HYDROCHLORIC ACID STORAGE AND PIPING SYSTEMS, 34 For further assistance and information on items referenced, contact: American Chemistry Council 700 Second St., NE Washington, DC 20002 202-249-7000 202-249-6100 (Fax) American Society of Mechanical Engineers (ASME) Two Park Avenue New York, NY 10016 800-843-2763 ‘https Jww.asme.org ANSI 1899 L Street, NW, 11!" Floor Washington, DC 20036 202-293-8020 202-293-9287 (Fax) httpsviwwawansi.org Chemical Transportation EmergencyCenter (CHEMTREC) 2900 Fairview Park Dr Falls Church, VA 22042 800-262-8200 or 703-741-5500 703-741-6037 (Fax) NACE International 15835 Park Ten Place Houston, TX 77084 281-228-6200 281-228-6300 (Fax) https:www.nace.org Superintendent of Documents Government Printing Office 732 North Capitol Street, NW Washington, DC 20401 202-512-1800 (Sales) httos://www. gpo.gow The Chlorine Institute 1300 Wilson Boulevard, Suite 525 Arlington, VA 22209 703-894-4140 703-894-4130 (Fax) American Petroleum Institute (API) 1220 Street, NW Washington, DC 20005-4070 202-682-8000 866-284-0169 (Order Desk) https/www.api.org American Saciety of Testing Materials (astm) 100 Barr Harbor Drive West Conshohocken, PA 19428 610-832-9500 610-832-9555 (Fax) httos:/;www.astm.org Canadian Transport Emergency Centre (CANUTEC) 330 Sparks Street, Suite 1415 Ottawa, Ontario K1A ONS (CANADA) 613-992-4624 for information 613-996-6666 for emergencies 613-954-5101 (Fax) Chemistry Industry Association of Canada 350 Sparks Street, Suite 805 Ottawa, Ontario KiR 7S8 (CANADA) 613-237-6215 613-237-4081 (Fax) National Tank Truck Carriers, Inc. 950 North Glebe Rd, Suite 520 Arlington, VA 22203 703-838-1960 703-838-8860 (Fax) httewiwww.tanktruck,org Transport Canada 330 Sparks Street Ottawa, Ontario K1A ONS (CANADA) 613-990-2309 Bis coe 8 (Fax) hittp//www.tc.ge.ca32 PAMPHLET 163 APPENDIX A Matar Proper NAME: Hydrogen Chloride Solution CHEMICAL FORMULA: HC! TRADE NAME: Hydrochloric Acid SYNONYMS: Chlorohydric Acid, Muriatic Acid, Aqueous Hydrogen Chloride PHYSICAL DATA, 20°Bé 22°BE 23°BE Weight Percent HCI 31.45 36.21 37.14 ‘Boiling Point “F: 178-183 142-146 118-125 (°C) (81-84) (61-63) (48-52) Freezing Point °F, 49 -26 “17 (CC) (-45) (-32) (-27) Vapor Pressure: 25 78 150 mmHg @ 20°C Sp, Gravity: 60°F/15,2°C 1.1600 1.1789 1.1885 | Molecular Weight: 36.465 Solubility in Water: Infinite ‘Appearance; Colorless to yellowish clear liquid Odor: A pungent, suffocating odor FIRE AND EXPLOSION HAZARD DATA: Flash Point; None Elammable Limits: LFL: N/A UFL: NA Fite and Explosion Hazards: Hydrochloric acid itself is nonflammable. However, a latent fire or explosion hazard exists due to hydrogen gas generation when acid is in contact with metals, REACTIMITY DATA: Stability: (Conditions to avoid): Contact with metals may cause generation of flammable Concentrations of hydrogen gas. (Materials to avoid): Hydrochloric acid will react rapidly, and sometimes violently, with metal oxides, some organic compounds and alkaline materials (i.e., caustic soda), Also, poison gas can be generated by reaction with hypochiorites, sulfides and cyanides,HYDROCHLORIC ACID STORAGE AND PIPING SYSTEMS. 33 Hazardous Decomposition Products; None Hazardous Polymerization; Will not occur HEALTH HAZARDS: Eye: May cause pain, lachrymation (tears), and severe irritation with corneal injury which may result in permanent impairment of vision, even blindness ‘Skin Contact: Short single exposure may cause severe skin burns Ingestion: Ingestion may cause gastrointestinal irritation or ulceration and severe burns to the mouth and throat. Inhalation: Excessive vapor concentrations are readily attainable and may cause serious adverse effects, even death. Excessive exposure may cause severe irritation and injury to mucous membranes (nose and throat) and lungs Repeated or prolonged exposure may cause erosion of teeth and bleeding and ulceration of nose, mouth, and gums HANDLING AND STORAGE PRECAUTIONS: Exposure Guidelines: OSHA PEL is 5 ppm (7 mg/m’) HCI ceiling Ventilation: Control airborne concentrations below the exposure guidelines. Local exhaust Ventilation may be necessary for some operations. Respiratory Protection: When airborne exposure guidelines and/or comfort levels may be exceeded, use an approved air-purifying respirator. For emergency and other conditions where the exposure guideline may be greatly exceeded, use an approved positive-pressure self- contained breathing apparatus. See OSHA 29 CFR 1910.134 for more information. Skin Protection: Use protective clothing impervious to acids. Selection of specific items such as gloves, coats, pants, boots, aprons, or full-body suits will depend on operations to be performed. Launder contaminated clothing before reuse. Dispose of contaminated leather articles. Safety shower should be located in immediate work area and tested on a regular basis, Eye Protection: Use chemical goggles. If vapor exposure causes eye irritation, use a full-face respirator. When splashes are likely, a face shield which allows use of chemical goggles, or full- face respirator should be worn to protect face and eyes. An eyewash facility should be located in the immediate work area and tested on a regular basis. ADDITIONAL INFORMATION Special Precautions to be Taken in Handling and Storage: Prevent all contact with eyes and skin. Avoid breathing irritating vapors, Avoid hydrochloric acid contact with metals Always add hydrochloric acid to water while providing agitation. Consideration should be given to the initial temperature so that temperature rise due to heat of dilution stays within design parameters.34 PAMPHLET 163 APPENDIX B FREEZING POINT CURVE Freezing Points of Hydrochloric Acid SolutionsHYDROCHLORIC ACID STORAGE AND PIPING SYSTEMS. APPENDIX C BOILING POINT CURVE 225 205 + 185 Temperature °F 0% 10% 20% 30% 40% Weight Percent HCI 3536 PAMPHLET 163 APPENDIX D SPECIFIC GRAVITY CHART Specific gravity and degrees baumé for HC! Solutions Siam erp ‘Baumé for liquids 145-145 At TO" fo 15° Bé., 0.025" Bé., or 0.0002 sp. g. for each °F reer anwar Se ANS Be aay ae) rams great AUPE co 00m ag: Sanita sens a Fea — Sa Spat Bocen Bat a 2 ae oy we May tee teil, a a en) we i Sat 8 Mm Bal # se a ee a te ‘tg ane | seen a a | Seo a a GH uo tee een | te seam 1300 1085 196) 86 10 na Mor 3083 333 ee ee ee oe BM BE Bek) RR feo oe ime mm eet] at ame 1S PR Be) oR oe Som ge mean] ae wan HOoHD Be Be Hl eb OF ee eee aHYDROCHLORIC ACID STORAGE AND PIPING SYSTEMS 37 g z 5 1000 APPENDIX E VAPOR PRESSURE CHART Vapor Pressure of Hydrochloric Acid Solutions TWOSPRERC 8 PTS 08 PARTIAL PRESSURE HCL mm hip38 PAMPHLET 163 APPENDIX F CONDUCTIVITY TESTING Note - Selection of equipment, conducting tests, and interpretation of results should only be ldone by trained personnel. Contact your hydrochloric acid supplier or other experienced personnel for specific requirements and procedures. Conductivity tests are often used for verification of interior lining integrity. The test is based on the fact that most elastomer linings are nonconductive. A perfect lining should not allow the Passage of electricity between the steel tank shell and a liquid cargo |nside the tank. The conductivity test can be used any time that a steel shell tank, a nonconductive lining, and a conductive cargo liquid are present. Conductivity testing provides the benefit of monitoring lining integrity each time a container is filled, If readings are tracked over time, gradual lining degradation may be detected before serious shell failure occurs. In addition, conductivity tests may reveal defects not detectable during a visual inspection. Even an invisible defect can result in contact between the HCI and the steel shell and eventual failure of the vessel. F.1 Technical Basis for Testing Elastomers used in linings of HCI vessels are good electrical insulators. Conductivity testing involves application of an electrical charge using the conductive tank shell and fully loaded cargo as part of an electrical circuit. If an elastomer ining is free of defects, there should be no completed circuit or electrical current flow. However, if defects are present which allow contact between the liquid cargo and tank shell, a circuit is completed and can be measured. The current flow measurement can indicate even very small defects in the lining F.2_ Measuring Instruments Megohm Test Instrument (Megger) The megohm meter is a standard resistance measurement device available from any electrical maintenance supply vendor. By generating a high voltage (500-1,000 volt), low current signal, small defects in insulating materials can be measured, Caution should be exercised when using one of these devices since an electrical shock, while not generally harmful, may startle the operator and cause a fall Milliamp Test Instrument An altemative method involves the construction of a 0-5 milliamp signal generator using a 3-6 volt battery source. This device will measure current flow through the lining rather than resistance across the lining. It has the advantage of lower cost and simpler design. but does not provide the sensitivity of a megohm meter. F.3 General ProcedureHYDROCHLORIC ACID STORAGE AND PIPING SYSTEMS, 39 FA The general procedure is the same for both types of measuring devices, One probe of the device must be securely attached to the outer steel shell of the vessel being tested while the second probe is brought into contact with the surface of the HCI contained in the tank, The measurement device is then activated and the reading recorded, As with any measuring process, it is essential that the procedure be consistent. Some of the critical factors in this process include + Aproper calibration check of the instrument + Confirmation of good electrical contact between the external probe and the shell of the tank + A fully loaded vessel (The test will only indicate lining condition below the surface of the HCI in the tank) + Accurate recording of the reading + Documentation of any unusual conditions which might affect the readings + Consistent interpretation of the results Interpretation of Results The readings from these instruments that correspond to an acceptable or failed lining are dependent upon the sensitivity of the instrument as well as the configuration of the lined vessel being tested. Interpretation of readings should be developed around a baseline measurement taken on the vessel when the lining is known to be in good condition. From that baseline, any abrupt decrease in resistance or increase in current flow should be investigated immediately. More gradual trends should be monitored closely and investigated if they continue. With a megohm meter, readings of 10,000 ohm or more on an HCI tank car are generally considered acceptable. Lower readings or successive readings showing a downward trend may indicate a failed or deteriorating lining. Interpretation of readings on a milliamp instrument will depend on the voltage level and must be evaluated by comparison to previous readings on the same vessel. If a suspicious reading is encountered, the car should be immediately unloaded and scheduled for cleaning and internal visual inspection by a qualified tank car facility.40 PAMPHLET 163 Variables: a, Xi p Pw x; v APPENDIX G HCI SOLUTION DILUTION EQUATION Initial volume of HCI solution (gallons) Initial HCI concentration in solution (weight percent, %) Density of initial HCI solution at reference temperature (Ibs/gal) Density of water at reference temperature (|bs/gal) Final desired HC! concentration in solution (weight percent, %) Volume of water at reference temperature to add to initial HCI solution to obtain final desired HCI solution concentration (gallons) »{A)-( By Note: Total volume of final desied HCI solution (Q, + V) may be slightly higher than calculated due to heat generated during the mixing process. This heat of dilution may cause a higher solution temperature and thus a lighter solution density. A lighter solution density corresponds to an increased solution volume,HYDROCHLORIC ACID STORAGE AND PIPING SYSTEMS 4 APPENDIX H Hydrochloric Acid Industry Warning i Me Fi In April 1997, a 5700-gallon fiberglass reinforced plastic (FRP) storage tank containing about 4800 gallons of 31% HC! ruptured during filing, releasing the contents. OSHA and EPA completed a joint accident investigation of this incident and published the report on their Internet website: Dttp/iwww.epa.govioem/docs/chem/surpass.pdf The cause of the failure was determined to be from overpressure of the tank at the end of the unloading process operation, The HC! trailer was being unloaded using 20 psig compressed air. The tank was overpressured due to the air surge from tank trailer at the end of the unloading and limited tank venting caused by a mostly restricted line in the scrubber. This Industry Warning is to broadly communicate this incident and the potential for overpressuring an FRP storage tank when using air pressure unloading. Other low pressure rated tanks could be subject to the same problem. Hydrochloric acid handling sites should evaluate their storage tank, unloading, and vent systems to be sure that tanks are not exposed to pressures above their design point. Most FRP tanks are low pressure design of around 10 inches of water (about 0.4 psig) and may fail when pressured to only 4-10 psig. During air pressure unloading, acid enters the tank and displaces the vapor in the tank to the vent scrubber system. This vent rate is low, equal to the trailer unloading rate, about 100 gpm or 13.4 cfm. As the trailer goes empty and the liquid in the line is blown clear, the vapor surge (over 1000 SCFM) will cause a rapid pressure rise in the tank, unless the vent system is sized properly. (See the attached chart that estimates the pressure in the tank at various times after the liquid line is cleared as a function of the vent line size and scrubber back pressure.) For a tank that is nearly full, has a 3-inch vapor line and a 2-inch unloading line, and has a minimum scrubber back pressure, the pressure in the tank will exceed the tank design (If itis 10 inches of water column (WC) in less than one second. Sites should also recognize that the scrubber back pressure can make a large difference in the pressure on the storage tank during unloading (see details in EPA-OSHA Surpass Chemical accident Investigation), Listed below are options for avoiding the potential overpressuring of the HCI FRP storage tank: 1. Use a pressure designed storage tank; the pressure rating should be based on the maximum potential pressure during unloading and normal operation. 2. Convert to a closed loop pump unloading operation. This uses a self-priming pump and returns the vapor from the tank to the trailer, This operation does not have the air surge at the end of the unloading.42 PAMPHLET 163 Size the vent system for the large vapor surge at the end of the air unloading. Include any other pressure/vacuum relief system that you may have on the tank. Note: Normal pressure/vacuum relief systems may not have high enough flow capacities to alone handle the vapor surge at the end of an air pressure unloading . Minimize the air pressure used to unload the HCI trailer. Restrict the flow of vapor to the storage tank by partially closing a valve as soon as the trailer goes empty. Note: The industry recommends that trucks/tank cars be fully de- pressured before being released back to the supplier. Insure that your vent lines to the scrubber are completely open and free trom obstructions or other restrictions that could reduce vapor flow. Avoid the use of a passive scrubber where the HCI vapor enters the bottom of a partially full vessel of water or alkaline neutralizing agent. Measure the pressure in the tank and interlock the inlet or automatically open a vent valve to the atmosphere. EPA/OSHA accident investigation recommendations included: Perform hazard analysis when making changes to equipment. Maintain environmental control systems to ensure reliable operation. Develop standard operating procedures for unloading into a storage tank and scrubber maintenance. Reevaluate the EPA’s RMP rule for HCl solutions greater than 30% (currently only applies to solutions greater than 37% HCl). If you have questions about this incident or recommendations on unloading facilities and practices, please contact your HCI supplier.HYDROCHLORIC ACID STORAGE AND PIPING SYSTEMS 43 Modeling of Pressure in an HCI Tank at the End of Air Pad Unloading Time after Tank Pressure (psig) Tank Pressure (psig) Unloading 2-inch Water Column 16-inch Water Column (seconds) Scrubber Backpressure Scrubber Backpressure 2inch vent 3sinch vent 4-inch vent 2-inch vent inch vent 4-inch vent 2 17 13 0.84 18 18 4.24 5 36 24 1.25 38 27 1.68 10 60 33 1.38 64 38 1.84 0 95 39 141 96 43 1.86 ‘Assumptions: 4. Unloading line size is 2 inches, 50 feet of piping, 10-foot elevation increase. 2. Tank trailer air pad pressure is 15-20 psig. 3. All valves to storage tank remain completely open after unloading is complete, 4, Storage tank is 8000 gallon capacity 5. Storage tank is 85% full at the end of the unloading 6. Vent line piping is about 40 feet from the tank to the scrubber. 7. Scrubber back pressure used is either packed column (2.inch water column back pressure) or a passive scrubber with vapor entering the bottom of a vessel with a liquid head (16 inches of water column back pressure).44 PAMPHLET 163 a4 12 12.4 122 APPENDIX | Recommended Practice — Natural Rubber Lining Application. ‘Specification for Storage Vessels in Hydrochloric Acid Service Introduction Scope This appendix provides guidelines, recommended practices and other useful information pertaining to the rubber lining of hydrochloric acid vessels. This includes all phases of the rubber lining process and responsibilities of the rubber lining manufacturer, rubber lining applicator, and the party responsible for the rubber lining. It represents a compendium of insttute membership and industry leaders’ experience as ofthe date of publication. Referenced Publications ASTM Standard Designations Standard Test Methods for Vulcanized Rubber and Thermoplastic Elastomers-Tension, Book of ASTM Standards; D412-16; ASTM International, West Conshohocken, PA 2016 Standard Test Method for Rubber Property-Adhesion to Rigid Substrate, Book of ASTM Standards; D429-14; ASTM International, West Conshohocken, PA 2014. Standard Test Method for Rubber Property — Effect of Liquids, Book of ASTM Standards; D471-16a; ASTM International, West Conshohocken, PA 2016. Standard Test Method for Tear Strength of Conventional Vulcanized Rubber and Thermoplastic Elastomers, Book of ASTM Standards; 0624-00(2012); ASTM International, West Conshohocken, PA 2012. Standard Test Method for Rubber Property - Durometer Hardness, Book of ASTM Standards; D2240-15; ASTM International. West Conshohocken, PA 2015. Standard Practice for Rubber-Materials, Equipment, and Procedures for Mixing Standard Compounds and Preparing Standard Vulcanized Sheets, Book of ASTM Standards; D3182-16; ASTM International, West Conshohocken, PA 2016. NACE Intemational White Metal Blast Cleaning, NACE Book of Standards; No. 1; NACE International, Houston, TX. 2005. Near-White Metal Blast Cleaning, NACE Book of Standards; No. 2; NACE International, Houston, TX. 2005. Commercial Blast Cleaning, NACE Book of Standards; No. 3; NACE International, Houston, TX. 2005.HYDROCHLORIC ACID STORAGE AND PIPING SYSTEMS 45 12.3 124 Brush-off Blast Cleaning, NACE Book of Standards; No. 4; NACE International, Houston, TX. 2005, Design, Fabrication and Surfac e Finish Practices for Tanks and Vessels to be Lined for Immersion Service, NACE Book of Standards; SP0178; NACE International, Houston, TX. 2007, Sheet Rubber Linings for Abrasion and Corrosion Service, NACE Book of Standards; ‘SP0298; NACE International, Houston, TX. 2007. U.S. Tire Manufacturers Association(formerly Rubber Manufactures Association) Protective Lining Publications, IP-4-1 through IP Association, Washington, DC. 2003. SSPC: The Society for Protective Coatings Solvent Cleaning, SSPC Surface Preparation Specifications; SP1; SSPC: The Society for Protective Coatings, Pittsburg, PA 13; Rubber Manufacturers Lining Service Conditions The commodity to be handled is aqueous hydrochloric acid, 30 - 37% solution, Storage Vessel Construction The storage vessel owner should ensure, as a minimum, that all welds in contact with the rubber lining be full penetration butt welds and that they are free of pinholes, undercuts, cold laps, and splatter. All vertical and overhead position welds should be made smooth by grinding. If grinding reduces the thickness of the metal below the minimum allowable thickness, the area should be built up with weld. All welds should have a minimum 3/8" radius, and inside comer edges should have a minimum 1/8” radius. All inside corner welds should be dye tested to assure that the weld is porosity free. All weld spatter and burrs should be removed by grinding. Welds should be prepared per NACE SP0178 “Weld Preparation Designation’ "A" or *C’. All bolt holes to be rubber lined should have rounded edges and holes overdrilled to compensate for the thickness of the rubber lining. Rubber lining applicator should visually inspect the welds that will be rubber lined and report deficiencies to the owner. Surface Preparation Surfaces should be inspected prior to the start of surface preparation to assure that they are dry and that visible deposits of oil, grease, chemicals, and any other foreign materials have been removed per SSPC - SP ~ 1, “Solvent cleaning prior to abrasive blasting’. Ambient conditions should be checked and recorded before and during operations, where bare metal will be exposed to determine the air and surface temperatures relative humidity, and dew point temperature. Surface preparations should not be permitted46 PAMPHLET 163 when the surface temperature is less than 5° F above the dew point. The compressed air supply for abrasive blasting should be inspected prior to and during operations for the presence of oil andlor water by means of the white fabric test, The test should be performed downstream of separators, The fabric should be free of visible contaminates of oil or water after being held in the air stream at a distance of 18” to 24” from the source for at least two minutes. All surfaces to be rubber lined should be blasted to a clean, gray white metal surface in accordance with SSPC-SP5. The interior of the tank car should be entirely vacuum cleaned and free of grit or other debris before any primer or cement application. The blasted surface should be coated immediately with the cement primer. If the surface is allowed to rust bloom, the surface should be re-blasted. The blasted surface should have a blast profile range of 1.5 mils to a maximum of 4 mils. The profile is to be tested using a TesTex Press-O-Film blast profile gauge. A minimum of six readings should be taken in each vessel. If areas of porosity in welds or plate show after blasting, the applicator should notify the owner so that repairs can be made Primer shall be applied only when the interior of the tank is free from scale, oxidation (rust), moisture, and all foreign matter. Surface preparation and abrasive blasting should be repeated as necessary to obtain this condition immediately prior to primer application, All areas blasted should be primed with one coat of primer as soon as possible after blasting. Allow to dry completely. Rubber Lining Materials It is preferable that the rubber lining used for 30-37% hydrochloric acid service be a natural gum rubber (25-45 Shore A durometer) using a base rubber grade with dirt content range of 0.02 - 0.05. The rubber content should be at least 90% of total content. White and black materials, which allow for the use of filer additives and reinforcements are acceptable as long as inert filers such as clay, talc and calcium carbonate are not used in the formulation, The base rubber should be at least 80% of total rubber content. The rubber lining, as received by the applicator, should be all new material. The surface should be free of defects such as blisters, tears and wrinkles, Fisheyes, although not desirable, are a result of the calendaring process and are not a cause for rejection of the material; however, the rubber manufacturer should use good practices to hold the amount of fisheyes to a minimum. ‘The rubber manufacturer should not ship to the applicator any rubber that does not meet the manufacturer's quality assurance measures. The applicator has the authority to reject any and all materials due to defects. The applicator should notify the rubber manufacturer of any rejected material and the manufacturer should replace the material, in a timely fashion, with acceptable rubber lining. The rubber manufacturer should use proper packaging materials to insure safe protection of the product during transit, The applicator should provide proper cold storage facilities for storage of the material, Since rubber is perishable it should be stored in accordance with the rubber manufacturer's recommendations and should be utilized prior to the expiration of the published sheff lifeHYDROCHLORIC ACID STORAGE AND PIPING SYSTEMS. 47 for that roll of rubber. Rubber that exceeds the shelf life can be utilized If itis approved by the rubber manufacturer. Adhesive systems should be approved for use by the rubber manufacturer. The rubber manufacturer should specify the method of application, material, cement and cure procedure for making pre-cure and post-cure repairs to the original rubber lining material, The rubber lining applicator should follow all of the rubber manufacturer's specifications and procedures. No substitution should be made for manufacturer's specified primers, cements, rubber, application procedures, or cure instructions without written approval from the rubber manufacturer, The adhesive system when cured propetly shall develop a minimum adhesion value of 25 pounds on a one inch width strip and 90 degree pull, as tested in accordance with ASTM D-429, method E. The party responsible for the lining should specify the rubber lining thickness to be applied Adhesion of Natural Rubber Strict adherence to environmental conditions as outlined in section 1.5 is required for all stages of the adhesive application, All cements should be thoroughly stirred and mixed sufficiently before and during use, so that solids will stay in suspension. Rubber Lining Application Strict adherence to atmospheric conditions is required during all stages of rubber lining application, Al layout marks on the rubber should be made using a chalk or chalk line, Use of a metal scribe or other device that cuts or scratches the rubber is not permitted. Skiving knives should be used to cut rubber sheets. Skived (beveled) edges should be cut to an angle of approximately 45 degrees. Water may be used during the cutiing to lubricate the knife. Rough, wavy irregular skive cuts should be rejected. Cut the rubber sheets to desired shape and size. The rubber lining may be installed either longitudinally or citcumferenially The rubber lining installers should document the batch numbers and/or roll numbers of the rubber installed into each vessel. This information must be kept with the vessel file as a permanent record. Prior to application, the rubber should be protected from dust, grease, and oil while lying on the cutting table, All cutting tables should be smooth, clean, and flat so that they will not leave an impression in the rubber. All panel seams must be approximately 45 degree skives with a two inch minimum overlap. All lining personnel should be familiar with skive joint requirements. Panels of rubber lining should overlap each other a minimum of two inches. The edge of48 PAMPHLET 163 1.10 the underlying panel is open-skived. The overlapping edge can be open or closed skive method of application, If the rubber sheet requires tackifying, swab with toluene or tack cement and allow to dry. The rubber is rolled into a lint free cloth liner. The rubber sheet is then positioned on the cemented metal surface while the liner cloth is gradually removed. The sheet lining should be rolled and stitched as required to exclude air between the lining and the metal surface. Care must be taken to minimize stretching of the rubber sheets during installation. Trapped air may be vented with a hypodermic needle, and the punctured area marked and covered with a four inch diameter overlay — per section 1.11 No four (4) comer joints are permitted. Triple corners are allowed, however the triple thickness should be removed by cutting out a piece of the second layer, approximately 1 %" square, overlaying the area with the third layer. After completion of the application, using a good light, inspect the entire lining surface looking for defects and air entrapment under the lining. Spark test the rubber lining surface according to RMA ~ IP-4-13 ‘Procedure for Spark Testing Elastomeric Sheet Lining" Application of Lining to Fittings All fittings surfaces that will be exposed to the lading should be lined with a hydrochloric acid resistant rubber. The owner of the lining should choose the lining type and thickness of rubber to be used in lining the fittings, provided that the chosen rubber lining is resistant to the lading and has a minimum thickness of 1/8” The lining on allflanges should be smooth. The manway cover and fittings should be spark tested after lining but prior to cure, All fittings should be autoclave steam cured. The fittings should be supported in the autoclave so that the rubber is not thinned or punctured during cure. Rubber Overlay before Cure Needle punctures from venting trapped air (blisters) should be covered with an overlay from the same thickness and type of the original rubber lining. All needle overlays should be a minimum of four inches in diameter with 45 degree beveled edges. If the blister area has lost adhesion, it should be cut out, inlayed and overlayed. The overlay should extend 2" beyond the inlay on all sides. Prior to curing, all rubber-lined surfaces should be inspected for blisters, pulls, lifted edges and surface defects. These areas should be reconditioned using acceptable rubber lining repair procedures. The entire rubber-iining surface should be visually inspected and spark tested according to the RMA — Bulletin 13. Leaks that are detected should be marked and numbered so that none of the areas are overlooked when making the actual overlays.HYDROCHLORIC ACID STORAGE AND PIPING SYSTEMS 49 ia 12 All overlays made prior to cure possess the same physical characteristics as the base lining and are not considered as repairs to the finished lining. Steam Curing of Natural Rubber Lining Sufficient boiler capacity should be available to raise the temperature in a relatively short time frame. Long uninsulated pipe runs from the steam source should be avoided. Low- pressure steam plus uninsulated lines promote excessive condensate. Check the manufacturer's specification sheet for time of cure. Prior to cure, the rubber lining applicator should attach thermocouples to the exterior of the vessel, The thermocouples should be checked continuously and recorded. The lining shall be cured per the lining manufacturer's curing procedure. The curing process includes start up of cure, curing and cool down. After the liner curing procedure, ensure proper vacuum relief is available while the tank cools. Significant damage can occur if the tank cools without adequate air flow through an open nozzle. Final Rubber Lining Inspection A visual inspection should be conducted after the cure to assure that all seams and joints are secure. As specified in section |.8, all panel seams shall have a two (2) inch minimum overlap, Loose lap seams or feathered edges may be buffed or cut off if it does not decrease the width of the lap seam by more than a ‘4’. If the buffed or cut off area decreases the lap seam to less than 1 %4" width, the area must be buffed and a 3° wide cover patch applied. A spark test must be repeated to prove the integrity of the rubber lining. Use a strong flashlight, held parallel to the surface of the rubber lining to inspect for blisters and irregular surface conditions All pinholes indicated by breakthroughs when spark testing should be repaired. The repair materials, application methods, and curing procedures should be based on type, size, and frequency of the defects. Patching with materials, other than those recommended by the rubber lining manufacturer should not be permitted. Defective or blistered areas should be cut back to good adhesion, repaired and tested. Areas less than one square foot should be cut away and prepared for repair. Using a pattern, cut an inlay patch with the edges that have been buffed and skived to a 45 degree bevel and overlay this patch with a secondary patch that extends at least 2” over the original ining. Larger repairs may omit the overlay, The steel surface and surrounding rubber of a repair area, less than one square foot can be prepared by grinding the metal to a bright, clean condition and roughening the base rubber lining, Areas larger than one square foot should be blasted. When repairing soft natural rubber linings, primer and intermediate adhesives should be applied only to the metal substrate. Atter cure, chemical cure patches are acceptable for lining repairs.50 PAMPHLET 163 All repairs should be inspected to ensure that all edges are firmly adhered and spark tested for leaks. ‘A durometer (Shore A) hardness survey, in accordance with ASTM-D2240, should be made on the cured lining. Approximately ten durometer readings should be taken at various locations throughout the vessel to assure that all areas of the lining are properly cured. The lining should be allowed to cool to ambient temperature before durometer readings are taken. These readings should comply with lining manufacturer's specifications. Records of surface profile, adhesive operations, lining application (including manufacturer's roll and/or batch numbers, inspection as well as location of repairs and curing logs) should be maintained for each vesselHYDROCHLORIC ACID STORAGE AND PIPING SYSTEMS 51 YES APPENDIX J - CHECKLIST This checklist emphasizes major topics and is designed for someone who has already read and understood this pamphlet. Taking recommendations from this list without understanding related topics can lead to inappropriate conclusions and actions. Place a check mark (1) in the appropriate box below: NO NIA ITEM OD 1. Does the facility comply with the PPE recommendation for specific tasks involving handling hydrochloric acid? 1 OF 2 Does the facility have emergency/contingency plans in place for all areas of hydrochloric acid storage and handling? OOD 3. Does the facility have a storage tank of at least one and one-half times the delivery tank truck or tank car capacity as recommended (assuming no dilution) to provide sufficient reserve capacity between shipments? OOF 4. Are hydrochloric acid storage tanks in your facility located in an area that will minimize both employee exposure and off-site consequences in the event of a release? OO & Does the facility have emergency provisions including the recovery and disposal of any hydrochloric acid spilled? OF © Does the facility have a training program to ensure personnel are thoroughly trained to handle emergencies and spills effectively? 0 OO 7. Does the facility have a well-managed internal and external inspection and maintenance program for the hydrochloric acid storage tank(s)? OO 8. Does the facility adequately support piping to prevent sagging and resting on structural stee!? (1 9. Are the materials of piping and fitings consistent with section 5.3? 1) 10. Do you understand thet when selecting valves for hydrochloric acid service, itis important to fully understand the service requirements for each application, and have a good working knowledge of the performance characteristics of each valve type and available materials of construction? PAMPHLET SECTION {2.5} {3.1} (4.2.2) {4.3} {4.7} {4.7} {4.8} (5.2.3) {5.3} {5.4}52 PAMPHLET 163 1 11. Does the facility have a well-managed inspection and maintenance program for pipe flangesivalves and loading/unloading lines? (1) 12. Do you understand that the guidelines in Section 6 are intended to provide sound practices for the specification and application of pumps used in hydrochloric acid service? (13. Are the material properties understood? (14. Do you understand that the selection of equipment, conductivity tests, and interpretation of results should only be done by trained personnel? (15. Have the options for avoiding the potential ‘overpressuring of the HCI FRP storage tank and the EPAJOSHA accident investigation recommendations been reviewed? 16. Do you have records to show your rubber lined tanks meet the specifications of Appendix I? REMINDER: Users of this checklist should document exceptions to the recommendations contained in this pamphlet. {5.6} (6) {Appendix A Appendix B Appendix C ‘Appendix D Appendix E} {Appendix F} (Appendix H) {Appendix I