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VCM GAS MONITORING SYSTEM VCM TANK FARM AREA ABERDEEN CHEMICAL PLANT MARCH 8, 1985 A Work By Lcrvtvo- Frank G. Jeanson Process Engineer 1 Reviewed By: L',vWUk r Vernon L. Thornhill Senior Process Engineer Approved By: R. A. Frohreich Chief Process Engineer \ VAB.0001106271 VCM GAS MONITORING SYSTEM VCM TANK FARM AREA ABERDEEN CHEMICAL PLANT Table of Contents I. Purpose of Design II. Process Description III. Equipment and Instrument Specifications IV. Process Piping Schedule V. Work List VI. P&I Diagram mf VAB.0001106272 i 4 -r VCM GAS MONITORING SYSTEM RAILCAR UNLOADING AREA ABERDEEN CHEMICAL PLANT I. Purpose of Design The purpose of this design is to provide the VCM railcar unloading area with an additional gas monitoring system to detect serious VCM releases. Presently, there are six fixed point monitor locations that are tied into one of the plant's Honeywell GC's. These monitor locations are listed below: 1. Sphere (grade level). 2. Compressor shed (grade level). 3. Between railcar unloading stations number 1 and 6 (Top of railcar level). 4. Between railcar unloading stations number 2 and 7 (Top of railcar level). 5. Between railcar unloading stations number 3 and 8 (Top of railcar level). 6. Between railcar unloading stations number 4 and 9 (Top of railcar level). These existing monitors do not provide immediate response and are not distributed throughout the entire VCM tank farm area. Also, since this area is not monitored by plant personnel the majority of the time and since it has the potential for a serious release, additional protec tion is needed. In addition to the gas monitoring system, this design will provide a pressurization blower for the fire pump houses near the VCM tank farm. The purpose of this blower is to prevent VCM from entering the build ings in the event of a serious VCM leak. This design will also provide for Item 84-6 of the Underwriter's In surance Company recommendations. This item recommended installing vapor detectors for the sphere's VCM transfer pumps to the old and new module. mih mmm VAB.0001106273 VCM GAS MONITORING SYSTEM VCM TANK FARM AREA ABERDEEN CHEMICAL PLANT A II. Process Description This design will provide for the installation of ten VCM gas sen sors, AT-101 through AT-110, in the VCM tank farm area (see P&I dia gram for locations). These sensors will be tied into dual channel combustible gas monitors, AI-121 through 125. Each monitor will accept signals from two sensors and display the higher of the two readings. The monitors will indicate the percent of the lower ex plosive limit (LEL) of VCM gas in the air. The monitors will be tied into alarms in the vinyl control room. The first alarm will be set at 25% LEL and the second alarm will be set at 45% LEL. Should any of the monitors indicate a low level (25% LEL) of VCM gas in the air, the panel operator will notify the yard operator of the situation. If the monitors indicate a high level (45% LEL) of VCM gas in the air, the panel operator will then notify the yard operator to shut down any transfer or unloading equipment that is being used. When this equipment is off, the panel operator will isolate the sphere by pushing the sphere control valve override switch. This switch will close the following valves: (1) The valve on the vapor line to/from the compressors. (2) The valve on the liquid line from the compressors. (3) The valve on the liquid line to the VCM transfer pumps. (4) The valve on the liquid recirculation line from the VCM transfer pumps. The monitors will be equipped with relay connections to tie into the existing sphere isolation control valve override switch. However, the relay connection will not be tied into this switch until the REMOTE OPERATING VALVES project is installed. When this project is installed, additional equipment and valves will be shut off by the sphere isolation control valve override switch. This includes: (1) The valve on the liquid return line from the VCM vapor line knockout pot. (2) The five VCM compressors in the VCM tank farm. (3) The two VCM transfer pumps. After installation of this project, the relay connections from the gas monitors will be tred into the sphere control valve override switch. Should the monitors Indicate a high level (45% LEL) of VCM gas in the air, the sphere control valve override switch will automatically shut off all the valves ahd equipment mentioned above. When the isolation switch is used, it will override the motor con trols and shut down the units should they be in service. VAB.0001106274 VCM GAS MONITORING SYSTEM VCM TANK FARM AREA ABERDEEN CHEMICAL PLANT II. Process Description - Continued In addition to the vapor monitors, a pressurization blower, F-150, will be Installed for the fire pump houses. This blower will pro vide air to pressurize fire pump houses #1, #2, #3, and #4. Pressurizing the fire pump houses will prevent any VCM from entering the buildings in the event of a serious VCM leak. The blower*s controls will be tied into the 25% LEL alarm in the con trol room so that when this alarm goes off, the blower starts. The blower was sized to maintain a 0.25 inch of water pressure in the buildings while providing enough air to the diesel engines for combustion. This blower will be equipped with an extended inlet stack to provide VCM free air in the event of a serious release. A VAB.0001106275 VCM GAS MONITORING SYSTEM VCM TANK FARM AREA ABERDEEN CHEMICAL PLANT Instrument Specifications Item No. Description AI-121 AI-122 AI-123 AI-124 AI-125 VCM transfer pumps gas monitor South unloading stations gas molntor Middle unloading stations gas monitor North unloading stations gas monitor Compressor shed gas monitor AT-101 AT-102 AT-103 AT-104 AT-105 AT-106 AT-107 AT-108 AT-109 AT-110 Gas sensor north of VCM transfer pumps Gas sensor east of actuated valves Gas sensor south of unloading stations Gas sensor between #1 and #6 unloading stations Gas sensor between #2 and #7 unloading stations Gas sensor between #3 and #8 unloading stations Gas sensor between #4 and #9 unloading stations Gas sensor north of unloading stations Gas sensor north of compressor shed Gas sensor north of VCM sphere F-150 Fire pump house pressurization blower HS-130 Handswltch for F-150 w f t * m- rar-fl A MONITORS, INC 3037 ENTERPRISE STREET COSTA MESA. CALIFORNIA 02626 PHONE: (714) 6404806 TWX 678 372 TO: Nr. Prank Jenson Vista Polymers Box 91 Aberdeen, MS Your Reference: verbal request of 30 Janua: ITEM DESCRIPTION 1985 Date: 30 January 1985 GMI QUOTATION NO: 6150 QUANTITY Please Reference GMI Quote No On All Correspondence. UNIT PRICE EXT. PRICE Model 580 System to include one Dual Channel Monitor, 2 ea Sensor P/N 10001*1, 2 ea Sensor Bousing P/N 10007 and 1 ea Instruction Manual. Standard Relay Configuration. *Common Alarm Relays Alternate System Model 610 System to include one Four Channel Monitor, 4 ea Sensor P/N 10001-1, 4 ea Sensor Housing P/N 10007 and 1 ea Instruction Manual. Standard Relay Configuration. *Common alarm relays for all Four Channels. Common alarm set point adjustment. Note: For a discrete set of alarm relays (Malfunction Low and High) for each channel plus discrete alarm set point adjustment add $470.00 to unit price of item #1A. lb. Alternate System Model 4800 system to include one 16 Channel Monitor, 1 ea Extender Card for Channel Card and one for relay card and one Instruction Manual. Blank Panels included at N/C for inactive channels. Each active channel to include one each channel control card. Relay 6 ea X. 3 ea $1,764.00 $10,584.00 $2,973.00 $ 8,919.00 Signature: Name/Title Local Representative Address Sheet No Phone Sheets var nnm 106778 ^ J" T ' VI ; ' &" : rv"n Tjwdfc . * r1 b v- 3037 ENTERPRISE STREET COSTA MESA. CALIFORNIA 82026 PHONE: 1714) S40-4EM TWX 878-372 INC !>- r -%pt . Ji, * 'T l-A'VtaH- . x. - >.. -i L. rr * f.^r" ""J*P V 'i'-Jfl *yv-' l at"; :. .v h.J^' fc 4 TO: Mr. Frank Jenson Vista polymers Bock 91 Aberdeen, MS Your Reference: Verbal reguest of 30 January 1985 ITEM DESCRIPTION Date 30 January 1985 GMI QUOTATION NO 6150 QUANTITY Please Reference GMI Quote No On All Correspondence. UNIT PRICE EXT. PRICE Card, Sensor P/N 10001-1 and Sensor Housing P/N 10007. 11 active channels Standard Relay Configuration* Mote: The Standard Relay Configuration is Malfunction. SPDT, non-latching, energised Low Alarm . DPDT, non-latching, de-energized. High Alarm. DPDT, latching, de-energized. other relay options (Latching and energized) are available.** **Model 4800 Low & High alarm Relays are SPDT, add $22.00 for each active channel in Item #lb. DPDT $11,784.00 $11,784.00 $12,597.00 $12,597.00 $13,410.00 $13,410.00 $14,223.00 $14,223.00 $15,036.00 $15,036.00 $15,849.00 $15,849.00 Signature: Name/Title Ken Kaub Local Representative Address Phone Sheets VAB.0001106279 % Description General Monitors' Model 580 is a compact highly-versatile system for contin uously monitoring combustible gas concen trations in two locations. The system consists of two remote sensing assemblies and a solid-state controller. For safety, reliability, and ease of calibration, sensor outputs are not summed. Each channel is completely independent and has its own constant current sensor drive circuit. Sensors are available to meet various service requirements for most gases. The Model 580 independently moni tors two locations. The controller automati cally displays the higher reading channel on an analog meter, scaled from 0-100% LEL (Lower Explosive Limit). Manual over ride switching permits readout of the low channel at any time. Low and high alarm set-points are common to both channels. Calibration of each channel is done inde pendently, and an alarm override switch disables the alarms during the calibration mode. A 45 second time delay also disables the alarms on start-up. Customers may select from a wide variety of relay options, such as normally energized or de-energized high and low alarms, and latching or non-latching high and low alarms. The malfunction relay circuitry is normally energized and monitors both channels. Features "Peak Picking" Circuitry Automatically displays highest reading channel Compact Packaging Dimensions: 2WW x7"H x11.5wD (51 mm W x178 mm H x 292 mm D) Low Power Consumption Analog Meter Standard Independent 3 AMP/117 VAC DPDT High and Low Alarm Relays 3 AMP/T17 VAC SPDT Malfunction Alarm Relay Variety of Relay Options Normally energized or de-energized high and low alarm Latching or non-latching high and low alarm Remote Reset Superior Reliability Two week factory burn-in of system Single PC. board Solid-state circuitry Proven catalytic sensor Malfunction alarm circuitry Positive contact field terminals Time delay Constant current supply to sensor U Safe, Easy Calibration Fully accessible calibration adjustments Alarm relays automatically disabled while in calibration mode Low Cable Costs 40 ohm loop resistance, e g. 3000 ft. (910 meters) one way of #18 AWG cable 7600 ft. (2320 meters) one way of #14 AWG cable User Protection Two year warranty CSA approved Applications -- Protection from hazardous combustible gases in: Fuel Loading Facilities Compressor Stations LNG Processing and Storage Oil Well Logging L_i Sewage Plants _ Gas Turbine Enclosures Drilling and Production Platforms Solvent Vapors Sensor E lements General Monitors' sensors are designed for reliable performance and long life. Each sensor must undergo extensive burn-in and rigid quality control procedures before shipment. The sensors consist of two catalytic bead elements in a balanced Wheatstone bridge circuit (See Principle of Operation). These low temperature catalytic bead sensing elements require minimal sensor excitation current, greatly increasing sensor life. Principle of Operation A cataiytically treated ceramic active bead and a passivated ceramic reference bead form two legs of a Wheatstone bridge circuit Combustible gases diffuse through a flame arrestor and oxidize on the cataiyti cally treated active bead, causing an increase in its temperature and electrical resistance. This results in an unbalancing of the Wheatstone bridge circuit. The reference bead, inert to combustible gases, compen sates for ambient temperature, humidity and pressure changes. The difference in resistance of the active and reference beads is converted into a sensor signal which is amplified in the controller, sent to the indicator and alarm circuits, and displayed on an analog meter. The meter is scaled in percent of the Lower Explosive Limit (% LEL). In the Model 580 the two sensor inputs are continuously compared, the higher signal being displayed on the meter. Two adjustable electronic alarm circuits may be field-set for any alarm level up to 100% LEL. The low alarm signal indicates potentially hazardous gas accumu lations at low concentrations, allowing time for corrective action. The high alarm signal indicates immediate danger A flashing malfunction LED will indicate low input power, sensor removal or damage, "CAL'' mode, severed cable or current failure. Two LED channel indicators are provided to indicate the higher channel A variety of alarm relay options provides contacts for high, lowland, . n.oon malfunction alarms to be wi>eotc?MiQI?Q?y^^^^ lamps, horns, fans or shut-down eouioment. \\ : > i- lftMi* Analog output meter with linear seal* calibrated in tha percent oi tower Explosive Limit (% LEU Used (or normal operation or ciMbration When in the "CAL" mode high and low alarms are disabled. Status Indicators HIGH alarm -- flashing red LED LOW alarm -- flashing amber LED READY (power on)--steady green LED MALE (malfunction)--flashing amber LED *High channel indicators--green LED's Channel select switch--blade button HIGH and LOW alarms--set point adjustments located on circuit board SPAN and ZERO adjustments for each channel accessible through front panel RmaHultari Used for manual reset of latching high and low alarm circuits. Height 7* (178 mm) 5S0 4 -Jr mu i Width 7 (51 mm) Depth tl .5* (292 mm) Calibration By placing the recessed toggle switch on the front panel to the calibration mode, the high and low alarm relays are held in standby condition and the "MALF" LED flashes. Zero and span pots are accessible from the front panel Calibration is accom plished by adjusting the meter to zero and exposing one of the two sensors to a known concentration calibration gas and adjusting the meter with the span pot to indicate the concentration The alarm adjustments are located on the side of the controller to prevent tampering. Relay Options The versatility of the Model 580 is enhanced bv the availability of different relay operat ing modes for specific user requirements. These relay options include normally energized or de-energized high and low alarms, latching or non-latching high and low alarms and sealed relays CSA performance certified to C22.2 No. 152-1976 Controller Specifications Mounting Options: Rack, panel and wall Dimensions: 2"W x 7"H x 11 5"D (51 mm W x 178 mm H x 292 mm D( Weight: 4 lbs (180 kg) Temperature Range: 0F to 150F(--18C to +bbC) PoWf* 117 VAC 15% (220 VAC 15% optional), 50-60 Hz. 22-30 VDC, 8 watts nominal Meter Range: 0-100% Lower Explosive Limit (% LEL) Repeatability: 2% full scale Linearity: 5% full scale Alarm Circuits: High, low and malfunction: Standard high and low DPDT 3 AMP' 117 VAC resistive, malfunction SPDT 3 AMP/117 VAC resistive, high and low normally de-energized, malfunction normally energized LED Status Indicators: Flashing red for high alarm, flashing amber for low alarm, green for ready (power on), flashing amber for malfunction, flashing amber for calibration mode, steady green for each channel indicator Electrical Classification: General purpose for mounting in nonhazardous area Warranty: Two years Sensor Specifications Type: Continuous diffusion, low temperature catalytic bead. Standard Industrial Hydrocarbon Sensor, High Temperature Standard Industrial Hydrocarbon Sensor. Temperature Range: -65F to 200PF(-55C to +93*0; High Temperature Sensor to 400PF (200PC) Response Time: Typically 6-second time constant when exposed to 50% LEL of methane gas Zero Drift: Less than 5% per year Life: 3 to 4 years, normal service Electrical C lassification: NEC and CSA, Class I, Division 1. Croup B. C and D: VDE 0171 (Ex) sd 3n G5 Warranty: Two years Cable Length: Maximum 3 wire cable length allow able between controller and sensor assembly with one way resistance of 20 ohms (total 40 ohms loop) AWG 20 18 16 14 FEET 1900 3000 4800 7600 METERS 580 910 1460 2320 Represented by: 3037 Enleronse Street Costa Mesa. CA 92626 Tel (714) 540-4895 Telex 678-372 FAX 106281 VAB.OOOl tee 282 i t1 t p*w VCtA feAll-C-ML nbl^a VAB.0001106284 J ui t: J. 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