SOSO
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ORGANIC CONTAMINATION OF STEAM SYSTEM
BY:
T. Meyer
DATE: 3/26/91
REV: 10/20/08
Review Date: 04/02/12
DEPT: Operations
REV #: 6
NO. I-D-05.70
STATEMENT OF PROCEDURE
Potential problem areas in the Plant are organic lines and vessels that can develop equal
or greater pressures than the 50 psig steam system which can be used to clear the
equipment of organic liquids and polymers.
Organics in the steam system can do severe damage to mechanical equipment, i.e.
boilers, turbines and steam lines.
PROCEDURE
1.
2.
When organics contaminate the steam system, the following conditions occur:
a.
Boiler and condensate pH's decrease causing corrosion throughout the
system.
b.
Conductivity increases causing deposits throughout the system to form.
c.
Foaming can occur causing false condensate flows and level indications.
To eliminate organic contamination, the following steps must be taken
immediately. Note: SOP 1-W-08.73 (Organic Contamination of the Steam
System) has specific steps to be taken in the Acrylo Block.
a.
Notify area Shift Manager and the Production Manager or his designee
immediately of the situation and eliminate the condition causing the
contamination.
b.
Divert the 50 pound steam flash drum blowdown from the Cooling Tower to
the waste drain system.
c.
Depending on the degree of contamination, blowdown the reactor steam
drums, boilers and condensate system to the waste drain. Open live steam
to the recovery column, the quench contactors, and the quench strippers.
Start 10,000 to 30,000 lb/hr to the AOGI's.
d.
Foam the waste drain system if necessary to reduce vapors and fire hazard.
e.
Steam traps with discharge to the ground must be checked for organics
Acrylo, Aceto, HCN or whatever chemical contaminated the steam system if
necessary steam trap should be blocked.
I-D-05.70
SOSO
f.
Consideration must be given to cancel Hot Work Permit to reduce the fire
hazard. (Sound Alarm)
g.
Make a map (drawing) indicating the affected area(s) and develop a plan to
continue to check these areas until it is considered "safe".
**NOTE:
3.
B, C, & D are needed to minimize and/or eliminate atmospheric
contamination. DO NOT BLOWDOWN TO THE DITCH.
To prevent steam contamination, one must consider the operational equipment
needing use of the steam system other than NORMAL operation.
a.
Do not connect steam out lines to any equipment having higher or equal
pressure which is in service such as closed vessels and pump discharge
lines.
b.
Vessels requiring steamout must be depressured and properly vented to
the process flare or the chemical drain prior to steaming.
c.
Pump discharge lines needing steaming must be isolated and depressured
to the chemical drain prior to steaming. Some of the common pumps
having equal or greater pressure than the 50 pound steam system in the
Acrylonitrile unit, Acetone Cyanohydrin unit, and Aceto Purification unit are
listed on the following pages. This list is not all inclusive and prior to
connecting to any equipment not listed thought must be given to the
pressure and service involved.
ACRYLONITRILE UNIT PUMPS
I.
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Rev: # 6
Pump No.
Disch. Pres.
GA-102/S
GA-202/S
GA-3003/S
150 psig
150 psig
150 psig
GA-103/S
GA-203/S
GA-3004/S
GA-4004/S
160 psig
160 psig
160 psig
160 psig
Reactor Areas
A.
Process Condensate
1.
2.
3.
B.
#1 Train
#2 Train
#3 Train
Rich Water (to Recovery)
1.
2.
3.
4.
#1 Train
#2 Train
#3 Train
#4 Train
I-D-05.70
C.
SOSO
GA-101/S
GA-201/S
GA-3002/S
GA-4002/S
50 psig
50 psig
50 psig
50 psig
#1 Train
#2 Train
#3 Train
#4 Train
GA-104 A,B,C
GA-204 A,B,C
GA-3001 A,B,C
GA-4001A,B,C
70 psig
70 psig
70 psig
70 psig
#3 Train
#4 Train
GA-3005/S
GA-4005/S
80 psig
80 psig
GA-403/S
GA-405/S
120 psig
280 psig
GA-406/S
GA-407/S
130 psig
50 psig
GA-408/S
GA-409/S
75 psig
60 psig
GA-501/S
70 psig
GA-502/S
GA-519
80 psig
125 psig
RECOVERY AREA
A.
Recovery Column
1.
2.
B.
C.
Recovery Column Btms
Lean Water Surge Drum
Recovery Column Decanter
1.
2.
Water Boot Side
Organic Side
Aceto Fractionator
1.
2.
III.
#1 Train
#2 Train
#3 Train
#4 Train
Absorber Side System
1.
2.
II.
Disch Pres.
High Volume Recirculation
1.
2.
3.
4.
E.
Pump No.
Stripper Bottoms
1.
2.
3.
4.
D.
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Rev: # 6
Bottoms
Reflux
Purification Area
A.
Heads Column Bottom
B.
Product Column
1.
2.
Product Col. Bottoms
Product Col. Vacuum Pot
I-D-05.70
C.
SOSO
E.
Disc. Pres
Water Boot Side
Organic Side
GA-504
GA-505/S
140 psig
50 psig
Aceto Heads Column (A/H) Area
1.
2.
A/H Column Bottoms
Aceto Side Draw
GA-415X&SX
GA-416X&SX
130 psig
140 psig
3.
Overhead Condenser
GA-417X&SX
150 psig
GA-506/S
GA-603
GA-602S
50 psig
110 psig
150 psig
Acrylo Rundown Tank Area
1.
2.
3.
F.
Pump No.
Purification Decanter
1.
2.
D.
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Rev: # 6
Acrylo Transfer
Slop Water
Waste Drain
Chemical Additives
*Positive displacement pumps are capable of very high discharge pressures
1.
2.
3.
HQ (Heads Col.)
(Recovery Col.)
(Aceto Heads Col.)
MEHQ (Prod Col.)
(Rndn Tanks)
Glycolic Acid
(Heads Col.)
(Aceto Heads Col.)
GA-507
GA-507S
GA-510&B
GA-509&S
GA-508
Variable
" "
" "
" "
" "
GA-510&S
GA-517
" "
" "
GA-804/S
70 psig
GA-806/S
75 psig
GA-808/S
GA-810/S
GA-809/S
70 psig
50 psig
70 psig
ACETONE CYANOHYDRIN UNIT
A.
Generator Circ. Pumps
B.
Dilute Filter Feed Pumps
C.
1st Stage Pumps
1.
2.
3.
Feed Pump
Hotwell Cond. Pump
Bottoms Pumps
I-D-05.70
D.
SOSO
Page 5 of 5
Rev: # 6
Pump No.
Disc. Pres.
GA-812/S
GA-814/S
50 psig
55 psig
2nd Stage Pumps
1.
2.
Feed Pumps
Bottoms Pumps
E.
HCN Refrig. Compressor
175 psig
F.
Acetone Flush Pumps
(Positive Disp.)
Variable
G.
All Pumps in the Aceto Unit.
- Crude Rerun Pumps