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LOTTE PAKISTAN PTA

T-11 UTILITIES PALNT

UTY Plant Operating Procedure


ETP plant (Revision: 01)

Name
Author

Muhammad Ismail

Reviewed By

Rehan Siraj

Signature

Page 1

Date

LOTTE PAKISTAN PTA


T-11 UTILITIES PALNT

UTY Plant Operating Procedure


ETP plant (Revision: 01)

Table of Contents

Page No.

1. Buffer storage Area


2. Neutralization Area
3. Feed tanks Area (A1-2504A/B/C)
4. Feed chiller Package (Z1-2578)
5. Deep shaft package (Z1-2538)
6. Deep shaft operation procedure
7. Air Compressor (C1-2527A/B) system
8. Degasser (A1-2510A/B) system
9. Clarifier (A1-2511A/B) system
10. Tertiary treatment Package
11. Sludge Handling Package Z1-2549

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09
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31
35
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LOTTE PAKISTAN PTA


T-11 UTILITIES PALNT

UTY Plant Operating Procedure


ETP plant (Revision: 01)

1. BUFFER STORAGE SYSTEM SCOPE


This instruction describes the effluent storage in buffer tanks A1-2500A/B/C/D.It covers the intial lining
up of the effluet in the buffer tanks,shutdown and normal operation of the buffer tanks and the effluent
feed pumps G1-2501A/B/C/D.
1. INTRODUCTION:
Plant effluent from core and non-core plants is collected for treatment in buffer tanks; A12500A/B/C/D. Contaminated water run-off from non-core areas is collected in drainage pits and
pumped over to the buffer storage tanks A1-2500 A or C. The general effluent drainage of the
effluent from core plant is collected in the core pit A1-850 and is pumped to effluent plant as waste
water via G1-851A/B .Waste water stream is cooled by E1-2526 a plate and frame type heat
exchanger with bypass. Waste water steam is mainly acidic in nature due to high percentage of the
PTA, CTA, and ACETIC ACID etc. Sometimes it becomes basic due to the excessive caustic wash at
the core plant. The buffer storage also receives direct discharge of mother liquor by diversion of its
normal flow to the neutralization by manual isolation valve now this is not applicable.
2. EFFLUENT STORAGE IN BUFFER TANKS
1.1. INITIAL CHECKS
1.

Check all PTW are completed and duly signed off.

2.

Physically check all equipment for mechanical jobs completion.

3.

Ensure all slip plates are in proper position and all drains are closed.

4.

Check all instruments are in place and on line.

5.

Check availabilities of utilities like:


a.

Instrument air

b.

Seal water for transfer pumps

c.

Potable water supply in safety shower

4.

Check that FT-5001, FT-5008, FT-5021 and Ft-5024 are normal.

5.

Check instrument air supply to LT-5012, LT-5013, LT-5014 and LT-5015 (buffer tank A12500A/B/C/D tank level transmitters) bubbler type.

6.

Checks tank is ready to take the effluent.


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T-11 UTILITIES PALNT

UTY Plant Operating Procedure


ETP plant (Revision: 01)

3. NORMAL OPERATION
1. Mother liquor is not to be diverted to neutralization plant even mother liquor filter M1-1603 is inservice or not .It is due to the reason that pH probes of the both F1-2508 and F1-2519 may be
damaged due to the high temperature of the mother liquor.
2. Effluent of the plant to be lined up in the buffer storage tanks and changeover the mother liquor and
waste water accordingly.
3. Quality-wise the effluents of the plant to be lined up in the buffer storage tanks and divert the waste
water or mother liquor accordingly.
4. Physically check the level of the buffer tanks and update the DCS board man .In order to avoid the
overflowing the buffers due to malfunction of the level transmitters.
5. To increase the flow of effluent from the buffer storage tank or to take effluent from another buffer
tank FCV-5001/5008/5021/5024 should not open more than 5% at -a -time. This is due to avoid the
entrainment of the PTA powder to neutralization section and feed storage tanks A1-2504A/B/C/D.
6. Disturbance in the oxidation plant, i-e, M1-1603 by passing causes high COD effluent flow to the
buffer storage section, due to this lineup the mother liquor to the dedicated buffer. High COD
effluent will reduce the total hydraulic load of the deep shaft, so buffers management will be
required.
7. When waste water flow from the G1-851 A/B start to decrease than open the bypass valve of the
E1-2526 and check the flow, if it become normal, inform to the shift manager for chocking of inlet
strainer of E1-2526. The PTA in effluent causes chocking of E1-2625 inlet strainer.
8. Check that all pumps G1-2501A/B/C/D are available in healthy condtion and can be taken in
service.
4. EFFLUENT COLLECTION DURING PLANT SHUT DOWN
5. Select one buffer storage tank A1-2500 A/B/C/D before one week of the plant shutdown in order to
accommodate the plant flush effluent. Plant effluent may contain the metals which are toxic for the
bacteria.
6. Take maximum flow from this buffer storage tank during the week. It should not keep on filling.
Level need to be decreased up to minimum.
7. As the core plant put on flush after shutdown, then stop taking effluent from this buffer and lock
close the buffer outlet valve and stop the transfer pump G1-2501A/B/C/D.
8. Shift both waste water and mother liquor streams to this buffer storage tank, in order to collect the
effluent in one buffer.
9. Monitor the level of this buffer via DCS and also from area in order to avoid the overflowing of
effluent in other buffer storage tanks.
10. When core plant completes its flushing than take the sport sample of the both streams Mother
Liquor and waste water from IBCs sample point and check the cobalt and manganese result.
11. Line up the effluent in some other buffer storage tank if the result of the metals is normal.
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T-11 UTILITIES PALNT

UTY Plant Operating Procedure


ETP plant (Revision: 01)

12. Put the buffer in which contaminated effluent is collected on settling for 24 hours then take the
sample for metals and carry out test, if metals found normal then line up this buffer for feed
preparation otherwise inform to shift manager.
5. SHUT DOWN OF THE BUFFER TANKS:
There is no shutdown in the effluent collection section, the effluent collection stop which is only for
the time being. Buffer storage pumps remain in service on kickback if required otherwise can be
stopped

only feed

to

neutralization

will

is

to

be

stopped

by

closing

the

FCV-

5001/5008/5021/5024.from DCS. For the cleaning of the buffers storage isolate the valves of this
buffer storage tank and carryout the necessary preparation for cleaning as per given procedure.

1.2. Procedure for the PTA Sludge removal From Buffer Tanks A1-2500A/B/C/D
List of the equipment to be utilized for the cleaning of the buffer tanks
S#

Equipments

Quantity

1.

Crane

01

2.

Clamp Bucket

01

3.

Dump Trucks

List of the manpower required for the buffer cleaning purpose


S
#
1
2
3

Manpower

Quantity

Supervisor
Rigger
Assistant Riggers/Helper

1.
2.
3.

1. PTW will be issued for seven days and re-validate it daily in the morning. However job will be
started daily at 08:00 hrs till sunset and will continue on Sunday and gazetted holidays.PTW
revalidation will be done at site to avoid any delay in the job.
2. Safety signs would be displayed for crane and dumpers activity.
3. No entry signs to be posted for restriction of entry of unauthorized persons/traffic to avoid any
safety incident.
4. The crane and dumpers activity area to be hard barricaded with an entry gate. A crane and only
one dumper will be parked inside barricaded area. The other waiting dumper to be parked

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T-11 UTILITIES PALNT

UTY Plant Operating Procedure


ETP plant (Revision: 01)

outside the barrication. PTA will provide scaffolding team and material, while Descon will give
the exact requirement of scaffolding.
5. Tanker cleaning activity to be carried out during daylight only.
6. A scaffolding platform along with ladder on the tank to be erected by PTA scaffolding team
with plant scaffolding material.
7. Bucket movement will be controlled through a tie-rope by a rigger to avoid its hitting the tanks
walls or other surfaces.
8. The tank cleaning staff will wear proper PPEs including splash goggles, PVC gloves and
rubber boots.
9. Dump truck water arrangement will be made at working site and working staff will be changed
after every 60 minutes.
10. A resting area i.e. tank with bench/chairs will be provided near work area but outside the
barrication.
11. Immediately reported any safety incident to PTA plant area operator, who will report the matter
to Utilities shift manager.
12. All standard safety instructions and operating procedures must be followed at work site.
13. Dispensation for hot work permits for crane to be arranged by PTA (if needed).
14. Descon will explain the job method and give task instructions to their workforce before starting
the job.
15. Bucket will be inspected at least once a week. Inspection will be arranged by PTA planning, to
avoid the wastage of contractors man-hours inspection will be done in time.
6. BUFFER TANK CLEANING PROCEDURE WITH CRANE
1. Park the crane inside the barricaded area where it will be operated.
2. The crane weight will be taken on outer riggers (jacks) with no load on wheels to ensure
balanced operation of the crane.
3. In order to ensure that crane bucket is not touching with tanker bottom. The crane bucket rope
will be marked up to 6000 mm (including basket height) and this mark should be clearly visible
and must remain outside the top surface of the PTA sludge.
4. The tank will be prepared for the entry and it will be handed over to maintenance staff before
starting cleaning operation.
5. Once dumper is parked for loading sludge. Its engine must be switched off and driver should go
to the tent. No one will enter the work site without proper PPE.
6. The rope tied up with the bucket will be held by a rigger positioned at scaffolding platform; the
rope will further be knotted with scaffolding pipes. When the bucket is at height the rigger will
loose the rope slowly in such a manner that it will not hit the tank surface or sidewalls.
7. Another rigger must be positioned at scaffolding platform who will direct the crane driver
regarding bucket movement; He will watch the depth of bucket inside the sludge tank and will
ensure the depth mark on the bucket rope that it does not touch the sludge tank top surface.
8. The site supervisor must ensure that no person is doing any activity under the crane operation.

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T-11 UTILITIES PALNT

UTY Plant Operating Procedure


ETP plant (Revision: 01)

9. No sludge should fall on any person


10. Standard safety instructions for crane working must be followed.
11. The loaded dumpers will be weighed as per instructions sheet PTA Management, which would
be basis of sludge load calculation. Daily verification sheet be submitted along with the invoice.
12. Having loaded the dumper the empty bucket to be lowered down the ground and dumper would
be off loaded to desponding area.
13. Inside plant the dumper speed should not to exceed 25 km / hr.
14. The work site housekeeping must be carried out daily on closing the crane activity by Descon.
15. Crane boom will be assembled near the PTA engineering workshop area with the assistance of
PTA hydraulic crane.
7. Job method for the Leak Repair or Lining in Buffer Tank With Man riding basket
1. Crane Man riding Basket, Safety Harness, Ropes & Lifting Gear to be Inspected/Checked by
PPTA Rigging Supervisor.
2. Two trained experienced persons of Man riding Basket can do the job at-a-time.
3. Area barrication and sign posting must be done prior commencing the job.
4. Two guy ropes (Tag line) must attach with the Man riding Basket to prevent the unnecessary
swing.
5. Attached the harness with crane hook separately all the time and do not attach it with the man
riding basket.
6. The whole activity must be supervisor by the designated mechanical supervisor and job will be
audited time to time by SHE Department.
7. In case of any abnormality the activity shall be stopped immediately.
8. The maintenance staff shall secure their Tools/ equipment with a rope to prevent the equipment
falling in the pit.
9. The crane operator, with the help of a banks man shall keep the movement of the basket to the
minimum possible to avoid the basket from hitting the pit wall or lining and crane operator will
be in their cabin during the activity.
10. The whole activity to be carried out in daylight 8:00 to 18:30 hrs.
11. Instructed PPE for the job are clear L.E.P, Helmet with chin guard ,one Radio set and rubber
boots. ( If required )
8.

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LOTTE PAKISTAN PTA


T-11 UTILITIES PALNT

UTY Plant Operating Procedure


ETP plant (Revision: 01)

2. Feed Neutralization System


1. INTRODUCTION:
Effluent from the buffers storage is transfer to the first neutralization tank F1-2508 via G1-2501
A/B/C/D under flow control via FCV-5001/5008/5021/5024, with an option of taking mother liquor and
CRU spent soda ash effluent into it. Caustic soda is added in to it in the form of 5% and 47% for pH
controlling purpose between5.5 to 6.0.
Effluent from F1-2508 overflows into second neutralization tank A1-2519.Caustic and HCL can be
added to this tank (depend upon pH) but due to the presence of the acid mostly pH remains in the acidic
range so HCL tank is now relocated and lines are slip plated in this neutralization tank. The pH is
maintained between 6.0 to 6.5.The effluent overflows into outlet chamber A1-2502 from where this
effluent is supplied to feed storage tanks A1-2504 A/B/C via feed cooler E1-2518 A/B.
Feed storage tanks A1-2504 A/B/C receive the neutralized effluent for final flow to biological reactor in
secondary treatment section of effluent treatment plant. Feed flow is controlled via FCV-5068
accordingly to COD load on deep shaft.
2. STARTUP OF THE NUTRALIZATION SYSTEM
INITIAL CHECKS:
1. Check that all PTWS are signed off.
2. Ensure all slip plates are in proper position and all drains are closed.
3.
4.
5.
6.
7.
8.

Check all mechanical jobs are completed and system is ready to take the effluent.
Check the effluent level in the buffer storage tanks A1-2500A/B/C/D is sufficient.
Check that G1-2501A/B/C/D are available.
Check that FCV-5008/5001/5021/5024 are working normal.
Check that G1-2508 and G1-2519 are electrically energized.
Check the availability of the following utilities
i.
ii.
iii.
iv.
v.

9.
10.
11.
12.
13.
14.

47 % caustic soda.
Seal water
Cooling water
Instrument air
Portable water for the Safety shower

Check that QT-5027/28/30/31 are available and calibrated.


Check that LT-5032 is working normal and its stroke checks completed.
Check that G1-2503A/B area available.
Check that overflow line towards buffer tank is de-isolated
Check that mother liquor line to F1-2508 is slip plated.
Check that CRU soda ash supply is offline.

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T-11 UTILITIES PALNT

1.
2.
3.
4.
5.
6.
7.
8.
9.

UTY Plant Operating Procedure


ETP plant (Revision: 01)

STARTUP
For the cold startup open fire water in the F1-2508 and fill the tank up to 20 %.
Line up the buffer storage effluent via G1-2501A/B/C/D.
Fill the tank and overflow this in the A1-2519.
Check the pH of the effluent via QT-5027/28 and calibrate them if required.
Start the agitator of the G1-2508 when it level reaches up 75 %.
Fill the A1-2519 and take the G1-2519 in service.
Check the pH of the effluent via QT-5030/31 and calibrate them if required.
Complete fill the A1-2502 and lineup 47% caustic to maintain the pH.
Check any abnormal sound in the G1-2508 & G1-2519 and inform to shifty manager about

abnormality.(if any)
10. When the effluent is completely neutralized and downstream system is ready to take the
neutralized effluent then take the G1-2503A/B in service as per given startup procedure.
3. G1-2503A/B NUTRALIZATION PUMP STARTUP
1. Check all PTWS are signed off.
2. Check the system for the completion of all mechanical jobs.
3. Check that pumps G1-2503A/B are electrically energized.
4. Check that seal water line isolation valve is open and its pressure is normal on the local PG.
5. Check that sufficient liquid level is available in the A1-2502.
6. Check that E1-2518A&B are ready to take the effluent.
7. Check that E1-2518 A&B cooling water is lineup.
8. Check that feed storage tank A1-2504A/B/C is ready to take the effluent.
9. Confirm that feed tank ZCV-5040/5045/5050 is operational.
10. Check that pump kick back line is minimum 10 % open.
11. Open the suction and discharge valve of the elected G1-2503A/B.
12. Check that LCV-5032 is 50% open.
13. Pull emergency stop button and push the start button.
14. Check the pump for any abnormal sound.
15. Pressure on the discharge PG-5038/5033 must be 3.5 to 4.0 barg.
16. Confirm that suction and discharge isolation valves of the standby pump are isolated.
4. G1-2503A/B CHANGEOVER PROCEDURE
1. Ensure that seal water is lineup to the standby pump G1-2503SA/B.
2. Open suction and discharge valve of the standby pump.
3. Ensure that spill back line valve is minimum 10 % open.
4. Pull emergency stop button and push the start button.
5. Check the pump for any abnormal sound.
6. Pressure on the discharge PG-5038/5033 must be 3.5 to 4.0 barg.
7. Press emergency stop button of the running pump.
8. Isolate suction and discharge valves and put the pump on standby
5. NORMAL OPERATION:

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UTY Plant Operating Procedure


ETP plant (Revision: 01)

1. Physically check the level of the F1-2508 and F1-2519 should be full upto the overflow because
low level can damaged the agitator.
2. Physical check any abnormal sound from the agitator of the all neutralization tanks, i-e, G1-2508
and G1-2519.
3. Switch off /stop the agitator if any abnormality is observed from them and inform to shift manager.
4. To increase the flow or start taking effluent from buffer storage FCV-5001/5008/5021/5024 to be
opened slowly not more than 5% at a time.
5. Check any abnormality in the pH at DCS (in the Process value and set point).
6. Mother liquor not to be lined up in the F1-2508 neutralization tank even M1-1603 is (mother liquor
filter) in service or not. It must remain line up in buffer storage tanks.
7. When there is low pH problem then check the acetic acid concentration in the buffers and also
check the buffers tank level physically.
8. When pH value in the A1-2519 is lower than 6 then do not forward this batch to the feed tanks F12504A/B.
9. When pH become low then reduce the flow from buffers and increase QT-5027 /5030 pH set
point.
6. EMERGENCIES:
In normal operation of the neutralization systems following emergencies can occur.
1. High or low pH disturbance due to the powder in the feed from the buffer tanks.
2. High or low pH issue due the malfunction of the QT-5027/5030.
3. Gear box problem of the G1-2508 & G1-2519.
4. Actuator failure of the LCV-5032.
5. Power failure
6. MCC# 22 power failure or any other issue on the MCC#22.
7. 47% caustic header leakage or G1-2621A/B failure.
8. G1-2503A/B duty pump failure while standby is under maintenance.

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LOTTE PAKISTAN PTA


T-11 UTILITIES PALNT

UTY Plant Operating Procedure


ETP plant (Revision: 01)

3. Neutralized Feed Storage System


1. Introduction:
Neutralized and cold deep shaft feed is stored in the batch tanks A1-2504A/B/C. In A1-2504A/B/C
this feed is further circulated for cooling and mixing purpose. There are three tanks in this area; each
has working volume of 1350 M3. Neutralized feed is transfer in the batch tank where its sampling of
the COD and pH is carried out. If COD and pH are matching the required value ( i-e, <8000 and 6-9
respectively) then this batch is ready to transfer to the deep shaft otherwise this is diverted to buffer
storage area via divergent line located at outlet of the G1-2505A/B/C. in normal operation one feed
tank remains on filling second on the mixing and third on feed forward. Scope of this document is to
introduce the area operator about safe startup, shutdown and normal operation of feed batch tank area.

2. Start up of Feed/Batch Tanks A1-2504A/B/C


Initial checks

1.
2.
3.
4.
5.
6.
7.
8.

Check that all PTWs are signed off.


Physically check of all equipments for mechanical jobs are completed.
All slip plates are removed.
Check feed tanks are ready to receive the neutralized feed.
Check that neutralized feed is available in A1-2502.
Check that G1-2503A/B is available and are electrically energized.
Check that E1-2518A&B are available.
Check the availability of the following utilities:
i.
Cooling water
ii.
Raw water for sealing
iii.
Instrument air
9. Check the availability of the following instrument:
i.
Feed tanks inlet ZCV-5040, 5045and 5050 are in place and working normal.
ii.
Feed tanks LT-5041, 5046 and 5051 are in place and level indication is normal.
iii.
Feed tanks pH QT-5056, 5059 and 5062 are in place and working normal.
iv.
G1-2505A/B/C kick back ZCV-5044, 5049 and 5053 are in place and working normal.
v.
G1-2505A/B/C outlet ZCV-5044, 5049 and 5053 are in place and working normal.
vi.
Feed out let FCV-5068 is normal.
10. Check that G1-2505A, B& C are available.

Start up of the batch tanks A12504 A/B/C:


1. Open the inlet ZCV-5040/5045/5050 of the respective feed tank.
2. Open the isolation valves of the cooling water and process side of E1-2518A & B.
3. Check the system for any leakage of process and cooling water across the E1-2518A/B and
process inlet line of the A1-2504A/B/C .For this open suction and discharge isolation valves of
the G1-2503A/B and open the LCV-5032 100%.if observe any leakage then first rectify this
then start the G1-2503A/B.
4. Take G1-2503A/B in service as per SOP.
5. Open LCV-5032 with the set point of 50% on auto.

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UTY Plant Operating Procedure


ETP plant (Revision: 01)

6. Check E1-2518A&B discharge temperature on TIA-5067. It should be <45 0C.At-a- time both
E1-2518 A & B can be taken in service but one E1-2518A/B is enough for the maximum flow
of effluent.
7. Confirm LT-5041/5046/5051of the select feed tank working normal and cross check it from the
area.

3. Start up of the feed pump G1-2505 A/B/C:


1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.

Check all PTWS are signed off.


Check the system for the completion of all mechanical jobs.
Check that pumps G1-2505A/B/C are electrically energized.
Check that feed storage tank A1-2504A, B & C any two are filled with neutralized effluent.
Check that seal water line isolation valve is open and its pressure is normal on the local PG.
Check that sufficient liquid level is available in the A1-2504A/B/C.
Check that E1-2582 is ready to take the effluent.
Check that E1-2582 chilled water is lineup.
Check that G1-2583 chilled water pump is in service.
Check that deep shaft package is ready to take the effluent.
Check that chiller package is ready to be taken in service.
Check that pump kick back line is 100% open.
Check that each pump feed diverge line to buffer storage area is fully isolated.
Open the suction and discharge valve of the elected G1-2504 A/B/C.
Check that FCV-5068 is fully close.
Pull emergency stop button and push the start button.
Check the pump for any abnormal sound.
Pressure on the discharge PG-5055/5058/5061 is normal.

4. NORMAL OPERATION:
1.
2.
3.
4.

Take the reading as per log sheet.


Check if any abnormality is in the parameters.
Check any abnormal sound from the pumps and inform to shift manager.
Before line up of any feed tank on forward ask board man about the COD and pH result. Its

COD must be < 8000 PPM and pH =6-9.


5. Purge the QT-5056, 5059 and 5062 once the in the shift.
6. Divert the feed back to buffer storage tan if the pH and COD are out of order.
7. The feed flow to the deep shaft should not be less than 50 m 3/hr because absorption chiller will
tripped on 50m3/hr as per logic.

5. EMERGENCIES:
Following emergencies can be occurred on this plant
1. Power failure.
2. FCV-5068 mal function.
3. Feed Quality (if it is out of order then transfer this to the buffer storage are via divergent line).

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T-11 UTILITIES PALNT

UTY Plant Operating Procedure


ETP plant (Revision: 01)

ETP CHILLERS PACKAGE Z1-2578 OPERATING PROCEDURE


1. Startup of G1-2583 Chilled water pump:
1.
2.
3.
4.
5.
6.
7.

Check all PTWs are signed off.


Check that lube oil in the sight glass is 100 % full.
Open chilled water inlet & outlet valves of the G1-2583.
Check any leakage from E1-2582.
Take G1-2583 is in service.
Open the vent valve of the chilled water circuit located at the outlet line of G1-2583.
The expansion tank F1-2584 level should be 100 % full during the purging of the chilled water

circuit
8. On completion of purging close vent valve of the chilled water circuit
9. The sound of the G1-2583 should be normal.
10. Check the pump outlet pressure at the PG-5068; it should be around 2.5 brag

2. INTIAL PREPARATION OF Z1-2576 ABSORPTION CHILLER:


1.
2.
3.
4.
5.
6.

Check all work permits are signed off and returned.


Check all equipment for mechanical job completion.
Check G1-2583 is normal in service.
Check steam is available in the steam circuit.
Check steam inlet isolation valve is open and steam trap works normally.
Check condensate of the steam supply line is completely drained out from the steam circuit to

7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

avoid the hammering in steam circuit and in the tubes of the absorption chiller.
Check chilled water inlet & outlet valves are opened.
Check cooling water inlet and out valves are opened.
Check if there is leakage from the chiller all supply circuits.
Check the lube oil level in the vacuum pump G1-2596.
Checks purge tank pressure it should be less than 2.0 kPa.
Check cooling water inlet pressure on the PG-5106 it should be higher than 3.5 barg.
Check chilled water supply pressure on PG-5105 it should be 2.5 barg.
Check absorption chiller power supply is resumed.
Check that the millennium panel works normally.
Check all parameter and set point of the absorption chiller.
Check that chiller ready to start is indication is appearing and on pressing the status key NO

MALFUNCTION appear.
18. Check that local mode is selected before taking the chiller in service.

3. Z1-2576 ABSORPTION CHILER STARTUP


1.
2.
3.
4.
5.

Complete the startup checklist.


Check ready to start indication is appearing on the millennium panel.
Before chiller startup inform to DCS board man.
Press the startup key of the absorption chiller.
Sequence of the absorption chiller startup is given as.
i.
First condensate drain will be open.
ii.
L.P Steam control valve FRC-5100 opening on panel in will start to increase.
iii.
When 1st stage generator pressure will reach to 6kpa then refrigerant pump will take
iv.

start.
When 1st stage generator pressure will reach to 15kpa then Solution pump will take
start.

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v.
vi.

UTY Plant Operating Procedure


ETP plant (Revision: 01)

Confirm that condensate coming out from condensate line properly.


Lithium bromide solution concentration will appear on the panel when 1 st generator

temperature will reach to 1210C.


vii.
Confirm that solution concentration should not exceed 63%.
6. Ensure that chiller is normal in service.

4. Z1-2576 NORMAL OPERATION


1. Take the reading as per log sheet
2. Manually increase the steam flow by opening drain isolation valve and communicate to DCS
3.
4.
5.
6.

board man.
Now check the chiller parameters and confirm that it is normal in service.
Check if any abnormality is in the parameters.
Check any abnormal sound and leakage from any header and inform to shift manager.
Keep the feed flow rate should be >50 m 3/hr in order to avoid the tripping of the absorption
chiller.

5. ABSORPTION CHILLER SHUT DOWN


1. Press stop button to stop the absorption chiller.
2. Check dilution cycle is started and it will remain for 20 minutes.
3. For the longer period physically isolate the L.P steam valve and ensure that no steam is passing.

6. Method for fault resetting of the Absorption chiller


Following are the steps to reset the fault.
1. Press Status key on the Panel of absorption chiller to check the
fault.
2. Press the Access Code on the panel.
3. Enter the password YORK. 9675
4. Press Enter on the panel and access accepted will appear on the
screen.
5. Press the MODE on panel and select the service mode.
6. Again press Enter on panel for the selection of service mode.
7. First press the Reset button second to start button (new changed
one) than press the warning reset on panel.(hold this for 30 seconds
to one min)
8. Press Status again on panel than warning should not be appearing.
9. Again repeat the steps #2, 3, 4, 5 to change the mode from service to
local only if the timer has expired, otherwise just repeat the step # 5,6
to change the mode (service
local).
10.
Take the chiller normal in service.

7. Method of Manual purging of purge tank:


NOTE: Dont open purge valve of condenser in any case while the absorption chiller is in service.

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1. The purge tank to be purge when the pressure exceeds 60 mmHg. The purge tank will be
evacuated until tank pressure is reduced to 30 mmHg.
2. The Micropanel should be set to operate in the manual purge mode.
3. Operate purge pump G1-2596 for 10 minutes to warm up oil with gas ballast open, leak rate
valve open and all purge system valves closed.
4. Check that the purge pump G1-2596 is capable of pulling down to at least 3 mm Hg by opening
manual valves slowly and reading the purge pump pressure on the vacuum indicator gauge.
5. Slowly open purge tank valve to read the purge tank pressure on the vacuum indicator gauge. If
the pressure exceeds 30 mm Hg absolute, the purge tank may be purged although it is not
necessary unless the tank pressure is equal to or exceeds 60 mm Hg absolute.
6. Slowly open purge tank valve. Watch the purge tank pressure. When it is lowered to 30 mm Hg
absolute, close the valves.
7. Run purge pump for 10 minutes more to clean up oil.

8. Method of Manual purging of the absorber:


NOTE: Do not purge the absorber if the absorber solution level is in the top sight glass of the
absorber shell, or solution may be drawn into the vacuum pump.
Dont open purge valve of condenser in any case while the absorption chiller is in service.
1. The Micropanel should be set to operate in the manual purge mode.
2. Operate purge pump G1-2596 for 10 minutes to warm up oil with gas ballast open, leak rate
valve open and all purge system valves closed.
3. Check that the purge pump G1-2596 is capable of pulling down to at least 3 mm Hg by
opening manual valves slowly and reading the purge pump pressure on the vacuum indicator
gauge.
4. Open the absorber purge valve to G1-2596.
5. After purging is complete, close purge valve to G1-2596.
6. Run purge pump for 10 minutes more to clean up oil.

9. EMERGENCIES:
Following are the possible emergencies in the absorption chiller.
1. Power failure.
2. L.P Steam failure
3. L.P Steam MOV failure
4. Cooling failure
5. Chilled water failure
6. Feed pump failure or lower flow rate <50 m3/hr.

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ETP plant (Revision: 01)

CENTRIFUGAL CHILLER C1-2580 A/B/C STARTUP


1. Initial checks:
1.
2.
3.
4.
5.
6.
7.
8.

All jobs are completed and PTW are signed off.


Check that chiller Z1-2580A/B/C main motor and auxiliaries power is on.
Check G1-2583 is in service.
Check that oil level in the sight glass is normal.
Check that oil reservoir temperature is > 60 0C or it must be refrigerant temperature plus 50 oC.
Check chilled water inlet and outlet isolation valves are fully opened
Check cooling water inlet and outlet valves are fully opened.
Check parameters and set points of chiller from the local panel (comfort screen) as
pressMENU from (CCN, LOCAL RESET, MENU) keys.
9. Then Press STAUS KEY
10. Bring the cursor to STATUS O1 by pressing PREVIOUS or NEXT key then press
SELECTKEY. The screen will start showing the status of all parameters on that condition and
respective keys will change to NEXT,SELECT,EXIT,
11. After checking all the parameter press EXIT KEY twice to come at first screen.
12. To check the set points press the MENU KEY and then press SET POINTkey. The screen
will show the set points as
i.
Base demand limit
100 %
ii.
LCW set point
9.0 oC
iii.
ECW set point
18 oC
iv.
Ice build set point
4.4 oC
13. Bring the first screen by pressing the ENTER and then EXIT key.

2. STARUP OF THE C1-2580A/B/C


1. LOCAL STARTUP (MANUAL STRATUP):
i.
Local startup is initiated by pressing LOCAL menu soft key on comfort screen. Local
start-up can proceed when the chiller schedule indicates that the current time and date
have been established as a run time and date, and after the internal 15-minute start-tostart and the 1-minute stop-to-start inhibit timers have expired. The timer must expire
ii.

before the chiller will start.


Once local start-up begins, chiller; control system performs a series of pre-start tests to
verify that all pre-start alerts and safeties (i.e. number of starts , bearing temperature,
motor

temperature,

compressor

discharge

temperature,

evaporator

refrigerant

temperature, oil sump temperature, condenser pressure and line voltage) are within the
iii.

limits then control reads PRESTART otherwise the startup will be delayed or aboard.
If chiller reads PRESTART then the following sequence will start.
a. The chilled water relay energizes, and the MAINSTAT screen line now reads
STARTUP.
b. After Five seconds, the cooling water relay energizes.
c. After point b (minimum 30 seconds to maximum 5 minutes) the control system
monitors the flow of chilled water and cooling water by the PDS-5230/32/5234 &
PDS-5229/31/5233 respectively.
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d. Now control system will check the chilled water temperatures against set point. If
temperature will be below or equal to the set point plus chilled water dead
band then sequence will not proceed and if the chilled water temperature is high
enough, then start-up sequence continues.

e. Now control will check the guide vane position. If the guide vanes are more than
f.

4% open, the start-up waits until the control system closes the vanes.
If the vanes are closed and the oil pump pressure is less than 4 psi (28 kPa), the oil
pump relay energizes. The control system then waits until the oil pressure reaches
a maximum of 18 psi (124 kPa). Oil pressure verified (15 seconds minimum, 300

seconds maximum after point e.)


g. After oil pressure is verified, the control system waits for 40 seconds, and the
compressor start relay (1CR) energizes to start the compressor.

3. NORMAL OPERATION OF C1-2580 A/B/C


1. Take the reading as per log sheet.
2. Check the Running System After the compressor starts, the operator should monitor the
control screen display and observe the parameters for normal operating conditions.
3. The oil reservoir temperature should be above 120 F (49 C) during shutdown.
4. The bearing oil temperature accessed on the COMPRESS table should be 120 to 165 F (49 to
74 C). If the bearing temperature reads more than 180 F (83 C) with the oil pump running, stop
the chiller and determine the cause of the high temperature. Do not restart the chiller until
corrected.
5. The oil level should be visible anywhere in one of the two sight glasses. Foaming oil is
acceptable as long as the oil pressure and temperature are within limits.
6. The oil pressure should be between 18 and 30 psid (124 to 207 kPad) differential, as seen on the
control panel default screen. Typically the reading will be 18 to 25 psid (124 to 172 kPad) at
initial start-up.
7. The moisture indicator sight glass on the refrigerant motor cooling line should indicate
refrigerant flow and a dry condition.
8. The condenser pressure and temperature varies with the chiller design conditions. Typically the
pressure will range between 60 and 135 psig (390 to 950 kPa) with a corresponding
temperature range of 60 to 105 F (15 to 41 C). The condenser entering water temperature
should be controlled below the specified design entering water temperature to save on
compressor kilowatt requirements.
9. Cooler pressure and temperature also will vary with the design conditions. Typical pressure
range will be between 60 and 80 psig (410 and 550 kPa), with temperature ranging between 34
and 45 F (1 and 8 C).
10. Check the chiller for any abnormal sound and inform to shift manger about the abnormality.
11. Check G1-2583 for any abnormal sound and the cavitation of the pump.

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12. Check any external leakage in E1-2582 (large quantity of the makeup water indicates that there
is some leakage of the chilled water inside the circuit this continuous makeup water will not
give the required cooling).
13. If two chillers are parallel in service and chilled water entering temperature reaches to the 16 0C
then stop one of the chillers in order to run one chiller on maximum load.
14. Start the second chiller when the chilled water entering temperature is 22 to 23 0C.

4. SHUTDOWN OF THE C1-2580A/B/C:


In normal operation there is no shutdown of the chillers, it is only stopped when there is low heating
load at the chiller, the feed flow to deep shaft is below than 5o m 3/hr or any maintenance is required.
Chiller shutdown begins if any of the following condition occurs:
1. The STOP button is pressed for at least one second (the alarm light blinks once to confirm the
stop command)
2. A recycle condition is activated
3. The time schedule has gone into unoccupied mode
4. The chiller protective limit has been reached and chiller is in alarm
5. The start/stop status is overridden to stop from the control network.
The chiller shutdown sequence is given as below:
a. When a stop signal occurs, the shutdown sequence first stops the compressor by deactivating
the start relay (1CR). Status message of SHUTDOWN IN PROGRESS, COMPRESSOR
DEENERGIZED is displayed, and the compressor on time and service on time stop.
b. The guide vanes are then brought to the closed position.
c. The oil pump relay and the chilled water pump relay shut down 60 seconds after the
compressor stops.
d. The condenser water pump shuts down at the same time if the ENTERING CONDENSER
WATER temperature is greater than or equal to 115 F (46.1 C) and the CONDENSER
REFRIGRANT TEMP is greater than the CONDENSER FREEZE POINT plus 5 F (150C).
e. The stop-to-start timer now begins to count down. If the start-to-start timer value is still
greater than the value of the start-to-stop timer then this time displays on the control logic
display screen.
*Certain conditions that occur during shutdown can change this sequence.
f.

If the AVERAGE LINE CURRENT is greater than 5% after shutdown, or the starter contacts
remain energized, the oil pump and chilled water pump remain energized and the alarm is

displayed.
g. The condenser pump shuts down when the CONDENSER PRESSURE is less than the COND
PRESS OVERRIDE threshold minus 3.5 psi (24.1 kPa) and the CONDENSER REFRIG
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TEMP is less than or equal to the ENTERING CONDENSER WATER temperature plus 3 F
(1.6 C).
h. If the chiller shuts down due to low refrigerant temperature, the chilled water pump continues
to run until the LEAVING CHILLED WATER temperature is greater than the CONTROL
POINT temperature, plus 5 F (3 C).

5. OPERATION OF CARRIER COMFORT SCREEN


1.

When chiller is in normal operation a massage on the LED screen appears RUNNING
TEMPERATURE CONTROL LEAVING CHILLED WATER. it changes to indicate the abnormality
(alarm/trip).

2. For checking the history and trouble guide from the screen carry out the following actions.
i.

Press

MENU

KEY

(This

key

changes

to

STATUS

ii.

SCHEDULE,SETPOINT,SERVICE
Press 1key four time to enter the password and you will observe the **** on the main

iii.

screen.
Note the alarm history / massage and press EXIT key.

6. SETPOINT CHANGING METHOD


NOTE: set point changing can only be done by the shift instrument tech ,shift manager or
3.
4.
5.
6.

plant manager.
Press MENU key
Press SETPOINT key.
Bring the cursor to the desire setpoint by pressing NEXTOR PREVIOUS KEYS.
Press select key
The cursor on that set point and the keys will change to

INCREASE,DECREASE,QUIT,ENTER.
7. Press key INCREASEOR DECREASE to change the value of the required set point
8. Press key ENTER
9. Again press keyEXIT;

7. Refrigerant charging (HFCKLEA134a)


When chiller is in operation and refrigerant makeup is to be done.
1.
2.
3.
4.
5.

Confirm evaporator bottom valve which is used for the refrigerant charging is close.
Remove the plug of the refrigerant charging line slowly.
Fit the Gas charging adaptor at the place of plug .
Fit charging manifold at adopter.
Slightly open the gas charging valve then manifold valve to remove the air from the manifold

pipes.(air purging is carried out to avoid air mixing with the refrigerant)
6. Fit manifold middle pipe at the cylinder valve and keep this valve with minimum opening,
slightly open the manifold valve, as some refrigerant starts coming from this then tight manifold
pipe.
7. Keep cylinder valve open in downward direction and open the cylinder valve then manifold
valve and start the refrigerant charging in the chiller.

8. Manual Guide Vane Operation:


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It is possible to manually operate the guide vanes in order to check control operation or to
control the guide vanes in an emergency. Manual operation is possible by overriding the target
guide vane position.
1. Access the COMPRESS screen on the control screen and scroll down to highlight TARGET
GUIDE VANE POS.
2. To control the position, use the INCREASE or DECRESE soft key to adjust to the percentage of
guide vane opening that is desired.
3. 0% is fully closed and 100% is fully open. To release the guide vanes to automatic control, press
the RELEASE soft key.
NOTE: Manual control overrides the configured pull down rate during start-up and permits the guide
vanes to open at a faster rate. Motor current above the electrical demand setting, capacity overrides,
and chilled water temperature below the control point override the manual target and close the guide
vanes.

9. EMERGENCIES:
Following emergencies are possible
a) Feed is not available for deep shaft due to high pH and high COD in A1-2504A/B/C and the level of
the feed tanks is full.
1. Stop all chillers and divert 50 % feed tank in buffer A/C.
2. Add high pH effluent in this feed tank and check the pH from the lab and also calibrate the pH
analyzer of this feed tank.
3. When pH is in the normal range, then open feed to deep shaft at the minimum flow rate of 55 m 3/ hr
via FCV- 5068 and start the chiller.
4. If the FCV-5068 close stuck then all chillers need to stopped, as there is no bypass available for
5.
6.
7.
8.
9.
10.
11.

FCV-5068.
Heavy leakage in the cooling water circuit.
Heavy leakage in the chilled water circuit..
Failure of the G1-2583.
Heavy leakage in the E1-2582.
Fault in the MCC#21 & 22 the chiller trips.
Power failure
Chiller control mal operation.

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DEEP SHAFT PACKAGE (Z1-2538) OPERATION


1. INTRODUCTION:
The Deep shaft effluent treatment package (Z1-2538) treats effluent from PTA plant. The objective of the
deep shaft is to reduce the chemical oxygen demand and concentrates the suspended solids in order to
achieve the discharge effluent quality.
The PTA plant deep shaft package (Z1-2538) consists of the mixing box (A1-2562), deep shaft head tank
(A1-2547), deep shaft (A1-2507), Degasser (A1-2510A/B), degasser blower package consists of the two
degasser blowers (C1-2509A/B) with two degasser ventilation fans (C1-2514 A/B),clarifier basins (A12511A/B) with clarifier scrapers (G1-2511 A/B), RAS pumps (G1-2512A/B/C) and air compressor
package consisting of two Air compressor (C1-2527A/B) with auxiliaries equipment.
The mixing box (A1-2562) receives the effluent from the three areas of the effluent treatment plant. The
main flow is aqueous effluent from PTA plant which has been neutralized and then cooled by the chiller
package Z1-2578.The remaining flow consists centrifuge concentrate return via G1-3107A/B and
tertiary clarifier A1-3102 sludge transfer pumps G1-3104 A/B.These effluents are mixed with the return
activated sludge from the clarifier basin A1-2511A/B coming through the RAS pumps (G1-2512 A/B/C).
These influents are fed continuously via an underground side pipe to the down comer side of the deep
shaft (A1-2507) which dilutes the large volume of the liquor recirculating with in the deep shaft. In deep
shat the effluent is contacted with the biomass and oxygen to biochemically oxidize the organic
pollutants. The oxygen for the biochemical reaction is provided by air compressor package (C12527A/B).Air is injected in the deep shaft via six down comers and six risers sparge pipes. The treated
effluent liquor overflows form deep shaft head tank to the integral off-take channel to A1-2510A/B
degasser. Degassing is achieved from the bubbling air through the liquor via a system of sparge pipe
situated on the floor of the degasser. Air for degassing is supplied by C1-2509 A/B. This degassed liquid
is transferred to the clarifier A1-2511A/B via underground pipes under the gravity flow. The settled
sludge is transferred to the deep shaft via G1-2512A/B/C (Return Activated sludge pumps) and
remaining fluid is bleed off to sludge centrifuge M1-2548 A/B as WAS (waste activated sludge).The
overflow of the clarifier is mixed with coagulant and then flocculent then it moves to the A1-3102
tertiary clarifier. The sludge of A1-3102 is transfer to deep shaft via G1-3104A/B and the treated effluent
is drained to outfall.

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1. DEEP SHAFT OPERATION:


Deep shaft operation is maintained on the basis of plant load and effluent condition, there are three
defined ways to operate the deep shaft process and details of each method are given below:

NORMAL OPERATION
This condition refers to plant operating at process feed flow sheet of combined influent of 213.6
m3/hr and a COD load of up to 18.4 te /day. Under this regime normally both degasser and both
clarifier basins are operational. However it is possible to run the plant with one degasser lane and
one clarifier. During the normal plant operation one degasser and one clarifier can be handed over
for maintenance.

MAXIMUM OPERATION
This condition refers to the plant operating at process feed flow rates of combined influent between
213.6 m3/hr to 322.6 m3/hr with COD load between 18.4 te /day to 26.5 te/day. Under this regime
both degasser lanes (A1-2510A/B) and clarifiers (A1-2511A/B) must be operational.

TICKOVER OPEARTION
Deep shaft is designed to operate continuously. During the period of plant shutdown the deep shaft is
operated at low flow which is called tickover (to run the plant at low COD load without any major
change) operation.
Under above described conditions the plant must be left on tickover to prevent anaerobic condition
occurring in the process. This requires one compressor, one degasser blower, both clarifiers scarpers
and at least two RAS pumps in service. In this condition one clarifier can be taken offline. It is
necessary to reduce the MLSS concentration in the deep shaft during tickover to prevent excessively
low F/M (How much food a single pound of organisms will eat every day) ratio which loads to
the long sludge age. Long sludge age may lead to nitrification in the clarifier basins. This in turn can
lead to sludge floatation as the nitrogen attaches itself to the flocs.

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DEEP SHAFT OPERATING PROCEDURE


2. FILLING OF THE DEEP SHAFT PACKAGE
NOTE: only applicable for initial start up of deep shaft or when deep shaft is completely drained out
1. Check all work permits are signed off and retuned.
2. Check all isolation gates are removed for plant normal operation.
3. Check that isolation gate is located on its position for positive isolation if one of the degassers
4.
5.
6.
7.
8.

or clarifiers is under maintenance work.


Put a fire water hose into the mixing box (A1-2562) and open the water.
Check that deep shaft is completely filled with fire water.
Confirm that deep shaft, degasser and clarifier basins are completely filled with water.
Stop the fire water filling in the deep shaft package.
Deep shaft system has been filled with water and is ready for biomass seeding.

3. SEEDING THE DEEP SHAFT WITH BIOMASS


NOTE: It is applicable only for
Initial startup
After any ETP shutdown
After loss of MLSS during the normal operation of ETP
1. Check that whole system is filled with water/ liquor.
2. Check that sufficient activated sludge seed is available near the deep shaft mixing box. Seed
may be provided by the vendor or by local resources.
3. Check that maximum biomass seed is available on the site because it should take minimum
4.
5.
6.
7.
8.
9.

time to seed the maximum biomass in the deep shaft.


Confirm that WAS outlet valve is lock closed, to avoid the loss of the biomass.
Start the degasser blower C1-2509A/B
Start the clarifier scraper G1-2511A&B
Start the RAS transfer pump G1-2512A/B/C any two selected pumps.
Start the deep shaft air compressor C1-2527 A/B.
Confirm the concentration of the dissolve oxygen on DCS at QT-5142 and also locally check it

with the help of portable DO meter. It must be greater than 2 ppm.


10. Start the dosing of the Nutrient by taking the G1-2525A/B in service and maintain the reserves
11.
12.
13.
14.
15.
16.
17.
18.

of phosphate, ammonical nitrogen and ammonia in the deep shaft.


Add the activated sludge in the deep shaft gradually in the mixing box.
Check the MLSS on daily basis.
Line up fresh neutralized feed to deep shaft by opening the FCV-5068 gradually.
Check the deep shaft feed temperature it should be less than 18 oC on TT-5083.
Start the chiller package (Z1-2578) to cool the deep shaft feed up to desired temperature.
Increase the flow to deep shaft as MLSS concentration increases in the deep shaft.
Stop the seeding of biomass as MLSS concentration reaches to 5000.0 mg/l in the deep shaft.
Adjust all the parameter of deep shaft as per design operating conditions.

4. DEEP SHAFT START UP FROM TICKOVER/SHUTDOWN


1. Confirm that sufficient biomass is present in the deep shaft.

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2.
3.
4.
5.
6.
7.
8.
9.
10.

UTY Plant Operating Procedure


ETP plant (Revision: 01)

Confirm that deep shaft is filled with liquid.


Start the degasser blower C1-2509 A/B after filling its startup check sheet.
Start the Clarifier scraper of G1-2511A&B after filling its startup check sheet.
Start the air compressor (C1-2527 A/B) and lineup the air to deep shaft.
Confirm the rotation of the deep shaft; it must be anticlockwise from the head tank.
Confirm the degasser (A1-2510 A/B) is giving the even distribution of the air bubbles.
Start the chiller package (Z1-2578) as per SOP.
Start the RAS pump G1-2512 A/B/C any two of three pumps.
Adjust the RAS and WAS flow as per deep shaft condition by adjusting the air flow at

pneumatic PCV-5213 also check the pressure on the PG-5376.


11. Gradually increase the load on the deep shaft.
12. Monitor all the parameters of the seep shaft.

5. INCREASE THE LOAD FROM NORMAL TO MAXIMUM OPERATING


CONDITION
1. Check that both degasser lanes (A1-2510 A/B) are in service and normal.
2. Check that both clarifiers (A1-2511 A/B) are in operating condition, if one of these is not in
operation then increase in flow is not permitted.
3. Check the flow rate according to COD load.
4. Increase the air flow rate to deep shaft up to the required amount at the defined rate, by
opening the guide vanes of the on duty air compressor C1-2527A/B.
5. Check that chiller package is ready to take the high heat load.
6. Increase the flow to deep shaft via FCV-5068.
7. Increase the RAS flow rate adjusting the requirement by the PVC-5213, FCV-5130 (vortex
type) in order to maintain the deep shaft MLSS concentration in the region of 5000 mg/l.

6. DECREASE THE LOAD FROM MAXIMUM TO NORMAL OPERATING


CONDITION
Such condition occurs when either one degasser / clarifier needs to be handed over for
maintenance job or effluent COD condition dictate to reduce the load.
1. Reduce the load on deep shaft.
2. Check the COD of the feed samples (ET-06/07/08).
3. Decrease the air flow to deep shaft by decreasing the guide vanes of the duty compressor.
4. Decrease the RAS flow by maintaining the set point of the PCV-5213.inorder to maintain
the MLSS concentration in the region of 5000 mg/l.
After these changes one degasser and clarifier can be handed over for maintenance job
.

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DEEP SHAFT NORMAL OPERATING INSTRUCTION


1. Startup of the deep shaft (Air introduction)

1.
2.
3.

Ensure that biomass is present in the deep shaft.


Ensure that deep shaft is filled with liquid.
Start the air compressor (C1-2527A/B), ask DCS board man to open the FCV-5120 up to

4.

100%on manual.
Check that all the air is flowing to the riser pipes and the shaft liquor is circulating. Once all

5.
6.
7.
8.

the air flow is established to the risers and carryout the following steps
Wait for 10 minutes
Manually adjust the flow at FCV-5120 up to 1600 m3/hr.
Wait for further 15 minutes
Once the dissolved oxygen value reaches to >2 mg/l, adjust the air flow using the air

9.

compressor inlet guide vanes to its correct operating value of 4581 Nm 3/hr.
Confirm the deep shaft is now circulating at its normal operating point.

2. Normal operation of the deep shaft


1. Check the color of the effluent in the deep shaft head tank A1-2547, if the color is blackish
increase the WAS flow rate.
2. Check air flow and adjust by maintaining the dissolves oxygen in the head tank A1-2547, if
it is less than 2 PPM then increase air flow to deep shaft.
3. Check the foam on head tank A1-2547, if excessive foam is observed then add anti- foam
after asking from shift manager.
4. Check the temperature of the deep shaft tank A1-2547 if it is increasing above 38 0C open
fire water at deep shaft.
5. When feed to deep remains off line for a longer time then increase the air to risers by100
m3/hr.
6. Check the level of A1-3100, if it is higher, and then increase the RAS flow to deep shaft.
7. Check the air distribution is homogeneous in the degasser A1-2510 A/B. (Air is coming
from all sides) if air is not coming from effluent surface then check C1-2509 A/B discharge
pressure which should be higher than 0.5 brag. Otherwise start the standby blower.
8. Fortnightly change over the compressor as per plant routine document and follow the routine
change over procedure.

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3. Shutdown of the deep shaft


1. Stop the flow of the return activated sludge to the deep shaft feed mixing box by closing the
2.
3.
4.
5.
6.

pump outlet on the RAS line.


Reduce the RAS flow to the deep shaft and maintain the flow towards WAS.
Open the drain valve of the RAS line into the drainage pit.
Stop the influent flow to deep shaft; stop the feed pump G1-2505A/B/C.
Insert the isolating stop logs in the splitter box located at the outlet of the A1-2510A/B.
Increase the air flow rate from the compressor package to its maximum value by opening the

inlet guide vanes.


7. Open the riser air flow control valves FCV-5120 fully.
8. Stop the flow of WAS by stopping the RAS pump (G1-2512A/B/C).
9. Stop the clarifier scraper (G1-2511A/B/C) according to the SOP.
9.

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4. AIR COMPRESSORS (C1-2527A/B) STARTUP


Initial checks
1.
2.
3.
4.
5.
6.

All work permits are signed off on compressor and returned.


Check the power is available on compressor CMC control panel
Check the availability of the instrument air.
Check that cooling water valves (inlet and outlet) are fully opened.
Check that air outlet manual valve of the compressor is fully opened.
Open air bleeding valves of the stage cooler for a short time for removing the trapped air in cooling

water circuit then close.


7. Check that seal air valve is fully open. Logically compressor pre-lube oil will not take start without
seal air availability, in order to avoid the ingression of oil in the inter stage coolers.
8. Check that air knob is at zero, to start the compressor with no flow to deep shaft.
9. Check that the compressor is on un-load condition.
10. Check that down comer individual valves at the inlet of the each down comer are completely deisolated.
11. Check that the main isolation valve on the risers side is fully open. Ask Utilities DCS board man to
open FCV-5120 fully.

Air Compressor (C1-2527A/B) startup


1.
2.
3.
4.
5.

Fill the startup check list of the compressor.


Release emergency switches of the selected compressor.
Switch on the controlling power and check that the pre-lube oil pump is started.
Check the lube oil pressure it must be higher than 168 kPa.
Check that all parameters in the C1-2527 A/B MP-3 panel are normal and compressor ready

indication is appearing.
6. If compressor ready indication does not appear on the MP-3 panel then check all the parameters of
the compressor and identify the wrong parameter.
7. Inform to shift manager and see the trouble shooting guide.
8. Push the start button.
9. Keep the compressor in operation on unload condition for small time then press the load soft key on
10.
11.
12.
13.

CMC panel.
Confirm the opening of inlet valve and closing of the bypass valve.
Ask DCS Boardman to put the FCV-5120 on manual and open up to 100 %.
Turn the flow knob of the compressor from 0% to 100% gradually.
Increase air flow to deep shaft by rotating knob of air flow and set at 3000 m 3/hr (read at FIA-5360

A/B).
14. Check the flow direction of deep shafts, if it is normal, increase the flow to 3500 and then to 4000
m3/hr, otherwise decrease the flow to zero and find the reason.
15. Open the six valves of the deep shaft and check the direction of the deep shaft.
16. Ask DCS Boardman to put the FCV-5120 on auto with set point 1550 to 1600 m3/hr.

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17. Adjust the total air flow from air compressor to 4250 to 4300 m 3/hr at the FIA-5360, as per
requirement.
18. Check passing of stand by compressor discharge valve.

5. NORMAL OPERATION OF THE COMPRESSOR (C1-2527A/B)


1. Take the reading periodically of the air compressor as per log sheet.
2. Check any abnormal sound from air compressor if there is any abnormality then stop/changeover
the compressor and inform the shift manager about the abnormality.
3. Check that air traps are working properly; check the direction of deep shaft flow.

6. SHUT DOWN /CHANGEOVER OF THE ON DUTY COMPRESSOR


(C1-2527A/B)
1. On duty compressor can be changed over to the standby compressor
2. Compressor package is stopped completely due the some maintenance work on the compressor
discharge line.
3. For the compressor change over just apply the change over procedure of standby compressor
4. For the compressor shutdown carry out the following steps
5. Inform to DCS Boardman about compressor shutdown decrease air flow to zero by rotating the
knob to zero position and then unload the compressor.
6. Keep it un-load during for a few minutes and then push the stop button.
7. Keep the pre-lube oil pump in service for about fifteen minutes and then switch off the control
power.
8. Hand over the line for the maintenance
9. Stop G1-2505 A/B/C and fresh feed to deep shaft is standby compressor is not available.

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7. Start up of the degasser (A1-2510A/B) system


Initial Startup
1.

Check that splitter box, degasser and degasser outlet tank are full of liquid to the normal operating

2.
3.
4.
5.
6.

level.
Confirm that isolation stop-log in the splitter box and degasser outlet line is free to take in service.
Check the clarifier is ready to take the effluent.
Check that C1-2509A/B are ready to be taken in service.
Check that G1-2514 A/B ventilation fan is in healthy condition.
Select the degasser blower to be taken in service, start the ventilation fan of that blower and

7.

confirm that it is working normal.


Start the selected duty blower (C1-2509 A/B) as per startup procedure, and confirm that it is

normal in service.
8. Check that air bubble can be seen breaking the surface of the liquor in the degasser.
9. Check the discharge temperature of the blower at the TG-5244 it should be less than 100 0C
10. Check the discharge pressure of the blower at the PG-5242 and it must be less than .5 barg.
Degasser (A1-2510A/B) system is now operating normally.

8. Start up of the degasser standby blower C1-2509A/B


Before the startup of the blower ensure that both the standby blower and its ventilation fans are in
healthy condition.
1.
2.
3.
4.

Check all permit to work are signed off and returned.


Check that power of the blower is on.
Check that system is ready to be taken in service.
Check that plant air is available on nearby utility point with air hose, and air fitting is installed on

5.
6.
7.
8.
9.
10.
11.

the inlet line of the degasser.


Open the discharge valves of the selected blower (C1-2509A/B).
Start the ventilation fan of the standby blower and ensure that it is working normal.
Start the C1-2509A/B standby blower as per procedure.
Check that it is working normal.
Stop the running blower; stop the ventilation fan of this blower.
Close the discharge valve of the stopped blower.
Check that air bubble can be seen breaking the surface of the liquor in the degasser and that these

bubbles are evenly distributed across the surface.


The standby blower degasser blower has now been successfully started and lined up

9. Shutdown of the Degasser (A1-2510A/B) both/one lane


The degasser system will have shut down due to the following conditions
I.
Maintenance of the blower
II.
Air supply pipe maintenance
III.
Sparger pipe work maintenance

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10. Shutdown due to maintenance of C1-2509A/B


For the maintenance of the degasser blower the standby unit needs to be taken in operation to
continue the treatment.
1. Shut down due to Air supply pipe maintenance
For the maintenance of the air supply pipe work the degasser system must be completely shutdown.
If the maintenance period is likely to increase beyond 24 hrs and temporary plant air hose cannot
meet the requirement of the degasser then it is recommended to pump out the degasser and the
clarifier and put the deep shaft on just aeration. For shorter maintenance period it is not necessary to
pump out and flush the system.
2. Shut down due to Sparger pipe work maintenance
Degasser sparger piping maintenance requires the complete shutdown of the respective degasser
A1-2510A/B. For this following procedure applies.
1.
2.
3.
4.
5.
6.
7.

Ensure that deep shaft load has been deceased.


Stop the degasser blower C1-2509A/B and C1-2514A/B as per procedure.
Isolated the discharge valve of the degasser blower C1-2509A/B.
Insert the isolation stop logs in the splitter box and degasser outlet.
Drain the degasser completely for maintenance purpose.
Put the pneumatic pump in the degasser for completely draining it out.
After the complete draining erect the scaffolding, remove the pipe, carry out the maintenance and

installed back the sparger pipe.


8. Remove the scaffolding and revert the system on normal condition.

11. Normal operation of the Degasser A1-2510A/B


1. During normal operation air from the duty degasser blower is continuously sparged into the two
lanes of degasser.
2. It is possible to run with only one operational degassing lane at normal load flow although this
3.
4.
5.
6.

would only occur if one of the lanes had been shut down for maintenance.
Ensure that regular sampling of the degasser liquor is sampled to confirm the MLSS concentration.
Monitor the blower discharge pressure at PG-5242 and discharge temperature on TG-5244.
Check that the duty degasser blower is in healthy condition.
Check that a regular distribution of bubbles can be seen breaking the surface of the liquor in the

degasser.
7. Ensure that all the alarms are regularly monitored.(i-e,FSL-5314,etc)
8. Respond to alarm condition and rectify as necessary.
9. Ensure that degasser blower is running normal.

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12. ETP Clarifier A1-2511A/B system


This section describes the startup, shutdown, normal operation and maximum operation of the
clarifier system.

Startup of the clarifier Scrapers (G1-2511A/B)


1. Ensure that clarifier liquid level is at its normal operating level.
2. Ensure that all clarifier conditions are normal.
3. Start the clarifier scraper
The clarifier scarper is now operational.

Startup of the clarifier basin


1. Ensure that both stop-logs in the degasser outlet are removed.(if one clarifier is under
maintenance then the stop-log of that clarifier must be left in place)
2. Ensure that effluent starts to flow into the clarifier basin. This can be checked from the top of the
clarifier scraper bridge.
3. Check that effluent from the clarifier basins overflow the weir into the launder.
The clarifier basins are now operational normally.

13. Startup of the RAS pump G1-2512A/B/C

Initial Checks and Startup

1.
2.
3.
4.
5.
6.
7.

Check all work permits are signed off and returned.


Check pumps are electrically energized.
Check the lube oil level in the sight glass.
Check that suction isolation valves are open.
Check that discharge valve is close.
Check that WAS discharge valve is close.
Ensure that deep shaft is operational and is ready to accept the RAS and that the clarifiers are

full of liquid.
8. Ensure that before the start-up all conditions relating to RAS pumps to be started are healthy.
9. Start the selected RAS pumps (G1-2512A/B/C) after filling the startup chick list.
10. The RAS pump to be run with the isolation of the WAS valve unless the MLSS concentration in
the deep shaft reaches the operating level of the 5000 mg/l or sludge blanket level in the
clarifiers reach up to 3 feet.
11. Check that sludge centrifuge M1-2548A/B are ready to accept the WAS.
12. Open the WAS valve when MLSS concentration in the deep shaft ET-10 sample reaches to
operating level of 5000 mg/l.
13. Open the WAS take-off valve slowly to 100%.

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14. Increase the RAS pump discharge flow on FI-5130

by adjusting the opening of the pneumatic

air to the PCV-5213 located on the RAS line to its normal operating rate before opening the
WAS valve.
15. Daily monitor the concentration of the MLSS in the deep shaft and adjust the RAS flow to
maintain it accordingly.
The RAS pumps are operating normally 2 out of 3

14. Shut Down of one clarifier:


Under normal operating condition both clarifier basin are in use. However each clarifier is sized to
take all of the normal flow so that one clarifier basin can be shut down for maintenance without
effecting the operation of the plant. If the plant is operating on maximum load conditions then flow
must be reduced as per normal load conditions. One clarifier is mostly off lined due to the following
conditions.
1. For the cleaning of the clarifier basin
2. The inspection of the clarifier

15. Shutdown of one clarifier for cleaning


1.
2.

Insert the stop -log to the clarifier basin to be shut down


Drain the clarifier until all of the sludge has been pumped out by the RAS pumps. The decrease

3.
4.
5.
6.
7.

in the sludge blanket level can be monitored visually


Close the under flow valves from the drained clarifier.
Insert the blinds to prevent the back-filling from the A1-3100 coagulant mixing tank.
Stop the clarifier scarper of the shutdown clarifier basin.
Stop one of the duty RAS pump according to the requirement of the RAS flow.
Drain the remaining water from the shutdown clarifier basin using a submersible pump. The

8.

water should either be pumped to the working clarifier basin or the degasser outlet.
Put one fire water hose down to the bottom of the clarifier basin with water open for leaning

9.

purpose and pump out with the help of submersible pump.


Continuously monitor the sludge blanket level in the working clarifier and adjust the RAS / WAS

flow accordingly.
10. Check that clarifier is ready for the required job.
11. Carry out the necessary checks before entering the vessel.
12. Clarifier basin is now ready for the maintenance job.

16. Normal operation of the Clarifiers


During normal operation:
1. Ensure that samples of the deep shaft head tank liquor and the clarifier basin under flow are taken
to confirm the MLSS concentration in ET-10 sample.
2. RAS flow is adjusted according to the requirement of the plant.
3. Ensure that all alarms are regularly monitored.
4. Respond to all alarms conditions and rectify as necessary.
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5. Ensure that water is available for flushing when RAS pumps are stopped.
Ensure RAS pumps run in accordance with the required operating instruction.

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17. EMERGENCIES:
1. Air compressor may trip due to any reason, e.g. due to power dip, power failure, tripping of
MCC# 21, or any compressor internal FAULT.
2. Start up air compressor as per procedure.
3. Mal operation of FCV-5120 can reduce the deep shaft risers flow to zero. Due to which the deep
4.
5.
6.
7.

shaft may rotate in reverse direction.


Rectify FCV-5120 mal operation and start the deep shaft as per procedure.
Tripping of the C1-2509A/B
Unavailability of the C1-2509 A/B due to maintenance work.
Tripping of the G1-2512A/B/C

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TERTIARY TREATMENT
1. Introduction
The tertiary treatment stage of the effluent treatment plant operates when the clarifier effluent from
A1-2511A/B does not meet the discharge effluent quality .To polish the effluent by the removal of
residual suspended solid and subsequent reduction in COD. The effluent gravitates through
conditioning (coagulant and flocculent dosing) clarification and filtration stages before discharge
from site outfall to the Sea.
When the effluent from A1-2511A/B dose meet discharge quality then tertiary treatment stage can be
bypassed and effluent sent directly to final effluent pit A1-3105.

2. SARTUP OF THE PACKAGE

INITIAL CHECKS

1.
2.
3.
4.

Check all PTWs are signed off


Physically check all equipments for mechanical jobs completion
All spectacle plates are in appropriate position
All slip plates are removed
Check the electrical energisation of :
1. G1-3100 Coagulant mixing tank agitator
2. G1-3101 flocculent tank agitator
3. G1-3102 scrapper motor
4. G1-3104 A/B sludge transfer pumps
5. G1-3107A/B are backwash pumps
6. Z1-3110 polymer preparation package drives are electrically energized.
Checks availability of :
1. Treated effluent
2. Compressed air
3. Tertiary polymer(Nalco-9916)
4. Raw water
5. Nalco 8105/PC-306
Checking of instrument and control valves
Check stroke and close manual the following valves
1. LCV-5184 level control valve in concentrate return line to deep shaft mixing box A1-2562 from
concentrate transfer pumps G1-3107A/B.

3. Preparation of the Polymer solution in the package Z1-3110


A. POWEDER:
Polymer powder is blown by the polymer powder blower C1-3115 from polymer powder
hopper P1-3112 for a pre-determined time to polymer mixing tank F1-3114.In F1-3114 it is

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mixed with a known volume of the filtered water to make a batch of 0.5% W/W polymer
solution. The batch is transferred to polymer stock tank F1-3125 by the polymer solution
transfer pump G1-3123 for 30 minutes .After transfer a new batch is immediately prepared in
F1-3114 and subsequently transfer to F1-3125 on low level in F1-3125.
B. Liquid
Polymer liquid system is not being used at plant, but its option is available in the polymer
preparation package. The sequence will be started automatically by sensing low level and will
continue until stopped. We are not using this on the plant.
0.5% W/W polymer solution batch preparation from powder of Nalco-9916
1. Ensure dehumidifier M1-3117 is operational in powder hopper enclosure
2. Ensure that enclosure door are closed
3. Ensure raw water line isolation valve to package is open; Fire water can be used if raw water
4.
5.
6.
7.
8.
9.

is un-available.
Open appropriate valves of pumps and tanks to prepare package for operation
Select the powd or liq switch on the control panel.
Release all stop button and press emergency stop reset button on control panel.
Check that there is polymer powder in the polymer powder hopper P1-3112.
Move switch from OFF to Auto on control panel.(sequence will be started automatically)
On sensing the low level of the F1-3114 batch preparation tank by LSL-5713 the polymer

preparation sequence will be started as:


1. The raw water supply SOV-5795 will open first.
2. Tank level will increase up to 20% then agitator G1-3114 will take start.
3. Now polymer screw feeder P1-3112 will take start. Screw feeder feed is adjustable from the
control panel it can be increased and decreased with the help of instrument tech.
4. Now polymer powder transfer blower C1-3115will take start
5. Solution preparation will be stared in F1-3114 and will stop when high level will be sensed
by LSH-5713.
6. Main raw water supply SOV-5795 will become close.
7. Agitator will remain in service up to 30 minutes for solution preparation completion.

4. Start-up of the flocculent tank agitator G1-3100 and Flocculent tank


Agitator G1-3101
8. Open the coagulant mixing tank F1-3100 tank inlet valve in the effluent line from clarifier
9.
10.
11.
12.
13.

A1-2511A/B.T his tank receives the gravity flow from the secondary clarifier.
Ensure that by pass line valve to the tertiary treatments is in close position.
Establish the level in the F1-3100 tank and verify form area.
Confirm the level of Nalco-8105 in the IBC.
Start the F1-3100 agitator G1-3100.
Confirm the pH analyser QIA-5171 is working normal otherwise calibrate it. It must in the

range of 6-9.
14. Establish the level in the A1-3101(flocculent mixing tank).
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15. Confirm that sufficient level up to 50% is available in the F1-3101(tank fills with effluent
under flowing coagulant mixing tank A1-3100).
16. Start the G1-3101 Flocculent tank agitator.
17. Confirm the dosing rate of the Nalco-9916.

5. Dosing of Tertiary Polymer Solution:


To add polymer solution prepared in the polymer preparation package Z-3110 into secondary
treatment effluent in flocculent tank A1-3101.This chemical addition provides the flocculation
and settling of suspended fines solids.
1. Ensure that there is sufficient polymer solution of .5 % w/w concentration the polymer
2.
3.
4.
5.
6.

storage tank F1-3125.


Ensure that F1-3100 is filled with treated effluent and agitator is in running condition.
Open the discharge isolation valve of the F1-3125.
Open the suction isolation valve of the G1-3116A/B selected pump.
Ensure that valves of the standby pump are in close position.
Open the Selected pump discharge isolation valve and check the pressure on the discharge

PI-5715A/B.
7. Confirm that raw water SOV-5797A/B is open condition.
8. Open the raw water line isolation valve located on the downstream of the dosing pumps
G1-3116A/B, control the raw water flow manually to dilute the polymer solution up 0.1%
W/W .Raw water flow can be adjusted manually with the help of the rota meter .(1unit =1
9.
10.
11.
12.

m3/hr),Now its isolation valves are opened up to 60 %.


Release all stop buttons and press emergency stop Reset button on the control.
Turn the selector switch to Hand position.
Start duty polymer dosing pump G1-3116A/B.
Set required dosing rate using the manual pump speed control on the polymer package
door panel.

6. Start-Up of The Tertiary Clarifier Scraper G1-3102


1. Ensure that tertiary clarifier overflow line isolation valve is open.
2. Ensure that A1-3105 is ready to receive the treated effluent from the A1-3102.
3. Open the valve in the effluent line inlet to tertiary clarifier to the A1-3102.(effluent flows
to the tertiary clarifier by gravity from A1-3101)
4. Ensure that tertiary clarifier bypass line isolation valve is closed.
5. When the tertiary clarifier A1-3102 liquid level is at its normal operating level (i.e., 50 %)
then start the clarifier scraper A1-3102.
6. Check that torque value is normal in area on local torque indicator XI-5173.

7. Start-Up of the Sludge transfer pumps G1-3104A/B


Typical sludge concentration in the A1-3102 remains 0.8 %.

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1. Check pumps G1-3104A/B seal flush valves are open and confirm the seal water pressure
on PG-5177/78.
2. Ensure that tertiary clarifier is full with liquid.
3. Ensure that pumps suction and discharge drain valves are fully close and drains blanks are
fitted.
4. Open the suction and discharge isolation valves of the duty pump. Dont start the G15.
6.
7.
8.
9.
10.
11.
12.
13.
14.

3104A with close isolation valve.


Ensure that suction and discharge valves of the standby pumps are fully closed.
Ensure that PG-5176 and 5179 is working normal.
Ensure that A1-2562 is operational and is ready to receive the effluent.
Start the duty sludge transfer pump G1-3104A/B.
To start the stand by pump, open the suction and discharge isolation valve of the pump.
Start the pump and check against any abnormal sound.
Stop the de-selected pump.
Close the deselected pump suction and discharge valve.
Remove the blanks and drain pump.
Connect the water hose with the suction and flush the pump with water. Carry out the

pumps flushing until clean water started to come from discharge drain.
15. Remove the hose, close the drain valve and refit the blank.

8. NORMAL OPERATION
1. Check the system against any abnormality.
2. Fill are logs sheet and monitor the changes.

9. Use of tertiary bypass


If the secondary treated effluent overflowing from clarifiers A1-2511A/B meets the discharge
contents then it is not necessary to use tertiary treatment stage for removal of the suspended
solids and reduction in the effluent COD.
1. Open the isolation valve of tertiary treatment bypass line to final effluent PIT- A1-3105.
2. Close the F1-3100 inlet line isolation valve.
3. Stop the Nalco -8105 dosing pump and close its three way valve.
4. Stop coagulant tank A1-3100 agitator G1-3100.
5. Stop the on duty polymer dosing pump G1-3116A/B and isolate it physically.
6. Stop the raw water flow on the downstream of the pump.
7. Stop the flocculent tank F1-3101 agitator G1-3101.
8. Stop the duty sludge transfer pump G1-3104A/B.

10. G1-3107 A/B operation


The G1-3107 A/B are called backwash Pumps .These are installed on the A1-3106 Pit which
receives effluent from the sludge centrifuge M1-2548A/B concentrate and backwash water
from the sand filters. Currently sand filter are bypassed. These pumps are used to transfer
1.

this effluent to deep shaft.


Check G1-3107A/B seal flush water valves are open.
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2.
3.
4.
5.

UTY Plant Operating Procedure


ETP plant (Revision: 01)

Check that A1-3106 is filled with liquid.


Check that all pumps drains valves are closed and blanks are fitted.
Open duty pump suction valve.
Ensure that isolation valve in the suction and discharge of the standby pumps are in close

position.
6. Open LCV-5184 up to 20 % on manual from DCS.
7. Confirm that deep shaft mixing box is ready to take the effluent and it is in operational
condition.
8. Start the duty by backwash pump G1-3107A/B.
9. Ensure that there is kick back flow to F1-3106 through ROP-5210/5227.This spill back flow
will protect the pump in case of no forward flow.
10. Slowly open the pump discharge valve.
11. Check the pump discharge pressure on PG-5211/12.
12. Control level in the A1-3106 at required level on auto on LICA-5184.
Note: both pumps can be taken in service parallel when the level inA1-3106 is high.

11. To start the stand by pump G!-3107A/B


1.
2.
3.
4.
5.
6.
7.

Open the suction isolation valve of the standby pump.


Start the standby G1-3107A/B.
Ensure that there is spillback flow to A1-3106 through ROP -5210/27.
Slowly open the pump discharge valve.
Check the pump discharge pressure on PG-5211/12.
Stop the duty pump.
Close the Deselected pump suction and discharge valves.

12. Shutdown of the clarifier A1-3102


If the Tertiary clarifiers A1-3102 need cleaning:
8.
9.
10.
11.
12.

Empty the tertiary clarifier until all the sludge has been removed via G1-3104A/B.
Stop the clarifier when basin is empty.
Clean the clarifier with fire water.
On complete emptying of the clarifier stop and isolate the G1-3104A/B.
Carry out the clearing of the clarifier.
Note: after complete cleaning of the A1-3102 take this in service as per start-up procedure.

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UTY Plant Operating Procedure


ETP plant (Revision: 01)

Sludge Handling.
1. Introduction:
There are two Guinard centrifuges at effluent treatment plant. It uses centrifugal force to
separate the component of the mixture with different densities clarification is carried out by the
rotating horizontal bowl. The bowl of the centrifuge decanter has cylindrical and conical
sections. The sludge enters the decanter through a feed tube and enters the bowl through a
distribution chamber. As the bowl rotates the solid rapidly settles against the walls of the
spinning bowl. A screw conveyor rotating slightly lower speed than the bowl moves the solid
through the conical to the solid discharge section. At the same time the liquid effluent flow
flows through the cylindrical section to the liquid discharge.
Each centrifuge can process 11.2-27.4 M3/hr sludge contains 0.2 tons/hr of dry solid maximum.
The sludge is feed to the centrifuge from discharge header of the return activated sludge pumps
G!-2512A/B/C. The feed is under flow control. One unit is sufficient at full load of effluent
treatment plant.
Polymer is injected with the feed to the centrifuge in proportional to sludge flow. Normally it is
cationic polymer, diluted to 0.1 % W/W, for addition to centrifuge. The sludge from the outlet of
the centrifuge is transferred to the road dumper by the dedicated sludge transfer pump G1-2560
A/B with bridge breaker P1-2565 A/B. Speed of these two machines can be vary via gearbox
manual variation, provided flow range of 0.5 to 2.5 m3/hr at 6 barg pressure. The centrate water
goes to backwash pit A1-3106, from where it is send back to the deep shaft.

2. SARTUP

INITIAL CHECKS

1. Check all PTWs are signed off.


2. Physically check of all equipments for mechanical jobs are completed.
3. All slip plates are removed.
Check the electrical energisation of :

1.
2.

All drives of package Z1-2549 are electrically energized.


All drives of Package Z1-2554 are electrically energized.
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UTY Plant Operating Procedure


ETP plant (Revision: 01)

Checks availability of :
1. Waste activated sludge (WAS)
2. Backwash pit A1-3106
3. polymer solution (Nalco-9916)
4. Raw water
5. Road dumper for sludge
Checking of instrument and control valves

Check, stroke and close on manual the following control valves.

1.

FCV-5189 flow control valve in sludge feed water line to sludge centrifuge M1-2548 A from

2.

RAS pumps G1-2512 A/B/C.


FCV-5138 flow control valve in sludge feed water line to sludge centrifuge M1-2548 B from
RAS pumps G1-2512 A/B/C.

3. ZCV-5236 in raw water line to sludge feed line of M1-2548A.


4. ZCV-5235 in raw water line to sludge feed line of M1-2548B.
5. ZCV-5238 three ways valve in dewatered line to sludge road dumper of M1-2548A.
6. ZCV-5237 three ways valve in dewatered line to sludge road dumper of M1-2548B.
3. Polymer solution Nalco-9916 preparation in package Z1-2564
0.2 W/W solution is prepared in batches from powder in solution preparation package Z1-2564
1. Ensure dehumidifier M1-3117 is operational in powder hopper enclosure.
2. Ensure that enclosure door is closed.
3. Ensure raw water line isolation valve to package Z1-2564 is open; Fire water can be used if raw
water is un-available.
4. Open appropriate valves of pumps and tanks to prepare package for operation
5. Select the powd or liq switch on the control panel.Liq is not used at for the preparation of
solution.
6. Release all stop button and press emergency stop reset button on control panel.
7. Check that there is polymer powder in the polymer powder hopper P1-2571
8. Check that makeup tank F1-2574 low low level not illuminated if illuminated press reset
alarm button until light goes out; this puts water into the tank.
9. Move switch from OFF to Auto on control panel.(sequence will be started automatically)
10. On sensing the low level of the F1-2574 batch preparation tank by LSL-5703 the polymer
preparation sequence will be started as
11. The raw water supply SOV-5790 will open first.
12. Tank level will increase up to 20% then agitator G1-2574 will take start.
13. Now polymer screw feeder P1-2571 will take start. Screw feeder feed is adjustable from the
control panel it can be increased and decreased with the help of instrument tech.
14. The polymer powder transfer blower C1-2567will takes start.
15. Solution preparation will be started in F1-2574 and will stop at 90 %, when high level will be
sensed by LSH-5703.

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UTY Plant Operating Procedure


ETP plant (Revision: 01)

16. Then solution will be transferred via G1-2572 to the solution feed tank F1-2568, when low
level 10 % will be sensed on LS-5701.
17. The solution transfer pump G1-2572 will be stopped at high level 90% indication on LS-5701
.this switch will stop the pump automatically.

4. Start-up of sludge centrifuge M1-2548 A/B

1.
2.
3.

Start up initial checks.


Check that sludge inlet isolation valve of the centrifuge M1-2548 is open.
Open the raw water isolation valve to the centrifuge M1-2548 A/B.
Open the manual isolation valve in the polymer and sludge feed line to the duty
centrifuge. Normally one centrifuge remains in service, one standby. Polymer should
be fed to the feed inlet line of the centrifuge M1-2548A/B. The second injection valve
is located on the main inlet line of the sludge centrifuge. It should always be locked

closed.
4. Ensure that duty two RAS pumps G1-2512A/B/C are in service and WAS (waste
activated sludge) discharge valve towards M1-2548 A/B is in open condition.
5. Ensure polymer preparation package Z1-2564 is on auto preparation condition and
solution tank is > 80%.
6. G1-2575 A/B is on auto and mode and pumps suction and discharge valves are open.
7. Check that seal water supply to the G1-2560 A/B is open and water is coming from
the drain.
8. Ensure that backwash pit pump G1-3107 A/B should be in the service and LICA5184 is set to control the level in the A1-3106 pit at 40% on auto. This is used to
transfer the concentrate back to deep shaft.
9. Ensure that road dumper is in place for the collection of the wet sludge.
10. Start the M1-2548 A/B duty centrifuge. Ensure that all emergency stop buttons are
released.

5. M1-2548A/B start up:


1. Press the starts cycle button on the panel in the PLC room. Green light indicates
ON and following automatic timed operating sequence will start.
i. Centrifuge starts, speed increases up 2800 RPM in 200 seconds.
ii. Polymer dosing pump G1-2575 A/B starts.
iii.
Sludge feed valve FCV-5138/5189 opens.
iv. Sludge transfer pumps G1-2560 A/B and bridge breaker (lump breaker) P12565 A/B starts.
2. Set the required polymer feed to the centrifuge at DCS. The pump speed can be
control on auto and manual.
i.
Auto: the pump speed is linked to WAS flow to the centrifuge through
FFY-5138/5189 ration control.

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ETP plant (Revision: 01)

ii. Man: pump speed is set by HIC-5204 A/B.


3. Set the required sludge feed to the centrifuge on FIC-5138/5189.The varying sludge
flow depends upon
i. The amount of WAS to be processed.
ii. The torque signal from centrifuge.
iii.
When the torque value is on lower side then high liquid will be produced
by the centrifuge, so the level in the backwash pit A1-3106 also based the
flow of WAS to centrifuge.
iv. Capacity of the road dumper availability or wet sludge process
4. Take the round of the centrifuge to check the vibration and any abnormal sound. If
any abnormal sound/vibration appears then shutdown the centrifuge and identify
the fault and rectify it.
5. Ask DCS Boardman to give set point of HIC-5204A/B and FIC5138/5189 of the
centrifuge. Confirm that polymer pump G1-2575A/B Hic value is more than 21 %
otherwise polymer pump will trip.
6. Check the centrifuge PLC screen which shows centrifuge step on. The torque
will increase and when it will Crosse the sediment level set point, three ways valve
will opens towards local sludge carrier.
7. Ensure that on local screen that sediment level is ON. The centrifuge will start to
discharge it sludge to its hopper.
8. Check the parameter of the centrifuge which should bre in the normal given range.
9. Check the vibration of the centrifuge on the local panel on the VAH-9616A/B. This
should be less than 20 Mm/sec.
10. Check the level of the hopper on the local mounted LT-9623A/B, and also auto
start-up of the bridge breaker and sludge discharge pump. Centrifuge has tripping
on the hopper high high level.

6. Normal operation of M1-2548A/B


1.

Check the sludge concentrate. If it contains sludge then change the value of the torque
through reducing WL by 01. The relative speed of the bowl and the screw will increase,

2.

due to the high separation. Maximum relative speed must be kept upto 5.0.
If the centrifuge tripped due to the increase in torque, then bring it to the previous setting
and start to increase the polymer doing after its start-up. Some time centrifuge tripped due

polymer low dosing rate and does not show any indication.
3. Have the normal round of the centrifuge and check it against nay abnormality. If any
4.
5.

abnormality appears then seek instruction from shift manager.


Take the reading as per log sheet. Compare the reading with the previous and find the change.
Check the level increase in the hopper of the centrifuge and also prove at least one cycle of the
sludge discharge pump G1-2560A/B.

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6.

UTY Plant Operating Procedure


ETP plant (Revision: 01)

Check that P1-2665A/B started normal with G1-2560A/B respectively. Otherwise centrifuge will trip
on hopper high level.

7. Check that G1-2540A/B grease pumps are on auto. To confirm that bearing are properly
greased.
8. Check that batches of the polymer are properly consumed. To check the proper
consumption of the chemical Nalco-9916.
9. Check the dehumidifier of the polymer package is in service and is controlling the
humidity. Its failure will cause the lump formation of polymer powder.

7. M1-2548A/B shut down:


Note: Always stop the centrifuge after running wash cycle in order to avoid the chocking of
the centrifuge.

4. Press the wash stop button on the panel in the PLC room, This sequence will also
happens automatically if a lack of torque is detected for any specific length of the
time. The following automatic timed operating sequence will be initiated and
centrifuge will be washed.
i. Wash water solenoid valve ZCV-5235/5236 opens
ii. Sludge feed valve FCV-5138/5189 closes
iii.
Polymer dosing pump G1-2575A/B stops
iv. High speed wash,10 minutes at 2800 RPM
v. Low speed wash,500 sec at 900 RPM then water valve will close
vi. Centrifuge stops
vii. Sludge transfer pump G1-2560 a/B and lump (bridge) breaker P12565A/B stop on low level (after the draining of the centrifuge)
12. Start the standby centrifuge if it is required when the duty centrifuge is on wash
cycle.

8. Working instruction for running the M1-2548A/B without Bowl


1. For the adjustment of the torque sensor, centrifuges bowl hood removal is
required.
2. After initial adjustment of the torque, it is required to run the machine without the
reinstallation of hood in order to verify the accuracy of the torque sensors
adjustment.
3. Torque adjustment PTW will be hold by the SM-UTY before start-up of the
machine, and no job will be done on the said machine jest before energisation of
the machine and the tie when machine is running.
4. Before running the machine without hood, area will be tape barricaded and no one
will be allowed to stay in the barricaded area.

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UTY Plant Operating Procedure


ETP plant (Revision: 01)

5. After having the observation during the first run of the centrifuge, if instrument
team will be in need to proceed with further adjustment, the centrifuge will be
stopped and isolated again before the re-initiation of the job.
6. For further test run, instruction mentioned in step (3) and (4) will be followed.
7. The permission for said job will be given by the Plant manager Utilities plant.

9. M1-2548A/B Emergencies:
8. CentrifugeM1-2548A/B vent on wash cycle without any indication. Restart the
centrifuge and check all the parameter, and find out the reason.
9. Centrifuge trips on high high level, first check the sludge level in the hopper if is
actual then start the sludge discharge pump on manually form local panel and open
the local drain of the sludge discharge line and provide a water hose. Secondly
check the bridge breaker P1-2565A/B is rotating or not .If it is not rotating then
stop sludge pump and inform to shift manager for the replacement of the bridge
breaker pin.
10. If the bridge beaker is ok and a fault indication is appearing on the panel then clean
the sensor with the help of the shift instrument teach and take the centrifuge in
service.

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