462511 WATER PCB-SD0000045312 33. August 1957 Itea 121: El-Boiler Collectiag Tank (1-Raqulrad) Fuactioa: Operatio*: Materials Haidlad: Services: Sire & Type: Openings: Steam Ceil: Capacity: Materials of Coastructiom: Rote: Referemce: To provide a receiviag amd cooliag task for the distilled hi-boiler. At the completioa of the crude dipheayl distillatioa, the hi-boiler formiag the residue ia the till is pumped by the still circulatiag pump to the -hi-boiler collectiag task. The hi-boiler is allowed to cool sad at iatervals reheated aid poured imto drums for coaveyiag to the crude Saatowax storage area. Also, the hi-boiler nay be pumped to the Saatowax plait for use, depesdiag upoa requiremeata. Hi-boiler coaslatiag aaialy of terphemyl. Steam to steam coil vfaem aeeded. 5'-6" I.D. r 5'-6n high vertical talk with flat top aid dished bottom. 4" ialet 4" vest 4" gagiag hatch 22" maahole 2n bottom outlet 1^" diameter seamless pipe coil approximately 80' loag. 1000 gal. 1/4" stael plate Oie taak is aov coaaected to service both stills. Drawings Moasaato Hi-Boiler Task. 9C-7876 0SnN 4626"'2 WATER PCB-SD0000045313 34. August 1957 I tarn 122: High Boiler Pump (1-Requlred) Fuactiom: Operation: Materials Handled: Controls: S ervices: Sire & Type: Manufacturer: Kotor: Drive: Location: To deliver hi-boiler from the hi-boiler task to the Santowax storage task or the Santowax till pot. Periodically Hi-Boiler Kaaually operated by motor etartiag switch. A magliglble amount of power consumption per day. Sump pump Taber Pump Company 7% HP, 1735 rpsa, 3 phase, 60 cycle, 220/440 v. Geaeral Electric vertical motor Direct coaaected with flexible couplimg. Mounted oa hi-boiler collecting tank. DSW 462513 WATER PCB-SD0000045314 35. August 1957 Itw 123: Distilled Benzol Collecting Tank (1 Required) . Function: To provide a catch tank for the bemzol fractiom distilled fro the crude diphenyl. Operation: The first fractio* distilled over from the crude diphemyl coses over at 80C. end is rum by gravity lato the bemzol task. The bemzol is mot rum back directly to the feed tamk because of the possibility of making a mistake amd allowing some of the heads to rum back with the bemzol. Therefore, it is mecessary to check the color of the bemzol for clearness before it is periodically pumped back to the bemzol feed tamk. Materials Handled: Bemzol distilled from the crude diphemyl. Services: Sterna to steam coll. Size & Type: 7'-0" I.D. x 4'-5" high vertical tamk with dished heads. Openings: Top: 21%" I.D. taamhole centrally located. Three 2" standard pipe coup1lags. Side: Four nozzles fabricated as follows; Oae piece of 4" dia. standard pipe x 3^" long welded all arouad outside to shell plate. Ome standard 3/4" pipe coupling (seamless) welded to shell plate amd hole cut. 3/4" pipe is con centric to 4" pipe. (Nozzles are presemtly closed off). Bottom: 2" pipe mipple cemtrally located Manufacturer: John Hooter Boiler Works, St. Louis, Missouri Capacity: 1500 Galloms - Working pressure 3# gas. Given Hydo. test @ 10# DSW 462514 WATER PCB-SD0000045315 123 Continued: Materials of Construction: Insulation: Steam Coil: Location: Reference: 36. Mild steel plate - structural quality A.S.T.M. A10-34 The sides aad bottom are insulated with 2%" blanket insulation, V' Eagle "66" iasulatioa aad covered with a 22 gage blank irom jacket. The steam coil is a removable uait fabricated to the asshole cover. The coil coasists of 8 turns @ 4n pitch aad is made from 1%" seamless steel pipe. The overall length of the coil measured from the bottom of the cover plate is 6*-4". Coil by Crame. Located im the crude diphenyl sump pit. Drawings Monsanto Details of Sump Tank Detail of Coil 9C-8152 9C-7874 Bill of Material 9BM-48 DSW 462515 WATER PCB-SD0000045316 August 1957 Item 124: Distilled Benzol Return Pnap (1-Required) . Function: Operation: Materials Handled: Controls: Services: Size & Type: Kantif acturer: Material of Construction: Kotor: Drive: Location: References: To deliver the recovered beazol from the distilled beazol collectlag taak to the beazol feed taak. Periodic Beazol recovered from the crude dipheayl. Manually controlled by motor starting switch. Estimated 2 KWH per day. Figure 3004, size 2n, aiagle stage, end suction centrifugal pump aounted on bedplate. Gould Pump Company Standard except for stainless steel shaft. 3 HP, 1750 rpm, 220/440 v., 60 cycle, 3 phase, enclosed fan cooled, class 1, group D, type K, General Electric induction motor. Frame 225. Direct connection with flexible coupling. Located on concrete foundation in crude diphenyl sump tank pit. Bill of Material 9BM-48 DSW462516 WATER PCB-SD0000045317 38. Angust 1957 Item 125: Diphenyl Storage Tanks (2-Reqnired) Function: Operation: Materials Handled: Controls: Services: Size & Type: Openings: ( S tears Coils: Manufacturer: Capacity: Materials of Construction: To store distilled diphenyl prior to shipping. Continuous Distilled diphenyl at 71C. minimus temp. A thermometer well is provided for use in determining the temperature of the diphenyl. Steam for steam coils. 10'-6" O.D. x 37 ' -4 " long horizontal tank with dished heads. Top: Steam coil inlet, 3" sch. 80 pipe nozzle Measuring port, 2" sch. 80 pipe w/cap. Thermometer well, 3" sch. 80 pipe nozzle Pump opening, l'-9^" I.D. flanged nozzle Diphenyl inlet, 2\n sch.80 pipe nozzle Manhole and relief opening, 2'-0" I.D. flanged nozzle Vent, 3n sch. 80 pipe Bottom: Steam coil outlet, 2" steam coil pipe welded Drain, 3" flanged nozzle w/cover plate Hairpin type flat coil 36'-0" long with eight runs -mm- of 2n sch. 80 seamless steel pipe spaced at 6". A pump well is provided surrounded by two turns of copper tubing with separate steam con nections . Rogers and Wright, Incorporated 25,000 gallons. Shell tested with 25# hydrostatic pressure 3/8" steel plate. oS^j 4625^ WATER PCB-SD0000045318 Item 125 Continued: Intulntion Location: References: 39. Tank is insulated vith 1%" Eagle blanket Insulation type 201 with Eagle 66 (E2) applied at all butt joints of blanket insula tion where necessary to fill up cracks. Entire surface is covered with 20 gage galvanized iron jacket. All the joints on top half are made water tight by soldering. Tanks are located 31'-6" apart centers and installed lengthwise in a NS direction. The center of the east tank is 61'-2-3/8" east of the center line of the diphenyl building vest column row. The tanks are 30'-0" south of the muriatic acid storage tanks measured from end to end. Elevations: centerline of tanks gTade top of dike 768' 4-3/16" 758'-0" 761'-0" Drawings Monsanto Location plan diphenyl storage tanks Details storage tanks Foundation details Diphenyl piping to and from tanks 9C-9076 9C-9Q57 9C-9081 9CT9083 Procurement Record 9PR-87 DSW 462518 WATER PCB-SD0000045319 August 1957 Itaa 126: Dipheayl Loadtag Ftmpa (2-Raqalred) . Function: Operation: Hatarials Handled: Controla: Services: Sire & Type: Manufacturer: Materials of Construction: Kotor: Drive: Location: Reference: To deliver diphenyl from the diphenyl storage tanka to tank cars for shipping. Periodic Distilled diphenyl Manually operated by motor starting switch. Estimated 15 KWH per day (max.) Figure S 1790-No. 2-type F sump pump measuring ll'-8-3/8" from bottom auction to underside of cover plate. Rumsey Pump Company Iron 5 HP, 1750 rpa, General Electric vertical motor. Direct drive vith flexible coupling. Mounted on storage tanka (Item 125) Drawings Monsanto Pumps for storage tank* 9C-9Q88 SVV 462si9 WATER PCB-SD0000045320 SERIES 200 - BIPHENYL PUTTS Item 201; Benzol Vaporiser (I-Required per Quit) 41. August 1957 Function: Operation: Materials Handled: Approximate Heat Balance: 1. To vaporize the benzol feed to each diphenyl unit. 2. To recover sensibis heat from the exhaust gases used in heating the preheater and converter pots. Continuous. The benzol makes a single pass through the vaporizer, flowing countercurrent to the hot flue gas. Benzol - Rate: 1700#/hr, 170 GPS Temperature-In: 30C. approx, in feed tanks Out:200C. approx. Pressure: Out: 100 psig approx. Exhause gas - Rate: Flue gas 1250#/hr. approx. Excess air 220#/hr. Temperature-In: 780C. . Out: 400C. Benzol: 1. Heating liquid to B.P. 1700 (136-30)(1.8)(0.34) = 110,000 BTU/hr. 2. Vaporizing benzol 1700 (150) = 255,000 3. Super-heating vapor 1700 (200-136)(1.8)(0.39) = 8,000 Total 373,000 BTU/hr. Some of this heat load la absorbed by passing the benzene through the small coil in the column before it enters the vaporizer. Ho temperature data are available to determine the exact load on the vaporizer coil. oSW 462520 WATER PCB-SD0000045321 42. Item 201 Continued: Controls: Services: Size & Type: Units Outside Area, Ft,^ 2,3 4,5 6,7,8,10 ' 123 186 180 9 11,12,13 180 240 Normally no controls are needed. However, it is necessary to avoid overheating the vaporizer when benzol is not being fed during start-ups and shnt-dowas. To prevent overheating during start-ups, the exhaust gas is diverted from the vaporizer by exhausting through a special by-pass stack. During shut-downs, cool air is vented into the exhaust stack to cool the vaporizer. The benzol feed outlet temperature, the ex haust gas inlet temperature, and the exhaust gat outlet temperature are recorded on the 12 point temperature recorded. Hone required. The housing for the vaporizer coil is described separately (Item 209). The coils are all essentially the same in regards to purpose but the details of con struction vary as follows: Summary of Vaporizer Design No. Coils No. Turns Dia. Pipe Dia. Coil Single Single Single Single Single 36 38 37 39 37 52 lk"xfl 2 "xH 2 "xH 2 "xH 2 "xH 2 "xH 2'6" 2'6" 2'6" l'liV 2'6" 2'6" Pitch 2V 3" 3" 3" 3" 3" Length 90' 95' 92.5' 78' 92.5' 130' Manufacturer: Hos. 6,7,8,9, and 10 units originally had a double coil but the inner coil burned out and is disconnected. Crane Company DStV 462521 WATER PCB-SD0000045322 Item 201 Continued: Materials of Conatraction: Location: References: 43. Extra heavy standard steel pipe The vaporiser coil la located la a vertical stack lined with insulating refractory brick and containing a stainless steel inner shell designed to give a maximum exhaust gas velocity over the pipe coil. . Drawings Monsanto Vaporizer Assembly, Units 11, 12, Vaporizer for Ho. 1 Unit Vaporizer for Ho. 4 Unit Vaporizer for Units 6,7,8,9,10 13 9C-9026 9C-6841 9C-7840 9C-8150 WATER PCB-SD0000045323 44. August 1957 t I tea 202: Heat Exchanger (1-R.equired) Installed on Units 4 & 5 Only Comment: The use of a heat exchanger on units 4 and 5 deviated from the prevailing design. The heat exchanger replaces the preheater and conserves fuel by recovering aeasible heat from the converter vapors. Function: 1. To further super-heat the benrol vapor from the vaporizer. 2. To recover some of the heat from the vapors leaving the converter. Operation: Continuous. The converter vapors make a single pass through the tubes, countercurrent to the benzol vapor making a single pass through seg mental baffles on the shell side. Materials Handled: (The conditions stated -were taken from Phosphate Division Engineering Report No. 117. Actually, ( the units may be operated up to a 240 gal./hr. Benzene Feed Rate.) Shell fluid: Benzol vapor - 1200#/hr. Tube fluid: Converter vapors - 1200#/hr. (benzol vapor) (diphenyl vapor) (hi-boiler vapor) (hydrogen gta) Heat Balance; Shell fluid temperature: In Out - 160. 525C. Tube fluid temperature: In Out - 720C. 405C. LHTD: 220C. Duty: 405,000 BTU/hr. Heat transfer coefficients (outside surface) Tube film: Tube scale: 11 BTU/hr 400 n Tube wall: 3300 n ( Shell film: Shell scale: 28 500 n n DSW 462523 WATER PCB-SD0000045324 45. 202 Continued: Heat Balance Coatd: Type: Size: Nozzles: Manufacturer: Design: Materials of Construction: Insulation: References: Overall U-theo: Overall 0: 7.56 5.44 Total effective surface: 188 ft.2 10'-0" eff. length Note: Source of above data is report by D. A. Rober on Design of No. 4 Unit. Vertical packed expansion joint, removable tube bundle. Single section with 16" O.D. shell, with seventy-two (72) ln O.D. #12 BWG tubes at IV square pitch, and with twenty-one (21) 3/16" thick transverse baffles spaced at 5" centers. Shell Nozzles - inlet: 3" T&G outlet: 3" T&G Tube Nozzles - inlet: 4" T&G outlet: 4" T&G Series 30 Series 30 Series 30 Series 30 Struthers-Wells Operating pressures - tubes: 5# ga. Shell: 45# ga. Max. Working Pres. - tubes: 50# ga. Shell: 50# ga. Max. Temperatures - tubes: 1400F. Shell: 1000F. Shell: Tubes: Baffles: Steel 4-6 chr. 0.5 tao. Steel The exchanger is insulated with 3" of Eagle #88 rock wool, with bolted flanges exposed. Drawing 9SC-2577 Bill of Material 9BM-29 9BM-35 DSW 462524 WATER PCB-SD0000045325 46. August 1957 I tea 203: Preheater (1-Raquired) #4 and #5 Only , Function: ' Operation: Materials Handled: Hast Balance: Contrail: Services: To farther super-heat the benzol vapor coming froa the heat exchanger to the reaction temperature necessary for pyrolysis. Continuous. The benzol vapor passes through a distributor pipe with the end emerged la colten lead in the preheater pot. The vapor bubbles up through the molten lead and is discharged through a gooseneck pipe to the converter. The pot is suspended in a firebrick setting and the temperature of the lead maintained by burning natural gas in burners extending through the firebrick. In addition, the hot flue gases from the converter are used to heat this preheater. (The conditions stated were taken from Phosphate Engineering Report Ho. 117. Actually, these units may be operated up to a 240 gal./hr. benzene feed rate.) Benzol Vapor - 1200#/hr. Benzol vapor temperature: Flue gas temperature: In: Out: In: Out: 525C. 675C. 1800C. 1150C. IXTD: 850C. Duty: 374,000 BTU/hr. Overall 0: 7.0 BTU/hr., ft.2, F. Total effective surface: 35 ft.2 Temperature of lead recorded on 12 point recorder. Natural gas, approximately 350# CFH. Make-up lead has to be added periodically. DSW 462525 WATER PCB-SD0000045326 Item 203 Continued: Size & Type: Manufacturer; Capacity: Materials of Construction: References: Comments: 47. 24" 0.D z 72" long dished bottom pot filled with 37" to 42" of molten lead and suspended in a firebrick setting. The distributor pipe is a straight 4" O.D. z 3" I.D. tube located in the center of the pot, A small baffle covers the vapor outlet to prevent lead being splashed directly into the outlet pipe. The outlet pipe is 4" XS pipe. The top of the pot is welded carbon steel plate and is bolted to the pot. Blaw-Knor Company 100 lbs. of lead adds 1%" to the level of the lead in the pot. Type 309 stainless steel plate 5/8" thick. Drawings Monsanto 9SC-2852 9SC-2575 The firebrick setting consist of one unit for both the preheater and the converter partitioned by a firebrick wall vith an opening left for the flue gas to pass from the converter side to the preheater side. . OSW 462526 WATER PCB-SD0000045327 48. August 1957 Item 204: Ho. 1 Preheater (1-Required per Unit) All Halts Except #4 and #5 Function: To farther super-heat the benzol vapor from the vaporizer to a mid-point temperature between the vaporizer temperature and the re action temperature. Operation: Continuous. The benzol vapor passes through a distributor pipe with the end emerged in molten lead in the preheater pot. The vapor bubbles up through the molten lead and is discharged through a gooseneck pipe to the No. 2 pre heater. The pot is suspended in a firebrick setting and the temperature of the lead main tained by burning natural gas in burners ex tending through the firebrick. In addition, the hot flue gases from the converter and the No. 2 preheater are used for heating the No. 1 preheater. Materials Handled: (The conditions stated were taken from Phos phate Engineering Report No. 117. Actually, these units are operated at benzene feed rates greater than 1200#/hr.) Benzol vapor - rate: 1200#/hr. Temperature: In: Out: 140C. 425C. Controls: Temperature of lead recorded on 12 point temperature recorder. Services: Natural gas. Make-up lead added periodically. Type & Sise: Identical to Item 203. Cosaeati: The firebrick setting consists of one unit for Items 210, 211, and 212, partitioned by a . ' firebrick vail wth an opening left for the flue gasea to pass from the Ho. 1 preheater and converter to the No. 2 preheater. qSW 462527 WATER PCB-SD0000045328 49. August 1957 Itaa 205: Ho. 2 Preheater (1-Required per Dalt) All Units Except #4 and #5 Function: Operation: Katerials Handled: Controls: Services: Type & Size: Comments: To super-heat the benzol vapor fro the No. 1 preheater outlet temperature to the reaction temperature for conversion. Continuous. The benzol vapor from No. 1 preheater passes through a distributor pipe with the end eaersed in moltea lead in the pre heater pot. The vapor bubbles up through the molten lead and is discharged through a jumper pipe to the converter. The pot is suspended in a firebrick setting and the temperature of the lead maintained by burning fuel gas in burners extending through the firebrick. In addition, the hot flue gases from the converter are used for heating the No. 2 preheater. (The conditions stated were taken from Phos phate Div. Engineering Report Ho. 117. Actually, these units are operated at benzene feed rates greater than 1200#/hr.) Benzol vapor - rate: 1200#/hr. Temperature: In: Out: 425C. 700C. Temperature of lead recorded on 12 point recorder. Natural gas Hake-up lead added periodically. Identical to Item 203. The firebrick setting consists of one unit for Items 204, 205, and 206 partitioned by a firebrick wall with an opening left for the flue gases to pass from the No. 1 preheater and converter to the No. 2 preheater. SW 462528 WATER PCB-SD0000045329 c I tea 206; Converter (1-Requlred per Unit) 50. August 1957 Function: To maintain the benzol vapor at the reaction temperature for a short sojourn time sufficient for about 2OS conversion to diphenyl. Operation: Continuous. The benzol vapor passes through a distributor pipe with the end emersed in molten lead in the converter pot. The vapor bubbles up through the molten lead and is discharged through a pipe to the lead trap. The pot is suspended in a firebrick setting by burning natural gas in burners extending through the firebrick. The exhaust flue gas passes through an opening in the firebrick partition to the chamber surrounding the No. 2 preheater. Materials Handled: (The conditions stated were taken from Phos phate Div. Engineering Report No, 117. Actually, these units are operated at benzene feed rates greater than 1200#/hr.) ( Material In: benzol vapor - rate: 1200#/hr. Temperature: 700C< Material Out: benzol vapor - 974#/hr. diphenyl - 181#/hr. Hi-boiler - 42#/hr. hydrogen - 3#/hr. diphenyl - 4344#/day Temperature: 750-810C. Controla: The temperature of the lead in the pot must be maintained exactly at 750-810C. This is done by a temperature recorder controller control ling the gas burners. Size & Type: Identical to Item 203 on all units except Omits Nos. 4 and 11. The converts on Units 4 and 11 have a standard vertical pot section welded to the top of the standard pot to provide additional sojourn time. Am externaive report ha been prepared on the materials of construction of the converter pot. See Research. Report #2211, Interim Report on Alloy Testing and ( Biphenyl Pot Corrosion. Constructive criticism la presented which may be of value in future construction. DSW 462529 WATER PCB-SD0000045330 51. August 1957 It* 207: Burners (18-Required on Units (14 Required on Units (19 Required on Units (24 Required on Units 2,3) 4,5) 6,7.8,9,10) 11,12,13) Function: To provide for the combustion of natural gs.s in the firebrick setting housing the lead pots (Items 203, 204, 205, and 206). Operation: Continuous. Nozzles operate with 1# to 1-1/8# back pressure with 15# gas on the burner. Materials Handled: (The conditions stated were taken from Phosphate Div. Engineering Report No. 117. Actually, the burners are presently operated at approximately 25 pslg. The actual quantity of gas being burned is not known.) Natural gas with about 15T excess air. (Ap proximately 2000 CFH (? 25C. and 760 ss of gas is required for each unit.) ( Controls: The burners servicing the converter pot are automatically regulated by a single point temperature recorder and controller activated by the temperature of the molten lead in the converter pot. The gas flow is also auto matically cut down when the benzol flow is cut down (Units 11, 12, and 13 only). The burners servicing the preheater are manually regulated by the operator to maintain the molten lead within the desired temperature range. The temperatures are recorded on a 12 point temperature recorder. Pressure gages are provided for Indicating the gas pressure. Type: Surface Combustion tunnel burners with high pressure inspirators. Size: \ #1333 tunnel burners, lfc" nozzle #1333 TN alloy tunnel retainers #224-B, type 1, burner adapter castings #N-54 high pressure Inspirator sets #405 lighting hole assemblies DSW 462530 WATER PCB-SD0000045331 Ite 207 Continued: Manufacturer: . Capacit7: Materials of Construction: Refareace: 52. Surface Coabuation, Toledo, Ohio 2850 CFH when burning natural gas at 20 psig Standard Bill of Material 53K-87 DSW 462531 WATER PCB-SD0000045332 Item 208; Start-up By-Pass Stack (1-Required par Unit) 53. August L957 Function: Operation: Materials Handled: Controls: Sire & Type: Manufacturer: Materials af Construction: Location: Reference: To provide a means of by-passing tbe hot flue gases around the cold vaporizer prior to beginning the benzol feed. Deed only during start-up periods. Hot flue gaaes from, the preheater and con verter units. The flue gaaes are diverted from the exhaust stack to the start-up by-pass stack by means of a butterfly type valve. The stack i* constructed in two sections, a lower stack and an upper stack. The lower stack Is 2'-6" I.D. r 11'-0" high and has an adjustable damper over the top. It is welded vertically to the horizontal header between the converter units and the exhaust stack (Item 209). A butterfly type valve is installed in the horizontal header between the by-pass stack and the exhaust stack. The upper stack is 2'-O'1 I.D. x 29 '-6" high with a 4'-0" I.D. x 2'-6" high funnel at the lower end over the lower stack. . Southern Car & Manufacturing Co., Birmingham, Ala. The lower stack is 1/4" steel plate and the upper stack 3/16" steel plate. The stack is installed vertically with its center 4'-11" from the center of the final preheater. Drawing Monsanto Detail of Stack 9C-7845 ' DSVV 462532 WATER PCB-SD0000045333 54. August 1957 I tea 209: Exhaust Stack (l-Reuuired per gait) Function; Operation: Materials' Handled: Controls: Sise & Type: Manufacturer: Materials of Construction: Insulation: Location: 1. To provide a means for exhausting the flue gas from the preheaters and con verter to the atmosphere. 2. To provide a means for passing the gaa around vaporiser colls for heat recovery. Continuous except during start-up periods. Exhaust flue gases from the preheaters and converter. A door is provided at the bottom of the stack for venting in air to cool the vaporiser coil when shutting down the diphenyl unit. Vertical stack lined vith insulating refractory and containing a stainless steel inner shell, designed to give a maximum gas velocity over the vaporiser coils- The housing for the vaporiser is split and hinged for access to the coil.. Outer Shell: Inner Shell: Upper Stack: Snyder Tank Company Birmingham, Alabama Decatur Iron & Steel Company Decatur, Alabama Southern Car & Mfg. Company Birmingham, Alabama All mild steel with the exception of the inner shell which is Type 304 stainless. The horizontal gas header between the exhaust stack and the converter shell is lined with 4%" of firebrick and the vertical vaporiser shell with 4" of Carey Hi-temperature #19 cement. The center of the stack la 9,-ln from the center of the final preheater. DSW 462533 WATER PCB-SD0000045334 < I fees 209 Continued: Referenced: Insulation: 55. Drawings Monsanto Detail of Stack Details of Vaporiser Shall 9C-7845 9C-9025 The horizontal gas header between the exhaust Stack and the converter shell is lined with 4%" of firebrick and the vertical vaporizer shell with 4" of Carey-Ei-temperature #19 cement. ( DSW 462534 WATER PCB-SD0000045335 August 1957 Itaa 210: Lead Trap (1-Required per Unit) Function: Operation: Materials Handled: Size & Type: Manufacturer: Materials of Construction: References: To trap entrained lead coming over with the \ benzol vapor from the converter. X Continuous. The trap is periodically cleaned out when necessary while the unit is shut down. Benzol and reaction products from the converter X* Entrained lead. Hew Design . 24" dia. welded steel pipe 3'-1^" long. Outlet is' a 3" Crane #1545 fig. to a 8" x 3" E.X. reducer with an 8" 309 S.S. nozzle extending l'-4" into trap. Inlet is a 3" E.X. W.S. pipe, opening tangential to the trap and 9-9/16" down fro, top. Old Design 24" dia. W.S. pipe with 3" E.X. nipple on top for outlet with 3" Crane #1545' flange. Inlet is 3" E.X. pipe opening tangential to trap 9" down from top - 3" Crane #1545 flange. Callahan Grinding & Machine Company Anniston, Alabama New Design: 5/8" sides, bottom 3/4" top 309 S.S. outlet cylinder Old Design: 3/8" side, %" bottom 3/4" top Drawings Monsanto Lead Trap Details 9C-8143-4 osw 462535 WATER PCB-SD0000045336 57. August 1957 Item 211; Fractionating Column (1-Requlred per Halt) Function: Operation: . Kateriala Handled: Controls: ' 1. To function as a cooling enlum to condense the vapors from the converter. 2. To utilize the heat in the vapors from the converter to effect a partial separation of the benzol from the converted products. Continuous. The benrol fractionating column is 12 plate bubble cap rectifying section with the feed la oi the bottom plate as super-heated vaper. The liquid crude diphenyl containing hi-boiler end liquid benrol is discharged from the bottom and benzol vapor and hydrogen from the top. The reflux is returned to the top plate. The column is operated with the top temperature below 100C. (The conditions stated were taken from Phos phate Div. Engineering Report Ho. 117. Actually, these columns are operated at rates greater than 1200#/hr.) In: Benzol vapor Diphenyl vapor Hi-boiler vapor Hydrogen gas 974 181 42 3 1200# Air. Out: Bottom - Liquid benzol Liquid diphenyl Liquid Hi-boiler Top - Benzol vapor . Hydrogen gas 14#/hr. 181 42 960 ____ 3 1200#/hr. The temperature of the top of the column and the sump are recorded on the 12 point tempera ture recorder. The column la controlled by the operation of the condenser and split flow box. DSW 462536 WATER PCB-SD0000045337 Itw 211 Continued: SUe & Typ-e: Manufacturer: Material! of Congtraction: Reference*: 58. 12 plate babble cep rectifying column, 3'-0" dia. with 12" tray apacimg. (Halts 4,5 column la 2`-6" die.) Plata spacing Ho. of plates Ho. of babble caps per plate Cap diameter Slot area/cap. Total slot area/plate 12 la. 12 28 3" . 3.43 in.2 0.666 sq.ft. Riser pipe - 2" O.D. x 10 BWG Riser pipe area/riser - 2.35 ia.2 Total Riser Area^- 0,45 sq. ft. Liquid depth oa plates Liquid height above slots Tower height 1.5" 0.5" 18' Hooter Boiler Works, St. Louis, Missouri (11, 12, 13) Leader Iron Works (6, 7, 8, 9, 10) A.S.T.M. specification A-283-46T Grace C (A-10) steel. Drawlags Monsanto Fractionating column (Halt Ho. 2) Fractionating column (Halt Ho. 3) Fractionating column (Halts Ho. 6 thru No. 12) 9C-5582 9SC-7279 9C-8131 DSW 462537 WATER PCB-SD0000045338 59. August 1957 Item 212; Benzol Coad anser (1-Required per Unit) . Function: Operation: Materials Handled: r 1. To partially condense the benzol vapor from the top of the column. 2. To control the top temperature of the column at 100C. by sub-cooling the con densed benzol which is refluxed to the column. Continuous. (The conditions stated were taken from Phos phate Div. Engineering Report No. 117. Actually, this equipment is operated at higher rates than those stated.) Shell fluid - benzol vapor: 290d#/hr. (Usual rate under favorable conditions) Tube fluid - water: Usually operated at max. available pressure. ( DSW 462538 WATER PCB-SD0000045339 Item 212 Continued: 60. Heat Balance: Coatrola: Sise & Type: The condenser duty for all the units should be substantially the same and should consist approximately of the amount of super-heat in the vapors from the converter leas the amount of heat loss from the surface of the fractiona ting column. This duty has been calculated to be about 625,000 BTU/hr. average based on a study as reported in a memo to Mr. J. F. Reeves, 5/25/48 written by Mr. G. W, Jordan. The present system of control is to run the condenser with the water valve wide open and the split flow box adjusted to maintain the top of the column at 100C. The temperature of the cooling water and the efficiency of the condenser therefore deter mine the rate of benzol flow through the shell and the cooling water outlet temperature. This system of controlling has the advantage of simplicity but does not provide the most effective use of the condenser and cooling water. Smmiary Units Type Eff. Surface Shell Dia. Ho. Tubes Tube Dia. (O.D.) Pitch Tube Length 3 2.5 4.6,8,9 11.13 7,10,12 Vertical 70 14" Horizontal Horizontal Vertical 113 162 90 20" 14" 132 139 1" 5/8" triangle 13/16"sq. 72" 97-7/8" Vertical 207 10-3/4" 88 3/4" - Manufacturer: Andale Callahan Cal1ahan Andale Struthers Wells DSW 462539 WATER PCB-SD0000045340 Item 212 Coatiaued: Paita ____ 32^54.6.8.9 Capacity: Oper. Pre. - Tubes - Shell Max.wk.Press.: - Tubes - Shell Max.Testp.: - Tubes - Shell 75# ga. 1# ga. 75# ga. 75# ga. 130F. 17 6F. 11,13 7,10,12 15# ga. 100# ga. " 150# ga. 150# ga. 150# ga. 150# ga. 500F. Materials of Construction: Shell Tubes Steel #10 BWG Steel $12 BWG Steel #12 BWG Steel #10 BWG Steel #16 BWG Ref ereaces: Drawings Monsanto Coadeaaer Details, Sheet 1 Coadeaser Details, Sheet 2 (4,6,8,9) , 9C-8157 9C-8158 Foreign Aadala Condenser #13 XA-36 type 206X Sketch #1261 Dwg. #5845 Struthers-Wella Type H Group 3 Sice 10 HI2 61. SW 46254Q WATER PCB-SD0000045341 I ten 212 Continued: 62 The operating conditions of these condensers after physical claiming in 1956 were as fallows: Unit Ho. Beaseae Feed Hate gal./hr. % Reflux Benzene F.sflax Tss&p. 2 175 3 165 4 245 5 245 6 230 7 210 8 220 9** 220 10 245 11 330 12 250 13 180 701 78C. 75 34 60 66 40 41 75 40 90 40 75 50 70 73 60 28 48 24* 75 42 85 42 Approximate Overall Water, GPK Coefficient 0. (Old data from Rpt.117) (Old data frca Report Ho.117) 80 90 35 170 95 65 80 90 95 65 -- 95 65 95 65 - -' 75 -. 250 - 75 250 with column coil Ho. 9 condenser is mounted vertically QSW 462541 WATER PCB-SD0000045342 63. August 1957 Item 213; Split Flow Box (1-Requirad per Unit) . Function: To control the saouat of liquid benzol returned to the column as reflux. Operation: Continued*. Ratio adjusted as necessary to maintain the top of the fractionating column below 100C. Materials Handled: Liquid benzol. Control*: Mechanically Indicated ratio adjusted manually by operator to maintain temperature of top of fractionating column below 100C. Temperature of runback indicated by thermo meter well. Sight glasses provided in reflux and runback lines for checking flow. Size Sc Type: The split flow boxes for Units 2 thru 5 are identical to the biphenyl still split flow boxes. Manufacturer: Units 11 - 13 are provided with standard manu factured rotawairs, figure 192-special, size 10 with owe 2" horizontal inlet connection. and two 2" vertical outlet connections. Units 6-10 are slightly dissimilar. Units 6-13 furnished by Fischer fit Porter Company, Hatboro, Pennsylvania Capacity: Outlets Capacities: Forward: Min. 100 GFH Norm. 150 GPH Max'. 250 GPH Reflux: Kin. 200 GPH Norm. 420 GPH Max. 750 GPH Materials of Construction: Cast iron fittings, stainless steel weir tubes and gears, and steel shells. DSW 462542 WATER PCB-SD0000045343 213 Continued: Location: References: 64. Located aear top of column oa condenser platfora. . Drawings Monsanto Layout Rotawelr & Condenser Split Flow 5u& Details Piping at Rotawalr & Condenser Piping at Rotawelr & Condenser Details 9C-9055 9C-7836 9C-8163 9C-8164 Foraiga 13" Rotawelr with metal shell Rotawelr Rotawelr 5-6727 6-11591 S-4228 DSW 462543 WATER PCB-SD0000045344 65. August 1957 Item 214: Carbon Trap (1-Requlred par Halt) Function: Operatic*: Size & Type: Openings: Manufacturer: Materials of Construction: Location: References: To trap any carbon and sludge la the strap product from the fractionating column. Continuous. The crude diphenyl Is decanted through a side outlet in the trap and the carbon and sludge settled to the bottom from where it is drained periodically when necessary. A steel tank 18" O.D. r 3'-l-3/4" long with flat bottom and top. ' Top: 6" dia. XS nipple with flange, inlet. Side: 2" XH coupling, overflow. Bottom: 2" XH coupling, drain. Callahan Grinding & Machine Company Anniston, Alabama 3/4" steel plate, top 1/2" steal plate, bottom 18" O.D. x 3/8" thick W.S. pipe, aide wall Bolted to bottom outlet of fractionating column. Drawings Monsanto Lead trap details 9C-8145 0s^ a6254A WATER PCB-SD0000045345 SERIES 300 - BIPHEKTL STILLS 66. August 1957 Item 301; Biphenyl Still (1-Required per Still) Function: Operation: Materials Handled: Controls: Services: Sire & Type: Openlags: Manufacturer: Capacity: Materials of Comatraction: Insulation: To provide a reservoir for heating the charge of crude diphenyl which is being distilled. Batchviae - time required for distilling one batch is approximately 10 hours, depending on operator. Approximately 30,350# or 4,120 gal. of crude diphenyl per batch. A thermowell is provided for recording the temperature of the crude diphenyl. Steam to steam coils. (Biphenyl must be in liquid state before it can be circulated through still heater.) 7'-0" O.D. x 14'-0" long horizontal tank with dished heads. Par. 0-69 ASHE construc tion. 3" opening for thermowell 3" charging inlet 4" inlet from heating coil 10" vapor outlet 2" reflux inlet 22" opening for circulating pomp 22" opening for steam heating coil R. D. Cole Manufacturing Company 4300 gals. Tested for 50# pressure at 750F. 1/2" steel plate Tha still is insulated with 4" of rock wool, %" of Eagle 66 and covered with a sheet metal jacket. DSW 462545 WATER PCB-SD0000045346 ( Item 301 Continued: Steam Coil: References: 1-1/4" pipe coil Drawings Diphenyl Still Diphenyl Still Body Bill of Material Monsanto 9C-7873 9SC-2526 9BM-55 67. ( ( DSW 462546 WATER PCB-SD0000045347 68. August 1957 Item 302: Crude Diphenyl Circulating Pump (1-Required par Still) Fuactlon: Operation: Materials Handled: Control#: Services: Sire & Type: Manufacturer: Capacity: Motor: To cycle the crude diphenyl through the Still and the heating coil of the gas fired heater. Continuous, during batch distilling operation. The crude diphenyl is returned to the still from the heating coil and is recycled until the distilling operation ia completed. Crude diphenyl Controlled manually by motor starting switch. The rate of flow is not controlled but al lowed to seek, its maximum. Estimated 80 KWH per day (max.) Ho. 1 Still: Special Ho. 2, figure S1790 vertical, all iron, Rumsey simp pump with a 96" set length and provided with special water cooled stuffing boxes. Ho. 2 Still: 3" inlet x 2%" outlet, CV-5 vertical pump, figure 19,435 with cast iron water jacketed stuffing box where shaft passes through cover plate. Discharge pipe has stuffing box not water jacketed. Pusap is of iron, 96" long from bottom of cover plate to end of pump inlet with inter mediate cast iron bearings in the column. Shaft is of steel. Impeller of cast steel. Ho. 1 Still: Rumsey Pump Company Ho. 2 Still: Taber Pump Company Ho. 2 Still; 200 GPH vs. 70' TDH Ho. 1 Still: Ho. 2 Still: 5 HP, 1750 RPM, 3 phase, 60 cycle, 220 v., vertical explosion proof 7% HP, 1750 RPM, 3 phase, 60 cycle, 220 v., vertical explosion proof motor. DSW 462547 WATER PCB-SD0000045348 Item 302 Continued: Drive: Location: Reference: 69. Direct connected with flexible coupling Located on diphenyl still. Drawings No. 1 Still Pump No. 2 Still Pump Bill of Material Taber - F-246A 901203 9BM-55 DSW 462548 WATER PCB-SD0000045349 70. August 1957 Item 303: Gee Fired Heater (1-Rsquired per Still) . Function; Operation: Materials Handled: Heat Duty: Controls: Services: Sire & Type: ' Manufacturer: Materials of Construction: Heating Coil: Gas Burners: Insulation: Location: To supply the heat required for distilling the crude diphenyl. Continuous during batch operation. Crude diphenyl - rate: 200 GFM approx. 400,000 BTU/hr. ia the average net heat available from the still heater for heating and vaporising charge. The combustion rate of the fuel gas is con trolled automatically so as to raise the temperature of the liquid passing through the coil approximately 20 to 25C. (difference betveen inlet and outlet temperatures in the coil). Hatural gas - estimated requirement is 1,000 CFH @ 30C. and 7 60 mm (avg.) max. capacity approx. 3,200 CFH 4* -0" I.D. x 8'-3" high shell with an inner core and stack. Chattanooga Boiler Works Steel outer shell, 304 S.S. inner shell The heating eoil consists of 18 turns of 2" W.I. pipe l'-6" in dia. (approx. 53 sq.ft, of outside heating surface). The heater la fired with four Surface Com bustion #55 H.P. Inspirators with each inapirator supplying the mixture for two #1345 tunnel burners. The steel shell is lined with 9" of B&W #111 firebrick. Located at second floor level ia the diphmyl plant machine shop immediately outside of the distilling rooms. SW 462549 WATER PCB-SD0000045350 ( Item 303 Continued: References 71 Drawings Monsanto Diphenyl Still Heater Shell, #1 Still 9C-6372 Diphenyl Still Heater Shell, #2 Still 9C-8211 Stack Coyer & Heater Core 9C-8078 Stack 9C-7939 Heater Shell Base 9C-8230 Platform & Supports 9C-8217 Bill of Material 9BM-55 ( DSW 462550 WATER PCB-SD0000045351 72. August 1957 Itaa 304: Still Column (l-Required par Still) . Function: Operation: Materials Handled: Sire & Type: To separate the crude diphenyl into benzol, hi-boiler, heads and tails, and diphenyl. Continuous during batch operation. The vapors from the still enter the bottom of the column. The lover boiling fraction passes overhead to the total condenser and part re turned as reflux above the top plate. The high boiling fractious are returned to the still. The first jr oduct from the column is benzol, with the top of the column at 80C. The second product cut is taken until the crystallizing point of the distillate reaches 68.6C. The next fraction, diphenyl, is collected until the still pot temperature reaches 340-350C. and then the balance is diverted into the heads and tails task. The high boiler, remaining in the still as residue, is pumped to the high boiler catch tank. Crude diphenyl which la separated approxi mately into the following fractions: Diphenyl .High Boiler Benzol Heads & Tails Oil Material Lost 60.87X 14.01 22.49 0.10 2.53 100.00% The still column is a 20 plate, bubble cap, rectifying column,'3'-0" I.D. x 25'-2" high. The plates are spaced 12n apart and each tray contains thirty-six (36) 3" din. pressed steel bubble caps and two 4" din. downspouts. . DSW 462551 WATER PCB-SD0000045352 Item 304 Continued: Openings: Manufacturer: Materials of Construction: Insulation: Reference: 73. Each, plate is provided with two 10" dia. handholes im the shell. The vapors from the still eater the column below the bottom plate through a 20" dia, combination man hole and vapor inlet. The lower boiling products leave the top of the column through a 16" dia. manhole which is reduced to a 6" dia. vapor pipe. Reflux enters through a 3" nozzle above the top plate and the over flow from the bottom tray is returned to the still through a 3" line. Leader Iron Works Company Steel The column is insulated with 4" of rock wool, of Eagle 66, and covered with a sheet steel Jacket. Drawings Monsanto Diphenyl Still Column 9C-7870 Bill of Material 9BK-55 DSW 462552 WATER PCB-SD0000045353 74. August 1957 Item. 305: Diphenyl Still Condenser (1-Requirad par Still) Function: To condense the overhead vapors fro the still column. , Operation: Continuous during batch distilling operation. The cooling water makes 8 passes through the tubes and vapors condensed outside of the tubes. Materials Handled: Tubes Shell 70 GPK City Water 4080#/hr. benzol. Heat Duty: Shell fluid temp. - In: 176F. Out: 176F. Tube fluid temp. - la: 130F. Out: 150F. LKTD: 34F. Duty: 690,000 BTU/hr. Overall heat transfer coefficient: 100 Total effective surface: 200 ft.2 Size & Type: Hozzlas: 200 sq.ft, horizontal, floating head, re movable tube buadle condenser with 25n O.D. . shell and 152 tubes 1" O.D. constructed of #12 BWG tubing and pitched 1^". The shell has been enlarged to the same size as the floating head bonnet and a special outlet added to insure complete drainage of each product from the condenser. Shell: Inlet 6" Outlet 2" Tubes: Inlet 3" Outlet 3M Manufacturer; R. D. Cole Manufacturing Company Materials of Construction: Steel Insulation: Shell insulated with 2" rock wool, V' and covered with a sheet metal Jacket. 66, References Drawings Condenser Bill of Material Monsanto 9C-7872 9BK-55 DSW 462553 WATER PCB-SD0000045354 Item 306; Split Flow Box (1-Raouirad par Still) 75. August 1957 Function: Operation: Materials Handled: Controls: Services: Sire & Type: To control the amount of condensate re turned to the column as reflux. Continuous during batch distilling operation. The condensed vapor from the condenser is dis charged into a basket installed inside of a container with the bottom partitioned into 2 outlets. The basket has holes drilled in the side so that by rotating the basket the discharge from the holes may be directed to either aide of the bottom partition in the shell. The split flow box is usually operated on a 1:1 reflux ratio. Heat is supplied from a small heating coil when the diphenyl fraction is being distilled. All of the overhead products from the column pass through the split flow box. The reflux rstio is controlled by a selector lever setting the position of the basket in relation to the partition between the 2 out lets. The control of the basket is extended to the still operating floor by means of a shaft and gears so that the reflux ratio may be changed during a distillation without ascend ing to the condenser platform. Steam for the heating coil. Shell casing: Basket: 18" O.D. x 18" high gas tight casing with dished heads. 12" I.D. x 6%" deep with a 9" I.D. concentric screen- parti tion. The basket has 19 equally spaced dia. holes 7 apart. oSW 462554 WATER PCB-SD0000045355 Item 306 Continued: Openings: Manufacturer: Capacity: Materials of Construction: Gaskets: References: 76. August 1957 Two 2" X.5.W.S. pipe outlets in the bottom, one for reflux and the other for the product A 5/16" plate partitions the reflux side of the shell casing from the product side. One 2" X.H.'rf.S. pipe side inlet for the con densed vapors from the condenser. One 2" X.H.W.S. pipe side nozzle for vent through flame arrestor and conservation vent Three 5-5/8" I.D. sight nozzles using Pyrex glass. Two located on top and one on the side for observing the flow from the basket. Stuffing box and gland 1-3/4" I.D. centrally located on top for selector lever shaft. Fischer and Porter Company 800 GFH normal capacity 1600 GPH maximum capacity The split flow box is made of steel except basket, screen, and packing gland which are made of monel metal. Gaskets are #901 Gar lock, ring type, 1/16" thick and must not swell when handling hot diphenyl or benzol. Drawings Monsanto Split Flow Box Details 9C-7836 Bill of Material 9BM-55 DSW 462555 WATER PCB-SD0000045356 77. August 1957 Item 307; Bead & Tails Catch Tank (1-Required per Still) Function: Operation: Materials Handled: " Controls: Services: Sire & Type: To provide a catch tank and storage for the heads and tails distilled from the crude diphenyl. After the tcnsol fraction has been distilled off the crude diphenyl, the next fraction distilling between 80, a hold point of 68.6C. is diverted to the heads and tails catch tank. After most of the diphenyl has been distilled and the temperature in the still reaches about 300^0., the flow is changed again to feed into the heads and tails tank. The heads and tails that were collected are returned to the diphenyl still for redlstillatlon with the next batch. The small amount of heads and tails oil left over is discarded. The "heads" are light oils with boiling points nearing that of diphenyl and the "tails" is diphenyl containing a little hi-boiler fraction The heads and tails as collected is mainly diphenyl, which is recovered on redistillation. The amount of heads and tails oil produced is very small, consisting of only about 0.1% of the crude diphenyl. The heads and tails tank is provided with a 4" gaging hatch for measuring the level in the tank. Steam, for heating coil. 5'-0" O.D. x 5'-0" high vertical tank with flat top and dished bottom. ' OSw62556 WATER PCB-SD0000045357 Item 307 Continued: Openings: Stem Coil: Capacity: Insulation: Reference: 78. The tank is provided with a 4" inlet nozzle, a 4" vent, a 22" I.D. nozzle for a sump pump, a 4" gaging hatch, and a steam heating coll inlet and outlet. The steam coil consists of about 30' of 1%" dia. standard seamless pipe. 800 gallons The sides and bottom of the tank, are insula ted with 2" of Tock wool, a V of Eagle 66, and covered with a sheet metal jacket. Drawings Monsanto Reads & Tails Catch Tank 9C-7876 DSW 462557 WATER PCB-SD0000045358 79. August 1957 I ten 308: Head sad Tails Return Pump (1-Rcqulred per Still) Function: Operation: Materials Handled: Comtrola: Services: Sire & Type: Manufacturer: Material* of Construction: Motor: Drive: Location: Reference; To return the heads and tails from the catch tank to the still for redistHintion. Periodic Heads and tails fraction from crude diphenyl distillation. Manually controlled by motor starting switch. Estimated 3 KWH per day (maximum) 2^n x 2" CL-4 vertical sump pump, 5'-6" long Taber Pump Company Iron casing with steel shaft and cast steel impeller. 3 HP, 1750 RPM, 3 phage, 60 cycle, 220/440 v., TEFC explosion proof vertical motor with ring base. Direct drive with flexible coupling. Installed in heads and tails tank. Bill of Material 9BM-55 DSW 462558 WATER PCB-SD0000045359 80. August 1957 Item 309: Diphenyl Catch Task (1-Required per Still) Function: Operation: Materials Has died: Controls: Services: Sire & Type: Openings: Capacity: Materials of Coma tract ion: Insulation: Reference: To receive the diphenyl fraction from the crude diphenyl distillation. The operator sets the swivel flow box to deliver to the diphenyl catch tank after the hold point of the distillate reaches 68.6C. The flow is changed again from the diphenyl catch tank to the heads and tails catch tank after the; temperature in the still reaches 300C. Distilled diphenyl The tank contains a thief hatch for Sampling the diphenyl. Steam to steam coil. 7'-6" I.D. x 6' --O'1 high vertical tank with a flat top and dished bottom. The tank is provided with a 4" inlet, a 4" vent, a 22V I-D. nozzle for a sump pump, a 16" dia. manhole, and a 6" thief hatch. 2100 gallons. 1/4" steal tank The sides and bottom of the tank are insula ted with 2" rock wool, a 1/2*1 of Eagle 66 and covered with a sheet metal Jacket, Drawings Monsanto Diphenyl Catch Tank 9C-7877 DSW 462559 WATER PCB-SD0000045360 81, August 1957 I tea 3X0: Distilled Diphenyl Transfer Pump (1-Required per Still) Function: Operation: Materials Handled; Controls: Services; Sire & Type: Manufacturer: Materials of Construction: Motor: Drive: Location: Reference: To deliver the distilled diphenyl from the diphenyl catch tank to the diphenyl storage tanks. Operated at the completion of the batch distillation. Distilled diphenyl at approx. 100C. Manually controlled by motor starting svitch. Estimated 15 KWH per day (maximum) Ro. 1%B, figure S 1790 vertical sump pump with a length of 7'-3". Rumsey Pump Company Iron 3 HP, 1750 RPM, 3 phase, 60 cycle, 220 volt, vertical explosion proof General Electric motor. Direct connected by flexible coupling. Installed in diphenyl catch tank. Drawing Rumsey Pump Foreign F-246-A DSW 462560 WATER PCB-SD0000045361 -! SERIES 400 - IHSTRUHEKTATIOH 82. August 1957 Item 401: Automatic Let-Dew Level Control (1 Halt For Each Feed Task) Function: Operation: Type: Manufacturer: To automatically maintain a supply of benzol i> the feed tank and to sound an alarm in case of high or low level. The operator must manually select one of the five storage tanks from which to feed. A five-point pump switch located at the feed tank is provided for this purpose which places the system in automatic control to feed from that particular storage tank selected. The automatic control system maintains the level of the benzol in the feed 'tank within a range of 6M"with the high "level "9" below the top of the tank, "if the system fails had the high dr low level exceeds this range by 3", asalarmii sounded by a separate level control system. Special TF-.2 EF tandem magnetrol control with glass float. Two'omits"are required, one for control and one for the alarm. Fred Hi Schaub Engineering Company, Inc. Chicago, Illinois DSW 462561 WATER PCB-SD0000045362 83. August 1957 Item 402; Benzol Feed Control Function: Range: Type: Manufacturer: To automatically meter a specified quantity of benzol to each unit. 0-400 GPH - Omits 4 through 13 0-250 GPH - Units 2 and 3 Each control consists of: 1 - 12" M/10 Stabilog flow controller type 7115 1 - S.I. orifice'plate for 1" lime 1 - 1" A6A S 30 orifice flange 1 - Set liquid meter piping 1 - %" control valve, code 32110 BA 1 - Set liquid seal chambers Foxboro DSW 462562 WATER PCB-SD0000045363 84. August 1957 Item 403: Twelve PoLat Temperature Recorder Fuactiom: Rasge: Type: Manufacturer: To record the following temperatures: 1 - vaporizer coil outlet, laser aad outer coils (if double coil unit) 2 - exhaust flue gas to vaporizer - islet asd outlet 3 - Ho. 1 preheater pot 4 - Ho. 2 preheater pot 5 - top of fractiomatimg colons 6 - cosdesser'vater outlet ' 7 - beazol "rtm-bick" from coadeaser 8 - bottom of fractioaatiag column sump 0-10O0OC. #40362-17-special model micromax tempera ture 12 polat iadicatlag recorder. Irom - Coastaatia #8759-S thermocouples Leeds aad Horthrup DSW 462563 WATER PCB-SD0000045364 85. August 1957 Itea 404: Slagle Foist Temperature Recorder and Controller Function: Range: Tjpa: Kanuf actorar; To indicate, record, and control the temperature of the converter by regulating the natural gas burners. 100-1100C. #40617"A2-H-83 Model S Microaai tempera ture indicating and recording controller. Pneumatic control - Automatic droop correction - Motor 110 v. 60 cycles 3/4" Mason-Heilan pneumatic valves Masoa-Neilan valve repositioners with air sets and parts. Mo. 8755 Iron-Constantin pipe type thermo couples with standard 778A element and P1-181A head, 66" long Leeds and Sorthrup os* 564 WATER PCB-SD0000045365 86. August 1957 Item 405: Natural Gas Mater Function.; Type: Manufacturer: To record the quantity of gas consumed per emit r still. No. 35 B metric iron case meter for natural gas service. Top connections. Maximum working pressure 100#. American Meter Company OSW 462565 WATER PCB-SD0000045366 87. C August 1957 I tea 406: Temperature Recorder - Diphenyl Still (1-Reqalred per Still) Function: Type; Manufacturer: To record the following temperatures: 1 - still body 2 " still ialet 3 - outlet - circulating line 4 - top of column 5 - reflux to column 6 - condenser water-out. #40356-55M-special Kicrocaax 6 point 115 v. 60 cycle temperature recorder Leeds and Northrup C ( DSW 462566 WATER PCB-SD0000045367 88. August 1957 Item 407: Temperature Control Still Heater Function: Type: Manufacturer: To control the temperature dtfferemce between the heater inlet ad outlet by regulating the gas burners. #40617 A3 - Model S Micromax single point recording temperature controller Maaon-Neilan #30 valve repoaitioners vith 3/4" pneumatic valves, air sets and part*. Leeds and Horthrup DSW 462567 WATER PCB-SD0000045368 89. August 19S7 I tea 408: Blphaayl Palt - Automatic Safety Switches for Hataral Gas (1-Raqulrad par Pait) Fuactiom: Kaaufacturer: To protect the equtpaeat im the eveat of am emergeacy, by gtopplmg the flow of aatural gas to the Ho. 2 preheater whea the tessperature exceeds a predetaraised maximum. Forboro - Poteatioaieter Comtroller DSW 462568 WATER PCB-SD0000045369 SERIES 500 - imLITIES 90. August 1957 501: Lightimg The diphemyl bulldimg housing the comversiom omits is provided with slightly better them gemersl lightimg. The lights ere stemderd lights with reflectors. The two still rooais ere provided with gesersl lightimg atilizimg Appletom Electric Compemy Cet. #26537 explosiom proof pemdamt fixtures with' shallow dome reflector. %" hah size, 200 wstt lamps. The hydrogem compressor room has mo lightimg facilities lm the room but receives its lightimg from the outside from special explosiom proof lights shimiag through the windows. DSW 462569 WATER PCB-SD0000045370 91. August 1957 502: Power Wlriag The STiamm connected horsepower is shoot 180 S? sad the daily power consumption shout 1845 Ei average st full productioa capacity. Wirimg, relay switches, tramsformers, etc., are provided according to standard electrical practices. The control paael is located outside the building 1m a special enclosure. DSW 462570 WATER PCB-SD0000045371 :ea Ho. 101 103 107 111 117 119 302 121 123 308 310 125 I tom Oaloediag Pump Traaefer Pump Benzol Food Pump Hydrogaa Comprtaaor Benzol Recovery Pumps Sump Ptmp Still Charglag Pumpa Still Clrculatlag Pump High Boiler Pump Baaxol Recovery Pump Heads & Tail Pump Tranafar Pumps Loadiag Pumps QuaatitT Esc. Max. KWH HP RPM Voltage day Remarks 1 3 1740 220/440 10 5 2 1800 9 SCg. Taaka 1 10 3470 11 175 Howell Klac. Co. 1 7.5 1175 It - V-balt drive 2 40 1175 tl 700 Paaa.Coupraaaora 1 30 1175 II Worthiagtoa Comp. 1 3/4(?) 1 1 (?) 1 1/2 1750 220 aag Crude dipheayl sump 2 5 1750 220/440 20 2 5 1750 220 80 1 7.5 1750 220 - 1 3 1750 220/440 2 Diatilled beazol 2 3 1750 11 3 2 3 1750 220 15 Diphesy 1 3 5 1750 220 15 Dipheayl Ln o o 3 ft *a A<*- I DSW 462571 M WATER PCB-SD0000045372 503: Product Piping The bearol unloading piping ud transfer piptag is team traced aad Insulated. All product pipiag imcludimg crude dipheayl,high boiler, aad distilled dipheayl are steam Jacketed aad provided with "homemade" diaphragm expansion joiats betweea all coaaectioaa. The product pipiag from the carboa traps aad the split flow boxes are constructed to fora a deep liquid trap to prevent hydrogen from venting into the feed or catch tanks from the column. . Piping is provided for the hydrogen gas from the split flow boxes and condenser to the hydrogea coolers and compressor room. 93. DSW 462572 WATER PCB-SD0000045373 94. August 1957 Item 504: Water Piping Cooling water pipimg is provided from the Plamt water maim pump to the comdemaera. amd the hydrogem coolers. The return pipimg from the various umita termimate im a coenoa header for draimage back to the gemeral plamt coolimg pomd. The water from the codlimg pomd ia straimed 'aaid pumped back to a codlimg tower. The water from the coolimg tower is piped back to a booster pump for reuse. City water pipimg is provided for drimkimg purposes amd for the emergamcy showers placed at strategic points throughout the building. 0SW 462573 WATER PCB-SD0000045374 Item 505: Fuel Gas Piplag Fuel gn piping is provided to the preheaters ud converters and to the gas fired heaters. Am Individual gas meter is provided la each lime. 95. August 1957 Item 506: Steam Limes Steam limes are provided to all the jacketed product limes amd to the coils im the catch amd storage tasks, amd to the split flov box. Also, a cdamectiom is provided to the recirculated water system. Steam is provided at 90-100# pressure. DSW 462574 WATER PCB-SD0000045375 96. August 1957 Item 507: Buildimg The dipheayl emits, crude dlphemyl stills, compressor room, Aroclor plsmt, comtrel rooms, offices mad machime shop are mil located la a 3-story stamdard mill buildimg with a one-story leaa-to cm each side. The maim buildimg sectiom measures 60' x 220', total area 110' x 220''accouated for by a 20' leaa-to oa the west side amd 10* caaopy om the east side ewer the loedimg platform. Am area'measur lag 100' x 180' at the south ead is allocated to dipheayl operatioms. Comatructiom is of steel throughout with hollow' tile aid stucco outside walla." Fire walls amd fire doors separate the dipheayl omits imto three groups amd separate the dipheayl stills from each other amd from the rest of the plamt. DSW 462575 WATER PCB-SD0000045376 I tea 508: Sewer* 97. August 1957 Item 509: Fire Protection Equipment Item 510: Grenada aad Geaeral Area DSW 462576 WATER PCB-SD0000045377 98. August 1957 Item. 511: Painting The control piping is painted with distinguishing colors: blue for water, green for natural gas, and orange for benzol. Storage tanka are painted with one shop coat (outside only) of blue lead as per Monsanto specification #1007. Item 512: Insulation I tea 513: C0? Piping DSW 462577 WATER PCB-SD0000045378 WATER PCB-SD0000045379 :-rr "8/ftiyi A/yr>. 66rf . P/p/r/\s. i ** `t* e^S2gp WATER PCB-SD0000045380 99. August 1957 Is Flowsheets and Diagrams B-5114 C-5240 C-5440 C-6258 C-6374 C-6830 C-4831 A-7812 9C-7850 9C-7851 9C-7875 9C-8466 9C-8546 Biphenyl Plant Flow Sheet Diagramaatic Layout Temperature Pressure Curves for Mercury, Diphenyl Diphenyl Plant Layout Diphenyl Plant Layout General Layout June 1935 DiagTaamatic Flow Sheet ' Heat Balance on No. 3 Unit Diagrammatic Flow Sheet for 4 Pot Unit Diagraamatic Flow Sheet for 2 Pot Unit Diphenyl Still Diagransutic Flow Sheet Diagramaatic Flow Sheet Showing Prim. Equipment and Control System Map Diphenyl Area Water 2: Corner*1 Plant Details of Steam Jacket Expansion Joint Thermo-well Detail Preheater Pot and Head Reaction Pot Preheater Terminal Bars Cast Alloy Reaction Pot Typical Diphenyl Unit Detail Reaction Pot Detail Pot Cover and Flange Chrome Steel Fittings for Lead Pots Detail Beams and Counter Fortes Lead Pot Setting Details of Fractionating Column Converter Unit - Plate Structure Work Converter Dnit Structure Frame Diph. Col. & Condenser Hanger for Lead Pot Flange Gooseneck for Still Connection Nine Pass Expt. Tabular Converter Dnit Brickwork Reaction Cover Diphenyl Distributor Pipe Gaaket for Benzol Still Stainless Steel Distributor Cup for Converter Cover for Reaction Pot Lead Bath and Ser. Converter Units Water Piping at Top Platform for 4 Units Fire Protection for Still and Benzol Tanks Pan for Diphenyl Detail Cast Steel Pot Cover 9AA-9058 9AA-8832 C-4092 B-4012 B-4052 C-4061 B-5205 C-5233 C-5234 C-5235 C-5236 C-5237 C-5238 C-5239 AA-5299 AA-5541 C-5760 C-5883 AA-6333 A-6497 AA-6699 C-6714 C-6815 C-7861 C-7893 AA-8061 9C-8166 DSW 462580 WATER PCB-SD0000045381 100. All Welded Pipe!lag, Insulation and Jacket a for Goosenecks Detail of Goosenecks Cover Plate Detail for Reaction Pota AA-8531 9C-9085 9C-8147 9C-9019 Benzol Storage Benxol Underground Storage, Wooden Pusp House Benzol Storage Tank Relocated Above Ground Detail Benzol Storage Tank Above Ground Benzol Storage - Pmsp Platform, Piping at Tank Benzol Storage Tanka, Cyclone Fence Benaol Storage Tank, Hew Layout Benzol Storage Tank, Detail Benzol Storage Tanka 3, 4, 5 C-6259 C-6668 C-6669 C-6685 C-6691 9C-7960 9C-7961 9C-8252 Benzol Feeding Feed Tank and Pump Foundation S rasp T ank Feed Tank Cover, Pipe Trough and Supports & Mic. Benzol Feed Tanka, Piping Layout Benxol Feed Tanks, Piping, Supports 4 Jacket Benzol Feed Pumps, Piping and Fence Handrail for Benzol Feed Tank Alterations to Pimp Plate at Benzol Feed Tanks Fence for Benxol Tanks Piping for"Benxol Pumps 5 and 6 Benzol Feed Tank Platform Benzol Piping Inside of Building Detail Housing Detail Housing Benzol Feed Tanks, Layout Benzol Feed Tanks, Detail Piping from Building to Tanks Piping at Control Room Piping at Building Line Benzol Feed Tank Foundation, Sheet 1 Benzol Feed Tank. Foundation, Sheet 2 Steel 9C-7857 9C-7858 9C-7859 9C-7862 9C-7863 9C-7864 9C-7898 9C-8I49 9C-8153 9C-8154 9C-8200 9C-8201 9C-8202 9C-8203 9C-8205 9C-8206 9C-8207 9C-8208 9C-8209 9C-8250 9C-8251 Units 1 and 2 ` C-5241 C-5580 AA-5581 C-5582 C-5583 Preheating and Vaporizing Colls Diphenyl Plant 2nd Unit - Reactor Pots Diphenyl Plant 2nd Unit - Detail Special Brick for Converter Unit and Traps Diphenyl Plant 2nd Unit - Detail of Fractionating Column .... Diphenyl Plant 2nd Unit - Setting for Converter Unit DSW 462581 WATER PCB-SD0000045382 101. c C-5584 Diphenyl Plant 2ad Gait - Door and Burner Castings C-5585 Diphenyl Plant 2nd Unit - Steel for Converter Unit B-5586 Diphenyl Plant 2nd Unit - Stack for Coav. Unit and Location Burners C-5587 Diphenyl Plant 2nd Omit - Stainless Steel Piping at Coav, Unit ' C-5588 Diphenyl Plant 2nd Unit - Kiev. Steel Work Around Comvi Unit ' C-5589 Diphenyl Plant 2nd Unit - Plan Steel Work Around Coav. Unit B-5590 Diphenyl Plc-6 2nd Unit - Foundation for Coav. Gait and Steel Platform C-5591 Diphenyl Plant 2nd Gait - Layout of Subway Grating and Handrail"on S. G. C-5592 Diphenyl Plant 2nd Gait - Inside Fittings for Frac tionating Column ......... C-5593 Diphenyl Plant 2nd Gait - Gas Piping for Conv. Gnits C-5594 Diphenyl Plant 2nd Gait - Hot Water Storage and Heating"System " C-5595 Dipheayl Plant 2nd Gait - Layout of Auxiliary Piping C-5596 Diphenyl Plant 2nd Unit - General Layout C-6841 Diphenyl Plant 2nd Gait - Beniol Vaporizer for No. 1 Gait AA-7337 Dipheayl Plant No. 1 Gait - Cohn, to Lead Trap 9C-7551 Dipheayl Plant No. 2 Gait - Detail Supports for Cond. ( 9C-7900 and Flow Box ' Diphenyl Plant No. 1 Gait - Piping at Lead Trap 6: Gait No. 3 C-7279 C-7280 C-7281 C-7282 C-7283 C-7284 C-7285 C-7286 C-7287 AA-7322 9C-7335 9C-8139 Fractionating Column for Gait No. 3 Unit No.' 3 - Diphenyl Still Dipheayl Plant - Gait No. 3 Dipheayl Plant - Gait No. 3 Steel Kiev. Diphenyl Plant - Oh.it Ho. 3 Steel Sections Diphenyl Plant - Unit Ho. 3 Evaporator and Stack Dipheayl Plant - Gait No. 3 Lead Traps Dipheayl Plant - Gait No. 3 Assembly Plans Dipheayl Plant - Gait Ho. 3 Assembly Kiev. Diphenyl Plant - Gait Ho. 3 Adapter Flange - Cond. to Split Flow Box Diphenyl Plant Split Flow Box Installation on Diphenyl Still Column Diphenyl Plant - Gait No. 3 Cooling Coils for Column 7: Gait Ho. 4 9C-7830 9C-7831 9C-7832 Gait Ho. 4 General Assembly Gait No. 4 Burner Setting Gait No. 4 30" Dia. 12 Plate Fractionating Column c DSW 462582 WATER PCB-SD0000045383 102. 9C-7833 9C-7834 9C-7835 9C-7836 9C-7837 9C-7838 9C-7839. 9C-7840 907841 907842 907843 9C-7844 907845 907846 907847 9C-7848 907849 907852 9C-7855 90 7856 9AA-7860 9AA-7865 07 866 07867 07869 07935 7936 7937 9M-7955 Halt No. 5 907970 90 7971 907972 90-7973 907974 907975 90 7976 9G-7977 907978 90 7979 907980 Omit Ho. 4 Shell for Converter Omit Ho. 4 Gas Piping to Burners Omit Ho. 4 Piping at Top of Cols. 1 and 4 Omit Ho. 4 Split Flow Box Details Omit Ho. 4 Fire Brick Setting Unit Ho, 4 Lead Traps Omit Ho. 4 Heat Exchanger Omit Ho. 4 Vaporiser Omit Ho. 4 Section and 2nd Floor Plan Omit No, 4 Section and 3rd Floor Plan Omit He. 4 Floor Grating Omit No, 4 Holes for Burners in Shell Onit Ho. 4 Stack & Connection to Vaporiser Onit Ho. 4 Reaction Pot Assembly Omit Hoi 4 Reaction Pot Details Onit Ho. 4 Carbon Trap Omit Ho. 4 Piping at Converter Onit Omit Ho. 4 Piping at Suiap Tank Omit Ho. 4 Condenser,"Trap, and Flow Box Support Omit Ho. 4 Foundations Omit Ho. 4 Condenser Support Omit Ho. 4 Burner Adapter Omit Ho. 4 6" die. Coll. Main for Ventilating Sump Tanks Onit Ho. 4 Gas and Benzol Feed Omit Ho. 4 Support for Vaporiser Omit Ho. 4 Fractionating Col. Jacket Omit Ho. 4 Emerg. Pipe Conn. Carbon Trap to Col. Omit Ho. 4 Alterations to Reaction Pot Omit Ho. 4 C. Steel Pipe Flanges Unit Ho. Onit Ho. Dmit Ho. Unit Ho. Unit Ho. Unit Ho. Unit Ho. Unit Ho. Unit Ho. Unit Ho. [fait Ho. 5 Layout 5 Steel Supports 5 Steel Supports 5 Floor Grating 5 Detail Sheel For Converter 5 Burner & Lighting Holes Converter 5 Pipe fro Converter 5 Detail Pipe - Cols, to Sump Tank 5 Gas Piping to Burner 5 Detail of"Piping 5 Beasol Feed Control Piping n$VV 462583 WATER PCB-SD0000045384 103. t 9: Unit Ho. 6 908131 Oait Ho. 6 Detail of Fractionating Coloam 9C-8140 Oait Ho. 6 Layout 9C-8141 Oait Ho. 6 Fouadatiom 9C-8142 Ouit Ho. 6 Structural Steel 9C-8143 Oait Ho. 6 Lead Traps 9C-8144 Oait Ho. 6 Piping at Col. and Coad.a etc. 9C-8145 Oait Bo. 6 Detail Converter Shell 9C-8146 Oait Ho. 6 Layout S.S. Piping at Converter 908147 Oait Ho. 6 Detail S.S. Piping at Converter 908148 Ouit Ho. 6 Assembly of Preheater 908150 Omit Ho. 6 Vaporiser Details 908151 Oait Ho. 6 Firebrick Setting 908152 Omit Ho. 6 Detail of Sump Tank 908155 Oait Ho. 6 Burner Settiag 908156 Oait No. 6 Gas Piping to Burners 908157 Omit Ho. 6 Condenser 9C-8158 Oait No. 6 Condenser and Covers 908159 Oait Ho. 6 Vaporizer Manhole Frame and Cover 908160 Oait Ho. 6 Piping aad Layout for Sump Tank 908161 Ob: it Ho. 6 Detail of Vaporizer Coils 908162 Omit Ho. 6 Diphenyl Line to Sump Tank 908163 Oait Ho. 6 Piping at Rotaweir and Condenser ( 908164 Oait Ho. 6 Piping at Rotaweir and Condenser Detail Units 7, 8, 9, 10 908190 908191 9C-819 2 908193 9C-8194 908195 908196 908197 908198 908199 908202 908203 908467 Onlts 7, 8, 9, 10 Layout Unit* 7, 8, 9, 10 Details of Vaporizer Shell Units 7, 8, 9, 10 6000 Gal. Catch Tank Omits 7, 8, 9, 10 Layout Crude Catch Tanks Omits 7, 8, 9, 10 Layout Diphenyl Piping Omits 7, 8, 9, 10 Details Diphenyl Piping Omits 7, 8, 9,10 6000 Gal. Catch Tank Foundation Omits 7, 8, 9, 10 6000 Gal. Catch Tank Pit H.R. Oa its 7; 8, 9, 10 Platform Sheet 1 ' Onlts 7, 8, 9, 10 Platfom Sheet 2 Omits 7, 8, 9, 10 Detail Housing Omits 7, 8, 9, 10 Detail Housing Diphemyl Omits 6, 7, 8, 9, 10 11. Units 11. 12. 13 9C-9021 9C-9022 9C-9023 9C-9024 Diphenyl Units 12 and 13 Details Col. Fdms. Diphenyl Units 11, 12, & 13 Converter Shell Det Diphenyl Unit 11 Structural Framing Vaporizer Coil Detail ( SW 462584 WATER PCB-SD0000045385 104. <. 9C-9025 Vaporizer Shell Detail 9C-9026 Vaporizer Assembly Haiti 11, 12, aad 13 9C-9054 11, 12, aad 13 Gai Piping to Barters 9C-9055 Layout Hotaveir aad Coadeaser 9C-9056 Diphenyl Piping Lead Trap to StorageTank 9C-9059 Units 11, 12, and 13 Pipe & Support Detaili-Rotaveirs and Coad. ' 9C-9069 11, 12, and 13 Layout Benzol Ruaback Lines 9C-9014 Plot Plan Units 1, 11, and 12 9C-9015 Layout Units 1, 11, and 12 9C-9017 12 and 13 Structural Steel Framing 9C-9018 12 aad 13 Structural Steel Framing 9C-9019 Unit Assembly aad Details Preheater 12: Hydrogen Compressor C-7363 Layout of Hydrogen Compressor C-7364 Hydrogen Compressor Structural Steel for Building C-7365 Hydrogen Compressor Room C-7366 Hydrogen Compressor Room Wiring & Control Piping Diag. C-7367 Hydrogen Compressor Tanks C-7370 Compressor Room Foundation Plan C-7901 Relocating Hydrogen Condensers C-8014 Layout of Hydrogen Compressor Platform ( C-8040 C-8132 Layout and Detail Hydrogen Pipe from Coad. Ext. to Hydrogen Compressor Room Plans & Elev. of Bldg. C-8133 Ext. to Hydrogen Compressor Room Struc. Steel for Bldg. C-8134 Ext. to Hydrogen Compressor Room Layout C-8165 Hydrogen Compressor Wiring aad Piping Diagram C-8179 Hydrogen Compressor Plan and Elev. Bldg. C-8180 Hydrogen Compressor Floor Plan Sec. and Detail C-8181 Hydrogen Compressor Detail Door Frames C-8182 Hydrogen Compressor Foundation Plan and Sections C-8188 Hydrogen Compressor Layout aad Piping C-8189 Hydrogen Compressor Details aad Bill of Material C-8279 Units 7, 8, 9, 10 Layout if Hydrogen Piping 13: Crude Diphenyl Storage 9C-8152 9C-8160 9C-8162 9C-8174 9C-8175 9C-8176 9C-8192 9C-8193 9C-8194 9C-8195 Detail of Sump Tank Piping and Layout for Sump Tank Diphenyl Line to Sump Tank Steel Support & Platform for Crude Diphenyl Storage Storage Tank Steam Coils & Thermowell Crude Diphenyl Storage Tank 6000 Gal. Catch Tank Layout Crude Catch Tank Layout Diphenyl Piping Details Diphenyl Piping ( DSl^5*5 WATER PCB-SD0000045386 105. 908196 908197 908198 908199 9C-8249 9C-8276 908277 908278 6000 Gal. Catch Task Foundation 6000 Gal. Catch Tank Pit Platform, Sheet 1 Platform, Sheet 2 ' Sprlmkler System for Crude Dipheayl Storage Sprinkler System for Crude Dipheayl Catch Tank Vent Piping for Crude Dipheayl Catch Tanks Crude Catch Tanks, Varec Gage 14: Dipheayl Distillation 907870 907871 907872 907 873 907876 907 877 90-7878 90 7879 907880 90 7881 907883 907884 90 7885 907886 90 7887 907888 90 7889 90 7890 9C-7891 907892 9C-7895 9C-7896 907897 9C-7939 907940 9AA-7S41 907943 907944 9C-8076 908077 908078 908079 9C-8081 908264 Fractionating Column Hew Layout Still and Auxiliary Equipment Detail Condenser Still Detail Details Heads and Tails Tank and High Boiler Details Diphenyl Catch Tank Still Foundation Still Supports, Sheet 1 Still Supports, Sheet 2 ' Still Supports, Sheet 3 Mlsc. Pipe Details, Sheet 1 Floor Grating Mlsc. Pipe Details, Sheet 2 Swivel Split Flow Box and Misc. Steel Wise. Pipe Details, Sheet 3 Condenser Details Misc. Pipe Details,. Sheet 4 Misc. Pipe Details, Sheet 5 Detail of Vents Misc. Details Assembly of Flow Box Control Details of Split Flow Box Control Vent Fan for Swivel Flow Box & High Boiler Drum Fill Detail Still Heater, Sheet 1 Detail Still Heater,'Sheet 2 Flanges for Still Piping Assembly of Heater Detail of Heater Inner Core Still Heater, Assembly Still Heater, Details Sheet 1 Still Heater, Details Sheet 2 Diphenyl Still Revision to Heater Platform Dipheayl Still, Heater Gas Piping New Stairs at Ho. 1 Diphenyl Still DSW 462586 WATER PCB-SD0000045387 106. 9C-8210 9C-8211 9C-8212 9C-8213 9C-8214 9C-8215 9C-8216 9C-8217 9C-8218 9C-8219 9C-8220 9G-8221 9C-8222 9G-8223 9C-8224 9C-8225 9C-8226 9C-8227 9C-8228 9C-8229 9C-8230 9C-8254 9C-8262 9C-8263 Layout of Ho. 2 Diphenyl Stil1 Ho. 2 Still Heater Shell Ho. 2 Still Heater Assembly Ho. 2 Still Catch Tasks Ho. 2 Still Heads and Tails Task No. 2Still,Layout Piping Samp Tank to Still Ho. 2Still, Detail Piping Sump Tank to Still Ho. 2Still, Heater Platform Ho. 2Still, Heater Platform Plan No. 2 Still, Platform, FI. L. and Grating No. 2 Still Platform - Section and Details No. 2 Still Platform - Stairs and H.R. Ho. 2 Still Foundation Ho. 2 Still Layout of Rotaveir No. 2 Still Detail of Rotaveir Ho. 2Still, Details Vents and Piping, Sheet 1 Ho. 2Still, Details Vents and Piping, Sheet 2 No. 2Still, Details Vents and Piping, Sheet 3 No. 2Still, Details Vents and Piping, Sheet 4 No. 2Still, Details Vents and Piping, Sheet 5 No. 2 Still, Heater Detail Manhole Frame and Cover No. 2 Still, Layout of Piping No. 2Still, Stair Details No. 2Still, Stair Details 15: Distilled Diphenyl Storage 9C-9057 9C-7882 9C-7894 9C-9071 9C-9082 9C-9071 90 9083 9C-9076 9C-9088 9C-9087 Storage Tank 10'-6" r 37'-4n Detail Foundation for Diphenyl Storage Tank Storage Tank, Detail Loading Line Supports Pipeline to Storage Tanks Steel Platform over Diphenyl Tanks Pipe Line Supports and Foundations Piping to and From Diphenyl Storage Tanks Location Pika, 2 - 25,000 Gal. Tasks Pumps for Storage Tasks Steam Piping to Storage Tanks 16: Building C-5418 C-6378 C-7853 C-7868 9AA-7899 C-8183 . c-8184 C-8185 C-8186 C-8187 08264 Buildings - Elevations of Diphenyl Building Diphenyl Building - Asbestos Roof, S.E. Corner 2nd and Top Floor Plans Shoving Units, 1, 2, 3, and 4 Roof Truss Reinforcing ' Diphenyl Development Bldg. Areas - Floor Lighting Diphenyl Building 40' Extension - Foundation Diphenyl Building 40' Extension - Floor Drains Diphenyl Building 40' Extension - Lean-to Still Diphenyl Building 40' Extension - Framing for Units 7, 8, 9, 10 Diphenyl Building 401 Extension - Framing for Units 7, 8, 9, 10 Nev Stairs at No. 1 Diphenyl Still DSW 462587 WATER PCB-SD0000045388 107. 17: CoatroL* 9C-8754 907942 907949 9C-8204 9C-8208 9C-9060 9C-9061 Walls & Iastnnaeat Panels - Comtrol Room Diphenyl Plaat Comtrol Room Diphenyl Plant Control Panel - Detail Control Roan Units 7, 8, 9, 10 Panel Benzol Feed Tanka - Piping at Control Room . Process Control - Instrumentation Diagram General Plant, 1947 Additions - Power and Control 18: Power 9AA-8265 9C-8266 9C-8269 908539 908540 9C-8881 Diphenyl Plaat - Power, Crude Diphenyl Power Panel Diphenyl Plant Service Room - Gas & Elec. Con. Diphenyl Power Transformer Guard " Electrical - Electric Services in Diphenyl Area ' Electrical - Power in Diphenyl Bldg. - One Line Diagram Power Distr. - Power Paaels & Layouts & Schedules 19: Bills of Material 9BM-26 9BM-27 9BM-28 9BM-29 9BH-35 9BM-36 9BM-44 9BM-47 9BM-48 9BM-50 9BM-51 9BM-52 9BM-53 9BM-54 9SM-55 9BM-56 9BM-57 9BH-63 9BM-74 9BM-87 Benzol Feed Tanks Diphenyl Units 1-2 New Still and Accessories (No. 1 Diphenyl Still) 4th Diphenyl Unit 5th Diphenyl Unit Benzol Storage (9C-7960) Diphenyl Still Heater (9C-8076) Hydrogen Compressor 6th Diphenyl Unit Crude Diphenyl Storage ' Diphenyl Units - Extension to Building Relocating Hydrogen Compressor Benzol Storage Four"Diphenyl Units Diphenyl Still No. 2 Water Supply . Power Supply High Boiler Line to Storage Pit Steam Line to Diphenyl Building Diphenyl Units 11, 12, 13 DSW 462588 WATER PCB-SD0000045389 EQUIPMENT SOMBER. LIST OF tfcE IH DEPT. 20 - BIPHENYL Equipment Honber 17 --7 17-10 17-15 17-16 17-17 17-20 17-21 17-22 17-23 17-24 17-25 17-31 17-32 17-33 20-1 20-64 20-107 20-110 20-113 20-126 20-220 20-226 20-230 20-234 20-235 20-247 20-263 20-264 20-274 20-275 20-276 20-285 20-286 20-287 20-288 20-289 20-290 20-291 20-292 20-293 20-296 20-298 20-335 Description Converter #2 Converter #3 Converter #4 Converter #5 Stiir Heater #1 Converter #6 Converter #7 Converter #8 Converter #9 Converter #10 Coil Heater #2 Still Converter #11 Converter #12 Converter #13 Split Flow BOz #5 Unit Storage Tank, Heads and Tails Catch. #2 Still Storage Tank, Heads and Tails Catch #1 Still Water Tank #1 Still Hi-Boiler #2 Still Tank Benzol Storage Tank. - Yard Benzol Feed Tank Air Receiver 24" *6' Inter Cooler - Receiver #2 Split Flo Box #1 Still Split Flo Box #3 Unit . Split Flow Box #2 Unit Split Flow Box #4 Unit Benzol Storage Tank 10'-0" x 18' Receiver After Cooler #1 Comp. Receiver Inter Cooler #1 Comp. Samp Tank #3 Benzol Storage Tank Benzol Storage Tank Benzol Storage Tank Biphenyl Catch Tank Still #1 Biphenyl Catch'Tank Still #2 #2 Biphenyl Sump Tank Sooth #1 Biphenyl Sump Tank Horth Benzol Catch Tank #1 - Comp. Room Vacnun Receiver - Comp. Rows #3 Benzol Feed Tank Sump Tank - Cooling Water Biphenyl Storage Tank 108. OSW 462589 WATER PCB-SD0000045390 Equipment Humber List Continued: Equipeat Huaber Description 20-236 20-516 20-517 20-518 20-528 Biphenyl Storage Tank Benzol Recovery - Comp. Room Benzol Recovery - Comp. Room Benzol Feed Tank & Platform Isopropyl Alcohol Tank 26-13 26-18 26-22 28-80 28-81 28-82 28-83 28-84 28-85 28-140 28-141 28-142 Sump at Benzol Storage Task - Yard Concrete Catch Basin - #3 Benzol Feed Tank Safety Dike - #2 Biphenyl Storage Task Rotaveir - #6 Unit Rotaveir - #7 Unit Rotaveir - #8 Unit Rotaveir - #2 Still Rotaveir - #9 Unit Rotaveir - #10 Unit Rotaveir - #11 Unit Rotaveir - #12 Unit Rotaveir - #13 Unit , 33-60 33-79 33-84 33-129 33-135 33-137 33-138 33-145 33-156 33-157 33-158 33-165 33-166 33-167 33-168 33-169 33-170 33-171 33-177 33-215 33-216 33-218 33-246 33-261 Pump - Ramsey 26/37 Benzol Storage Task Pump - Gould - Crude Storage Pump - Viking 1189619 - Benzol Storage #1 Pump - Ramsey 26811 - Biphenyl Storage Pump - Worthington - Still Rocks #1 Still Pump - Ramsey - #1 B&T Tank Pump - Viking - #2 Benzol Storage Pump - Worthington - Comp. Room Pump - Worthington - #2 Still Pump - Blackaer 246737 - Benzol Storage #3 Pump - Blackmer 246738 - Benzol Storage #5 Pump - Taber 395 - #2 Still Pump - Taber 249 - Pit Pump Pump - Taber 384 - Catch Task Pump - Taber 384 - Catch Tank Pump - Westco BR507 - Comp. Room Pump - Taber 37764 - Crude Storage Pump - Taber 37765 - Crude Storage Pump - Westco 43036 - Benzol Unloading Dock Pump - Taber 45132 - #1 Biphenyl Still Pump - Taber 45497 - Biphenyl Still (Spare) Pump - Viking - Benzol Storage #1 Pump - Gould 29QA048 - Benzol Feed (Yard) (3) Benzol Feed Pumps 109. DSW 462590 WATER PCB-SD0000045391 Equipment Huaber Lilt Continued: Equipment Hmber Description 34-74 34-98 Poitp - Gould 176415 - Benzol Feed (1) Puap - Gould 185143 - Benzol Feed (2) 35-22 35-33 35-34 35-37 35-45 Compressor #1 Hydrogen Compressor #2 Air Compressor #3 Air Compressor #2 Hydrogen Compressor #3 Hydrogen 51-17 51-24 Biphenyl Still #1 Biphenyl Still #2 52-6 52-17 52-22 52-23 52-27 52-28 52-29 52-30 52-32 52-33 52-34 52-36 52-37 52-42 52-43 52-44 52-45 52-53 52-54 52-55 52-56 52-57 52-58 52-59 52-60 52-61 52-62 52-76 52-77 52-78 52-80 52-81 Vaporizer #2 Unit Vaporizer #3 Unit Vaporizer #4 Unit Condenser #3 Unit- ' Condenser #2 Converter Heat Exchanger #1 Still Heat Exchanger #4 Unit Condenser #4 Unit Condenser #1 Still Heat Exchanger #5 Converter Condenser #5 Converter Vaporizer #5 Unit Benzol Condenser - above Deck Sled Vaporizer #6 Unit Condenser #6 Unit Inter Cooler #1 After Cooler #1 Condenser #7 Condenser #8 Condenser #9 Condenser #10 -Vaporizer #7 Unit . Vaporizer #8 Unit Vaporizer #9 Unit Vaporizer #10 Unit (in stack) Heat Exchanger #2 (Still) Condenser #2 (still) Vaporizer #11Unit Vaporizer #12 Unit Vaporizer #13 Unit Condenser #11 Unit Condenser #12 Unit .. 110. 05^ ^62591 WATER PCB-SD0000045392 Equipment Humber List Continued: Equipment lumber Description 52-82 52-88 52-91 52-92 52-147 52-148 52-149 52-150 52-151 52-155 52-157 Condenser #13 After Cooler later Cooler - Comp. Room After Cooler - Comp. Room Condenser - Comp. Room Condenser - Comp. Room Heat Exchanger - Hydrogen Cooling Heat Exchanger - Hydrogen Cooling Preheater Coil - Biphenyl Column Heat Exchanger Heat Exchanger 53-13 53-14 53-15 53-17 53-18 53-19 53-20 53-21 53-22 53-23 53-24 53-26 53-27 53-28 Fractionating Column #1 Biphenyl Still Fractionating Column #4 Converter Fractionating Column #2 Unit Fractionating Column #5 Converter Fractionating Column #6 Converter Fractionating Column #2 Biphenyl Still Fractionating Column #3 Converter Fractionating Column #7 Converter Fractionating Column #8 Converter Fractionating Column #9 Converter Fractionating Column #10 Converter Fractionating Column #11 Converter Fractionating Column #12 Converter Fractionating Column #13 Converter 55-177 55-291 55-295 Han Cooler Fan Fan, Utility Blower - Hydrogen Coap. Roam 61-157 Hand Track - for Pots sad Traps 63-93 63-134 Gear Box on Controller Speed Reducer - Flaker 64-40 64-41 64-47 64-48 64-57 64-58 64-66 Jacketed Process Piping Steam Feeder ' Piping - Storage and Loading Piping - Instrument Service Piping - Units Piping Benzol Recovery Piping Benzol Unloading and Storage 65-21 65-74 65-75 Hydrogen Compressor Control Lines Process Piping Benzol Feed Tank Water Cooling Tracer DSW 462592 WATER PCB-SD0000045393 112. Equipment Number List Continued: Equipment Humber Description 73-49 73-84 73-94 73-95 73-96 73-99 73-104 73-105 73-106 73-107 73-108 73-109 73-123 73-124 73-125 Chain Hoist #2 Converter Chain Holst #3 Converter Chain Holst #4 Converter Chain Holst #5 Converter Chain Holst #5 Converter Chain Holst #4 Converter Chain Holst Chain Hoist - Trolley Chain Holst - Trolley Chain Hoist - Trolley Chain Hoist - Trolley Chain Hoist - Trolley Chain Hoist #11 Converter Chain Hoist #12 Converter Chain Hoist #13 Converter Trolley Trolley Trolley 75-21 75-66 75-67 Power Feeder - Underground to Biphenyl Storage Pumps Temperature Control Wiring - Unita Motor Wiring 78-170 78-171 78-174 78-177 78-178 78-189 78-190 78-197 78-242 78-243 79-18 79-106 79-152 79-157 79-301 79-308 79-414 79-519 79-531 79-561 79-571 79-589 79-593 79-610 Power Panel #1 Converter Motor Control Cabinet #1 Converter Heat Control Board #1 Motor Control Board - Benzol Storage Pumps Motor Control Board - Compressor Room Control Cabinet - Compressor Room Control Cabinet - Control Room Motor Control Board #2 - #1 Converter Room Power Cabinet - Benzol Feed A Hydrogen Compressor Motor Control Frame - Storage Tank Motors Motor - G.E. 5560247 - 40 HP - #2 Hydrogen Comp. Motor -LA 311416 - 1% HP - on Viking Pump Motor -LA 3648018 - lfc HP - Benzol Storage Motor - Howell 5132 J 1 - 15 HP - Benzol Feed Motor - G.E. - 5 HP - Biphenyl Motor - G.E. - 5 HP - Biphenyl Motor - G.E. U HP ' Motor - Howell 5131 J2 - 10 HP - Feed Pump Motor - G.E. - 30 HP - #1 Hydrogen Comp. Motor - Allis Chalmers 52694 -2 HP - Id 5 Bid. 27 Motor - G.E. 6768195 - 40 IP - #3Hydrogen Conp. Motor - L A - 7k HP - #1 Still Motor - G.E. - 3 HP - Yard Motor - GE r EM 2900 - 5 HP - Biphenyl Storage DSW 462593 WATER PCB-SD0000045394 113. Equipment Number List Continued: Equipment Humber __________________ Description_________________ . 79-612 79-614 79-642 79-683 79-712 79-758 79-824 79-878 79-914 79-922 79-923 79-926 79-927 79-963 79-975 79-976 79-978 79-979 79-980 79-987 79-1139 79-1192 Motor -LA 368542 - 1 HP - Aroclor Boiler - Hyd. Comp .Room Motor - GE - H1314 - 5 HP - Biphenyl Storage Motor - GE - FW879 - 5 HP - Circ. Water #1 Still Motor - GE - EW2292 - 5 HP - Air Comp. Motor - Courtney - 1/6 HP Motor - GE- AP1990 - 3 HP - Flake D. Dryer Motor - GE - EP2055 - 3 HP - Biphenyl Task Motor Reducer - Foxboro - 1/6 HP Control Room Motor - G.E. - 3 HP - Sump Task Motor - G.E. - 5 HP - Catch Tank #2 Still Kotor - G.E. - 5 HP Motor - G.E. - MR2065 - 3 HP - (om Gould pump) Motor - G.E. - MR2067 - 3 HP - (oa Gould pump) Motor -LA- 7V HP Motor - L A - HP - #2 Biphenyl Still Motor - 1/2 HP - Sump Task Kotor - Howell 296186 - 2 HP - Blackmer Pump Motor - Howell 287229 - 2 HP - Blackmer Pump Motor - Howell 306991 - 2 HP - Blackmer Pump Motor - W'hse - 7 HP - om Hartzell Fan Motor -LA 1827991 - 15 HP - om Benzol Pump 33-246 Benzol Feed Pump and Motor 82-226 82-227 82-228 83-11 83-13 83-17 83-33 83-34 83-35 83-40 83-44 83-60 83-114 83-116 83-117 83-118 83-119 83-124 83-125 83-126 83-127 83-128 Watt Hour Meter G.E. 19366523 in Panel 78-170 Current Trans. G.E. 400/5 - in Panel 78-170 Current Trans. G.E. - in Panel 78-170 Controller - Benzol Comp. Ind. Recorder - LAN 293220 Temp. Indicator - LAN 292382 - Control Room Temp. Controller - Wilaon-Macnlen Temp. Controller - Wilaon-Macalen Temp. Controller - Vilaom-Kacalen Temp. Controller - Wiltom-Mncalem - 9575 H47A Temp. Controller - Wllaoa-Hacalem - Crows Nest Temp. Controller - Wilaon-Mncalen Ind. Recorder - LAN 329967 Gas Control Valve Control Valve - Foxboro 490478 Control Valve - Foxboro 563776 Benzol Valve - Foxboro 563781 Temp. Recorder - LAN 350456 Temp. Recorder - IAN 338835 Gas Valve - LAN - #5 Converter Control Valve - Foxboro 619301 Control Valve - Foxboro 619302 DSW 462594 WATER PCB-SD0000045395 114. Equipment Humber List Continued: Equipment Humber Description 83-132 83-136 83-142 83-145 83-146 83-147 83-148 83-149 83-150 83-151 83-152 83-153 83-154 83-155 83-156 83-166 83-168 83-169 83-170 .83-171 83-172 83-174 83-175 83-176 83-177 83-179 83-180 83-181 83-182 83-183 83-185 83-186 83-187 83-188 83-189 83-190 83-191 83-192 83-193 83-194 83-196 83-197 83-198 83-253 83-256 Magnetic Valve - On Preheater #5 Pressure Balance Valve - L&N Temp. Controller - L&H 350682 Pneumatic Recorder - L&H 366481 Control Valve - Foxboro Potentiometer Controller - Foxboro C58872 - Hydrogen Coap.Rjm. Potentiometer Controller-Foxboro C-58873- Gas Valve - L&H Temp. Recorder - L&H 350738 Temp. Recorder - L&H 350744 Gas Valve - L&H ' ' Control Valve - Foxboro 697076 Control Valve - Foxboro 697077 Control Valve - Foxboro 697078 Control Valve - Foxboro 645409 Gas Valve - #2 Still ' Temp. Recorder - L&H 350802 Temp. Recorder - L&N 350803 Temp. Recorder - L&H 350805 Taap. Recorder - L&H 350796 Temp. Recorder - L&N 350784 Temp. Recorder - L&N 381506 Temp. Recorder - L&N 381509 Temp. Recorder - L&N 381528 Temp. Recorder - L&N 381541 Temp. Recorder - L&H 350806 Temp. Recorder - L&H 381525 Temp. Recorder - L&H 350800 Potentiometer Recorder - L&H 381467 Potentiometer Recorder - L&N 381419 Potentiometer Controller - Foxboro C-63869 Potentiometer Controller - Foxboro C-63870 Potentiometer Controller - Foxboro C-63871 Potentiometer Controller - Foxboro C-63872 Control Valve - L&H - V/AB Air Set Control Valve - L&H - W/AB Air Set . Control Valve - L&H - V/AB Air Set Control Valve - L&N - V/AB Air Set Control Valve - L&H - W/AB Air Set Control Valve - L&H - W/AB Air Set Ratox Press Controller - Foxboro C93641 Diff. Press Controller - Foxboro C66930 Motor Controlled Valve - Foxboro 470763 Pressure Valve - L&N Rec. Temp. Controller - L&N 576007 DSVV 462595 WATER PCB-SD0000045396 115. Equipment Humber List Continued: Equipment Humber Description 83-257 83-258 83-259 83-260 83-261 83-262 83-263 83-265 83-266 83-267 83-268 83-269 83-270 83-271 83-272 83-328 Rec. Temp. Controller - L&H 576010 Rec. Temp. Controller - L&H 576015 Rec. Temp. Controller - L&H 690411 Temp. Recorder - L&H 690470 Temp. Recorder - L&N 690473 Potentiometer - Foxboro F83911 Potentiometer - Foxboro F83912 Ind. Press Controller - Foxboro 95626 - Hyd. Coop. Roots Coat. Benzol Valve - Foxboro 1619914 Control Benzol Valve - Foxboro 1619963 Control Benzol Valve -Foxboro 1619976 Control Gas Valve-Mason-Heilan J-29871C8276 Control Cas Valve-Mason-Neilaa J29872C8276 Control Gas Valve-Mason-Seilan J-29873C8278 Controlled Valve-Foxboro F25FB-Hydrogen Compressor Gas Controller - Foxboro J19649 84-18 84-19 84-20 84-23 84-24 84-28 84-29 84-30 84-31 84-32 84-53 84-54 84-55 84-56 84-57 84-58 84-59 84-60 84-61 84-62 84-63 84-64 84-65 84-70 84-71 84-72 Biphenyl Flow Controller Biphenyl Flow Controller Biphenyl Flow Controller Foxboro - #4 Converter Foxboro C33473 Foxboro C32422 Biphenyl Flow Controller Foxboro C37533 Biphenyl Flow Controller Foxboro C37534 Biphenyl Flow Controller Foxboro C55147 Biphenyl Flow Controller Foxboro C63568 Biphenyl Flow Controller Foxboro C-63569 Biphenyl Flow Controller Foxboro C63570 Biphenyl Flow Controller Foxboro C-63571 Pneumatic Transmitter-Foxboro F75356 Pneumatic Transmitter-Foxboro F75357 Pneumatic Transmitter-Foxboro F75358 Pneumatic Traasmttter-Foxboro F45926 Pneumatic Transmitter-Foxboro F45927 Pneumatic Transmitter-Foxboro F45928 Pneumatic Transmitter-Foxboro F45929 Pneumatic Transmitter-Foxboro F45930 Pneumatic Transmitter-Foxboro F45931 Pneumatic Transmitter-Foxboro F45932 Pneumatic Transmitter-Foxboro F45933 Pneumatic Transmitter-Foxboro F45934 Pneumatic Transmitter-Foxboro F45935 Intergrating Flow Controller-Foxboro F75359 Intergrating Flow Controller-Foxboro F75360 Intergrating Flow Controller-Foxboro F75361 DSW 462596 WATER PCB-SD0000045397 116. Equipment Number List Continued: Equipseat Humber _De script ion 86-2 86-5 86-7 86-17 86-24 86-29 86-30 86-31 86-32 86-33 86-49 86-50 86-51 99-20 99-26 Gas Meter - 016398 - #5 Unit Gas Meter - 016463 - #11 Unit Gas Meter - 016489 -#13 Coaverter Gas Meter - 829070 - Biphenyl Still Gas Meter - 016397 - #12 Unit Gas Meter - 027352 - #7 Converter Gas Meter - 028002 - #4 Converter Gas Meter - 028003 - #6 Converter Gas Meter - 028004 - #2 Converter Gas Meter - 028265 - #3 Converter Gas Meter - 051935 - #10 Unit Gas Meter - 051936 - #9 Unit Gas Meter - 051936 - #8 Unit Fence - at Benzol Storage Tank Fence - Storage Pit 106-132 106-253 106-276 106-283 106-365 106-377 106-391 106-525 106-533 107-16 107-33 110-39 110-42 110-56 110-68 110-69 110-70 110-82 110-83 110-84 110-85 110-95 110-99 112-16 Flood Lights - Feed Tank Clock Synchonous High Boiler Storage Pit - "Lake Clegom" Benzol Unloading Dome Transmitter Stand - Meter Room Pneumatic Wrench ' High Boiler Storage Pit - Storage Crude Santovax Pipe and Coils for #12 and #13 Units Conversion Measurement System . Fire Extinguisher - on 2-Wheel Truck Emergency Foam Line - at Benzol Feed Tank Platform at Storage & Shipping Tank - S.E. Comer Bldg. Platform #2 to #6, and #11 Units - Mid, Conv. Room Supports for Benzol Feed Piping - S.W. Bldg. 27 Platform at #1 Still Platform at Biphenyl Still Heater . Walking Platform, above Deck Shed Roof-Benzol Loading Platform 7,8,9,10 Units Platform #2 Biphenyl Still Platform Benzol Feed Tank Unloading Platform Platform'#12 and #13 Units Platform, Including Grating & Stairs, Tovers to Handle Sub. Pump 27 Control and Alarm System . DSW 462597 WATER PCB-SD0000045398 117. Equlpotent Number List Continued: Equipment Number Description 116-98 Aroclor Hester (From CC Job - At Ho Value) 117-201 Tool and Supply Locker (4) 206-57 206-72 Feed Pump Structure (Fence sad Concrete Floor) Operating Structure-Biphenyl Sump Tsai (Catch Basin, Fire Wall, Platform) (v DSW 462598 WATER PCB-SD0000045399 118. August 1957 MAINTENANCE SURVEY SERIES 100 - GENERAL PLANT Itea 101: Benzol Tank Car Unloading Praap (1 Required) Function: Maintenance Required: To unload benzol from railway tank cars to the benzol storage tanks. Hone Item 102: Benzol Storage Tanks (5 Required) Function: Maintenance Required: To provide Benzol raw material buffer storage between receipt and use. Nome Item 103: Benzol Transfer Pumps (5 Required) Function: Maintenance Required: To transfer benzol from the benzol storage tanks to the benzol feed tanks. Maintenance trill be done on MRO - proposal has been nude to test suction of pumps to determine if a fever number of pumps can be used. - Itea 104: Isopropyl Alcohol Storage Tank (1 Required) Function: Maintenance Required: To provide buffer storage for isopropyl alcohol. Hone DSW 462599 WATER PCB-SD0000045400 I ten 105: Isopropyl Alcoho* Transfer Pump 119. August 1957 Function: Maintenance Required: To transfer isopropyl alcohol to the isopropyl alcohol feed tank. Hone Item 106: Benzol Feed Tank (2 Required) Function: Maintenance Required: 1. To provide a source of benzol for feeding the Biphenyl units. 2. To provide a catch tank for the benzol returned from the Biphenyl process. None Item 107: Benzol Feed Pumps (3 Required) Function: Maintenance Required: To deliver the benzol feed from the benzol feed tank, to the benzol vaporizer coil of each Biphenyl unit. Hone Item 108: Isopropyl Alcohol Feed Tank Function: Maintenance Required: To provide a eo urce of isopropyl alcohol for feeding to the benzene feed. Home DS^ 462600 WATER PCB-SD0000045401 Item 109: Isopropyl Alcohol Feed Paap 120. August 1957 Function: Maintenance Required: To transfer Isopropyl Alcohol to the suction of the benzol feed pumps. Hone I ten 110: Hydrogen Coolers (6 Required) Function: Maintenance Required: 1. To cool the gas and vapors from the benzol condenser la order to decrease the vapor load oa the hydrogen compres sors. 2. To condense some of the benzol vapor from the hydrogen gas. Clean each cooler on the water side. This cleaning should consist of acid washing and inspection to determine if physical clean ing is. necessary. Item 111: Benzol Catch Tank (1 Required) Function: Maintenance Required: To trap condensed benzol from the hydrogem gas. Hone Item 112: Hydrogen Compressors (3 Required) Function: Maintenance Required: To compress the hydrogen sad condense the benzol vapors contained in the hydrogen. None DSVJ 462601 WATER PCB-SD0000045402 Item 113: Istar Coolers (3 Required) 121. August 1957 Function: Maintenance Required: To condense benzol from the hydrogen gas after the first compression stage. None Item 114: Low Pressure Receiver (3 Required) Function: Maintenance Required: To provide a trap and collecting tank for the benzol condensed from the hydrogen gas after the first compression stage. Hone Item 115: After Coolers (3 Required) Function: Maintenance Required: To condense benzol from the hydrogea gas after the second compression stage. None Item 116: High Pressure Receiver (3 Required) Function: Maintenance Required: To provide a trap and collecting tank for benzol condensed from the hydrogen gas after the second compression stage. Visual inspection indicate no maintenance required. However, thickness ef these tanks should be checked. DSW 462602 WATER PCB-SD0000045403 Item 117; Benzol Return Pump Task (1 Required) 122. August 1957 Function: Kaimteaaace Required: To collect the condensed bemzol from the receivers tad the bemzol catch task. Home Item 118: Recovered Bemzol Retura Pump Fumctio Maimtemamce Required: To return the recovered bemzol lm the pump tanIf to the bemzol feed tamk. Home (Larger bemzol pumps are meeded.) (A separate project is beiag submitted.) Item 119: Crude Biphenyl Catch Teaks (Sump Tanks) (2 Required) Fumctiom: Maimtemamce Required: To catch the crude Biphemyl from the Bipheayl emits amd store it prior to batch distillatiom. Repair sheet metal weather-prooflmg over lmsulatiom om No. 1 Sump Tamk. Item 120; Still Chargiag Pomps (2 Required) Function: Maintenance Required: To deliver the crude Bipheayl from the catch tanka to the still. Home DSI/V 462603 WATER PCB-SD0000045404 Ita 121: High Boiler Collecting Tank (1 Required) 123. August 1957 Function: Maintenance Required: To provide a receiving and cooling tank for the distilled high boiler (Santowax C). The insulation on this tank is saturated with Biphenyl. Remove old insulation and retssulate. Provide new weather-proofing. Item 122: High Boiler Pump (1 Required) Function: Maintenance Required: To deliver high boiler from the high boiler tank to the Santovax C Storage Tank. None Item 123: Distilled Benzol Collection Tank (1 Required) Function Maintenance Required: To provide a catch tank for the benzol fraction distilled from the crude Biphenyl. None Item 124: Distilled Benzol Return Pump (1 Required) Function: Maintenance Required: To deliver the recovered benzol from the distilled benzol collection tank to the benzol feed tank. Repair motor casing where it has corroded through. DSW 462604 WATER PCB-SD0000045405 C Itm 125: Biphenyi Storage Tasks (2 Required) 124. August 1957 Function Maintenance Required: To store distilled Biphenyl prior to shipping. Hone Itaa 126: Biphenyl Loading Pumps (2 Required) Function: Maintenance Required: To deliver Biphenyl from the Biphenyl storage tanks to tank cars for shipping. Hone ( ( OSW 462605 WATER PCB-SD0000045406 125. August 1957 smKS 200 - BIPHSHYL OHITS Item 201? Benzol Vaporizer (1 Required per Unit) Function: Maintenance Required: 1. To vaporize the benzol feed to each Biphenyl unit. 2. To recover sensible heat from the exhaust gases used in heating the preheater and converter pots. Unit Ho. 2 through 13: Check each vaporizer coil core and coil support. Suspend all vaporizer coils from the top and support each turn of the coil. Replace the S.S. coil cores as required. Item 202: Heat Erchtager (1 Required on Quits 4 and 5 Only) Function: Maintenance Required: 1. To farther super-heat the benzol vapor from the vaporizer. 2. To recover heat from the vapors leaving the converter. Unit Ho. 4 and 5: Hone OSV'J462606 WATER PCB-SD0000045407 126. August 1957 Items 203, 204, 205, 206, tad 207: Fire Box and Associated Preheater Pots, Converter Pot. Burners, ate. Function: Maintenance Required: To super-heat the henrol vapors to the pyrolysis temperature. Firebox: Check brickwork in firebox of Units 2 through 13 and repair as required. Burners: Unit Ho. 4: Replace broken Inspirator on preheater. Unit No. 5: Replace missing burners on converter. Unit No. 7: Replace missing burners on converter. Replace broken Inspirator on Ho. 1 preheater. Unit Ho. 8: Replace missing burner on No. 2 preheater. Unit No. 9: Replace broken Inspirator on No. 2 preheater. Unit No. 10: Replace broken Inspirator on con verter and No. 2 preheater. Unit No. 11: Replace broken Inspirator on Ho. 2 , preheater. Unit No. 12: Replace broken Inspirator on converter. DSW 462607 WATER PCB-SD0000045408 Itea 208: Start-Up By-Pan Stack (1 Required par Quit) 127. August 1957 Ftraction: Maintenance Required: To provide a means of by-passing the hot flue gases around the cold vaporizer prior to beginning the benzol feed. Check the butterfly type valve in the horizontal header between the by-pass stack and exhaust stack of Units 2 through 13. Repair as required. Item 209: Exhaust Stack (1 Required per Unit) Function: Maintenance Required: 1. To provide a means for exhausting the flue gas from the preheater and converter to the atmosphere. 2. To provide a houa iug for the vaporizer coil. Check the firebrock in the exhaust stacks of Units 2 through 13 and repair as required. Repair all holes in these stacks. Item 210: Lead Trap (1 Required per Unit Except Unit Hos. 4 and 11) Function: Maintenance Required: To trap entrained lead coming over with the benzol vapor from the converter. Ho maintenance required. (These lead traps will be eliminated as aoujoum pot sections are installed on the converter pots.) oS\N 462608 WATER PCB-SD0000045409 August 1957 Item* 211, 212, 213 and 214: Fractionating Column Carbon Trap, Condenaer and Split Flow Box (1 Repaired per Unit Function: Maintenance Required: 1. To function ae a cooling system to condense the vapors from the converter. 2. To effect a partial separation of the benzol from the converted products. Check the supports on the #2 Unit column and provide additional supporta as necessary These supports should be adequate to support the column and associated equipment when the column is filled with water. / DSW 462609 WATER PCB-SD0000045410 SERIES 300 - BIPHEKYL STILLS 129. August 1957 Itea 301: Biphenyl Still Pot (1 Required par Still) Function: Maintenance Required: To provide a reservoiV for heating the charge of crude Biphenyl which is being distilled. Still Ho. 1: None Still Ho. 2: None Item 302: Biphenyl Still Circulating Pimp (1 Required per Still) Function: Maintenance Required: 1. To circulate the crude Biphenyl in the still pot through the heating coil of the gaa fired heater and back to the still pot. 2. To puap the residue in the still to the high boiler collecting tank. Still Ho. 1: Hone Still Ho. 2: Hone Item 303: Gas Fired Heater (1 Required par Still') Function: Maintenance Required: To supply the heat required for distilling the crude Biphenyl. Still Ho. 1: Recondition or replace two bad inspirators and reconnect to gas line. Still Ho. 2: Hone DSW 462610 WATER PCB-SD0000045411 130. August 1957 Items 304, 305, rad 306: Biphenyl Still Colmaa, Condenser, rad Spilt Flcrg Box (1 Set Required par Still) Fraction: Maintenance Required: To separate rad condense the crude Biphenyl report into benrol, high boiler, rad Biphenyl. Still Ho. 1: Hone Still Ho. 2; Hone . Item 307: Heads sad Tails Catch Tank Fraction: Maintenance Required: To provide a catch tank and storage for the heads and tails distilled from the crude Biphenyl. Still Ho. 1: None Still No. 2: None Item 308: Heads rad Tails Return Pump (1 Required per Still) Function: Maintenance Required: To return the heads rad tails from the catch tank to the still pot. Still Ho. 1: Hone Still Ho. 2: Hone Item 309: Biphenyl Catch Tank (1 Required per Still) Fraction: Maintenance Required: To receive the Biphenyl fraction rad temporarily store the Biphenyl during . the distillation. Still Ho. 1: Hone Still Ho. 2: None DSW 462611 WATER PCB-SD0000045412 Item 310: Distilled Biphenyl Transfer Pntsp (1 Required par Still) August 1957 Function: Maintenance Required: To 4elivr the distilled Biphenyl from the Biphenyl catch task to the Biphenyl storage tanks Still Ho. 1: Hone Still Ho. 2: Hone DSW 462612 WATER PCB-SD0000045413 SERIES 400 - IMSTRPHEHTATIOS AMD CONTROLS 132. August 1957 Item 401: Automatic Let-Down Level Control (1 Required on Primary Feed Tank Paly) Function: Maintenance Required: To automatically maintain a supply of benzol In the feed tank and to sound an alarm In case of high or low level. Hone Item 402; Benzene Feed Control (1 Required per Unit) Function: Maintenance Required: 1. To automatically meter a specified quantity of benzene to each unit. 2. To automatically shut off the natural gas flow when the feed stops. Hone Item 403: Twelve Point Temperature Recorder (1 Required per Pait) Function: Maintenance Required: To record the critical temperatures. Check the instrument on each unit and repair as required. Each instrument is to record: 1. The condenser water outlet temperature. 2. The vapor temperature on the top plate. 3. The flue gas temperature leaving the vaporizer coil section of th.n exhaust stack. 4 . The temperature of the material flowing through the sump line. DSW 462613 WATER PCB-SD0000045414 Item 403 Continued: MalateMac* Required Continued: 133. 5. The temperature of material leaving the vaporizer coil. 6. The temperature of the lead in the Ho. 1 preheater. 7. The temperature of the lead in. the Ho. 2 preheater. 8. The temperature of the flue gae entering the vaporizer coil section of the exhaust stack. Item 404: Single Point Temperature Recording Controller (1 Required per Unit) Function: Maintenance Required: To indicate, record, and control the temperature of the converter by regulating the natural gas to the burners. None ' I tea 405: Natural Gas Meters (1 Required per Unit and 1 Required per Still) Function: Maintenance Required: To record the quantity of natural gas used on each Biphenyl Unit and each Biphenyl Still. Clean, recondition, and check all gas netera. Relocate one of the two meters now on Ho. 12 Unit to Ho. 7 Unit. DSVV 462614 WATER PCB-SD0000045415 August 1957 Item 406: Biphenyl Still Twelve Point Temperature Recorder Function: Maintenance Required: . To record the critical temperatures on the Biphenyl Stills. Still Ho. 1: Hone Still No. 2: None Item 407: Biphenyl Still Furnace Temperature Recording Controller Function: Maintenance Required: To control the temperature differential between the heater inlet and outlet by regulating the flow of gas to the burners None Item 408: Biphenyl Unit Automatic Safety Switches for Natural Gas (1 Required per Unit) Function: Maintenance Required: To protect the equipment in the event of aa emergency, by stopping the flow of natural gas to the No. 2 preheater when the temperature exceeds a predetermined maximum. Check, clean, recondition and repair as required. DSW 462615 WATER PCB-SD0000045416 Itm 5011 Lighting Maintananea Required: SERIES 500 ~ UTILITIES 135. August: 1957 1. Install adequate Llghtiag la benserne unloading dock area. 2. Provide adequate llghtiag la Biphenyl Oait rooms, let, 2nd, aad 3rd floors. Lighting should be of the flood light type aad should be located near vails aad windows so that the lights do not overheat. Item 502: Power Wiring Maintenance Required: 1. Install insulated switch buttons on benzol unloading pump switch. 2. Replace the insulation button on the high boiler catch tank pump starter switch. 3. Replace the insulation buttons on both the So. 1 and Ho. 2 still heads and tails return pump starter switches. 4. Replace the insulation buttons on the Ho. 1 still Bipheuyl transfer pump starter switch. 5. Replace the ennymerable conduit covers throughout the entire area. DSW 462616 WATER PCB-SD0000045417 Itan 503: Process Piping Maintenance Required: 136. August 1957 1. Extend the leg in the benzene rtm-back ' line frn the roof cooler to make leg 8* high. (Completed) 2. Remove the swivel flow box from each till cad install ia their place a sight glass (steam jacketed) aad a 3-way, "Y" type, valve. Provide a sample port ia the line. (This change will reduce Biphenyl sublima tion in the area and eliminate a source of product contamination.) 3. Repair e&nuaerable steam leaks through out the area, 4. Replace the bent sump tank vent header so that condensed benzene can run back to both sump tanks. Itan 504: Plant Water Piping - Maintenance Required: Dismantle copper tubing to benzol feed puap bearings and Install 1/4" steel piping. Item 505: natural Gas Piping Maintenance Required: Ho maintenance is required except for general renovation of unusable valves, gauges, and general wandering pipe runs. DSW 462617 WATER PCB-SD0000045418 137. August 1957 I teg 506: Stem Piping - Benzol Loadlag Dock Area Maintenance Required: 1. Install steam trap os task car um~ loading liae tracer near pomp. Supply steam to this tracer near base of pump and trap aear this point. Coademsate will draia back down the tracer to trap. 2. Disaaatle copper tablag feediag tracers ob beasol feed pump discharge line and iastall in schesaetrical fashion. 3. Survey all steam traps la the area and repair or replace those not operating. Item 507: Bqildlmg Maintenance Required: ' Removal of the walls in the Biphenyl Dnit area is desperately needed. This report is by no means presenting the design for that undertaking because it is beyond the scope of this survey. However, the author does encourage those concerned to act upon the removal of these walls at their earliest opportunity. . Item 508: Sewers Maintenance Required: Provide sewer for benzol feed tank drain. SVV462618 WATER PCB-SD0000045419 138. August 1957 Item 509: Fire Protectioa Equipmeat Iacludimg Sprinklers Maiateaaace Required: This equipmeat is ia fairly good coaditioa but some of the equipmeat should be replaced with up-to-date equipmeat. Item 510: Grounds aad General Area Beasol Daloadiag Dock Area: Maiateaaace Required: 1. Reaev guard rail arouad task car dome sliag. . 2. Remew the 2 beazeme pipe lime supports due south of hydrogea compressor room aearest the Muriatic Acid area. 3. Kxtead feace arouad beasol storage taaka to iaclude isopropyl alcohol storage task. 4. Repair steps to aorth Beasol feed tank. 5. Repair beasol feed task dike. 6. Remove the float valve from the sump pump at the coacrete dikes arouad sump taaka aad beasol receiver. Provide a manual switch so the water cam be draiaed frost this dike. (A project has beea submitted for the reaeval of the Bipheayl traasfer liae aad the pipe supports.) Item. 511: Paiatiag Maiateaaace Required: Paiatiag of the Bipheayl Flaat is, ia geaeral, aeeded. This, however, is beyoad the scope of this survey. Paiatiag ia this area should be oa a scheduled basis aad should begla iwaedlately. DSW 462619 WATER PCB-SD0000045420 Item 512: Insulation Maintenance Required: Item 513: CO^ Piping Maintenance Required: 139. August 1957 Insulate: 1. all lines between vaporizer coils and Ho, 1 preheater 2. all lines between the Ho. 1 preheater and the No. 2 preheater 3. all lines between the Ho. 2 preheaters and the converters! and 4. all lines between the converters and the columns. Insulate al1 steam jacket piping. (A project has been approved for the installation of CO2 distribution piping. Consequently, no recommendations for in proving the present system will be a&de.) DSW 462620 WATER PCB-SD0000045421