KEY POINTS 1. Grease is unloaded to the . The grease is heated and stirred as it is circulated through a .2. The oil drum is used to that is used in the preparation of the .3. The oil and grease are pumped to the where powdered Catalyst is added.4. Catalyst is metered to the process from one of two cylinders. One cylinder is - Catalyst to the process. The other cylinder is being , or is full of Catalyst and for .5. This system is important in the polymerization process because it involves the preparation of the _____ used to produce Polymer.6. In the Catalyst dispersion drum, is blended into a _______ mixture.7. D140 A/B have a capacity of _______ liters. 8. FRC-1503 is located in the of the catalyst metering pumps.9. P151 A/B will start when the discharge pressure drops below _____and will stop when the pressure reaches _____.SECTION FOURTROUBLESHOOTINGThis lesson covers some of the common problems you might encounter when operating this step. PROBLEM CAUSE SOLUTION TEAL flows to the Precontacting pot to activate the catalyst.Whenever loss of TEAL or low or erratic flow is experienced, the catalyst feed to R200 shall be stopped until the problem is solved.1. Low TEAL flow due to low suction pressure 1.1 Cause: Plugging of suction filter F110. Solution: By pass filter through manual valve. If flow is regained, flush filter with oil and change out. Then put filter back in service as soon as possible. This event is exceptional. Normally as a precaution the filtering cartridge in the filter F110 is replaced once a year during the general shutdown. 1.2 Cause: Low level in TEAL metering drum D110. (Level in D110 should never be lower than 30%) Solution: If level is low, charge TEAL from TEAL storage cylinder following the filling procedure.2. Low TEAL flow due to high pressure in discharge line. When TEAL pumps pressure reaches 70 barg (without any previous low TEAL flow signal having been noticed by the operator): The pump in operation shall be stopped (together with catalyst and Donor metering pumps) andThe plugging cause shall be detected and removed before restoring TEAL, Donor and catalyst feed. 3. Erratic TEAL flowCauses: a) Fouling of internal ball check valves on suction or discharge of P110A/Bb) Erratic calibration or leakage of the internal relief valve of P110 A (or B). Solution: Switch pump and call for maintenanceCause: Erroneous flow indication.Solution: Use level drop local LI as crosscheck 4. Loss of seal in TEAL Seal pot D112 (LAL 115).Solution : Level shall be re-established by adding oil through the HV up to 50% of D112 level.5. P110 A/B diaphragm rupture (signaled by PA)Solution: Stop the pump in operation and start the spare one, then perform the required maintenance activities.6.Donor issuesa)Donor diluted in oil must always be kept agitated.If the agitator stops, Donor will settle thus giving false Donor feed readings.b)Breakdown of one of the diaphragms of metering pumps P120 A or P120 B, indicated by the diaphragm PA, is not particularly alarming. This just requires changing the pump in use.c)Nitrogen bubbles present in the intake lines downstream of the filters can cause the Donor flow to stop. Thus, time will be lost during start-up. To prevent this problem, purge from the bleed at the PI, located downstream of the pumps, before start-up. d)Normally, as a precaution, the filtering cartridges in the filters F120 A/B are replaced once a year.7.Atmer 163Since Atmer 163 solidifies at about 67°C, take care to prevent such a condition in lines or pump not in operation.8.CATALYSTThe most critical occurrence in the catalyst mud preparation and metering section is loss of refrigerated water.In this case, due to the tendency of the solid catalyst to settle, it is necessary to empty back D150 A or B to D141 A or B and then to the dispersion drum to homogenize the mud again.Once refrigerated water supply has been restored, catalyst mud feed can be restarted.Since in some cases the line between D150 A/B and R200 cannot be emptied back, when catalyst is restored, purge the catalyst paste from the R200 inlet sampling nozzle until a homogenized mud comes out.Another possible source of trouble in the catalyst metering package is a leakage of the four-way valve V1, which can be detected from erratic catalyst feed t