Document 6BN8MdwQgNLzDbeb2jjrKe993

ABD00242956 VCM EXPOSURE REDUCTION ABERDEEN CHEMICAL PLANT November 11, 1983 * Work By: / Steve C. Hillman Process Engineer Reviewed And Approved By: R. A. Frohreich Chief Process Engineer ^iDDQoaiaocT' VCM EXPOSURE REDUCTION ABERDEEN CHEMICAL PLANT Table of Contents I. PURPOSE OF DESIGN II. DESCRIPTION OF DESIGN III. SAFETY EVALUATION IV. INSTRUMENT SPECIFICATIONS V. PIPING SCHEDULE VI. TIE-IN LIST VII. P & I DIAGRAM A ABD00242958 VCM EXPOSURE REDUCTION ABERDEEN CHEMICAL PLANT I. PURPOSE OF DESIGN The purpose of this design is to reduce the possibility of VCM overexpo sure to personnel working with equipment in the old and new module recovery systems. Also, several drains where VCM contaminated water can be drained to an open sewer will be eliminated. Routine dosimetry monitoring over the past two years shows that approxi mately 29% of the employee overexposures to vinyl chloride result when the operator or mechanic has worked with or in the area of the recovery systems. Of these recovery system overexposures, the operators or mechanics had been working with the recovery vacuum pumps and compres sors in approximately 33% of the cases and with the new module south knockout pot and south recirculation pump in 13% of the cases. Listed are recovery systems related overexposures for the period of September 1981 through August 1983. Vacuum pump and compressor related New module K.O. pot/recirculation pump related Seal water filter charge related Recovery exchanger related ERS tanks 702 & 703 related Blowdown tank strainers related Blowdown tank pumps related Blanks installed in recovery line Other recovery area related overexposures Total 17 =8 =3 4. = .2 -1 =2 = .2 = 13 52- 33% 15% 6% 7% 4% 2% 4% 4% 25% 100% To reduce the possibility of overexposure to VCM while working with recovery system equipment, isolation valves, bleeders, and drains to the blowdown tank or batch water stripper will be added to the recovery system equipment where not already existing so that the equipment can be flushed or steam stripped prior to opening. In order to facilitate draining and flushing of resin from equipment and lines where resin-could builduputility water at .100 PSIG minimum will be connected to the drain lines between two valves so that these drain lines can be flushed back to the equipment or to the blowdown tank or batch water strippers. This is the same type flushing set up that Oklahoma City has used on some of their recovery equipment with success. The piping modifications have been designed so that the following procedures can be implemented for cleaning equipment prior to opening. Compressors And Vaccum Pumps 1. Isolate the vacuum pumps and compressors with the manual valves on the inlet to the vacuum pumps and the outlet to the compressors. Isolate the compressant seal water to the units and the pressure equalization lines also. ABD00242959 VCM EXPOSURE REDUCTION ABERDEEN CHEMICAL PLANT PURPOSE OF DESIGN (Continued) Compressors and Vacuum Pumps (Continued) 2. Connect a flexible hose between the bleeder near the compressor discharge isolation valve and the local recovery line to the blow down tank or BWS. 3. Hookup a steam hose from the utility water/steam hookup point pro vided to the bleeder near the isolation valve at the vacuum pumps inlet. 4. Flush the VCM contaminated water to the BWS or blowdown tank. 5. Shut off the flush water and open the steam to the vacuum pumps and compressors and steam out the units. (Flush water to the double mechanical seals should be left running. Inboard seal water to the vacuum pumps should not.) 6. After completing recovery install blinds at the inlet and outlet of the individual unit prior to opening. Process Pumps And Filters 1. Isolate the pump and filter train on the inlet of the pump and the outlet of the filter. 2. Connect a utility flush water hose to the bleeder provided on the pump suction. 3. Line up the recovery drain line at the filter to the blowdown tank or BWS. 4. Flush through the pump and filter for several minutes. The bleeder provided on drain line can be used to flush back to the filter to remove pluggages or to help flush solids to the blowdown tank or batch water stripper. 5. After flushing, connect a steam hose to>.the same bleeder and steam out the pump and filter to remove any entrapped VCM. 6. Blind the equipment upstream and downstream prior to opening. Heat Exchangers 1. Isolate the unit on the process inlet and outlet. 2. Connect a steam hose to the bleeder provided. 3. Line up the recovery drain line to the blowdown tank or BWS. 4. Steam out the exchanger. 5. After steaming install blinds on the inlet, outlet and drain lines of the exchanger prior to opening the heads. ABD00242960 VCM EXPOSURE REDUCTION ABERDEEN CHEMICAL PLANT PURPOSE OF DESIGN (Continued) Knockout Pots 1. Isolate the vessel at the process inlet, recirculation water outlet, and water spray inlet. 2. Flush and drain the vessel to the blowdown tank or batch water stripper. 3. Isolate the flush and drain lines. 4. Connect a steam hose to the bleeders provided and recover through the vacuum pumps and compressors. 5. After recovering, isolate and blind the vessel'per the proper equipment entry procedure prior to entry. Seal Water Separators 1. Isolate the vessel at the process inlet and outlets. 2. Flush and drain the vessel and level gauge to the blowdown tank or BWS. The old and new LRS separators have HPSW piped to them. The ERS separators T-702 & T-703 will have to have a flush water hose connected at the top of the vessel. 3. Connect a steam hose to the bleeder on the water outlet on the LRS*1 separators and on the top of T-702 & T-703 and recover. The LRS's separators have recovery lines piped to them but T-702 and T-703 will be recovered through the drain line. 4. After recovery, isolate and blind the vessel per the proper equipment entry procedure prior to entry. ABD00242961 VCM EXPOSURE REDUCTION ABERDEEN CHEMICAL PLANT II. DESCRIPTION OF DESIGN* VII For a description of this design refer to the P & I Diagrams in section VII of this design. A major potential VCM overexposure problem area is the preparation and opening of the recovery vacuum pumps and compressors for maintenance. To reduce the potential for overexposure, this project will provide water flush and steam stripping connections and recovery connections so that water and steam can be flushed through these vacuum pumps and compressors to the blowdown tank or BWS to remove trapped VCM prior to opening. When steam stripping these units the double mechanical seal flush water will be left running to prevent overheating the seals. Low pressure steam, flush water, and recovery hose hookup points will be provided near the vacuum pump inlet and compressor outlet. Manual block valves will also be added on the vacuum pumps inlet and compressors outlet to prevent leakage. Another major problem in the new module recovery system is PVC carry over into the knockout pots. Resin and chunks of PVC are knocked out in these pots by circulating water. The resin and chunks plug the pump and knockout tanks. Currently, there is no method of removing solids and chunks from the system. The pumps plug often and must be taken out of service and cleaned out. Each time the pump is cleaned, there exists the potential for overexposure. A backflush filter to remove solids from the seal water system will be installed with the Recovery System Revisions Project under AFE 9771. However, there will still not be adequate means of flushing resin and chunks from the knockout pots. This design will install a 4 inch drain line from the bottom of the knockout pots to the blowdown tank. This line will gravity drain and will have utility water connections for flushing. The south knockout pot has a small standpipe in it on the suction to the recirculation pump. This standpipe will be extended to 24 inches and a 24 inch standpipe will be installed in the north knockout pot. With these measures, material can safely be routinely removed from the knockout pots with minimal possibility of overexposure. Presently, on much of the recovery system equipment there are inade quate connections and drains for flushing and recovery prior to opening for maintenance. To facilitate draining and recovery of individual pieces of equipment, enclosed drains to the blowdown tank or BWS have been added where none existed. Also, to improve draining and flushing of equipment and lines where a potential for resin build up exists, a bleeder will be tied in to the drain lines between two valves so that the lines can be flushed either back to the equipment to unplug the outlet or to the blowdown tank or BWS. Connections for flush water and steam will also be added to the new module seal water coolers, new module recirculation cooler, the old module seal water pumps, the blowdown tank strainers, and T-702 and T-703 in the ERS so that they can be flushed or steamed through prior to being opened. 4 ABD00242962 VCM EXPOSURE REDUCTION ABERDEEN CHEMICAL PLANT DESCRIPTION OF DESIGN (Continued) The outlet of the old module seal water separators sight glasses will be piped to drain to the BWS. The existing water makeup and flush to the new module knockout pots are 2" process water connections. At times, the pressure in the knockout pots exceeds process water pressure and VCM has backed up into the process water header. In order to eliminate this problem and also improve solids flushing capabilities, two 1 inch utility water connections will be installed on each new module knockout pot. These connections will tie into each knockout pot tangentially- at 180 apart and below the normal liquid level in the area where solids accumulate. This will aid in flushing solids and chunks of PVC out of the knockout pots. The utility water for flushing will be supplied at 100 to 120 PSIG by the Utility Water System project to be AFE'd in the first quarter of 1984. In the old and new module recovery systems there are several drains where contaminated water can be drained to an open sewer. With the improvements in enclosed drains to the blowdown tank and batchwater strippers these open drains will be removed from service and the valves blinded. ABD00242963 A VCM EXPOSURE REDUCTION ABERDEEN CHEMICAL Pt.amt III. SAFETY EVALUATION The purpose of this design is to provide adequate connections and drains so that recovery system equipment can be flushed, stripped, and drained to prevent possible VCM overexposure when the equipment is opened. Safety is the main consideration in making the modifications of this design. Major design safety considerations are: 1. Providing sufficient isolation valves> flush water/st;eain connections, and drains to the batch water strippers or the blowdown tank so that equipment can be isolated flushed, steam stripped, and drained prior to being' opened for maintenance. 2. Providing utility water bleeders and isolation valves on drains so that pluggages can be fiushed either back to the equipment or to the blowdown tank or batch water strippers. 3. Enlarging the new module knockout pot drains to 4 inches diameter, installing standpipes 0n the suction to the recirculation pumps and installing tangential flush nozzles to allow resin and chunks to be flushed and drained routinely so that these Pots or downstream equipment will not have to be oPened for cleanout of pluggage. 4. Eliminating several drains where VCM contaminated water can be drained to an open sewer. With this design, attention should be giVen t0 the following ltems ln order to maintain personnel safety. A. Proper lift techniques should be followed when handling flush water and steam hoses. B. Avoid contact with hot surfaces during steam stripping of equipment. C. Care should be taken to maintain a l0w pressure on the Bingham vacuum pumps in both recovery systems, since these units have only been hydrotested to 35 PSIG when constructed. ADD002I290I A CONOCO PI ANT A&Ffl.btttr ENGINEERING CENTER date /c--23 B. M. NO. PONCA CITY, OKLAHOMA A. F. E. NO__________ SPECIFICATION SHEET CONTROL VALVES W. Q. NO. ___________ REQ. NO. ___________ MADE BY A/ INO. NO. P. O. NO. PROJECT VtM EXPOSURE PEJCUCmOhf GENFRAL 1 ITEM NO. & TAG 2 SERVICE 3 LINE SIZE 4 MANUFACTURER 5 MODEL NO. 6 C1/-/0/ Cl/- lo-Z. CV - Zo/ C t/- Zx?Z. P/?F^ PttitSCT/DsJ fkttf?e-rxJzr/<vi PPTSS Pc/jUCT/bfJ Pr+r^. ft * PifL TEA n> STfiAn r vl/mTA Pfi/L S *->ja Av fz>r A /" A* \* t" P /SAsr P P/SPPP. IT u <75 (- 9s-* 9&A- SERVICE CONDITIONS 7 FLUID B TEMP *F NORMAL MAX. 9 PRESS., INLET.. NORMAL MAX. io A P MIN. NORMAL MAX. 1 1 MOLECULAR WEIGHT `A.P.I. 12 SP. GR. ; 60'F. 13 WEIGHT Z VAPOR iN ft4 VISCOSITY *> F.T. P. S F T. OUT -- /$ /S2 A2a C?,0<5 / /Oa stham/watbg ZUa 1 /a 1 I /sJz <2 / 2<=> G.OQ / /o gr&4M/ '2-G>& 3 62 1/-<? so JZo /Z '>,00/ Z&>o 36 <& /0 /3> /r 0.00 / /Q O 15 RATE. NOR.. LB/HR. (SCFH) GPM 16 RATE. MAX.. L8/HR (SCFHl GPM 17 NORMAL FLOW Cv ia Outi.pt PPPSSi/PP BODY 19 BODY SIZE PORT SIZE 20 TYPE (ANGLE OR GLOBE) 21 MATERIAL 22 END CONNECTIONS 23 BONNET 24 Cv 25 LUBRICATOR 26 PACKING ISO. VAL. 1C fsuz f" a) 35 7" SC.tLhrJ.GrQ ZQ PS/fC, f\ Cj) As 1" Sc/t&JCD "3 PsfC, /" 1 a) ss l " OLG*)Q 7^0 PSfG* f" 1 u) 55 l" SCG&*J^ 27 TRAVEL INDICATOR 29 TRIM l ` " i l 129 TYPE INNER VAL. ) NO. OF PORTS 30 PLUG ft SEAT MATERIAL 31 32 TYPE ACTUATOR 33 FAILURE POSITION 34 POSIT ONER 35 INPUT SIGNAL OUTPUT SIGNAL 36 BYPASS GAUGES 37 MANUFACTURER 38 MOOEL NO. ACCESSORIES 39 NOTES: (ij jz (it A SCLP Of&UZTEQ STcfrr^ Rec-uowc. /2.<SGvfc-ATOfL. fz) C'J -/OZ C-'J-UO'L. WIf-L PR&\/iC>- fb^CXuP ?P0TB<JTiO^ I* OF FAILURE. IfJ CV'tOl I/-2.01, ( ) INDICATES ITCM C-ANGED ON LATEST REVISION.. IX) INOICATES MANUFACTURER TO GIVE REOUFSTFn INFORMATION IN NIA OtJOTATION FMFFT nc DPI/ --435--S A CONOCO ENGINEERING CENTER PONCA CITY, OKLAHOMA DATE __________ a. M. NO. A. F. E. NO. ___________________________________ SPECIFICATION SHEET CONTROL VALVES pi AMT Ate/t DTTP' CP/zrfTir A/. A/_/iA7~ W. Q. NO. INQ. NO. PROJECT REQ, NO. P. O. NO. . MADE BY Cc A/_______ APP'D BY V'CM EXPOSURE. PEJOUCTIOM GENERAL 1 ITEM NO. 6 TAG 2 SERVICE 3 LINE SIZE 4 MANUFACTURER S MODEL NO. 6 C i/~ to / PtfL STgArt't-WATEU /" A'/ZArTf* 7-r" L. Cl/' / 0 ^ Ci/ - 2.0/ C '/- 2-OZ. Rmur.r/.-'j 7 /?OUCT/W y-^rT 7 PAvrp /" /'W.F/? T7/Z 5 v->Ji -V r r`/A'-/Z of CVWl*- v4- h/\-0 f" A/SAPP SERVICE CONDITIONS 7 FLUID 715AM/ir/A72Sfi> STEAM/wATEA S TEMP. 'F NORMAL MAX. 9 PRESS., INLET., NORMAL MAX, IO A P MIN. NORMAL MAX. 11 MOLECULAR WEIGHT A.P.I. 3*^ / S2& Z-l.^CZ / />' A 1 / i'd 12 SP. OR. 60'F, 13 WEIGHT Z VAPOR iN 14 VISCOSITY 1' F T. a P. ft F.T. OUT fi/.CC / /0 C <r..ca / /o 4T&4A1/ / UJAT&F AYbcO> Z.&& | 34 <2 L /C2? / / 2j? /S'o -/0 /3 c 0,02/ / 20 /? - 0.0a f SOo 15 RATE. NOR.. LB/HR. (SCFHl GPM 16 RATE. MAX.. L9/HR (SCFHl GPM 17 NORMAL FLOW Cv 518 Ou 7-/. er T PP/TS u&P BODY 19 BOOY SIZE PORT SIZE 20 TYPE 1ANGLE OR GLOBE! 21 MATERIAL 22 END CONNECTIONS 23 BONNET 24 Cv 25 LUBRICATOR ISO. VAL. 26 PACKING 27 TRAVEL INDICATOR 28 1 0 ps fa r| cO 55 7" SCZf.i'J&O 7,0 / / 0) <-7 /" ScPTUCO 3 0 /V/C /" 1 a) $5 r za> r' 1 to 5 -5 /" sc/psweci TRIM 129 TYPE INNER VAL. | NO. OF PORTS 1 ,| 1 30 PLUG a SEAT MATERIAL 31 32 TYPE ACTUATOR 33 FAILURE POSITION 34 POSIT ONER 35 INPUT SIGNAL OUTPUT SIGNAL 36 BYPASS GAUGES 37 MANUFACTURER 38 MODEL NO. ACCESSORIES 39 notes: (;) 7- f_V ^ jTrS-^iUp1 Aecyc/wc, Ai-SG>y^-Aror-. 1) C'J~/J7_ /4/VO CK/-ZOZ. YJii-L Pfto>\ltO& fefiCKuP ?Q T&crrsoO Op DiAPM/PAi^ C7`Oj .C, Cl < 1 INDICATES ITEM C'-ANCEO ON LATEST REVISION.. I I (*) INDICATES MANUFACTURER TO GIVE REQUESTED INFORMATION IN MIS QUOTATION. I SMPRT Pi ANT CONOCO ENGINEERING CENTER PONCA CITY. OKLAHOMA SPECIFICATION SHEET PRESSURE GAUGES C. A\ PROJECT VC A F t NO_____ , . DATE 'll O NO MAOC BY -S^W INO NO APP0 W.EAJ?..-- UtO NO H M NO___________ P O NO fr'C t's .V.CT'. 1 TAG 2 NO. 3 /=vZi-/& s 4 -/-r/ 5 G 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 2G 37 33 39 4(J 4) 42 43 44 451 46l 4/| 43! 491 501 5ll SERVICE 4S / isyyZ ~nrrj<* v //// W/C 0 1 !v s :Y instrument_ OPERATING. range. PSIG PRESS. PSIG '4 3o OPERATING TEMP., op ..2,7 s:... 2.7^ LOCATION t-SL-./C.b _________ 1_=_S_cjr. X e_?________ _ - - ------------- ------------------------ -------------- -- ---- --------------- ............ .......... -- -- -- --........................ ------------------------------- L-------------------------- ----------- ... -- -- - ------------ -- -- 52! 551 _Ai. QUOTATION WILL NOT BE CONSIDERED if SuPHUt RDOES NOT COMPl t T F RIGHT HANP COLUMN SHft! Of rv,, i '-j jl ; ta jjj QJ * * ~<L ,5 > "s. \0 o 4J 0 'H c W O >3 Ifl U H Q Cl. a. N ja Cd g C 15 uQi <a, Id Q u w 2 o 22 M a. W lj U l-i on 01 o 5 Ui uu c: a. 05 on Id y OC a* _y ABD00242967 >" <* Q) CNC c03 I ;; V.* 4. X o1 !' i O G) JJ 0? -r~i C U 0 'fa ffl Vj H Q tx a, ) 5 v p Qi < ail) aLU* XQ U w c? 2 2 MU SB CU VH o to 2 u) G u y CO O oo c: u; a- r) o a; (X * -V_ 1111 i'i i VCM EXPOSURE REDUCTION ABERDEEN CHEMICAL PLANT V. TIE-IN LIST 1. Replace the existing 2 inch drain nozzles on the new module knockout pots with 4 inch nozzles and run lines 4-HM-101 and 4-HM-102 from ' the knockout pots to the blowdown tank. These lines should be made free draining as possible since solids could accumulate. 2. Install two tangential nozzles on each new module knockout pot at 6 inches above the bottom straight wall and connect lines 2-WP-107, l-WP-109, 2-WP-110, and l-WP-112. These nozzles should be 180 apart and in the opposite direction of the process inlet. Remove the existing process water connections. 3. Tie 1 inch utility water flush bleeders into the drain lines for the following equipment: a. New module recirculation cooler drain. b. Nnew module east seal water cooler drain. c. New module north seal water separator drain. d. New module north seal water filter drain. e. New module west seal water cooler drain. f. New module south seal water separator drain. g. New module south seal water filter drain. h. Old module recirculation pumps drain. i. Old module south seal water separator drain. j. Oid module north seal water separator drain. k. Old module knockout pots drain. l. New module recirculation pumps drain line. 4. Install drain lines l-HM-103 and l-HM-104 from the blowdown strainers to line 4-HM-101. 5. Install drain line l-HM-105 from the new module vacuum compressors area to the existing drain line to the blowdown tank. 6. Install isolation valves on the following lines: a. The process inlet and outlet to the N.M. recirculation cooler. b. The drain line from the N.M. east seal water cooler. c. The drain line from the N.M. west seal water cooler. d. The drain line from the N.M. east seal water filter. e. The drain line from the N.M. west seal water filter. f. The process outlet from the N.M. east seal water filter. g. The process outlet from the N.M. west seal water filter. h. The old module knockout pots 2 inch drain line. i. The process inlet to the old and new module vacuum pumps. j. The compressant seal water inlets for the new module vacuum pumps and compressors and the old module compressors. k. The process inlet to the O.M. north seal water filter. l. The drain from the ERS tank T-703. m. The process outlet from the new module compressors. ABD00242970 VCM EXPOSURE REDUCTION ABERDEEN. CHEMICAL PLANT TIE-IN LIST (Continued) 7., Install 1 inch bleeder connections for steam and flush water on the following lines: a. The new module recirculation cooler process inlet. b. The old module seal water separators outlets. c. The old module seal water pumps inlets. d. The old units seal water filters. e. The blowdown tank strainers outlets. f. The inlet line to the new module vacuum pumps down stream of the new isolation valve. g. The outlet line from the new module compressors upstream of the new isolation valve. h. The old module recovery compressors outlets. i. The old module recovery vacuum pumps inlets and outlets. j. T-702 and T-703 in the emission recovery system. 8. Tie in the following drain lines in the old module to the existing drain to the batch water strippers. a. Line 3/4-HM-206 from the seal water separators level instrument drains. b. Lines 2-HM-201 and 2-HM-202 from the seal water filter outlets. c. Line 2-HM-205 from the recirculation cooler outlet. d. Line l-HM-208 from the LRS vac pumps and compressors area. e. Line 2-HM-207 from ERS separator T-702. f. Lines 2-HM-203 and 2-HM-204 from the seal water coolers. 9. Blind the drains to open sewers from the following equipment. a. New module recirculation cooler. b. New module seal water coolers. c. New module seal water separators. d. New module seal water filters. e. Old module seal water separators level instruments. f. New module knockout pots.