The URL can be used to link to this page

Report o.q - 00L4 O o - si- k I) alSZ 10 r i co,Po;a,ion l November 13, 2009 HAZARDOUS LOCATION ELECTRICAL EQUIPMENT BOUNDARIES Prepared By Scott Stookey - Technical Consultant to PIas2Fue1 Corporation introduction PIas2Fuel Corporation (P2F) utilizes a proprietary process that extracts aliphatic hydrocarbons from recycled plastics. This is accomplished using a Plastic Recovery Unit (PRU). Each PRU creates ho t vapor that is routed to synthetic crude oil condenser that condenses the vapor into crude oil emulsion using water. A single condenser contains no more than 40 gallons of synthetic crude oil emulsion. The synthetic crude oil emulsion is pumped via a closed piping system to an outdoor 800 gallon vertical aboveground oil settling tank for final processing and subsequent transfer to an exterior 12,000 gallon horizontal aboveground storage tank. The synthetic crude oil is transferred by a pump and hose to a DOT 406 tank vehicle for transportation and sale to a refinery. Hazardous Locations (HAZLOC) are areas of a system in which electrical equipment is classified to ensure that when it is properly specified and installed, it does not constitute a potential source of ignition. Requirements for the classification and installation of HAZLOC equipment are set forth in Oregon State Fire Code (2006 international Fire. Code (IFCJ) Chapter 34, and Articles 500 through 504 of NFPA 70; National Electrical Code (NEC). This analysis is based on the 2008 edition of the NEC. Supplemental criterion in the 2004 edition of NFPA 497, Recommended Practice for the Classification of Flammable Liquids, Gases, or Vapors and of Hazardous (Classified) Locations for Electrical Installations in Chemical Process Areas and NFPA 499, Classification of Combustible Dusts and of Hazardous (Classified) Locations for Electrical installations in Chemical Process Areas, 2007 edition was also utilized. NEC Section 500.4(A) requires all areas d esignatedas hazardous locations be properly documented. This documentation must be made available to those authorized to design, install, inspect, maintain or operate electrical equipment at the location. HAZLOCs are classified in the P2F system are based on the properties of the flammable vapor, vapor produced by synthetic crude oil and vapors produced by the oil -water emulsion. The P2F process is divided into seven separate sections for the purpose of assigning hazardous location electrical equipment boundaries. Separating the equipment and its associated components allows for analysis to determine if hazardous location boundaries need to be established for each of the major operating elements in the P2F process and is allowed by NEC Section 500.5(A). Hazardous Location Ectuinment Designation In its finished form synthetic crude oil is classified as a Class IB flammable liquid in accordance with Section 3402.1 of the 2006 IFC. Synthetic crude oil has a vapor density of 3 -5, based on the P2F synthetic crude oil MSDS, making the vapor heavier- than -air. Based on this classification, electrical equipment that is selected for use in a location where it could become an ignition source shall be listed for Class 1 locations and the material classification is Group D in accordance with NEC Section 500.6(A)(4). NFPA 497 requires the process be evaluated based on the relative magnitude of a flammable liquid vapor release. NFPA 497 allows the hazardous location classification to be limited to the process equipment or the entire plant depending on the magnitude of a release. Based on the NFPA 497 criterion, all release scenarios in the P2F system processing the synthetic crude oil are treated as being even smaller because of the release HAZARDOUS LOCATION ELECTRICAL EQUIPMENT BOUNDARIES November 13, 2009 Page 2 of 6 amounts, pressure and flow rates are much smaller than criterion in NFPA 497. The NFPA 497 criterion for a low magnitude (small) release and the comparable P2F process variables are: • Size of System: < 5,000. gallons (Note: The maximum throughput of a single condenser connected to 4 PRUs cannot generate > 45 G PM of synthetic crude oil emulsion) • Pressure: < 100 PSIG (Note: The P2F system operates at vacuum pressure) • Flow Rate: < 100 GPM (Note: Each PRU operating at optimum peak capacity can produce a maximum of 11 gallons of synthetic crude oil /minute) When possible, P2F uses simple electrical apparatus so the equipment does not constitute a source of ignition. NEC Section 504.2 states simple apparatus is an electrical component or combination of components well defined electrical parameters that do not generate more than 1.5 volts, 100 milliamps, and 25 milliwatts, or a passive component that does not dissipate more than 1.3 watts. Simple apparatus are intrinsically safe systems and are allowed in accordance with NEC Article 504. Hazardous Location Analysis by Operating Element The analysis of the P2F process is divided into seven interconnected operating elements: • Direct Contact Cartridge • Condenser • Oil Settling Tank • Synthetic Crude Oil Storage Tank • Synthetic Crude Oil Transfer Pump and Hose • Direct Contact Cartridge Cleaning Room • Cargo Tank Vehicle Loading Pad In addition to the review of each operating element of the P2F system, a process summary and process hazard analysis was developed based on the discussion between P2F management and their technical consultant, a review of equipment shop drawings, and process flow diagrams. The following summarizes the area location classification based on the analysis. Operating Element Process Summary Process Hazards Area Location Classification Direct Contact Cartridge The DCC is loaded with The operating Division 1 Boundary: (DCC) approximately 1,000 temperature of the DCC is Interior of an operating pounds of solid plastic capable of heating lighter DCC and the hot plastic feed stock. Using heat molecular weight vapor duct. Drawing H- and vacuum pressure, hot molecules of the synthetic 1.1 gasified plastic is crude oil above its flash Division 2 Boundary: 18- extracted from the point temperature. The inch hemisphere from the feedstock. Using vacuum system is incapable of connection of DCC cover blowers the hot gasified heating the vapor above to the DCC vessel. The plastic is transferred via a the autoignition hemisphere is measured duct system to the temperature of synthetic around the circumference condenser. crude oil. of top of the DCC vessel measured from the Activation of a PRU interior vessel edge. Emergency Shutdown Drawing H -1.1 Device (ESD) requires a HAZARDOUS LOCATION ELECTRICAL EQUIPMENT BOUNDARIES November 13, 2009 Page 4 of 6 Operating Element Process Summary Process Hazards Area Location Classification mechanical ventilation system exhausting any released vapor at flow rate of 1 CFM /Ft. The mechanical ventilation system is connected to a optional standby power system to improve electric power reliability. Synthetic Crude Oil The condenser receives Loss of water in the Division 1 Boundary: Condenser the hot plastic vapor and hydraulic weir could Warm crude oil emulsion using hot and cold water, increase the depth of in the bottom of the condenses the vapor into warm crude oil layer, interior of condenser V- a hot crude oil emulsion which could allow for the 01. Drawing H -1.3 that is transported by volatilization of lighter gravity to a hydraulic aromatics. Division 2 Boundary: 6- weir. The water in the inch sphere at LT001 and weir is heated by an The operating elements LT004 instrument well. immersion heater. The of Level Transmitters (LT) Drawing H -1.3 crude oil emulsion is LT001 and LT004 are hydraulically forced over immersed in vapor. Oil Transfer Pump P -301. the weir wall where it is Drawing H -1.3 further condensed and separated into lighter hydrocarbon fractions. Oil Settling Tank (OST) Crude oil emulsion is Heating of synthetic crude Division 1: A 3 -foot transferred via a closed oil above its flash point sphere around the tank piping system and Pump temperature in the event normal vent and (P) -02 from the the tank water bottom is emergency vent. Drawing condenser to the Oil evaporated. H -1.4 Settling Tank (OST). The OST is located within a The conical area of the concrete containment tank where the water is structure. The tank is heated measured from elevated approximately the weld of the cone to 18- inches abovegrade. the tank shell to the bottom withdrawal Given water's specific flange. Drawing H -1.4 gravity, the synthetic crude emulsion resides on Division 2: A sphere more top of the water layer. than 3 feet but not more The water is heated to than 5 feet from the separate it from the normal and emergency synthetic crude oil and is vent. Drawing H -1.4 circulated to a water condenser and is The area of the circulated to the synthetic containment of the basin HAZARDOUS LOCATION ELECTRICAL EQUIPMENT BOUNDARIES November 13, 2009 Page 6 of 6 Operating Element Process Summary Process Hazards Area Location Classification metals. Notes 1. P2F has analyzed the DCC carbon and carbon black residual materials in accordance with ASTM D3175, Standard Test Method for Volatile Matter in the Analysis Sample of Coal and Coke, 1989. NFPA 499 Section 3.3.4.2 states that carbonaceous dusts are considered to be Group F materials when their particle size is < 420 p.M and dusts contains more than 8 percent total entrapped volatiles when tested in accordance with ASTM D3175. Assay samples by P2F have found that samples tested in accordance with ASTM D3175 have a volatile content of 5.59% as received in the testing laboratory. Second, carbon is not a regulated material in NFPA 499. Therefore, it has been concluded that the DCC Cleaning Room is a Nonclassified Room in accordance with the NEC. 2. The previous Paint Room is a Class I, Group D, Division 1 hazardous location in accordance with NEC Article 516. This room has been declassified as a Nonclassified Room, based on the analysis for the carbon and carbon black. P2F will maintain the current electrical equipment in good operating condition and in compliance with Articles 500 and 501 of the NEC. When equipment is replaced, P2F will remove the Hazardous (Classified) Location equipment and replace it with conventional Nonclassified location electrical equipment. % Ai $ ,. y ,,,,, „,,,,,o 0 .,,,,,,„:„, AI H H , C_ ■ erli' t Plastic I�.I�d ` r 1:: _I _ I , LReclamation ii Cleaning and j y DCC Cleaning Area De- Classification a �-� ' H. ° Filling !��!I � r (De- Classified) 4%1 Direct Contact Cartridge (DCC) Cleaning Room Will 1 ` ' D t Contact ° After recovering and processing of synthetic I ' crude %4 Cartridge i,A',Ai oil, the DCCs are removed and cleaned. The residual .._ _,, i material is carbon with residual trace metals. 'iii% i The remnant material is a mixture of carbon or carbon black with a limited amount of volatiles. 1 Area Location Classification 1 Nonhazardous, based on criteria in NFPA 499, 2007 1, edition. 2 i 1 Drawing Index - I` : H1.0 HAZLOC - Overall J H1.1 PRU and GTL H1.2 Vacuum Blowers and Typical Instrument H1.3 Condensing Skid _ H1.4 Oil Settling Tank Pe as lige� H1.5 Oil Storage Tank �, `I ` " � ` - torporatlonl H1.6 Fuel Delivery System and Vehicle Loading Pad 1 N PIas2Fuel 3335 NW St.Helens Rd ` Portland, OR 97210 7904 SW Hunziker Blvd. w Electrical Ph.503.922.1812 Tigard, OR 97112 Class 1, Group D, Division 2 ' '' '` contractor F :.503 g Services N.W. :•.:;:; Power •Control•Design /Build•Service Hazardous Locations — Overall Layout 1.0 Class 1, Group D, Division 1 .J% This is a design build document and is property of SIZE Drawn By • DWG NO REV Electrical Contractor Services Ton 9331- Hazardous Location Classification 1.0 Pa Connpb, LaraN •,d Enyn••nnp iMOmmtron Lwll nat b mpiaO. ISA — G (IS T • nical Consultant to PIas2Fuel Corporation ^_^• ° ' °:: - ^°^y^�^^•;°��•° »°^�••• � N •�rtno�x. M ecsrm�. o• m�.s�ro.. n�a o, onNmn. nowe,..:ai a SCALE None SHEET 1 of 7 ms oec•. ()Class 1, Group D, Div. 2 I 1 " '* _ g mm ! fi t I I r--,/-1, � Class 1, Group D, s � ��✓' Div.( 0 11 i IN ,,„„\ -- �-� ` -- h o t+...-.4>v � Cr.-1 f i' i �. � o f ` ' - I 1H I (o a i ► w - 1 � i � �I t 0 I i ` e i 3 LL 1 - U I I / : _ Direct Contact Cartridge and Quick Disconnect Basis for Division 2 Boundary The boundary area is based on the vapor density of the hot gasified plastic ( >1) and that as the vapor is released, it will condense and vapors will sink to the floor. ii The process generates less than 25 pounds vapor /minute, which equates to about 4 gallons /minute of equivalent vapor. Based on Figure 5.9.1 (c) of NFPA 497, a 80% reduction in the Division 2 boundary is justified. The total equivalent gallon /volume of vapor is 90% than the 100 GPM flow rate for a small system as defined in NFPA 497. The 6 -inch boundary sphere around instrument well openings is based on the duct is operate under vacuum pressure. The area around each PRU is provided with a mechanical ventilation system exhausting any released vapor at flow rate of 1 CFM /Ft. The mechanical ventilation sconnect system is connected to a optional standby power system to improve electric power reliability. DCC and the hot plastic vapor duct. Class 1, Group D, Division 2 .m the connection of DCC cover to the ❖: ❖: ❖ * * *...:❖:❖:❖: ❖:❖:•, '•' ••••••••••'• : : : : :• :• : :* Class 1, Group D, Division 1 ? u nd the circumference of top of the ��••'' •'••••' . �. y �. : t : ! . �. . .�..�. .�.�.� t . �..�.�.�, �I . edge. 18 -inch hemisphere from the N PI8S2Fuel 3335 NW St.Nelens Rd n any hot gasified plastic duct f Portland, OR97210 7904 SW Hunziker Blvd. W `: Electrical P4.503.922.1812 Tigard, OR 97112 i'� Contractor F:.503.2 %.5518 CCBM 155460 Services N.W. n s driving the vacuum blowers. Sheet Hazardous Locations — PRU and GTL P ower•C o ntro l •Design /Bu i Id •Service H 1 This is a design build document and is property of SIZE Drawn By. DWG NO REV Electrical Contractor Services NW(ECSNV Ton Oliverio 9331- Hazardous Location Classification 1.0 MI cencecte, tave,e a„ a Ergmeeaao information Shall not be Coe. ISA — ('. S r nical Consultant to PIas2Fuel Corporation m^ °a^=,• ^ ra „^ „•^,:. ^M.er ° ^�ea�.ea :,ry e,rtharvea q ECS NW. W mtnmo.s. nine a, ome,vnsa nagar reaaMlM or SCALE None SHEET 2 of 7 sup D, /f/r F w r FA - OE All 8" 7 02 P: ' 9 � 1 I � 1 A , . 4 SL. irilr.rd, , , , 1J 4—' i _„. 1 2 Gas Transfer Line Instrument Well — Thermocouple (Typical) N PI8S2Fuel 3335 Widens Rd Widens g Class 1, Group D, Division 2 04i ;, Portland, OR 97210 7904 SW Hunziker Blvd. w - Electrical Ph. 503.922.1812 Tigard, OR 97112 ' � Fn.503.296.5518 g Contractor CCBN 155460 :4 Services N.W. Hazardous Locations Class 1, Group D, Division 1 1 ;:..; Power •Control•Design /Build•Service Vacuum Blowers - Typical Instrument well .2 This is a design build document and is property of SIZE Drawn By: DWG NO REV Electrical Contractor Services NW(ECSNW) Ton Oliverio 9331- Hazardous Location Classification 1.0 NI Concepts. o-as e .y na. n . n . ,, ma ,w,o ..M+s n,aw...a6ry.� ... I SA — C C S T .m iical Consultant to PIas2Fuel Corporation s+w ,..a •, mry n SCALE None SHEET 3 of 7 "- . 0 Process Summary The condenser receives the hot plastic vapor and using hot and cold water, condenses the vapor into a hot crude oil emulsion that is transported by gravity to a hydraulic weir. The water in the weir is heated by an immersion heater. The crude oil 0 emulsion is hydraulically forced over the weir wall where it is further condensed and separated into lighter hydrocarbon fractions. -II / 2 \ Class 1, Group D Process Hazards \ I Div 2 : �I, 1 Loss of water in the hydraulic weir could increase - 1 the depth h of warm crude oil layer, which could gre \� _ !� . 1._.; i allow for the volatilization of lighter aromatics. IKON % 'ii vii The operating elements of Level Transmitters (LT) V -01 - 1 110 Crude Oil Condenser 3 lT LT001 and LT004 are immersed in vapor. I ■ n tas .1, Gro - • D, ;pow% ° Div. 1 ° Area Location Classification plij. O Division 1 Boundary: Warm crude oil emulsion in APAF ME =otton of Vessel l'ffl • ' � '_ the bottom of the interior of condenser V 01. i -.77._ _ 0 • ra /I �s � •A _ • Division 2 Boundary: 6-inch sphere at LT001 and enor in s1�'� �� LT004 instrument well. W 0 Oil Transfer Pump P -301. i 0 Class 1, Group D, \ / Div.2 N PI852Fuel 3335 NW S1.Helens Rd Class 1, Group D, Division 2 A ri Portland, OR 97210 7904 SW Hunziker Blvd. w - Elect Ph.503.922.1812 Ti ard, OR 97112 r , R.503.296.5518 g Contractor CCBH 155460 �� Services N.W. 1 3 ' • ' •'•'� Class 1, Group D, Division 1 Hazardous Locations - Condensing Skid ° . .�.�.� Power •Control•Design /Build•Service This is a design build document and is property of SIZE Drawn By DWG NO REV Electrical Contractor Services NW(ECSNW) Ton Oliverio 9331- Hazardous Location Classification 1.0 All concepts. Leaded and Engineering information shell not be copied. , ISA — C f S T ical Consultant to PIas2Fuel Corporation ^•^•^ •ror�.d^r c : ""°� °��^•^�nie.m ^�^^•°r r�„pp,. ° ^�° ° r.,doevN or °, ,NMECSnw. oo nor rsn.., oprr.,sa ni,w.r SCALE None SHEET 4Of7 this noose J 1 ' / :.. 7 ', ;-, J: 1 _.. r ;f r , r / ♦1 !J ,2.',:•:.://7.././..:///1/22:/:--///, , ! / / .,/ / ! I r - r' r ! ,-,,///, f x 777/ l.r r l i / „ /7 ",, V , l'/ 7 y . . r ; • r / ff, f r J' r f r f � ?- ' f k2 r ` ; ' '//, /- r iti /dt • V .,,.- , / f r !�/• / T///,,,,,,//::-///t/ / � r,, / / / / , / \r � -�_'' f f fJ r .'72',/// ' ''.4 - 2 / /,/,../://- dilA'./727:2,://;,; ' �Q� � / r / / ,, , ,, :: „..,,,,..... 5 .,... 5 , 4 , ? .../ /. .,, r : � o f r � - ! P f t f r f J /r .� �: �.�♦� / ' r J J : ' rr - /,-, f /' / ! !/ / f ■ ��,,, '` 1 y r rJ / /1 /.- ,/,.,,,/, • ■ / • :°i�i�i�i�i�i�i�i�i� 2 �:� 1 d / OST and Crude Oil Transfer Pump Location �� # Process Summary 1 ,. • ,� �� / Crude oil emulsion is transferred via a closed piping system and Pump (P) -02 from the ►�� condenser to the Oil Settling Tank (OST). The OST is located within a concrete t% A containment structure. The tank is elevated approximately 18- inches abovegrade. i Given waters specific gravity, the synthetic crude emulsion resides on top of the water 1 A layer. The water is heated to separate it from the synthetic crude oil and is circulated /�' to a water condenser and is circulated to the synthetic crude oil condenser. Process Hazards Heating of synthetic crude oil above its flash point temperature in the event the tank water bottom is evaporated. Area Location Classification O Division 1: A 3 -foot sphere around the tank normal vent and emergency vent. The conical area of the tank where the water is heated measured from the weld of the cone to the tank shell to the bottom withdrawal flange. I// d� /%/ .�� Division 2: A sphere more than 3 feet but not more than 5 feet from the normal and emergency vent. MSI . �� The area of the containment of the basin up to the height of the . containment wall. r ► �� NOTE: These dimensions and area limits are specified in Table ., / 3403.1.1 in the 2006 IFC. •: i/ O The electric motor driving the synthetic crude oil transfer pump 44.4 N PIaS2FueI 3335 NW St.Heteas Rd Portland, OR 97210 7904 SW Hunziker Blvd. w Electrical Ph.503.922.1812 Ti ard, OR 97112 Class 1, Group D, Division 2 p F:.503.2%.5518 g f Contractor CC&1155460 Services N.W. . Hazardous Locations - Oil Settling Tank Class 1, Group D, Division 1 Power •Control•Design /Build•Service H 1 This is a design build document and is property of SIZE Drawn By: DWG NO REV Electrical Contractor Services NW(ECSNVJ) Tony Oliveri 9331 - Hazardous Location Classification 1.0 al Concepts. Layout and Enain..nny inm,n.i.n WWI not be copied. ISA — C _.0 S T II Consultant to PIas2Fuel Corporation : :: ^ :- r�.d ^• ^,7^^ O otl.nr^rain n�,•readaGfdy o>�.^� a rorrem•rv. nide r .e niMerf SCALE None SHEET 5 of 7 Class 1, Group D, \ Div. 2 \ 3 %ow...As 0 mos ICI ' r�i►�i►�o�ir�� \ RAMS I v 1 1 c l Crude Oil Transfer Pump — Plan View Process Summary Refined synthetic crude oil is stored in the storage tank. Process Hazards External exposure fire; Fire involving the transfer pump electric drive motor. Area Location Classification n Division 1: The interior of the primary containment storage tank. A 3 -foot sphere around the tank normal vent and emergency vent. n Division 2: A sphere more than 3 feet but not more than 5 feet from the normal and emergency vent. n The electric motor driving the synthetic crude oil transfer pump. See Detail 2 -H1.4, 3 -H1.5 N 3335 NW SGNe1ens Rd PIaS2Fuel Portland, OR 97210 7904 SW Hunziker Blvd. Class 1, Group D, Division 2 W Electrical Ph.503.922.1812 I= Tigard, OR 97112 F.503.2%.5518 Contractor CCRN 155460 Services N.W. Hazardous Locations 1.5 Class 1, Group D, Division 1 Power •Control•Design /Build•Service Synthetic Crude Oil Storage Tank This is a design build document and is property of SIZE Drawn By DWG NO REV Electrical Contractor Services NW(ECSNW) Ton Oliverio 9331 - Hazardous Location Classification 1.0 - All Concepts. Layout and Er,M «dnommravrons,annutwcop»d, ISA— C;,C S T C onsultant to PIas2Fuel Corporation ma,nanswndm�aed� any nnnarorporposaunwaaspaa aiM aNM1Or¢ed by ECSNW. Do not renrova, M1keorodwm+se M1irMeru adaM1iiMoi SCALE None SHEET 6 of 7 Mn nob. • // APAP... A iiiii/ iiiiiiiiiiiiiiiiiiiiiii "iiiiiiiii�ii „�� -- A i o 0 0 • . 0 0 iwys / / / / � , , //e O 1A1 o Tank Vehicle Loading Pad — Plan View o Tank Vehicle Loading Pad — Elevation V Area Location Classification 1 to pump connected to a 3-inch diameter O Division•2: Within 3 Feet of any edge of pump, extending in all directions. ted for hydrocarbon service 2008NEC Table 514.3(B)(1) Remote Pump - Outdoor ietic crude oil into a DOT 406 tank vehicle. O Division 2: Up to 18” above grade level within 10' horizontally from any edge of pump. 2008NEC Table 514.3(6)(1) Remote Pump - Outdoor 1p seal, the mechanical connection on the of the pump, or a rupture of the hose. Division 2: 5 foot radius and envelope measured from the edge of echanical connection to the tank vehicle, or a 0 foundation. The envelope extends 18- inches above the finished grade. ose. N PIas2Fue1 3335 NW St.Helens Rd A _vii Portland, OR 97210 7904 SW Hunziker Blvd. W Electric Ph.503.922.1812 Tigard, OR 97112 Class 1, Group D, Division 2 D „'4 FL5o3.296.5518 g C ontractor CCBN 155460 Services N.W. Hazardous Locations 1 • 6 Class 1, Group D, Division 1 Power •Control•Design /Build•Service Fuel Delivery and Vehicle Loading Pad This is a design build document and is property of SIZE Drawn By: DWG NO REV Electrical Contractor Services NW(ECSNW) Tony Oliverio 9331- Hazardous Location Classification 1.0 ai conoems. Layout and Engneema e,ro,naeon shall not be coped. ISA — C Qs T _ Consultant to PIas2Fuel Corporation transme ted. o-ansmne dor used many:Isomeror purpose unless eperr iy None SHEET 7 of 7 a,M1Mraad Oy EGSNW. Do not rertave, M1itla or odarvnw M1inae, re.mdldy of SCALE Mrs noaca. � � AI i eeeeee °eeeeee4F e., • e e e e e e e a e a e e • e e e e e e e e e n e e e e e e e e e e e e e e e e e e e e e a e e e e y eeeeeeeeeeeeeeeeeeeeeeeeee, Class 1, Group D, ♦ eeeeeeeeee♦♦ ' ♦eeeeeeeeeee♦ Div. 1 \ ♦eeeeeeeeeee♦ ♦eeeeeeeeeee♦ ♦eeeeeeeeeeee! • e a ' • 'e Direct Contact • iee e • • 'ee Cartridge Interior • e e! e • e e!a:.e; • ; e e ee ,ee • e '' e i ' � e i! e ` iei ' • e • e e • e i • , e • , ,ee, \ •, 2 e e ,e e ! e{ • ee C 2 ) Class 1, Group D, a ! i'e.; e • ie:; Div. 2 ' • ' ;♦ : 4 ; e r, a �e 'a.: . *:u *, ■ ,.•.: .. Class 1, Group D, Div. 2 : , i , dr . ... (1)## 41 ._-- - _ _ A e , • ,,_ Agt - & 4 ' 641 . - NEF c f H 1 — = — - 1 1 7 2 H 1.1 Direct Contact Cartridge H 1 1/ Direct Contact Cartridge and Quick D Process Summary Area Location Classification The DCC is loaded with approximately 1,000 pounds of solid plastic ( 1 ) Division 1 Boundary: Interior of an operatin feed stock. Using heat and vacuum pressure, hot gasified plastic is extracted from the feedstock. Using vacuum blowers the hot gasified plastic is transferred via a duct system to the condenser. r ---\ 2 Division 2 Boundary: 18 -inch hemisphere fr \ / DCC vessel. The hemisphere is measured ar DCC vessel measured from the interior vess Process Hazards quick disconnect flange. The operating temperature of the DCC is capable of heating lighter molecular weight molecules of the synthetic crude oil above its flash (1) Division 2 Boundary: 6 -inch hemisphere fro point temperature. The system is incapable of heating the vapor above instrument well. Sheet H1.2, Detail 2 the autoignition temperature of synthetic crude oil. Activation of a PRU Emergency Shutdown Device (ESD) requires a controlled shutdown to 18 -inch hemisphere from the electric moto ensure remaining hot plastic vapor is routed to the condenser and the H1.2, Detail 1 DCC system is purged. The potential exists for a hot vapor release during the 1 -3 minute shutdown sequence Prepared By Scott Stookey — Tec r # . Crude Oil Transf- r Pump / , A 0 Syntheti . 00 . IIII '7 .c um, ;j ,..___I:' . • Cj / A - • /A Vacuum 1111111m Me - Blowers , ., _ wl .. - _ L ____ -„,---, ...,--- .,,,,.,.:y., --,.------ v x g prz=t. ., . , P .4," "4 -.1 ".. l' , a .7.---#=,- --= ■ '''' I t7. F -0 ' . i Jm — i! ..g '.. . ]] 1 , ' 7 re 2: 1 c_-,7-177.7._ r tt$ i ',—. _,.—,r__ , 4 , 1 ; .:0- 1 7' , ■ V, 0 ; V 11 ' , , 1 0 ,i '■ Il ' fr '4 ' 4 k / /L , 1 1 '/A L „_,,,___„, L . ± ... /,___1, 1_ L. 0 4 Gas Transfer Line 1 , . 14 14 - 1-1 14 = — NANWAROWNROAMOVANNA 444444+:4444444 440 0 0:44+:440:44,W4 :446:6tOtaot.::t6t431 Prepared By Scott Stookey —Tec HAZARDOUS LOCATION ELECTRICAL EQUIPMENT BOUNDARIES November 13, 2009 Page 5 of 6 Operating Element Process Summary Process Hazards Area Location Classification crude oil condenser. up to the height of the containment wall. Drawing H -1.4 and H -1.6 NOTE: These dimensions and area limits are specified in Table 3403.1.1 in the 2006 IFC. Synthetic Crude Oil Refined synthetic crude External exposure fire; Division 1: The interior of Storage Tank oil is stored in the storage Fire involving the transfer the primary containment tank. pump electric drive storage tank. Drawing H- motor. 1.5 A 3 -foot sphere around the tank normal vent and emergency vent. Drawing H -1.5 Division 2: A sphere more than 3 feet but not more than 5 feet from the normal and emergency vent. Drawing H -1.5 The electric motor driving the synthetic crude oil transfer pump. See Detail 2 -H1.4 Synthetic Crude Oil 350 GPM transfer pump Failure of a pump seal, Apply NEC Article 515 Transfer Pump and Hose connected to a 3 -inch the mechanical diameter transfer hose connection on the rated for hydrocarbon discharge outlet of the service pump, or a rupture of the hose. Cargo Tank Vehicle Transfer of synthetic Failure of the mechanical Division 2: 5 foot radius Loading Pad crude oil into a DOT 406 connection to the tank and envelope measured tank vehicle. vehicle, or a rupture of from the edge of the hose. foundation. The envelope extends 18- inches above the finished grade. Drawing H -1.6 Direct Contact Cartridge After recovering and The remnant material is a Nonhazardous, based on (DCC) Cleaning Room processing of synthetic mixture of carbon or criteria in NFPA 499, 2007 crude oil, the DCCs are carbon black with a edition. removed and cleaned. limited amount of The residual material is volatiles. carbon with residual trace HAZARDOUS LOCATION ELECTRICAL EQUIPMENT BOUNDARIES November 13, 2009 Page 3 of 6 Operating Element Process Summary Process Hazards Area Location Classification controlled shutdown to ensure remaining hot Division 2 Boundary: 6- plastic vapor is routed to inch hemisphere from any the condenser and the hot gasified plastic duct DCC system is purged. instrument well. Drawing The potential exists for a H -1.2 hot vapor release during the 1 -3 minute shutdown 18 -inch hemisphere from sequence the electric motors driving the vacuum blowers. Drawing H -1.2 Basis for Division 2 Boundary: The boundary area is based on the vapor density of the hot gasified plastic ( >1) and that as the vapor is released, it will condense and vapors will sink to the floor. The process generates Tess than 25 pounds vapor /minute, which equates to about 4 gallons /minute of equivalent vapor. Based on Figure 5.9.1 (c) of NFPA 497, a 80% reduction in the Division 2 boundary is justified. The total equivalent gallon /volume of vapor is 90% than the 100 GPM flow rate for a small system as defined in NFPA 497. The 6 -inch boundary sphere around instrument well openings is based on the duct is operate under vacuum pressure. The area around each PRU is provided with a K ) Class 1, GI Div. ; ,„,,, 4 al A l igr a 4 1, _ I /Ile 1 : At / / / / / / / / /%1 I-A Amotte /r. 111 AmAj _ . i1 � H 2 Vacuum Blowers 4 6 . 111( NI' 0 O 6" i U1 ° 0 ,. , i 2 � H1. / Gas Transfer Line Instrument Well — Pressure Transmitter (Typical) Area Location Classification Division 2 Boundary: (:_l) 6 -inch hemisphere from any hot gasified plastic duct instrument well. 18 -inch hemisphere from the electric motors driving the vacuum blowers � . *********.44 Prepared By Scott Stookey — Tech'. .:. I lc ; 0 . �__.,► (.(., �`,,,,., l Group D, 1 , f I %% ► 2 - 0 . I * • ill 0 I ,/ I III 1 . r 0 7 eft , Ail rip D, r 44 . 7 . -- 4 1011 /. „m. . 0 0 0 0 0 0 �- loom_ j ► Ilt, Class 1, Group D �, / u to � i � r `o Div. 1 � I 1Iiil ' Al 1 �\ bottom of Vess�J o �� C � � o Interior o a \41 ° ° I; °' 7------ r ■ on Ili — - - a , - -- II > =I= 1 001 1 AO MR _ ■, P , r 2 1 H1 3 / Condensing System Skid - Elevation 1 )Condensing System Skid - Plan View • . �. ❖. ❖. ❖. ❖. •. .. ❖. ❖. ❖. ❖ 4. •. ❖. ❖. . ❖ . ❖. ❖. •. . ❖. ❖. Prepared By Scott Stookey - Techr .' � �i� i �i � i � i0 � i• i � i �i � i � i � i i i . c �! * i"e � ! � ► I NP 4" ,fr � i � i �i � i � i �i � i �i i i i i i i i I. I. I. 4 . I. •'�! i i i i ! 7 I - . . ri, Via% /A!. 4 ,1 / A. et ice•. ►i �.�.i�N* 00 I • ■ % % %i %% % % % % / / / / / //. 7 / \si\ ... / .... / Ate ii r -,,, ,, \ Class D iv. 2 up D, /Agt A.- - i- i- i- ... - A ' \ H 1 .4 / Oil Settling Tank Prepared By Scott Stookey — Technic Class 1, Group D, __ Div.2 j PPP . ►•••• •••. • . ., • . • • 1/ A S":""•-• i / �• i • . 4 niiii • • • iiii•••iiiiii•• •• •i . �. • • .•.. ••s. • .. .•• Interior of Tank - • ►•iiiiii i � ►•i �i�O �i�i` i� •ii � ii � ►• i�i�i�i�� `i�� \ Class 1, Group D, • •i �' • 40, 4 , VO� ' . 41 • •0 , • ►•iii �iii�i O�i O' i �i' ii ii iN • . •�O•• ❖i ►••i••�ii�iO�i�i•••O�• 0.O•�•iii ❖.•iii• ••••.O•.• • DO ❖ • � •• O.. •;• •O ❖�' 4 ■ill / r 1 H1.5 Oil Storage Tank—Plan View Class 1, Group D, Div. 2 / ' ❖. . ❖ ❖ ❖ ❖ . ❖ .o ❖. ❖ ❖ •••...•...••.• 4.4.• . •••.•. .•• 444. , ••• • •• ••• ••••• . .•/ ••••4• 4 .4444•• ♦. 4.4 .• .•♦ •••• • ••��i�ii ► ii��i % % % % % % % % i • ��• • •"••• 1; ••• .i 1� • • • • C 4. • S S •••4 •• • ii0 • i i ►ii i i 0 •i�i i � :O • • • 0 4 * `• * • �ir 0•iiiiii � ' '•�i�i�i�iii�i�►•►�iiiii� •�� ■..1. � I ii.= 4 ►•. l Interior of Tank - \ Class 1, Group D, Div. 1 111. 5)On Storage Tank-Elevation R:************** iiiiiiiiiiiiiiiiiiiiiii Prepared By Scott Stookey — Technica / $ �, _ o o • ° o o r• �/ E.& r P-A2101 rep" r ,�.,p i/i d i / A . i. r A r o , • Ii Ai H1. Carg I L 1 1 H1 .6 H1 .6 1 �Carg H 1. 6 Fuel Delivery Pump — Plan View Process Summar / 350 GPM transfi transfer hose ra I _ 4 . 1 �/Ar// ', Transfer of syntl Process Hazards rote Haz Failure of a purr 2 discharge outle 1.6 Fuel Delivery Pump — Elevation Failure of the rupture of the . ....................... Prepared By Scott Stookey — Technica N p'� 31378 Dowd Rd. AVAILABLE FAULT CURRENT / ARC FLASH W —.w Electrical St. Helens, OR 97051 ti gi, Ph.503.366.6060 Contractor Fx.503.296.5518 CCB# 155460 Services N.W. LLC Job # 9331 Job Name: PIas2Fuel Arc Flash /Blast Data by: Tony Oliverio Overcurrent Device Equipment Rating If SCCR is below Flash Segment No.(Refer Short- Circuit Short- Circuit short-circuit Incident Energy Protection to Fault current Current(SCC Interrupting Current current, must Overcurrent Exposure @ 18 Level of Boundary diagram) Location of Short Circuit Current or AFC) Ampere Rating Rating(IR) Rating(SCCR) prove protection Protective Device inches(cal /cm2) PPE(cal /cm2) (inches) 1 (Existing)Panel 4 32,567 400 ? ?• ? ?- Current Limit Fuse: 0.25 1.2 6.21 2 Automatic Transfer Switch - ATS480volt 30 24,519 150 ??* >25K Molded Case CB 1.94 8 24.94 3 Panel SBH - 480volt 30 19,661 150 22K >22K Molded Case CB 1.56 8 21.51 4 X -2 - 480delta pri. 208/120Y sec 9,282 60 10K 10K Molded Case CB 5 Panel SBL - 208/120Y 100a Main Breaker 1,537 100 10K 10K Molded Case CB 0.25 1.2 6.21 6 UPS System - 480v 20kva UPS 9,715 50 10K 10K Molded Case CB 7 Panel UPS -H - 480v 30 fed from ups/bypass 9,048 60 10K 10K Molded Case CB 0.8 1.2 13.67 8 X -3 - 480delta pri. 208/120Y sec. 7,481 60 10K 10K Molded Case CB 9 Panel UPS -L 208/120Y 60amp Main Break. 806 60 10K 10K Molded Case CB 0.25 1.2 6.21 10 11 12 1 13 i 14 I 1 15 1 Note; interrupting rating of existing panels is unknown. Refer to NFPA 70E for proper PPE 1 i:ir,r. I ,... , ..,A t.• I ,,,,,,,, 3.24 2 .■1.%t Segment 1: Segment 2: Segment 3: Settmen1 4 Set:rums' 4: n t4nta1lxi 15.1:•". 4n 4.I n Iini4lier..R.47,42,245. 1 f.(11 4a1 Ad M Menaeli. 1 ."et 22a en r.i21.t2ilr. F.4rnee.ly - 1 2r. n M k. Racew;:i - 10 Fie4:0444 - 22' 15 - 22' . . . . .. . . . 36,063A 32,567A 24,519A 19,661A 9,282A 1,537A .2 4 1,1,10 SWF tt... 4.14 eilion 42.1 In-s ident !neer; Le...vtif 221 Pt C4,1.1 inn II .] 00--- ( e ;2 E 1 : :::;.: ;WO-Wrenn 214.n enti.ny Molded Ca$e CS 0.2S 6.21 dee ilea . 1.2 ,,.,c..,„ I), i _ 4Vdd I 43 9.715A 9,048A 7,481A 8081k :: 9, • ,...,. ::.f: ...!....!.'2,LT...."2„- : er9 lefr U05.1.. i0.04.0. le 104 2 di 04 ' 'Note: Fault currents Downstream of the UPS are calculated in - Bypass • Rtes./ Perade" for A warS1 rase scenario, Fa till rrent levels wifi be sionrfiCantty ■ lower while UPS is active. Point to Point Method used to c.alcularn faull current Segment 6: Segment 7: Segment 8: Segment 9: 1 :tei 216:::u in hietdli:: Rice.v3y 1 2.211213.122 11 1tal21 . Rovero■eray 1 ..47.1 223:21 21 24nrale:". {247.nreay 1 %zee 44nte in kintalin RAncr-eay .14 -2' - 11' - 20' t I,...., 1M ,1”1,1,, i 1,,i ,:! grot..I.I,,.. Irv. 2)2: 2 oil, Cs I rit'l .Z.I Idd,to,1■01, 2 t • f.x,11.1t, 3/1/ lone Ie.:Irene! i 120-0,1.. , i:irr2tu0re0! I {ti,>*..1■.■ «:, IN Pfit 0 4.2; 1:,,, tt“,,,•1.,, 1 :1 1 1 1 ■: , ..lise..1 , :. - .1f.r ......._ _ . .0,i.,... II AI;bnlji iC, i,,,,,::.: 2 0 , T. iv r D., lio in,11,148 ....,.. 4 - r,loienni r no rte 0.6. 1./ 11.62 tetekled Ctle CS 0.CI 1.1_ 11.47