SGQM 77 e 00

263-ILIaLlsa `xJ s
http://legacy.library.ucsf.edu/tid/gqm77e00/pdf
JOB SAFETY ANALYSIS
PARK 500 CODE :
Department : Production Page No ; 1 of 1
DESCRIPTION OF OPERP_TION JOB LOCATION

Washing Down Stairwells Stock Prep
T SK H__AZ ARD S SAFETY PRECAUTIONS
Washing Down Stairwell EYE INJURY - 1. Wear approved safety glasses

Splashes from water,
soap, etc .
HAND INJURY - 1. Use gloves to prevent cuts and irritation

Cuts, Irritation to skin from soaps, XL100, etc .
GENERAL INJURY - 1. Use caution when using soaps to

Slips, Falls, etc . prevent slips .
2. Watch for proper foot placement ; use

hand rails while going up or down .
FOOT INJURY - 1. Always wear approved safety shoes to

prevent injury to feet .
NOTE : 1. Safety signs "Wet Floor" should be

used whenever the task is done .
2031118369
Origimator : ._ . L . F . Pullano/
D . ;R . Ampey
Date : September 26, 1982
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
Department : Production Page No : 1 of 1
DESCRIPTION OF OPERATION JOB LOCATION

Stock Prep
Shoveling Up of Ove~flow Stock
TASKS HAZARDS SAFETY PRECAUTIONS
Shoveling up of HAND INJURY - 1. Wear rubber gloves to protect your

overflow stock hands from hot stock or to prevent
blisters from forming on your hands .
EYE INJURY - 1. Wear safety glasses to avoid the

possibility of stock splattering into
your eyes .
BODILY INJURY - 1. Take the proper stand and use the muscles
Sprains, Strains most capable of doing the job .
Trips, Falls
2. Never try to lift more than you are
physically able to .
3. Do not stand in the stock while shoveling .
4. Remove any obstacle in the area that

may be a slipping or tripping hazard .
GENERAL INJURY - 1. Wear ear protection in the designated

areas .
2. Wear safety shoes that have been

approved by Park 500 Safety Department .
2031118370
Originator : _ Vernon L . Tucker/
D . R . Ampey
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
Department • Production Page No : 1 of 1
Using ChemicaLl Drum Opening Tool Stock Prep
T SK HAZARDS SAFETY PRECAUTIONS
Opening Chemical Drum EYE INJURY - 1. Wear safety glasses/goggles whenever

handling chemical drums .
HAND INJURY - 1. Wear leather or rubber gloves to protect

hands against chemicals and/or
pinch points .
GENERAL INJURY - 1. Ensure proper tool is used for each

different type of drum top .
2. Apply pressure to top of tool while

attempting to turn it in order to
keep it in control .
3. Stand as far back from drums as possible

in case contents have been pressurized .
2031118371
Originator : _ Laure E . McBride/

D . R . Ampey
Approved :
JOB SAFETY ANALYSIS
t
I. LI/
C i
,
PARK 500 CODE :

Changing Plastic On Nitrate Chute Stock Prep
Removing Old Plastic EYE INJURY - 1 . While removing old plastic, wear approvec
Foreign Matter safety glasses with side shields .
Particles of nitrate crystals cling to
the plastic and could fly off into
the eyes .
Putting on New Plastic FALLING HAZARD 1 . Assume a safe position on the step
ladder while installing the new plastic .
Ascend and descend the ladder carefully .
GENERAL INJURY - 1 . Store ladder in its proper location

so as not to block passageways . Also,
place old plastic in dumpster .
2031118372
Originator : _ D . E . Chapman/
D . R . Ampey
Date : _ 7/18/82
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
nESCRIPTION' OF OPERP_TION JOB LOCATION

External Cleaning of DN Heaters Stock Preparation
External Cleaning of EYE INJURY 1. Wear Safety glasses . (Use XL-100)

DN Heaters and hot water to clean DN heater .
HAND INJURY - 1. Wear gloves made of rubber or leather .

Cuts, Burns, Bruises
2. Do not put hands on hot liquor lines
while cleaning DN heaters .
FOOT INJURY - 1. Be sure to roll up water hose when

Sprains, Strains finished washing DN heater .
2. Be very cautious when walking on wet

surface .
3. Do not use water on electrical motors .
4. Be sure heaters are off and locked

out before starting to clean DN
heaters .
_ 20311IN373
Originator : W . L . Williams/
D . R . Ampey
Date : . August 16, 1982
An-~,^n~ cr7 •
JOB SAFETY ANALYSIS
PARK 500 CODE :
Cleaning the Evaporator Seal Pit Stock Prep
Cleaning the HEAD AND BACK INJURY - 1. Be aware of slippery, slimy places
Evaporator Seal Pit Cuts, Abrasions, and on the Evaporator Seal Pits Basin
Punctures floor, which could cause you to slip
and fall .
2. Never enter the Evaporator Seal Pit

alone .
EYE OR FACE INJURY - 1. Wear Safety Glasses when cleaning

Cuts, Abrasions, or out the Evaporator Seal Pit .
Infection
2. Wear a Face Safety Shield when
shoveling or hauling residue out of
the pit with a bucket and rope .
HAND INJURY - 1. Wear Rubber gloves to avoid skin

Cuts, Abrasions or contact with the residue in the
Punctures, Infection Evaporator Seal Pit .
2. Beware of sharp pieces of metal or

glass that may be in the pit . Handle
it with care .
3. If you happen to get a cut or abrasion

or puncture go to the medical depart-
ment immediately before infection
sets in .
GENERAL INJURY - 1. Wear approved Safety Shoes .

Limbs or Torso
2. Wear ear plugs in designated areas .
3. Do not jump off any of the ladder

rungs going down into the Evaporator
Seal Pit .
4. Exercise caution when entering or

leaving the Evaporator Seal Pit .
Originator : V . L . Tucker/
D . R . Ampey
Date : _ Aucrust 15, 7 982
2031118374
JOB SAFETY ANALYSIS
PARK 500 CODE :
DeDartment : Production Page No ; i nf i
DESGRIPTION OF OPERATION JOB LOCATION

Sampling Of S tock Dumpster Stock Prep
Sampling of Stock HAND INJURY - 1. Wear approved gloves ; leather or rubber .

Dumpster Burns, Scrapes,
Cuts 2. Exercise care when reaching into
dumpster .
EYE INJURY - 1. Suggest wearing approved safety glasses .

Stock Splashes
GENERAL INJURY - 1. Due to floor area being wet, make sure

Bodily Injury, of proper foot placement .
Falls, Slips
1. Use caution when leaning over stock
dumpster ; possiblity of slipping .
Originator : R . H . Cummins/
D . R . Ampey
Date : 8/2/82
Anoroved :
2031118375
JOB SAFETY ANALYSIS
PARK 500 CODE :
nESCRIPTION OF OPERATION JOB LOCATION

Changing Plastic on the Nitrate Chiller Stock Prep
Removing old Plastic EYE INJURY - 1. Wear approved safety glasses or goggles .
Foreign Matter
Putting on New Plastic FALLING HAZARD 1. Assume a safe position on the ladder
while installing the new plastic .
GENERAL INJURY - 1. Ascend the ladder carefully to avoid

slipping, and store the ladder in its
proper place once the job is complete .
2031118376
Originator : _ D . E . Chapman/
D . R . pey
Date : 7/18/82
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
Department•_ Production Page No : 1 of 1

General Cleanup of the Cooling Tower Roof Stock Prep
General Cleanup of HAND INJURY - 1. Wear leather gloves when handling metal
the Cooling Tawer scraps .
Roof
2. Wear rubber gloves when scrubbing with
XL-100 .
EYE INJURY - 1. Wear safety glasses when spraying down

equipment with a waterhose .
GENERAL INJURY - 1. Use proper lifting techniques when

picking up heavy objects .
2. Do not throw away any objects off of

the roof ; they must be carried down .
3. Never work on the roof alone . There

must always be two people minimum when
on any roof .
2031118377
Originator : L . E . McBride/
D . R . Ampey
Date 7, 1 ~~82
Approved :
JOB SAFETY ANALYSIS
PARK 5 00 CODE :
Depart ment : Production Page No ; 1 of 1
DESC RIPTION OF OPER ATION JOB LOCATION

Changing Plastic on S pare Centrifuge Chute Stock Prep
TAS KS HAZARDS SAFETY PRECAUTIONS
Changing Plastic on HAND INJURY - 1. Wear rubber gloves

Spare Cen trifuge Chute Burn
GENERAL INJURY - 1. Always use two persons when changing

plastic .
2. Always wear approved safety glasses .
3. Never try to put plastic on chute while

hanging over rail .
4. Always remove nitrate bin . Never lean

ladder against bin to attach plastic .
2031118378
Originator : I• R . McLaughlin/
D . R . Ampey
Date : 7/9/82
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
DeDartment • Production Page No ; 1 of 1
T)ESCRIPTION OF OPERATION JOB LOCATION

Sampling of Stock Dumpster Stock Prep
Sampling of Stock EYE INJURY - 1. Wear approved safety glasses .

Dumpster Splashes From Stock
HAND INJURY - 1. Wear rubber gloves, due to stock

Burns, Bruises, being hot .
2. Use care when working around dumpster ;

watch for sharp edges .
BODILY INJURY - 1. Make sure of proper foot placement due

Falls, Slips to floor area being wet .
2031118379
Oriainator : R . H . Cummins/
D . R . Ampey
: 7/9/82
Date
Ap~roved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
i)ESCRIPTION OF OPERATION JOB LOCATION

Emptying Stock Dumpsters Stock Prep
Transporting Stock Dumpster Falling 1. Use prope r fork truck operating procedure
Dumpsters Off Forks while lifting and transporting the stock
dumpster to the dump site .
Emptying Stock Stock Spillage 1. Make sure that the dumpster is posi-
Dumpsters tioned properly over the stock bin
when releasing the tilt mechanism .
Releasing the Tilt HAND INJURY - 1. The surface of the lever may be rough,
Mechanism Cut, Metal Splin- wear leather gloves .
ter
GENERAL INJURY - 1. Wear approved safety glasses .

Foreign Matter
in Eye
2031118380
Originator :__ D . E . Chapman/
D . R . Ampey
Date : 6-21-82
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :

Cleaning Overhead Crane Tracks Stock Prep
T S HAZARDS SAFETY PRECAUTIONS
Cleaning Overhead ELECTRICAL SHOCK, 1. Follow the lock out procedure when
Crane Tracks BURNS, POSSIBLE cleaning crane tracks .
DEATH
2. Do not spray tracks with water base due
to motors below the tracks .
EYE INJURY - 1. When cleaning overhead, use goggles

Irritation, Burns to protect eyes from drips and splashes .
HAND INJURY - 1. Use rubber gloves when using any

cleaning solution .
GENERAL INJURY - 1. Follow the proper_procedure for using

Torso, Head, Limbs the high horse jack ladder .
2. Have hands free when climbing up or

down ladder and use hand rails .
3. Ensure ladder and shoes are free of

grease or grime that would cause
slipping .
2031118381
Originator :_ J . A . Ciliberto/
D . R . Ampey
Date : 6-29 J82
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
r)ESCRIPTION OF OPERATION JOB LOCATION

Use of Floor Buffer Stock Prep
Use of Floor Euffer ELECTRICAL SHOCK 1 . Always use ground fault interrupter with
the floor buffer .
2 . Inspect electrical outlet for loose wires

burn traces, etc . before plugging in
buffer .
3 . Always check•buffer cords for loose or

frayed wires or torn insulation .
4 . Do not leave buffer on and unattended .
GENERAL INJURY - 1 . Use caution as to cord placement so it

Torso, Head, Limbs does not become a tripping hazard to
others in the area .
2 . Use caution signs to alert passerby to

cord strung out across floor when
necessary .
3 . When hosing down floor after using buffe2

use caution so as not to wet down people
passing through the area .
4 . Roll up water hose immediately after

use .
20311-18382
Originator : J . A . Ciliberto/
D . R . Ampey
6-19-82
Date :
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :

Using Sky Horse Ladders Stock Prep
Positioning Out- HAND INJURY - 1 . Wear gloves when swinging our riggers
riggers Pinch"Points into position . Be sure hands and
fingers do not get caught between
pivot arm and ladder supports .
Raising and lowering 1 . When raising the cage, make sure fingers
cage are not in the area of the pivot bar
or where the cage rides along side of
the top platform .
Retracting Out- GENERAL INJURY,- 2 . Be sure outriggers are secure to ladder

Riggers base and fully retracted so that the
ladder can roll smoothly .
2031118383
Originator : D . E . Chapman/
D . R . Ampey
Date : 6/8/82
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
r)ESCRIPTION OF OPERATION JOB LOCATION

Breaking down of Hogsheads Stock Prep
Breaking down of HAND INJURY - Cuts, 1 . Wear gloves made of leather or other thick
hogsheads Abrasions, Punctures material .
EYE INJURY - Cuts, 1 . Wear approved safety glasses, including

Punctures side shields or goggles .
2 . Ensure no one is close by without eye

protection .
FOOT INJURY - Sprain, 1 . Wear approved safety shoes . Keep loose

Strain pin and wood off of floor .
GENERAL INJURY - 1 . Be alert of broken bands with sharp edges

Torso, Head, or and wood splinters .
Limbs
2 . Do not break hogsheads down in a thru-way
2031118384
Originator : F . N . Kelley/D . R . Ampe,
Date : 05/31/82
Approved :
,
JOB SAFETY ANALYSIS
PARK 500 CODE :

High Press Cleaning Presses Stock Prep Line II
TASKS HAZARDS SAFETY_PRECAUTIONS
High press cleaning EYE INJURY - 1. Wear approved safety glasses .

press sections . Splashes from H20,
stock 2. May want to wear disposable suit .
Falls, tripping 1. Due to close quarters, msut excercise

extreme caution when working on
platforms around press and watch for other
moving conveyors .
2. Make sure press is locked out before

proceeding .
GIINERAL INJURY 1. Due to high press comming from gun type

nozzle, make sure you have a good firm
grip on gun .
2. Make sure feet are planted firmly on

A solid foundation .
2031118385
Originator : _ R .CL&VINS/D . R . Anpey
Date :
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
Cleaning out Evaporator Seal Pit Stock Preparation
HAZARDS SAFETY PRECAUTIONS
Cleaning out EYE INJURY - 1. Wear approved safety glasses (including

Evaporator Seal Pit Irritation side shields) or face shield .
HAND INJURY - 1. Wear long rubber gloves .

Chemical Burns
GENERAL INJURY - ; 1. Use droplight with ground fault while

Torso, head, limbs,j hosing down pit .
electrical shock o~
possible death 2. Wear rubber boots .
3. Ensure seal pit manual water supply valve

is closed and chain locked out .
4. Two people should be in pit at all times .
5. Ensure all chemical drum pumps are

unplugged to prevent chemical from
dripping down .
6. Wear rubber protective suit .
7. Put cover plate back over opening when

finished .
203,118386
Originator :B. Wyche/D .R . Ampev
Date : April 26, 1982
Aporoved :
JOB SAFETY ANALYSIS
PARK 500 CODE :

Rinsing of Chemical Drums Stock Prep
Rinsing of chemical EYE INJURY - 1 . Wear approved safety glasses and

drums at seal pit Splashing face shield .
2 . Use extreme caution when rinsing out

drums .
HAND INJURY - 1 . Wear rubber gloves .

Burns
BACK INJURY - 1 . Use correct lifting procedures when

Strains handling drums .
BODILY INJURY - 1 . Must wear safety shoes .

Crushing Hands and
Feet 2 . Use extreme caution when handling drums
to prevent drum from falling on feet
or falling against another drum and
injuring hands .
2031118387
Orig-i-nator : R . H . Cummins/
D . R . Ampey
Date : 4-20-82
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :

:_ Production Page No ; 1 of 1
Department

Switching of Chemical Drums Stock Prep
Switching of Chemical BACK AND'ARM INJURIESJ 1) Use caution when moving drums .
Drums Strai in
2) Do not try to lift drum by yourself when
it falls .
3) Wear safety glasses, gloves .
FOOT AND HAND 1) Wear safety shoes when working with drums .
INJURIES - Bruises,
Crushing 2) Do not get fingers between drums .
EYE INJURY - Chemical 1) Handle drums with care - do not drop .

Splash
2) Wear safety glasses .
3) Use caution when taking bungs off

(pressure build up) .
GENERAL INJURY - 1) Always use extreme caution when

Bodily Injury, transporting drums to and from destinatior
Damage to Company
Property 2) Observe all departmental safety rules .
2031118388
Origi .nator : R• H . Cummins/
D . R . Ampey
Date : 04/12/82
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
Department : Production Page No- 1 of 1
Changing Plastic on Press Lines Stock Preparation
Changing Plastic on HAND INJURY 1) Wear gloves made of rubber to guard

Press Lines against hot stock .
2) Ensure press has come to a complete stop

before removing plastic .
BACK INJURY 1) Follow proper lifting procedure when

removing and installing the plastic .
GENERAL INJURY 1) Exercise extreme caution when working

on press to guard against slipping on
wet metal base .
EYE INJURY 1) Wear safety glasses-or goggles when

washing the presses down to guard
against splashing stock .
I
I .
, .
20311.18389
Originator : L . E . McBride/
D . R . Ampey
Date : 04/12/82
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :

Cleaning up Stock Spills Stock Pren
Cleaning up Stock BACK INJURY - 1 . Use proper lifting procedures when

Spills Strains, Sprains, shoveling stock off of catwalks and
Pulled Muscles floors and emptying into dumpsters .
2 . Do not overload shovel . Only shovel

amounts that can be comfortably handled .
HAND INJURY - 1 . Wear leather gloves when using shovels

Blisters, Punctures to removed stock spills .
from Splinters
GENERAL INJURY - l . Use proper foot placement when cleaning

Head, Torso, Limbs stock off of catwalks and floors to
prevent slipping .
2 . Be observant of low overhead clearance

areas under presses so as not to hit
the head .
3 . Do not leave water hoses strung out

across floors unattended .
4 . Be observant of other people passing

through area when using water hoses
so as not to wet them down .
203111833-19 0
Originator : _ J . A . Ciliberto/
D . R . Ampey
Date : 4-7-82
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :

Pulling Sewer Sample Stock Prep
Pulling sewer sample BACK INJURY - 1 . Follow proper lifting procedures .

Sprain
HAND INJURY - 1 . Wear rubber gloves .

Irritation, Burns
GENERAL INJURY - 1 . When removing sample cup rod from sewer

Head, Face, Eyes, hole, position it away from body .
and others
2 . Be aware of other employees or moving
equipment when handling long sample
cup rod .
3 . Return metal cover over sewer .
Originator : R . Wyche/
D . R . Ampey
Date : 4-7-82
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :

I Dumping of the Blue Dumpster Stock Prep
Dumping of the Blue HEAD INJURY - Cuts, 1 . Do not position yourself or the lift truck
Dumpster Punctures, Abrasions down wind when dumping the dumpster thus
allowing loose trash, wood and dust to be
blown down on you .
EYE AND FACE INJURY - 1 . Wear safety glasses when dumping .

Punctures, Cuts,
Abrasions 2 . Wear a face safety shield when dumping
and try not to position yourself or the
lift truck down wind . This will help
eliminate the possibility of eye and face
injury .
HAND INJURY - Cuts, 1 . Wear gloves whenever it is possible .

Abrasions
FOOT INJURY - Sprain, 1 . Wear approved safety shoes .

Punctures, Bruises,
Crushing 2 . Have no loose shoe strings or leather or
metal showing which could cause you to
trip .
I GENERAL INJURY - 1 . If a dumpster is full of stock it is best

Torso, Limbs, Head to use the 6,000 pound fork truck .
2 . To keep from climbing up on the fork truck

to push the lever up to dump the dumpster
a four foot light metalic prong type tool
shoulrl be used to push up the lever on the
dumpster to eliminate the possibility of
falling .
z.. 3 . Make sure that no one is close by in case

dumpster slips from the lift truck when
raised .
210 *' 3 111-9 ;*19 A2

Originator : V . L . Tucker/D . R . AmF
Date : 03/29/82
A= rovec. :
JOB SAFETY ANALYSIS
I PARK 500 CODE :

V
Department : Production Page No :
Cle Stock Pre
Cleaning Sewer Hand Injury, Cuts, 1 . Wear gloves made of leather or 6ther
Pinch, Bruises thick material .
Foot Injury, Bruises, 1 . Wear approved safety shoes .

Crushing
Back Injury, Sprain, 1 . Do not attempt to lift up sewer grate

Strain by hand . Lift grate with hook . When
lifting grate use established safety
lifting method .
General Injury, Leg, 1 . Keep walk way clear from employees or

Lower and Upper Body trucks passing through .
2 . Put up open trench safety sign while

cleaning sewer .
3 . Watch for tripping over grates .
4 . Put grates back in with proper side up .
2031118393
Originator : .Robert Wyche/D . Ampey
Date : March 20, 1982
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
Department : Production Page No t 1 of 1

Changing of Nitrate Bins Stock Prep Line II
Changing of Nitrate HAND INJURY 1. Wear gloves when handling cover

Bins Pinch Points, Cuts, under #2 Sharples .
Bruises
EYE INJURY 1. Wear approved eye protection due

to light powdery dust .
FOOT INJURY 1. Wear approved safety shoes .

Bruises, Crushing
2. Keep feet from underneath bin .
BACK INJURY 1. Never attempt to move empty bin,

Strain or full bin by hand .
GENERAL INJURY 1. Always check forklift before use

To Self & Property, to insure truck is free of
Injury to Pedestrian , maintenance deficiencies .
Damage to Company
Property 2. Always use extreme caution when
transporting a full or empty bin
through process areas . observe
speed limit .
3. observe all safety precautions in

each area .
2031118394.
Originator : R . H . Cummins/
D . R . Ampey
Date : 3/14/82
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
: Production Page No : 1 of 1
Department

Cleaning Press Pans Stock Prep
Cleaning press pans HAND INJURY 1. Wear leather gloves when opening
Cuts, Sprains, valve to sewer or closing .
Blisters, Abrasions
2. Wear rubber gloves while cleaning
out pans .
EYE INJURY 1. Wear safety glasses with side

Burns, Irritation shields .
HEAD INJURY 1. Stay alert and be perceptive

Bruises, Cuts, as overhead clearance is minimal
Scrapes, Concussion when opening drain valve or closing .
BACK INJURY 1. Due to low overhead clearance, squat

Strains, Pulled instead of bending to open and close
Muscle drain valve .
GENE RAL 1. Roll water hose up immediately after

Head, Torso, Limbs use .
2. Pay attention to foot placement when floors are wet and slippery
.
2031118395
originator : J . A . Ciliberto/
D . R . Ampey
Date : 3/14/82
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
nESCRIPT7:ON OF OPERATION JOB LOCATION
Blowing Down Dust Filters Stock Prep
Blowing down dust EYE INJURY - Cuts, 1 . Wear goggles, eyes must be totally
filters Abrasions enclosed .
TORSO, LIMBS - Dust 2 . Be sure purge air is turned off .

Irritation
TORSO, LIMBS - Dust 1 . Wear protective paper suit over uniform .
Irritation
BACK INJURY - Sprain, 1 . Use proper foot placement and proper

Strain lifting methods when opening doors to
dust filters as bolts are often stuck,
difficult to open, and above head level .
THROAT IRRITATION - 1 . Wear respirator to filter air when blowinc

Lung Congestion down dust filter .
GENERAL INJURY 1 . When climbing ladder to dust filter plat-

form ensure that bands are clean and dry .
2 . Use both hands to ascend or descend the

ladder .
3 . When climbing ladder ensure that safety

shoes are free of grease and grime .
4 . Do not use air to blow dust off of

clothes or body .
2 1.7 31,118396
Originator :_J . A . Ciliberto/
D . R . Ampey
Date : 03/06/82
Aparovec :
~, . . :
REVISED 1/23/87
TRAINING START DATE FINISH DATE
GUIDELINES .,TO-AID INtTRATNING'A NEW STOCK~'gREP''NUMBER-2 ;• OPERATOR
OPERATORS NAM1 : EVALUATING SUPV_
I. Process Equipment-and Flows
A . CEL Tanks
1 . Location and purpose of the CEL tanks .
2. Purpose of the. CEL level information loops .
. .. _ . .. - ~
3 . Tran_sferring CEL from Stock Prep to Stock`Prep .
B. Crystallizer Supply Tank

1 . Location and purpose of the crystallizer supply tank .
2 . Function of the automatic level control loop .
3 . Overflow of the crystallizer supply tank to the 24"
standpipe .
C . Crystallizer Supply Pumps

1 . Location, type and purpose of the crystallizer
supply pumps .
2 . Alternate methods of valving the supply to the crys-
tallizer trains .
/ 3 . Function and purpose of the flow elements .
4 . Function of the flow control loop .
D . Crystallizer Trains
1 . Location and purpose of the crystallizer trains .
2 . Purpose of the temperature transmitting loop on
the CEL supply lines to the crystallizer trains .
3 . Starting up or shutting down a crystallizer train
or an individual crystallizer .
4 . Running a split flow and when it is necessary .
5 . Recycling the CEL flow through the crystallizer
trains and-when it is`necessary .
6 . Purpose of the high/low current alarms'on each
crystallizer motor .
7 . Operation of the brine temperature control loop
on the individual crystallizers .
8 . Purpose of the high brine temperature alarm loop on
the brine supply line to each train .
9_ How to use CEL pressure to trains to find plugs
E . Brine System
1 . Location and dual purpose of the brine tank .
2 . Purpose of the temperature alarm loop on the supply
line from the brine chillers to the tank .
3 . Purpose of the level alarm loop on the brine .tank .
4 . Purpose and location of the brine pumps which supply
the chillers .
i 5 . Purpose and location of the brine pumps which supply
the crystallizer trains .
2031118397
Brine System, con't .
6 . Alternate ways to valve the brine supply to the
crystallizers .
7 . Function and purpose of the flow control loop on the
brine supply line to the crystallizers .
8 . Location and purposes of the chiller water cooling
tower . .
9 . Location and purpose of the cooling tower supply
pumps .
10 . Purpose of the temperature alarm loop on the cooling
water supply line to the chillers .
11 . Location and purposes of the brine chillers .
F . 'Sharples Denitration Centrifuges

1 . First stage centrifuge
a . Location and purpose of the Ist stage centrifuge .
b . Purpose of the dams and their effect on the effi-
ciency of the Ist stage centrifuge .
c . Differential speed and its effect on the operation
of the Ist stage centrifuge .
d . Purpose and location of the centrifuge water
chillers .
e . Operation of the flow control loop on the chilled
water for the 1st stage centrifuge .
f . Purpose and location of the chilled water rotameter .
and how to read the rotameter .
g . Purpose of the ch_lled water .
h . Where does the denitrated liquor go after it comes
out of the 1st stage centrifuge?
i . Wnere does the nitrate sludge go after it comes out
of the lst stage centrifuge?
2 . Second stage centrifuge

a . Location and purpose of the 2nd stage centrifuge .
b . How and why can the spare centrifuge be used as
either a 1st stage or 2nd stage centrifuge?
c . Effects of the dam setting and differential speed
on the efficiency of the 2nd stage centrifuge .
d . Where do the centrifuged nitrate ctystals go?
e . What happens to the chilled water after it has
been separated from the nitrate crystals?
f . Purpose of the nitrate bin and when it is necessary
to have it changed .
G . 18" Standpipe
1. Location and purpose of the 18" standpipe .
2. Function of the level control loop on the 18" standpipe .
3. How is the speed on the 18" standpipe discharge pumps
controlled?
4 . Where does the DNCEL go after it is pumped out of the
18" standpipe?
Z031118398
H . 16" Standpipe
2. What supplies the 16" standpipe?
3. Function and purpose of the temperature control
loop on the 16" standpipe .
4 . Function of the operation of the level control loop
on the 16" standpipe .
5 . How and when should the supply chute to the 16" .
standpipe be changed .
6 . Where do the contents of .the 16" standpipe go?
I . 24" Standpipe
1 . Location and purpose of the 24" standpipe .
2 ., What supplies the 24" standpipe?
3 . Purpose of the level alarm loop on the 24" standpipe .
4 . Where do the contents of the 24" standpipe go? -
J. DNCEL Holding Tanks ~

1 . Location and purposes of the DNCEL holding tanks'
2 . Function of the level alarm loop on the holding tanks .
3. How is DNCEL transferred from Stock Prep to Stock Prep?
4. Explain the various valving alternatives for the supply
to the various holding tanks and for supply to the
various DNCEL transfer pumps .
5. Where does the DNCEL go after the holding tanks?
K . DNCEL Heaters
1 . Location and purpose of the INCEL heaters .
2 . Location and purpose of the DNCEL recirculation pumps .
3 . Purpose and operation of the temperature control loop
on the DNCEL heaters .
4 . Explain the various valving alternatives for DNCEL
flow through the DNCEL heaters and back to the holding
tanks .
L . M9 .x Tank
1 . Purpose and location of the-mix tank .
2 . Purpose and operation`of the level control loop .
3 . Transferring DNCEL from mix tank to mix tank .
4 . Where does the DNCEL go after the mix tank?
II . Process Housekeeping
A . Explain how and when to clean the CEL tanks and the screen
1 baskets .
B . Explain how to flush the CEL lines from the CEL tanks to
the crystallizer supply tank .
C . Explain how to flush the crystallizer supply lines from
the outlet of the crystallizer supply tank through the
crystallizer supply pumps, flow elements and individual
train supply lines .
D . Explain how to flush an entire crystallizer train through
the crystallizer supply pumps to the lst stage centrifuge .
E . Explain how to valve off and flush an individual crystal-
lizer .
2+D31118393
I
,
F. Explain how to flush each Sharples centrifuge .

G. Explain how to steam clean the DNCEL lines from the 18"
~ standpipe to the DNCEL holding tanks .
H. Explain how and when to flush the 16" standpipe .
I. Explain how to clean the DNCEL holding tanks .
J. Explain how to flush the DNCEL heaters .
III . General Information

A. Types of Pumps
1 . Positive displacement pumps
f a . Types of positive displacement pumps .

b . How does a positive displacement pump operate?
What is a rotor? What is a stator?
p . What happens when a positive displacement pump
is deadheaded?
2 . Centrifugal pumps
a . Types of centrifugal pumps .
b . How does a centrifugal pump operate? What is a
coupling, an impellar?
c . What happens when a centrifugal pump is deadheaded?
B . Types of Valves
1 . Manual valves
a . Ball valve - 2 way, 3 way
b . Gate valve
c . Knife valve (Slide valve)
d . Diaphragm valve
e . Globe valve
f . Butterfly valve
g . Plug valve - 2 way, 3 way
h . How do you determine what position each of the
above valves is in?
2 . Automatic valves
a . Panel controller operation
1 .) Manual mode ~
2 .) Automatic mode
3 .) Set point
4 .) Valve position
5 .) Local control
6 .) Remote control
b . Types of automatic valves
1 .) Diaphragm valve
2 .) Ball valve
3 .) Gate valve
4 .) Knife valve (Slide valve)
5 .) Plug valve
6 .) How do you determine what position each of the
above valves is in by looking at the valve?
Z031118400
~
i
IV . Paperwork and Sample Schedule
` A . Brine Chiller Log Sheet

1 . Where to take the readings .
2 . When to take the readings .
Denitration Log Sheet

C . Material Sampling
1 . Where and when to take the following samples .
a . CEL tank sample
b . 18" standpipe sample
c . DNCEL holding tanks samples
d . Mix tank sample -
2 . Where to record the level information for the material
balance .
V . Interlocks
A. CEL tank supply selector switch .

B. CEL recycle interlock
C. Brine recycle interlock
D. CEL low flow i n t er l oc k s .
E. Crystallizer supply pumps selector switch
F. Sharples centrifuge se)ector switch
~
G. 18" transfer pump selector switch
H. 16" standpipe brine jacket hand/off/auto selector switch
I. DNCEL holding tank selector switch
J. -DNCEL heater/tank/recirculation pump selector switch
K. Chiller cooling tower fan hand/off/auto selector switch
PREPARED BY
APPROVED BY
DATE
Z0313118401
f
y
AT-1"/I4 ~TfrTOStock Prep #2 ;,C}perator

kI'ethodology ~
SEGMENT I (Classroom)
PURPOSE : TO GIVE OVERVIEW OF THE JOB
A\ Al ..l .-. .L ... ~.l .. .Cl ~ .C,..~ .v n .-._~ .t. A 1 .,_ T1 .~_~ .i 71
[7J C1AJ1.G 4V G11,k/1Ct .111 jJl-VliG7~ 11VW - A .L'V1Ll rU11Ll . L] liU rV .l.lll' D .
Line I B) Able to identify immediate supplier .

C) Able to identify immediate customer .
Line II D) Able to identify key variables in reference to supplier ; customer .
E) Identify key equipment expected to operate .
Line III
SEGMENT II (Field)
PURPOSE : FAMILIARIZE EMPLOYEE WITH AREA, AND EQUIPMENT LOCATIONS .
A) Review area Safety Rules

Line I B) Walk through area explaining process flow and locate :
1 . Equipment
Line II 2 . Motor control centers
3 . Control panels
Line III
SEGMENT III (Classroom)

PURPOSE : EXPLAIN PURPOSE OF SPC AND ITS RELATIONSHIP TO YOUR JOB
~
~
A) Explain concept of variation . '~
Line I B) Review and explain area/line philosophy as foundation block . ~'
-50
U.1% ew w y we ave C)s Ratx
ev i ar
h s, h parame
4- d d ers, an
t d
proce ures
d . „~ 0.
Line II D) Explain how control charts and control moves are used to reduce variatio
~ .r~'
rl- __ Line III ~ ~
)-A
~
~
~
~
sTV
f
SEGMF,NT IV (Field)
PURPOSE : PROVIDE DETAILED EXPLANATION OF JOB FUNCTIONS AND EQUIPMENT OPERATIONS
A) Review Purpose of Equipment

B) Explain operation of equipment to include : Controls and how to adjust, instrumentation and how to
adjust, interlocks and bypass, valves/valving, starting up/shutting down/switching/changing,
flushing/cleaning, safety requirements/precautions, troubleshooting, resetting breakers_
)
C~ Expl
_ a_i.n phi 1 ns n~hv
s•__--_-_
of -a•____-__
.~__„ nrnra-Fi nn tn,__-~__
i nr~ l nra-r_•-.---_
samri i=i n n•hanr3ar r~u
....~~__. ...._.. . .W.~ naramc.i-.pr•sz
r .~ .. ....~ ... . . . ...., . rnn~l-»nl mntrnv, niA
..~~ .. . . .. ... ..... . .~. ...
procedures .
S.taj~.re I - CEL Ta s
A) CEL tanks
Line I 1 . Location and purpose of CEL tanks
2 . Know when and how to switch CEL tanks
Line II 3 . Source of supply to CEL tanks
4 . Purpose, operation, switching of CEL pumps (Line I only)
Line III
Stage 2 - CrYstal_1_i2.erSu~pp1 rLTan({1jr-L17 ~
A) Crystallizer Supply Tank (L-II) \\\\\\\~ :

Line II 1 . Location and purpose of crystallizer supply tan16'0
2 . Purpose and operation of level control systems ~~
.-9 ® .
~. ~
~
~ >
~ 0
N
~
~
~
W
0SESai°IENT IV (Field)
PURPOSE : PROVIDE DETAILED EXPLANATION OF JOB FUNCTIONS AND EQUIPIMENT OPERATIONS
C) Explain philosophy of operation to include specific standards, parameters, control moves, and
procedures .
(Continued)
Stage 3 -Crysta],1 i,. . SzpplYPumpsTrai ns, an Brine System.
m A) Crystallizer Supply Pumps

Line I 1 . Location, type and purpose of the crystallizer supply ptunps and all controls
2 . Proper valving to and from each crystallizer supply pump
Line II 3 . Proper starting and operation
4 . Flow control and conditions effecting flow
Line III
) Crystallizer Trains
Line I 1 . Purpose of crystallizers
2 . Location of trains and individual crystallizers
Line II 3 . Flow of GEL from CEL tanks through crystallizers, discharge lines to first
stage sharples centrifuge and re-cycled back to CEL tank
Line III 4 . How to by-pass ann individual crystallizer
5 . How and where temperature is controlled for individual crystallizers
6 . Control of liquor flow through trains and the relationship of CEL solubles
and flow to crystallizer temperature
7 . Purpose of high/low amp alarm on each crystallizer
C) Brine System
Line I 1. Purpose
2. Location and dual purpose of the brine tank , , ~
Line II 3. Location of the brine chillers and condensors
4. Level control in brine tank
Line III 5. Purpose and location of brine chiller su pp l y pump s and all cont ro ls -a C)
~ 6. Purpose and location of crystallizer brine supply pumps and all controlog"O
7. How and when to switch brine chiller supply pumps ®-°
t3 . How and when to switch the crystallizer brine su pply pumps ~. ~
~ 9. Function and purpose of the flow control loop on the brine supply W ~
10 . Location and purpose of the brine chiller water cooling tower ~
N 11 . Location and purpose of the brine chiller water cooling tower >
~ 12 . Flow of brine through the entire system . ~
~
~,
Q
IP+
!
aEMhNT__Iy (Field)
A) Review Purpose of Bquipxnent

C) EXDl"dln
~ . b}17IOflnDj"1V
.~ - _ _ __- _ ..
of
.__ ne pra-F-inn to
_y_-~_--__ inrlnrlr~ niv~r--ifir
__ ___~___~_ i_______ _~nlan~iarrl~e
. .... . . ....... .. .. ..., tnaramrahearca
.... .. ...... ... ... . .. ..., rr~nf»nl mr .2TOQ ~nr7
... . .. . .... .. .. . . ...- . . .. .. ., .~. . ...
procedures_
(Continued)
Stage3 - Sharples Centrifuges
A) Sharples Centrifuges
Line
I 1 . First Stage Centrifuge
a . Purpose and location of the first stabe centrifuge and all controls
Line II b . Proper starting and operating centrifuge
c . Purpose, adjustment and effects of the centrifuge differential speed
~ Line III d . Proper valving to and from the centrifuge
e . Purpose, operation, and location of all chemicals for the chilled water
system to centrifuge
f . Flow of chilled water to centrifuges to include primary and secondary
source
g . How and when to switch centrifuge
h . Proper centrifuge cleaning techniques ~
2. Second Stage Centrifuge

Line I a . Purpose and location of the second stage centrifuge and all control-v
b . Purpose, adjustment and effects of the centrifuge differential speeV Q
Line I I c . Proper valving to and from the centrifuge ®~,
-.t~.
~ Line III ~ ~
W 3. Spare Sharples Centrifuge

1J' Line I a . Purpose and location of the spare and all controls n
on b . How and when to run as a first stage or second sta ge ~`
~..~ Line T I c . Proper valving to and from the centrifuge
d. Pro per val v ing of c hill ed wat er an d recyc l e when running split mode
~ Line III
P
SEGMENT IV (Field)
PURPOSE : PROVIDE DETAILED EXPLANATION OF JOB FUNG"TIONS AND EQUIPMENT OPERATIONS

('-1 R"aT'1 ain ^ . i„ > .1, . .~'i
I, 4 -F +- .oia a' auuiuuG
t 7--~- r.Lt1C
~ : standards, parameters, control
`Y~iui.3 ajx:C: moves, and
procedures_
( Cont irnied )
,
Sa- 1E3" Staridpipe (l-I& L-_

.I I)
A) 1l3" Standpipe (L-I & L-II only)

Line I 1. Purpose and location, and location of controls _
2. Purpose and function of the 18" standpipe level control
Line II 3. Sources of to the 18" standpipe
4. How and when to switch pumps and transfer line
B`ga--- 7 .6" & 24" Stand-pipes
A) 16" Standpipe
Line I 1. Purpose and location of the 16" standpipe and all controls
2. Sources of supply to 16" standpipe - . 9
Li ne II 3. Purpose o f chill e d water to t h e 1 6" standpipe
4. Proper valving to and from the 16" standpipe 00
Line III 5. Function and location of the level control systems and importance to propeg- ~
operation ®
^ 5~°
6. How and when to switch ptuups and/or discharge lines ~ (D ~
N
Q B) 24" Standpipe
~ Line I 1. Purpose of the 24" standpipe W
2. Sources of supply -to 24" standpipe C~
~
~~ ---- Line II 3. Function of level control system
4. Purpose and location of discharge pump and all controls
Z. Line III 5. How and when to switch discharge pumps
~ 6. Destination of liquor pumped from 24" standpipe
~
~
SEG E~f NT IV (Field)


flushing/cleaning, safety requirements/precautions, troubleshooting, resetting breakers .
C) Explain Uhilosophv of operation to include specific standards . -narameters . control moves .. and
procedures . -
(Continued)
°t -DUC ., a ks, Heaters . Mi-x_ Tan
A) DNCEL Holding Tanks

Line I 1. Purpose and locatio n of the tanks and agitator controls
2. Sources of DN to the DN tanks
Line II 3. Proper valving to an d from the DN tanks
4. Transferring DN between SPI & SPII
Line III 5. Interlocks
B) DNCEL Heaters
Line I 1. Purpose and location of DN heaters and all controls
I 2. Purpose, location, and operation of DN recirculation pumps
Line II 3. Purpose and operation of the temperature control system
4. Proper valving of DN and steam to and from the heaters
Line III 5. When and how to switch DN heaters
6. Interlocks
r'
ff
C) Mix Tanks
~ Line I 1. Purpose and location of the mix tank and agitator controla5' C)
~ 2. Source of DN to mix tank
~ Line II ~
ea
'= C~-
(D
~ Line III
~ W
0
~
~
l
SEGMNE T V (Classroom/Field)
PURPOSE : TO EXPLAIN MICROBIOLOGICAL ACTIVITY AND IDENTIFY CLEANING RESPONSIBILITIES
A) Able to identify trouble signs and corrective action responses .

Line I B) Review routine cleaning procedures .
C) Review bleaching procedures and shutdown cleaning .
Line II
Line III
SEGME(V'T,' VI (Field)
PURPOSE : TO FAMILIARIZE EMPLOYEE WITH DATA GATHERING ACTIVITIES .
A) Explain how to properly complete process logsheets .

Line I B) Explain how to record data on SPC System Reports .
C) Explain how to complete cleaning schedules .
Line II
Line III
SECMENT VII (Classroom)

PURPOSE : EXPLAIN IMPORTANCE OF TIMELY AND EFFECTIVE COMMIJNICATIONS .
A) Explain the need to communicate to :

Line I 1) Customers/suppliers inside and outside immediate area
2) Supervisor
Line II 3) Relief/employee being relieved at shift change
j~ B) Explain communications required by start-up/shut down procedures
~ Line III
tj
~A
~ ,Si;GI1ENT VIII (Classroom/Field)
~ PURPOSE : EXPLAIN REQUIREMENTS/JOB KNOWLEDGE UNIQUE TO YOUR JOB
,~
A) Make aware of hazards of "CONFINED SPACE", "RESTRICTED ACCESS" and "NO ENTRY'~~ ~
~ Line I locations in your area .
B) Explain how to accurately perform specialized testing required by your job . ~~
Line II C) Explain how to accurately perform specialized job duties required by your job ~~
(Changing machine clothing) = S
Line III D) Review applicable process/product specifications .
TITLE : C7 .eaning Electric }4otors
WHY IS THE OPERATION NECESSARY : To maintain a clean, efficient

operation and prolong motor life
via better cooling .
WHEN IS THE OPERATION NECESSARY : Whenever dirty .
HOW IS THE OPERATION PERFORMED :
I . Shut down conditions .
A . Shut down all equipmen t

13 . Pull breakers for all motors to be cleaned .
C . Wipe off with damp rag or brush off heavier buildup .
II . Operating Condition s
A . Wipe off with damp rag or brush off heavier buildup .

13 . Any water that is splashed on motor while cleanin g
equipment in area should be wiped off as soon as the
cleaning is finished .
Z
SAFETY :
1 . Never spray water directly on motor .

2 . Do not allow water to stand on motor after it has been
splashed on it .
3 . When wiping off running motor stay clear of turning parts .
KEY ITEMS :
1 . The conduit that runs to a motor must also be carefully

cleaned because of the ease with which water will run down
the conduit into the motor .
PREPARED BY
APPROVED BY
DATE
203111840 -191-- •
TITLE : Start-u and Shutdown of the Frick Brine .Chiller Units
WHY IS THE OPERATION NECESSARY : To cool brine to the proper

temperature for use in the
denitration process .
WHEN IS THE OPERATION PERFORMED : When shutting down for or start-

ing up after an extended shutdown
of the denitration system and when
starting up or shutting down indi-
vidual units for maintenance .
(After an extended shutdown start
chillers4 to 6 hours prior to
starting denitration to allow brine
to be chilled to proper temperature .)
A . Start-up
1) Check and make sure that the Brine Chiller selector

switches on the denitration panel are in the "ON" position .
2) Insure that the New Cooling Tower is full of water and in-
sure~ that drain valves are closed .
3) After opening the inlet anctd outlet valves, start either _
Cooling Tower Pump No .1 or No . 2 (there is an electrical
interlock that will not allow both pumps to run at the
same time) . Also start Cooling Tower Fan and place selector
switch in "rAUTO" position .
4) Check valves on oil cooler and condensors to insure cooling
tower water is flowing through each .
5) Visually inspect the level gauge for the Brine Tank to in-
sure there is sufficient brine to cover the baffle in the
tank . If the level is low add brine as outlined in the
Brin e Make-up Procedure .
6) After opening inlet and outlet valves, start either Brine
Chiller Pump No . 1 or No . 2 . Check valves and pressure
guages to insure brine is flowing through each chiller .
7) Go to the compressor room . It does not make any difference
in what order the compressors are started . Go through the
following steps when starting each unit :
(A) Check oil level in compressor . It should at
least be 3/4°s of the way up in the bottom
sight glass .
(E) The "CONTROL POWER" switch should be in the
"ON" position . If it is not, turn it on .
(C) Put the "OIL HEATERS" switch in the "ON" posi- a
tion at least 3 hours prior to start-up . Wait
for the oil temperature to reach at least 85oF
before proceeding to the next step . (NOTE :
P1•ocedures :for Start-up and Shutdown - Frick Brine Chiller Units
E'~~
. ., ~'e 2
There is an oil heater temperature set switch

inside the control cabinet that kicks the com-
pressor off if the oil temperature falls below
the temperature setting on the switch . The
switch is normally set on 110°F when running .
When starting a compressor it is very difficult
to get the oil temperature to 110°F without .cir-
culating the, oil through an operating compressor
so it may be necessary to cut the switch back to
850 until the compressor has been running for a
while .)
(D) Make sure the inlet and outlet valves .on the
water line to the oil cooler are open .
(F,) Put the "CAPACITY CONTROL" switch in the "AUTO"
position .
(F) Put the "PILOT CONTROL" switch in the "RUN"
position .
(G") Push the "RESET" button . -~ he oil pump should
start immediately and the compressor should
start in approximately 30 seconds . Should
neither of these actions occur a pilot light on
the "SAFETY CUT OUT INDICATORS" section of the
panel will indicate the reason . There is a
safety timer that will not allow you to attempt
another start for 30 minutes . The "RECYCLE
DELAY" light will go out when another start
can be attempted .
(H) Once the compressor has started, put the "CAPA-
CITY CONTROL" switch in the "HAND" position and
using the "HAND" switch above it, set the com-
pressor loading indicator (slide valve) on 40% .
This gives the oil a chance to heat up properly
before fully loading the compressor . After 5
minutes return the "CAPACITY CONTROL" switch to
the "AUTO" position .
B . Shutdown
1) Place "PILOT CONTROL" switch in the "OFF" position .
2) Place "OIL HEATERS" switch in the "OFF" position .
3) Shutdown Brine Chiller Pump .
4) Shutdown Cooling Tower Pump and Cooling Tower Fan .
SAFETY :
1) Wear proper ear protection in all designated areas .
2031118411
Procedure for Start-up and Shutdown - Frick Brine Chilier '' ; ; : ts
Page 3
SAFETY : Continued . .
2) Contact electrical or mechanical personnel when any
abnormalities in the operating sequence occurs .
3) Obey all area safety rules .
KEYPOINTS :
1) After an extended shutdown, start compressor 4 to G
hours prior to the time you anticipate starting deni-
tration .
2) Visually inspect•the level gauge for the brine tank
prior to starting-up .
3) If a compressor fails to start due to some abnormalitN, .,
you will have to wait 30 minutes'to attempt another
start .
4) Do not leave the "CAPACITY CONTROL" switch in the
"HAND" position after starting a compressor because
this control prevents the brine temperature from bein, :;
regulated by the chiller controls .
a
is
PREPARED
APPROVED BY Q,0~^ . A&" (iL
DATE 3 11 7 08
2031118412
TITLE : Starting Sharpless Centrifuges
r .WHY IS THE. OPERATION NECESSARY : In order to efficiently operate

the Denitration process .
WHEN IS THE OPERATION NECESSARY : When the Denitration process is

started up .or when centrifuges
are switched for cleaning or
maintenance .
1 . Put main breaker switch in "ON" position .

2 . Place back break lever in "ON" positon .
3 . Check lid on centrifuge, to insure it is tight .
4 . Place discharge chute in proper position . -First stage goes
into 16"standpipe and 2nd stage chute goes to nitrate contain-
er . Spare can be used as lst or 2nd stage . Plastic must
be attached to chute to extend it to container .
5 . Push "START" button, centrifuge will start in phases .
6 . Green running light will• come on when it reaches running speed .
7 . Position valves on C .E .L . Feed and discharge lines to direct
flow to desired location .
S . Insure that flow is established - check C .E .L . collector tank
N~i for 2nd stage and discharge valve for lst stage .
9 . Adjust differential speed (70-0) on pinion speed meter .
10 . After desired flow, speed and chute location has been insured
centrifuge interlocking switch, (located on DNCEL control
panel) must be set on centrifuges operating .
NOTE If centrifuges are being switched, interlocking switch
must be set after flow has been established to "NEW"
centrifuge .
SAFETY : Follow all area safety rules .
KEY ITEMS :
1 . Centrifuges should_never be started until the back break lever

is in the "ON" position .
2 . Be sure that the lid is tight before starting centrifuge .
3 . Never put back .break lever in "ON" positon after centrifuge
has started .
PREPARED BY~
APPROVED BY
DATE ,3 1/ 7/ ? g
2031118413
c
.
TITLE : Washing Sharples Centrifuges
WHY IS THIS OPERATION NECESSARY : To allow efficient operation of

r %/ Sharples centrifuges and to pre-
vent potassium nitrate buildup
within the centrifuge .
WHEN IS THE OPERATION NECESSARY : Refer to the cleaning schedule

in the Stock Prep Control Room .
A . Normal Conditions :
1 . Crystallizer train no . 1 discharge into Stage I
centrifuge through Line 1 .
2 . Crystallizer train no . 2 discharge into Stage I
3 . Feed from 16 inch stand pipe to second stage centri-
fuge through Line 1, Line 2 used as spare .
4 . Operate first and second stage centrifuges in series .
The spare centrifuge can be used in place of either
the first or second stage centrifuge .
B . Running se,cond stage centrifuge, switching to spare cen-

trifuge, and cleaning second stage centrifuge .
. 1 . Have general laborer place empty bin under chute of -
spare centrifuge .
2 . Start the spare centrifuge by depressing the start
button on the west wall, second floor in Stock Prep .
3 . Allow the centrifuge to reach its maximum running
speed .
4 . Go to the cat walk under the centrifuges and close
valve 26, open valve 27, and position three-way valve
25 to go to the collection tank . (see drawing 2) in-
sure that valves 31 & 34 are open and that valves 23,
24, 32, 33, 35 and 36 are closed (see drawing 3) .
5 . Go to 2nd floor, at the spare centrifuge set valves so
the liquor will flow into the spare from the 16" stand-
pipe . (DWG #1) Open valve 13 . Insure that valves
#9, 10, 11, 12, 14, 20 are closed .
6 . Go below to catwalk, open valve #39 and close valve
#30 .
7 . Liquor should now be going to spare centrifuge . Crack
open valve 20 (DWG #1) momentarily to observe liquor
flow .
8 . Once you aresure liquor is going to spare, stop the 2nd
stage centrifuge by depressing the stop button on .the
west wall of the 2nd floor in Stock Prep . and let cen-
trifuge coast to stop . (approx . 15-20 min .) .
Z031118414
Procedures for Washing Sharples Centrifuges
Page 2
9 . Once centrifuge has stopped, lock out switch on centri-

fuge and open .
10 . With tool provided chop out build up of crystals in-
side centrifuge, hose down good, close lid on centri-
fuge .
11 . Set valve position as follows : Close valve #29 and

position valve #28 to sewer (DWG 2) and close valve
#15 and #16 (DWG 1) .
12 . Start 2nd stage centrifuge, when running speed is
reached open valve #17, hot H20 will nQw be going to
the 2nd stage centrifuge .
13 . Let centrifuge run approximately 30 minutes .
14 . Close valve #17 and let centrifuge run an additional
15 minutesor until dry .
15 . Stop centrifuge .
C . .Procedure for washing first stage and spare centrifuges

is oia.tlined on the attached chart .
SAFETY :
T;.
. 1 . Observe all safety rules for the area .
2 . Observe caution, as floor area around centrifuges may be
slippery from SEL, CEL, or water spills .
3 . Be sure that the centrifuge to be washed has been locked
out before opening the lid .
KEY ITEMS :
1 . Check and double check all valves to insure that they are
set to the proper positions .
2 . Make sure all water valves are off when the wash cycle
is over .
3 . Try to minimize the amount of CEL and SEL sent to the
sewer .
PREPARED BY 1~-2 (~{ c•t~~,~f yt~7
APPROVED BY ~ L .
DATE J~ Z S~ 7 S
2031118415
Sharples Centrifuge Washing Chart
WASHING 1ST WASHING SPARE, WASHING 2ND

VALVE STAGE, RUNNING RUNNING 1ST- STAGE,RUNNING
'POSITION SPARE AND 2ND AND 2ND STAGE 1ST .AND SPARE
1 0 C, C
2 0 C C
3 C 0 0
4 C 0 0
5 0 C C
6 0 C C
7 0 0 0
8 0 0 0
9 0 C C
10 0 C C
11 C 0 C
12 C 0 C
13 0 0 0
14 0 0 0
C
15 C C
16 0 0
17 C 0
18 C C C
19 C C C
20 C C C
21 C 0 0
22 0 C C
23' 0 C C
24 C 0 C
25 O to 18" S .P . O to Sewer 0 to Collection tk
26 0 C C
27 C C 0
0 ollection
28 ~an~ 0 to collection tk 0 to sewer
29 0 0 C
30 0 0 C
31 C 0 0
32 C C C
33 C C C
2031118416
Page 2

VALVE STAGE, RUNNING RUNNING 1ST STAGE, RUNNING
POSITION `SPARE AND 2ND AND 2ND 1ST AND SPARE
34 C 0 0
35 0 C C
36 C C C
37 C C C
38 C C C
39 C• C 0 to spare
NOTE : Assuming feed from the 16 i~ch stand pipe to

the secon d stage or spare c ntrifuge is throug
' Line ]L .
~0a-11-184~ .~"~ - -
~
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Liiv,r 'M`2 d'rPo,y /6 +'.STA.tr.D .43'IOV
r
TITLE : Flushing Crystallizer Trains
WHY IS THE OPERATION NECESSARY : To remove CEL buildup from

crystallizers and lines .
WHEN IS THE OPERATION NECESSARY : Twice per week for each train
per cleaning schedule or when
necessary .
Flush one train at a time .
1) P1ace"CEL flow valve for train in recycle .

2) Place automatic temperature controllers in manual
and close automatic brine valves on train .
3) Place brine to crystallizer valve in recycle .
4) Close off manual valve on inlet of first stage
Sharples centrifuge for train being flushed and
open valve to outlet of hose .
*5) Connect spare inlet hose of crystallizer supply
pump to hot water flush line .
6) Valve off flow from CEL tank and valve on flow of
hot water to crystallizer supply pump .
7) Go to CEL tank and look at CEL return to tank .
When CEL looks thin, go back to control panel
and switch CEL flow valve to run position .
8) Flush until flow from hose by first stage Sharples
becomes clear (about one hour) .
9) Drain all water from crystallizers and lines when
finished .
*Line 1 only .
SAFETY :
1) Follow area safety rules .

2) Use caution around hot water valves and hot process
piping .
KEY ITEMS : 2031118421

1) Care should be taken to ensure no water is recycled
back to CEL tank .
2) Also that no water is sent to first stage Sharples .
Flushing Crystallizer Trains
Page Two
PREPARED BY
APPROVED
2
DATE
2031118422
TITLE : Specific Gravity and pH check of Dowtherm SR-1 and
Water Mixture in Brine Tank .
WHY IS OPERATION NECESSARY : To insure that the Brine system

is operated properly .
WHEN IS OPERATION PERFORMED : During July and Christmas shutdown .
HOW IS OPERATION PERFORMED :
1 . Obtain suitabl'e sample jar from lab .
2 . Go to warm side of Brine tank, chiller supply pump 21-196

or 21-195 .
3 . Place sample jar under sample line on inlet side of pump .
4 . Open valve and collect small amount (flushing sample port)

in container and collect approximately 400 ML of Brine solution .
5 . Close valve .
6 . Take sample to Control Lab .
7. Record results in Stock Preparation Log Book .
Discard small amount of Brine from flushing port into dumpster .
SAFETY :
1 . Observe all area safety precautions .
2 . Use caution when working on wet floors .
KEY ITE1•4S '
1 . Make sure sample valve is closed . 2®31118423

2 . No Brine is to go to sewer .
3 . Collect all Brine in containers and put into dumpster for disposal .
PAREPARED
Vol
APPROVED BY
DATE ~ z -9,h
v
TITLE : Starting and Shutting-Down DNCEL Heaters
' .7 WHY IS THE OPERATION NECESSARY : To insure that DNCEL is at the prop
temperature for size preparation .
WHEN IS THE OPERATION PERFORMED : Varies upon temperature and levels

of DNCEL Hold Tanks .

Starting DNCEL Heaters
1. Insure proper.valve selection is chosen for heater to be put
in service .
2. Start DNCEL heater recirculation pump .
3. Check for full flow back into DNCEL Tank .
4. Start DNCEL heater rotor drive, and insure DNCEL is re-
circulating to hold tank .
5. Ope :n manual steam valves (not manual by-pass valve), proceed
to Control Room and open automatic steam valve .
6. Monitor temperature to insure against over heating .
Shutting Down DNCEL Heater

1 . Close automatic steam valve in the Control Room, proceed
immediately to close manual steam valves at heaters . At
this time, check to insure that steam by-pass valve is closec'
~ 2 . Shut-off DNCEL heater recirculation pump .
3 . Fill DNCEL heater with water letting motor run .
4 . Flush thru to drain until water clears .
5 . Close drain valve, shut-off water . Shut-off DNCEL heater motor .
6 . Let water stand in heater to disolve scale from wall and rotor .
7 . At a time before heater is to be put in service, drain the
residue and flush thoroughly .
8. Drain valve remains open for all water to drain out of heater .
SAFETY :
1 . Observe all area safety rules .
KEY ITEr/IS :
1 . Insure seal water is on to heater seals during operation .
2 . Insure all steam valves are off when heater is not in
service, including steam by-pass valve .
3 . Double check valve selection prior to starting heater or
recirculation pump .
PREPARED BY
APPROVED BY
DATE 77
Z031118424
.7FTT7
TITLE : Cleaning of CEL and DNCEL tanks
WHY IS OPERATION NECESSARY : To provide a continuous and un-

contaminated supply of CEL for
processing and DNCEL for size
preparation .
WHEN IS O :PERATION PERFORMED : After each CEL or DNCEL-tank has

been emptied .
HOW IS OP]ERATION PERFORMED :
1 . Make sure that CEL or DNCEL tank to be cleaned is empty .
2 . Set-iap valves to isolate tank from operating system .
3 . Drain residue from CEL or DNCEL tank to be cleaned .
4 . Wash out CEL tank using hot water, inspect to insure it

is clean, then drain to sewer . In cases of DNCEL tank,
fill tank to approximately 24% with hot water . Wash sides
of tank using water hose . Recirculate hot water thru
heater . Drain both heater and DNCEL,tank .
5 . Fill out Stock Preparation Cleaning Log .
SAFETY :
1 . Obse :^ve all area safety specifications .
2 . Gloves will be worn while handling hot water hoses .
KEY ITEMS :
1 . Close attention must be made when changing valves, so as

not to lose any CEL/DNCEL or contaminate CEL/DNCEL in the
other tank .
2 . After cleaning tank, insure valves to sewer are closed .
2031118425
6
REVISED 1/23/87
TRAINING START DATE . FINISH DATE
GUIDELINES TO AID IN TRAINING A NEW STOCK PREP NUbiBER 2 OPERATOR
OPERATORS NAME EVALUATING SUPV_
I. Process Equipment and Flows
A . CEL Tanks
1 . Location and purpose of the CEL tanks .
2 . Purpose of the CEL level information loops .
3 . Transferring CEL from Stock Prep to Stock~:Prep .
B. Crystallizer Supply Tank

1. Location and purpose o f t he crys t alli zer supp ly tank .
2 . Function of the automatic level control loop .
3 . Overflow of the crystallizer supply tank to the 24"
standpipe .
C. Crystallizer Supply Pumps

1 . Location , t yp e and purpose of the crystallizer
supply pumps .
2 . Alternate methods of valving the supply to the crys-
tallizer trains .
3 . Function and purpose of the flow elements .
4. Function of the flow control loop .
D . Crystallizer Trains
1 . Location and purpose of the crystallizer trains .
2 . Purpose of the temperature transmitting loop on
the CEL supply lines to the crystallizer trains .
3 . Starting up or shutting down a crystallizer train
or an individual crystallizer .
4 . Running a split flow and when it is necessary .
5 . Recycling the CEL flow through the crystallizer
trains and when it is necessary .
6 . Purpose of the high/low current alarms"on each
crystallizer motor .
7 . Operation of the brine temperature control loop
on the individual crystallizers .
8 . Purpose of the high brine temperature alarm loop on
the brine supply line to each train .
9_ How to use CEL pressure to trains to find plugs
E . Brine System
1 . Location and dual purpose of the brine tank .
2 . Purpose of the temperature alarm loop on the supply
line from the brine chillers to the tank .
3 . Purpose of the level alarm loop on the brine .tank .
the chillers .
the crystallizer trains .
Z0311.18426
Brine System, con't .
6 . Alternate ways to valve the brine supply to the
crystallizers .
7 . Function and purpose of the flow control loop on the
brine supply line to the crystallizers .
8 . Location and purposes of the chiller water cooling
tower . .
9 . Location and purpose of the cooling tower supply
pumps .
10 . Purpose of the temperature alarm loop on the cooling
water supply line to the chillers .
11 . Location and purposes of the brine chillers .
F . Sharples Denitration Centrifuges

1 . First stage centrifuge
a . Location and purpose of the Ist stage centrifuge .
b . Purpose of the dams and their effect on the effi-
ciency of the Ist stage centrifuge .
c . Differential speed and its effect on the operation
of the lst stage centrifuge .
d . Purpose and location of the centrifuge water
chillers .
e . Operation of the flow control loop on the chilled
water for the lst stage centrifuge .
f . Purpose and location of the chilled water rotameter .
and how to read the rotameter .
g . Purpose of the chilled water .
h . Where does the denitrated liquor go after it comes
out of the Ist stage centrifuge?
i . Where does the nitrate sludge go after it comes out
of the lst stage centrifuge?
2 . Second stage centrifuge

a . Location and purpose of the 2nd stage centrifuge .
b . How and why can the spare centrifuge be used as
either a lst stage or 2nd stage centrifuge?
c . Effects of the dam setting and differential speed
on the efficiency of the 2nd stage centrifuge .
d . Where do the centrifuged nitrate ctystals go?
e . What happens to the chilled water after it has
been separated from the nitrate crystals?
f . Purpose of the nitrate bin and when it is necessary
to have it changed .
G. 18" Standpipe
2. Function of the level control loop on the 18" standpipe .
3. How is the speed on the 18" standpipe discharge pumps
controlled?
4. Where does the DNCEL go after it is pumped out of the
18" standpipe?
2031118427
H. 16" Standpipe
2. What supplies the 16" standpipe?
3. Function and purpose of the temperature control
loop on the 16" standpipe .
4. Function of the operation of the level control loop
on the 16" standpipe .
5. How and when should the supply chute to the 16"
standpipe be changed .
6. Where do the contents of the 16" standpipe go?
I. 24" Standpipe
2 .' What supplies the 24" standpipe?
3. Purpose of the level alarm loop on the 24" standpipe .
4. Where do the contents of the 24" standpipe go?
J. DNCEL Holding Tanks

1. Location and purposes of the DNCEL holding tanks .'
2. Function of the level alarm loop on the holding tanks .
3. How is DNCEL transferred from Stock Prep to Stock Prep?
4. Explain the various valving alternatives for the supply
to the various holding tanks and for supply to the
various DNCEL transfer pumps .
r•
. Where does the DNCEL go after the holding tanks?
K . DNCEL Heaters
1 . Location and purpose of the i)NCEL heaters .
2 . Location and purpose of the DNCEL recirculation pumps .
3 . Purpose and operation of the temperature control loop
on the DNCEL heaters .
4 . Explain the various valving alternatives for DNCEL
flow through the DNCEL heaters and back to the holding
tanks .
L . Mix Tank
1 . Purpose and location of the mix tank .
2 . Purpose and operation of the level control loop .
3 . Transferring,DNCEL from mix tank to mix tank .
4 . Where does the DNCEL go after the mix tank?
II . Process Housekeeping
A . Explain how and when to clean the CEL tanks and the screen
~ baskets .
B . Explain how to flush the CEL lines from the CEL tanks to
the crystallizer supply tank .
C . Explain how to flush the crystallizer supply lines from
the outlet of the crystallizer supply tank through the
crystallizer supply pumps, flow elements and individual
train supply lines .
D . Explain how to flush an entire crystallizer train through
the crystallizer supply pumps to the Ist stage centrifuge .
E . Explain how to valve off and flush an individual crystal-
lizer .
2 03111841400
F . Explain how to flush each Sharples centrifuge .
G . Explain how to steam clean the DNCEL lines from the 18"
standpipe to the DNCEL holding tanks .
H . Explain how and when to flush the 16" standpipe .
I . Explain how to clean the DNCEL holding tanks .
J . Explain how to flush the DNCEL heaters .
III . General Information

A . Types of Pumps
~j 1 . Positive displacement pumps
a . Types of positive displacement pumps .
b . How does a positive displacement pump operate?
What is a rotor? What is a stator?
c . What happens when a positive displacement pump
is deadheaded?
2 . Centrifugal pumps
a . Types of centrifugal pumps .
b . How does a centrifugal pump operate? What is a
coupling, an impellar?
c . what happens when a centrifugal pump is deadheaded?
B. Types of Valves
1 . Manual valves
a . Ball valve - 2 way, 3 way
b . Gate valve
c. Knife valve (Slide valve)
d. Diaphragm valve
e. Globe valve
f. Butterfly valve
g. Plug valve - 2 way, 3 way
h. How do you determine what position each of the
above valves is in?
2. Automatic valves
a . Panel controller operation
1 .) Manual mode
2 .) Automatic mode
3 .) Set point
4 .) Valve position
5 .) Local control
6 .) Remote control
b . Types of automatic valves
1 .) Diaphragm valve
2 .) Ball valve
3 .) Gate valve
4 .) Knife valve (Slide valve)
5 .) Plug valve
6 .) How do you determine what position each of the
above valves is in by looking at the valve?
2031118'423
IV . Pape rwork and Sample Schedule
A. Brine Chiller Log Sheet

1 . Where to take the rea di ngs .
B. Denitration Log Sheet

C . Material Sampling
1. Where and when to take the following samples .
a . CEL tank sample
b. 18" standpipe sample
c . DNCEL holding tanks samples
d . Mix tank sample
2. Where to record the level information for the material
balance .
V . Interlocks
A. CEL tank supply selector switch .

1B . CEL recycle interlock
!C . Brine recycle interlock
ID . CEL low flow interlocks .
E . Crystallizer supply pumps selector switch
F . Sharples centrifuge selector switch
s . 18" transfer pump selector switch
H . 16" standpipe brine jacket hand/off/auto selector switch
I . DNCEL holding tank selector switch
J . •DNCEL heater/tank/recirculation pump selector switch
K . Chiller cooling tower fan hand/off/auto selector switch
PREPARED BY
APPROVED BY
DATE
2031 .5.1 84 a.y 01

WHEN IS THE OPERATION NECESSARY : Twice per week for each train
.necessary .
HOW IS T$E OPERATION PERFORMED :
1 .) Place CEL flow valve for train in recycle .

2) Place automatic temperature controllers in manual
and close automatic brine valves on train . .
3) Place brine to crystallizer valve in recycle .
4) Close off manual valve on inlet of first stage
Sharples centrifuge for train being flushed and
open valve to outlet of hose .
*5) Connect spare inlet hose of crystallizer supply
pump to hot water flush line :
~ 6) Valve off flow from CEL tank and valve on flow of

hot water to crystallizer supply pump .
7) Go to CEL tank and look at CEL return to tank .
When CEL looks thin, go back to control panel
and switch CEL flow valve to run position .
8) Flush until flow from hose by first stage'Sharples
becomes clear (about one hour) .
.9) Drain all water from crystallizers and lines when
finished .
*Line 1 only .
SAFETY :
1) Follow area safety rules .

2) Use caution around hot water valves and hot process
I piping .
KEY ITEMS : 2031118431

1) Care should be taken to ensure no water is recycled
back to CEL tank .
2) Also that no water is sent to first stage Sharples .
Flushing C :rystallizer Trains
Page Two
.~rvVlt~tAh'fl K
PREPARED BY4 G ~
APPROVED B
DATE
2031118432
21/51-114
TITLE : Start-up and Shutdown of the Frick Brine Chiller Units
WHY IS THE OPERATION NECESSARY : To cool brine to the proper

temperature for use in the
denitration process .
WHEN IS THE OPERATION PERFORMED : When shutting down for or start-

ing up after an extended shutdown
of the denitration system and when
starting up or shutting down indi-
vidual units for maintenance, or
, when unit(s) shut themselves down
due to low load requirements .
(After an extended shutdown, start-
chillers 4 to 6 hours prior to start-
ing denitration to allow brine to be
chilled to proper temperature .)
HOW IS THE OPERATION PERFOMRED :
A . Start-up
1) Check and make sure that the brine chiller selector switches
on the denitration panel are in the "ON" position .
2) Ensure that that the new cooling tower is full of water and
ensure that drain valves are closed .
3) After opening the inlet and outlet valves, start-either cooling

tower pump No . 1 or No . 2 (there is an electrical interlock
that will not allow both pumps to run at the same time) .
Also start cooling tower fan and place selector switch in "AUTO"
position .
4) Check 'valves on oil cooler and condensers to ensure cooling

tower water is flowing through each .
5) Visually inspect the level gauge for the brine tank to ensure
there :is sufficient brine to cover the baffle in the tank . If
the level is low, add brine as outlined in the Brine Make-up
Procedure .
6) After opening inlet and outlet valves, start either brine

chiller pump No . 1 or No . 2 . Check valves and pressure guages
to ensure brine is flowing through each chiller .
7) Go to the Compressor Room . It does not make any difference

in what order the compressors are started . Go through the
following steps when starting each unit :
(A) Check oil level in compressor . It should at

least be 3/4`s of the way up in the bottom
sight glass .
2031118433
,.
21/51-114
Start-up and Shutdown of the Frick Brine Chiller Units

Page Two
(B) The "CONTROL POWER" switch should be in the "ON"

position . If it is not, turn it on .
(C) Put the "OIL HEATERS" switch in the "ON" position

at least 3 hours prior to start-up . Wait for the
oil temperature to reach at least 85°F before pro-
ceeding to the next step . (NOTE : There is an oil
heater temperature set switch inside the control
cabinet that kicks the compressor off if the oil
temperature'falls below the temperature setting on
the switch . The switch is normally set on 1109F
w:hen running . When starting a compressor, it is
very difficult to get the oil temperature to 110°F
without circulating the oil through an operating
compressor so it may be necessary to cut the switch
back to 85°F until the compressor has been running
for a while .)
(D) Make sure the inlet and outlet valves on the water line
to the oil cooler are open .
(E) Put the "CAPACITY CONTROL" switch in the "AUTO" position .
(F) Put the "PILOT'CONTROL" switch in the "RUN" position .
(G) Push the "RESET" button . The oil pump should start
immediately and the compressor should start in approx-
imately 30 seconds . Should neither of these actions
occur, a pilot light on the "SAFETY CUT OUT INDICATORS"
section of the panel will indicate the reason . There
is a safety timer that will not allow you to attempt
another start for 30 minutes . The "RECYCLE DELAY"
light will go out when another start can be attempted .
(H) Once the compressor has started, put the "CAPACITY

CONTROL" switch in the "HAND" position and using the
"HAND" switch above it, set the compressor loading
indicator (slide valve) on 40% . This gives the oil
ae chance to heat up properly before fully loading the
compressor . After 5 minutes, return the "CAPACITY
CONTROL" switch to the "AUTO" position .
B . Shutdown
1) Place "PILOT CONTROL" switch in the "OFF" position .
2) Place "OIL HEATERS" switch in the "OFF" position .
3) Shutdown . brine chiller pump .

2031118434
4) Shutdowr.L cooling tower pump and cooling tower fan .
21/51-114
Start-up and Shutdown of the Frick Brine Chiller Units

Page Three
SAFETY :
1) Wear proper ear protection in all designa,ted area .
2) Contact electrical or mechanical personnel when any abnor-

malities in the operating sequence occurs .
3) Obey all area safety rules .
KEYPOINTS :
1) After an extended shutdown, start compressor 4 to 6 hours-

prior to the time you anticipate starting denitration . Do
not start in "AUTOMATIC" with full load . Start in "MANUAL"
and loa,d slowly .
2) Visually inspect the .level gauge for the brine tank prior
to starting-up .
3) If a compressor fails to start due to some abnormality, you

will have to wait 30 minutes to attempt another start .
4) Do not leave the "CAPACITY CONTROL" switch in the "HAND"

position after starting a compressor, because this control
prevents the brine temperature from being regulated by the
chiller controls .
5) Cooling tower fans should be left in "AUTOMATIC" . They cut

themselves on and off as needed according to water temperature .
6) Line II can easily run on 2 chillers . tivhen load requirements

drop, the chillers are designed to shut themselves down . On .
Line I the number 1 chil,ler shuts down first, then 2, and then
3 . On Line II, the number 3 chiller shuts down first, then 2,
and then 1 .
PREPARED BY W . G . Estes
APPROVED BY
APPROVED BY
~
DATE
~
~
2031118435
21/51-118
TITLE : Specific Gravity Check of Dowtherm SR-1

and Water Mixture in Brine Tanks
WHY IS THE OPERATION NECESSARY : To insure that the brine systems

are operating properly,
WHEN IS THE OPERATION PERFORMED : During any scheduled,week-long

shutdown (normally three (3)
per year), or when problems
occur within the process which
indicate that the brine concen-
tration might have changed .
'1, Obtain suitable sample jar from lab .
2 . Go to warm side of brine tank, chiller supply

pump 21-196 or 21-195 if sampling Line I brine
tank . Go to warm side of .brine tank, chiller
supply pump 51-351 or 51-352 if sampling Line II
brine tanko
3 . Place sample jar under sample-line on inlet side

of pump that is being useda
4 . Open valve and collect small amount (flushing

sample port) in container and collect approxi-
mately 400 ML of brine solution .
5 . Close valve .
6 . Take sample to Control Lab .
7, Record Lab results of temperature, specific gravity

and per cent brine concentration on the Brine Log
Sheet . (See attached log .)
8 . Discard small amount of brine from flushing port

into dumpster .
SAFETY :
1 . Observe all area safety precautions .

118436
2, Use caution when working on wet floors .
3 . Safety glasses and rubber gloves will be worn

when obtaining samples .
21/51-118
Specific Gravity Check of Dowtherm SR-i

and Water Mixture in Brine Tanks
Page Two
KEY ITEMS :
1 . Make sure sample valve is closed .
2 . No brine is to go to sewer .
3 . Collect all brine in containers and put into

dumpster for disposal,
PREPARED BY D . E . Chapman
APPROVED BY
APPROVED BY / ~
DATE ~ ,? gO t
2031118437
Specific Gravity Check of Dowtherm SR-1 21/51-118
and Water r.[ixture in
Brine Tanks BRINE LOG
Page Three
SHIFT SPEC . % GALS . GALS . SPEC . ~
L nATE INIT . GRAV . TEMP . BRINE ~ ADD REMOVED GRAV . TEMP . BRINE COMMENTS
20 ~
I I
21/51-119
TITLE : Start-Up, Shutdown and Cleaning of the DNCEL

Heaters, Line I and Line II
WHY IS THE OPERATION NECESSARY : To insure that the DNCEL is at

the proper temperature for size
preparation . To insure that the
~ heaters are kept clean for effi-
cient heat transfer and the lines,
are kept clean for trouble free
operation,
WHEN IS THE OPERATION .PERFORMED : . It varies, depending upon tem-

perature and levels in the DNCEL
hold tanks . It is preferable to
flush the heaters at least once
per day, more often if necessary .
HOW'IS THE OPERATION PERFORMED :
Start-up of DNCEL Heaters LineI and Line II
1 . After there is at least 10% level in the DNCEL hold tank,

insure that the DNCEL system interlock switches, located
in the control room, are in the proper position . (See
attached sketch and explanation . ) ,
2 . . Manual valves from the tanks at the pumps and the heaters
must be set properly to permit desired operation based
on available equipment .
3 . Insure the selector switches for each heater located

in the field are set in the automatic position .
4 . Insure there is a sufficient flow of heater rotary shaft

seal water .
5 . Start the appropriate DNCEL recirculation pump .
6 . Claeck for full flow back into the desired DNCEL hold
tank .
I
7, Start the appropriate DNCEL heater rotor drive .
8, Open the manual valves before and after the automatic

steam control valve to be used, insuring that the by-
pass valves are closed and condensate valves are open,
9 . Open the automatic valve for the steam to maintain the

desired temperature ; controller located in the control
roomo
2031118439
L
21/51-119
Start-Up, Shutdown and Cleaning of the DNCEL

Page Two
G-1
10 . I'vionitor temperature to insure against over-heating .
11 . Monitor conditions at the tanks . to insure proper

flow through heaters and check for seal•leaks, on pumps
and heaterso
Shutting Down and Cleaning DNCEL Heaters : Line I .
1 . Close automatic steam control valve in the control-room,

proceed immediately to close the manual steam valves
before and after the automatic steam control valves at
the heaters . At this time insure the by-pass valves
are closed .
2 . Shut off the DNCEL heater recirculation pump and the

heater rotor drive will automatically stop .
3 . Close off the DNCEL heater inlet valves and the discharge
valves which are located down stream of the water flush
valves .
4. Fill the DNCEL heater with water by opening the water

fl ush valves . Start the rotor drive by turning the ;: :.< ,
field selector switch to the hand position, located
at the heater . Open the heater drain valve .
5 . Flush to the drain until the water runs clear and then
close the valve in the recirculation line at the top of
the DNCEL tank, open the valve to the sewer on this
line, close the drain line at the heater and open the
outlet valve of the heater, flushing heater and line
until water runs clear to sewer .
Close the hand valve to the sewer on the DNCEL recirculation

line, shutoff the water and shut off the DNCEL heater rotor
drive motor by returning the field switch to the automatic
position .
7 . Allow the water to stay in the heater and line to disolve

scale from the walls and rotor . Turn off the seal water .
9 . At a time before the heater is to be put in service,

drain'and flush line and heater thoroughly and wash the
floor area .
9 . Leave the drain valves open long enough for all water to
drain out of the lines and heater .
10 . Reset recirculation valving to DNCEL tanks for normal

operation . -
2031118440
L
21/51-119
Start-Up, Shutdown and Cleaning of the .DNCEL

Page Three
Shutting Down and Cleaning DNCEL Heaters• Line II
1, Close automatic steam control valve located in control

room . Proceed-immediately to close the manual steam
valves before and after the automatic steam control
valves at the heaters,
2 . Shut off the DNCEL heater recirculation pump and the

heater rotor drive will automatically stop,
3 . Shut off the discharge valve of the appropriate DNCEL .

recirculation pump and close the valve on the recir-
culation line into the top of the appropriate DNCEL
hold tank .
4 . Turn on water flush valve to fill the heater, then

turn on the heater drive by setting the field switch
t :o the hand positiono
5 . Open heater drain valve and flush until water runs clear .
6 . Close the heater drain valve, shut off the water flush
valve and shut down the heater by returning the field
switch to the automatic position,
7 . Allow the water to stay in the heater and line to dis-

solve scale from the walls of heater,
8 . At a time before heater is to be put in service, drain

water from heater and return valving ready for start-
up operation .
SAFETY :
Observe all area safety rules .-
KEY ITEMS
: 1, Insure seal water is on to the heater seals during

operation,
2 . Insure all steam valves are off when the heater is not
in operation, including the steam bypass valves and
the seal water,
3 . Double check valves selection prior to starting heater

or recirculation pump,
4 . Insure all interlock switches are set properly for the

desired mode of operation,
2031118441
21/51-119
Start-Up, Shutdown and Cleaning of the DNCEL

Page Four
5, Re~port any liquor spills to Waste Treatment immediately, ..
PREPARED BY W . Co Holloman
APPROVED BY !U Wt4,jI" .
APPROVED BY ~/
DATE ? p
2031118442
; ; ; 21/5{I-~.19 ;
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21/51-120
TITLE : Cleaning of CEL and DNCEL Tanks
WHY IS THE OPERAfiION NECESSARY : To provide a continuous and

uncontaminated supply of CEL
for processing and'DNCEL for
size preparation .
WHEN IS THE'OPERATION PERFORMED : After each CEL or DNCEL tank has

been emptied .
1 . Make certain that the CEL or DNCEL tank to be cleaned

has been run down to as low a level as possible .
2 . Set up the inlet and outlet valves so as to isolate the

tank from the operating system,
3 . Notify Waste Treatment as to what, and approximately

how much material is to be dumped . Drain remainder
of CEL or DNCEL from the tank,
4 . Wash out CEL tank using hot water hose . Inspect to

insure that tank is clean and debris has cleared
drain valve, then close drain valve .
~ . Wash out DNCEL tank with hot water hose, then fill
tank with hot water to 25% level . Recirculate water
t :.hrough the appropriate DNCEL heater as necessary .
Drain both the heater and tank and close drain valve
when draining is complete . _
6, Steam cleaning method for Line I CEL tanks .

If tank buildup persists after water washing :
a,, Insure steam is valved off to the 16" standpipe,

18" transfer lines to the DNCEL tanks, drain valve
at 18" standpipe and the CEL tank -in use .
b„ Valve in steam to the CEL tank from the small header

located at the denitration second stage supply pumps .
c ., Valve in steam at the CEL tank discharge (common

line between CEL Tanks 1 and 2) .
d . Continue to steam for two hours and then wash with

water and drain . Close drain valve on tank when
draining is complete .
2031118444
21/51-120
Cleaning of CEL and DNCEL Tanks

Page Two
70. Steam ,cleaning Method for Line I DNCEL . tanks .

] :f tank buildup persists after water washing :
2~ . Insure steam is valved off to the DNCEL

tank inuse, the appropriate DNCEL re-
circulation pump, and the drain valve is
open for the tank to be cleaned .
k) . Valve in steam from take-off line on 45 psi

steam station, -
c . Steam for two (2) hours and then wash with

water and drain . Close drain valve on tank
when draining is complete .
SAFETY :
1 . Observe all area safety rules .
2 . Gloves .will be worn when handling hot water hoseo
KEY ITEMS :
Close attention .must be made when changing valves, so

as not to lose any CEL/DNCEL or contaminate CEL/DNCEL
in the other tank(s) .
PREPARED BY D . A . Hall
2031R18445
21-116
TITLE : Washing Sharples Centrifuges, Line I

Sharples centrifuges and to pre-

A . Normal .Conditions :
1 . Crystallizer train no . 1 discharge into first stage

2 . Crystallizer train no . 2 discharge into first stage

3 . Feed from 16 inch stand pipe to second stage centri-

fuge throughLine 1, Line 2 used .as.spare .
s~.

The .spare centrifuge can be used in place of either
----the first or second stage centrifuge .
B . Running second stage centrifuge, switching to spare centri-

fuge, and cleaning second stage centrifuge .
1 . Have general laborer place empty bin under chute of

spare centrifuge .

button on the west wall, second floor in Stock Prep .

speed .
4 . Go to the catwalk under the centrifuges and close

valve-26, open valve 27 and position_three way valve
25 to go to the collection tank . (see drawing 2) en-
sure that valves 31 & 34 are open and that valves
23, 24, 32, 33, 35, and 36 are closed _(see drawing 3) .
5, Go to 2nd floor, at the spare centrifuge set valves

so the liquor will flow into the spare from the 16"
standpipe . (DWG #1) Open valve 13 . Ensure that
valves #9, 10, 11, 12, 14, and 20 are closed .
--- - - -- , -
6„ Go below to catwalk, open valve #39 and close valve
#30 . - _
2031115446
~
21-116
Procedures for Washing Sharples Centrifuges, Line I

Page Two
7 . Liquor should now be going to spare centrifuge . Crack

open valve 20 (DWG #1) momentarily to observe liquor
flow .
Once you are sure liquor is going to spare, stop the

2nd stage centrifuge by depressing the stop button
on the west wall of the 2nd floor in Stock Prep and
.let centrifuge coast to stop (approx . 15-20 min .) .

fuge and open .
t
10 . With tool provided chop out build up of crystals inside
centrifuge, hose down well and close lid on centrifuge .
11 . Set valve position as follows : Close valve #29 and

position valve #28 to sewer (DWG 2) and close valve
#15 and #16 (DWG 1) .
12 . Start 2nd stage centrifuge, when running speed is reached

open valve #17, hot H20 will now be goihg to the 2nd stage
centrifuge .
14 . Close valve #17 and let centrifuge run an additional

15 minutes or until dry .
C . Procedure for washing first stage and spare centrifuges is

outlined on the attached chart .
SAFETY :
1 . Observe all safety rules for the area .

3 . Be sure that the centrifuge to be washed has been locked

out before opening the lid .
)
KEY ITEMS : 2031118447

1 . Check and double check all valves to ensure that they are
set to the proper positions .
2 . Make sure all water valves are off when the wash cycle
is over .
3 . Try to minimize the amount of CEL and SEL sent to the

sewer
21-116
Procedures for Washing Sharples Centrifuges, Line I

Page Three
ls~
REVIEWED BY : J . S . Brown
)
PREPARED BY R . L . Cummins
APPROVED BY -2 • ~ '
DATE V 7
, 2031118448

POSITION SPARE .AND 21N-D AND 2\Z? STAGE 1ST AND SPARE .
1 0 C C
2 0 C C
3 C 0 0
4 C 0 0
5 0 C C
0 C C
.O 0 0
8 0 0 0
9 0 C C
10 C C
11 C 0 C
12 C 0 C
13 0 0
14 0 0' 0
__,:r.
15 C C C
16 0 0 C
17 C 0
18 C C C
19 C C C
20 C C C
21 C 0 0
22 0 C C
23 0 C C
24 C 0 C
25 O to Collection tfi '
26 C
27
28 tk
29
30
31
32
33
Page 2

11
I POSITION SPARE AND 2iVD AND 2ND 1ST AND SPARE
34 C 0 0
35 0 C C
36 C .
37 C C C
38 C C C
39 C' C 0 to spare
NOTE : Assumingi feed from the 16 i~ch stand pipe to ~

the secon' d stage or spare c ntrifuge is throug
I
Line 1 . 1
P031118450
G-9ivB G .Nb' L/NC LINg*
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LIN6 r'~.~ IrA~OI y /G 'r,'STiQN~!
Y
21-117

WHEN IS THE OPERATION PERFORMED : Twice per week'for each train

necessary .
1 . Place CEL flow valve for train to be flushed in

recycle .
2 . Place automatic temperature controllers in manual and

close automatic brine valves on train .
3 . Place brine to crystallizer valve in recycle .
4 . Close off manual valve on inlet of .first stage Sharples

centrifuge for train being flushed and open valve to
outlet of hose .
*5 . Connect spare inlet hose of crystallizer supply pump

to hot water flush line .
6 . Valve off CEL flow from the tank and valve on hot water
flow to crystallizer supply pump .
7 . Check the CEL return to the tank . When the CEL looks
thin, switch the hand valves directing the flow to the
sewer, and flush the recycle line .
8 . When the recycle line has been sufficiently flushed, go

to the control panel and switch CEL flow valve to run
position .
9 . Flush until flow from hose by first stage Sharples

Centrifuge becomes clear (about one hour) .
10 . I)rain all water from crystallizers and lines when

finished .
*Line I only .
2031118454
I
21-117
Flushing Crystalli.zer Trains

Page Two
SAFETY :
1 . Follow area safety rules .
2 . Use caution around hot water valves and hot process

piping .
3 . Clean floor areas where hoses and lines are flushed .
KEY ITEMS :
1 . Care should be taken to ensure no water is recycled

back to CEL tank .
2 . Also that no water is sent to first stage Sharples

centrifuge .
PREPARED BY C . J . Spriggs
APPROVED BY
>
APPROVED BY
DATE
2031118455 t-
21-122
TITLE : Cleaning Stock rep Process Piping

and Equipment with "Rapidyne"
WHY IS THE OPERATION NECESSARY : To prevent bacterial growth in

process piping and equipment
during period~ of lengthy shut-
downs .
WHEN IS THE OPERATION PERFORMED : Whenever the Plant is shutting

down for a long period of time .
1 . Insure that all Stock Prep process piping and equipment

has been cleaned according to normal shutdown cleaning
procedures and thoroughly,flushed with water .
2 . Have RBW tank drained and thoroughly washed out .
3 . Prepare "Rapidyne" solution in RBW"tank on a batch

basis as .needed using the following guidelines :
A . Wear eye protection, rubber gloves and an apron

when mixing solution .
--- B . Fill RBW tank to overflow with water (approximately

2,280 gallons) . :-
C ., Add 1-1/2 gallons "Rapidyne" and mix by opening

FCV-22-503C (on valve control panel at RBW tank
turn Switch "C" to hand position) and start RBW
to separator pump (22-510) .
D . Using test kit from the Main Control Lab, check

concentration of solution - see J . Whitman for
kit and assistance if needed . Solution should
be approximately 25 ppm solution or one (1) gallon
of 11Rapidyne" in 1600 gallons of water .
4. :Pump solution from RBW tank to press dilution tank and

several hundred gallons of solution into the pulper
head tank and into each pulper .
5 . Pump solution from press dilution tank through dilution

control valves into the horizontal conveyors after_each
press until conveyors are approximately 3/4 full .
6 . With all selector switches in the "NO INTERLOCK" position,

turn on each of the horizontal conveyors_and allow
solution to "slosh around" in conveyors .
7 . . Turn off conveyors and lock out electrical br00ake ;s1, q4t
use scrub brush on the accessible area of conveyors to
( :lean away slime (wear rubber gloves) .
21-122
Cleaning Stock Prep Process Piping

Page Two
8 . After cleaning conveyors, drain conveyors to sewer

and flush out with water .
9 . Open valves allowing RBW to go to hose stations at

pulpers .
10 . 'Using pulper .Moyno pumps, pump solution through

dewatering s.creens 1A and 1B after closing drain
valves on liquor pans 1A and 1B .
11 . Solution that drains into 1A and 1B liquor pans can

then be pumped to Sta-sieves and into cleaner feed
'tanks . Drain to sewer at this point .
12 . Make up a length of hose that will reach from the

second floor dilution station on "B" line down to
'the first floor all the way to presses 1A and 1B .
13 . Attach hose to normal RBW line (connection already

:in place) on t1B" line dilution station .
14 . Open valves on all inclined screw conveyors and

open inspection ports .
15 . lJsing hose, spray solution into open ports with

conveyors running allowing solution to drain down
conveyors through valves to sewer .
16 . Drop hose carefully to first floor and fill liquor

pans 2 .and 3 on both A and B lines with solution .
17 . Pump liquor pans 2A and 2B back to pulper head tank

and drain to sewer .
18 . Pump liquor pans 3A and 3B back to after Press No . 1

and also to pulper head tank and drain to sewer .
19 . iJse hose to spray solution into horizontal conveyors

as necessary (under covers, etc .) .
20 . After all cleaning is finished, flush all tanks,

pipes, conveyors, etc . where "Rapidyne" solution
was used .
nfOTE : The "Rapidyne" is 100% soluble in water

and FDA approved for cleaning of poultry
process equipment . 203111845~r
21-122
Cleaning Stock Prep Process Piping

Page Three
SAFETY :
1 . Wear eye protection, rubber gloves and apron when

mixing "Rapidyne" .
2 . Lock out equipment when cleaning inside of conveyors .
3 . Observe all safety rules in the area .
KEY ITEMS :'
1 . Mix "Rapidyne" in batches as needed at one (1) gallon

per 1600 gallons ratio .
2. :Flush all piping, etc . before and after cleaning with

"'Rapidyne" .
3 . Be sure all drain valves to all tanks, conveyors, etc .

are left open to prevent water from standing and going
sour .
.
PREPARED BY W . C . Holloman
APPROVED BY
,
APPROVED BY ~~, e Z~'?~-
i
DATE ,
. 2031118458
f
51-116
TITLE : Washing Sharples Centrifuges, Line II

Sharples centrifuges and to pre-

HOW IS THE OPERATION• PERFORMED :
A . Normal Conditions
1 . Crystallizer train no . 1 discharge into 1st stage

2 . Crystallizer train no . 2 discharge into 1st stage

3 . Feed from 16 inch standpipe to second stage centri-

fuge through Line .1, Line 2 used as spare .

The spare centrifuges can be used in place of either
the first or second stage centrifuge .
B . Running second stage centrifuge, switching to spare cen-

trifuge, and cleaning second stage centrifuge .
Have general laborer place empty bin under chute of

spare centrifuge .

button on the west wall, second floor in Stock .Prep .

speed .
4 . Valve #43 positioned to 24" standpipe, open valve

#44, ensure valve #46 and 48 are closed, valve #47
to 18" standpipe open .
5 . Go to 2nd floor at spare centrifuge, set valves so

liquor flows through spare centrifuge are from 16"
standpipe using Line 1 .
,
#10 closed, #11 closed, #12 opened, #15 opene&, #16
closed, #17 closed, and #18 closed .
6, Go to catwalk and position valve #42 to sewer .
Procedures for Washing Sharples Centrifuges, Line II
Page Two
7 . Liquor should now be going to spare centrifuge .
8 . Once you are sure liquor is going to spare, stop the

2nd stage centrifuge by depressing the stop button on
the west wall of the 2nd floor in Stock Prep and let
centrifuge coast to stop (approx . 15-20 min .) .

fuge and open .
10 . With tool provided chop out build up of crystals inside

centrifuge, hose down good, close lid on centrifuge .
11 . To wash 2nd stage after running speed is reached, close

valve #19, #20, and #21, open valves K and M, water will
.be going to centrifuge and .to sewer .
13 . Close valve K and M and let centrifuge run an additional

15 minutes or'until dry .
C . Procedure for washing first stage and spare centrifuges is ®

outlined on the attached chart . "
SAFETY :
1 . Observe all safety rules for the area .

3 . Be sure that the centrifuge to be washed has been locked out

before opening the lid .
KEY ITEMS :
1. Check and double check all valves to ensure that they are set
to the proper positions .
2 . Make sure all water valves are off when the wash cycle is
over .
3 . Try to minimize the amount of CEL and SEL sent to the sewer .
REVIEWED BY : J . S. Brown ®
APPROVED BY :
APPROVED BY : --~-,"
DATE :
2081118460
51-116
SHARPLES CENTRIFUGE WASHING CHART

C VALVE STAGE, RUNNING RUNNING 1ST STAGE, RUNNING
NO . SPARE AND 2ND AND 2ND STAGE 1ST AND SPARE
1 C C
2 C C C
3 C 0 0
4 C 0 0
5 C 0 0
6 C C C
7 C c C
8 C 0 0
9 0 C C c
10 C C C
11 0 C c
12 C C 0
13 C C C
14 0 C C
~ 15 0 C 0
16 0 C C
17 C C C
18 C C C
19 0 0 C
20 C C C
21 C C C
22 0 0 C
23 C C C
24 C C 0
25 C C C
26 C 0 0
27 C C C
28 C 0 0
29 0 C C
30 0 C C
31 C C C
~ 32 C C C
33 C C I C
2031118461
51-116
SHARPLES CENTRIFUGE WASHING CHART
Page Two

VALVE STAGE, RUNNING RUNNING 1ST STAGE, RUNNII\6
NO . SPARE AND 2ND AND 2ND 1ST AND SPARE
C C
C C
C C
C C
C C
C C C
C C C
C C C
Positioned to 24" Positioned to 24" Positioned to sewer
Positioned to 18" Positioned to sewer Positioned to 24"
C C 0
Positioned to sewer Positioned to 18" Positioned to 18"
0 C C
C 0 0
C C C
Z0311184£ ;?
,
A--
Q-,~) c~
(-i~ Fko,y
51-11 7
TITLE : Flushing of Crystallizer Train s
WHY IS THE OPERATION NECESSARY : Periodic cleaning of system to en-

sure proper flow and efficiency of
system is maintained . Individual
crystallizers are taken off line
and flushed when maintenance is
required .
WHEN IS THE OPERATION PERFORNED : Train flushing to be done per Stock

Prep Process Cleaning Schedul e
(see Operating Procedure 21/51-121) .
If scheduled flushings cannot be
accomplished, every effort should
be made to clean system at-th e
next available opportunity . Indi-
vidual crystallizers to be flushed
as necessary .
1 . Assuming Train 1 is being flushed .
A . Put #1 CEL recycle valve in recycle (FCV 341) .
B . Put #1 brine recycle valve in'recycle .
C . Put all temperature controllers in manual .(do not

move set points) .
/
D . Allow temperature at discharge of each crystallizer
to warm up (approximately five (5) minutes) .
E . Go to crystallizer supply tank"and simultaneously

open water valves (one at feed,and one upstream) and
close CEL supply valve .
F . Go to #8 crystallizer and check for water flow by

periodically opening and closing discharge valve
until water appears .
G . When water appears, go to the CEL tanks and watc :h for

water . When water appears, valve to sewer, flush
fifteen (15) minutes .
H . Go,to first stage centrifuge and valve to floor

drain .
I .11 After flushing recycle line fifteen (15) minutes,

J)ut FCV 341 back to normal, which will redirect
flow to centrifuges . Flush thirty (30) minutes .
2 . Reestablishing liquor flow through crystallizer train .
51-117
Flushing of Crystallizer Trains

Page Two
A . Close water valves at Crystallizer Supply Tank .
B . Open CEL (manual) valve at feed pump, starting CEL

flow .
C . Watch crystallizer outlet for CEL flow .
I) . When CEL flow has reached outlet of crystallizers,

go to first stage centrifuge . Keep manual valves
to sewer of feed to centrifuge (Line I) .
E . Put FCV 341 to normal and watch for CEL coming to

floor at centrifuge .
F' . When CEL starts coming out at centrifuge, put FCV

to recycle - go to CEL tanks and watch flow to
sewer .
G . When CEL starts going to sewer, manually valve to

tank and close sewer valves .
H . CEL flow is now established throughout the system .
4 I . Go to Control Room and set #1 brine recycle valve

(FCV 372 B) back to the normal position . Monitor
each CEL discharge temperature ; make adjustments
to individual crystallizers as necessary and when
operating conditions are met, close drain valve at
first stage centrifuge and reopen inlet valve to
centrifuge .
J . Set #1 CEL recycle valve back'to the normal posi-

tion to redirect CEL flow to the first stage .centri-
fuge .
3 . Flushing individual crystallizers . See attached drawing

a .s, an example .
A . Open bypass valve (B) to send'CEL to next crystal-

lizer #10 .
B, . Close inlet and outlet valves A and C .
C, . Open drain valves on inlet and outlet H and I .
D . Close auto brine valve in Control Room 3 $

20 :11-1 466
E . Close manual brine valves 7 and J at crystallizer .
F . Attach water hose to inlet of crystallizer and open 0

water valve - flush approximately one half hour to
one hour . • -
51-117
Flushing of' Crystallizer Trains

Page Three
G . When finished, close water valve and disconnect

hose .
H . Let crystallizer drain empty .
I . Close bypass valve (B), open inlet and outlet A

and C as soon as CEL comes out of drain on inlet
line, close drain valve - as soon as CEL comes
out of drain on outlet line, close outlet drain
valve : Crystallizer is now full of CEL .
J . Slowly bring temperature down by opening manual

_ brine valves at 7 and J and automatic brine valve
in Control Room .
SAFETY :
I
1 . Follow all departmental safety rules .
2 . Use caution around hot water and steam lines .
3 . Wear safety glasses and gloves when working with CEL,

steam, and water .
KEY ITEMS :
1 . Care should be used not to get water into CEL storage

tanks .
2 . Minimize CEL going to sewer and inform Wastewater Treat,

ment whenever abnormal amounts are lost to the sewer .
3 . Care should be taken to ensure that no water gets into

'the crystallizer system when individual crystallizers
are flushed .
PREPARED BY R . H . Cummins
~
APPROVED BY
_
APP5OVED BY
.
DATE
. ~
Z031118467
51-117
DRAWING NO . 1
*Note : Valves 4, 6,
B, and L ar?~
normally ®'
closed .
Bypassing #9 Crystallizer -'Close Manual and Automatic Brine Valves
1 . Open valve B .
2 . Close valves A and C .
3 . Open valves H and I .
4 . Attach hose to either H or I and flush .
To Start Crystallizer Up Again
1 . Disconnect hose .
2 . Open valve A and C .
3 . Close valve B . 2031118468

4 . When CEL starts flowing-from valve I- close .
When CEL starts flowing from valve H - close .
5 . Open manual brine valves .

is
6 . Open automatic brine valve slightly (from Control Room) .
Put in "Auto" when temperature gets near set point .
i
21/51-129
TITLE : Cleaning Sewers in Stock Prep
WHY IS THE OPERATION NECESSARY : To prevent build up of stems and

sludge in sewers where bacteria
can breed .
WHEN IS THE OPERATION PERFORMED : Sewers are cleaned in accordance

with sewer cleaning schedule .
1 . Using sewer grate hooks, remove the grate over the sewer
to be'cleaned, one section at a time .
2 . Build ups of sludge and stems must be shoveled from

sewers and emptied into dumpsters .
3 . After shoveling of sludge and stems is complete, flush

sewer with water hose . If there is no heavy build up
of stems and sludge, sewers may be cleaned by flushing
with water hose .
4 . Upon completion of sewer cleaning, use the sewer grate

hooks to replace sewer grates . Ensure that sewer grates
are replaced right side up .
SAFETY :
1 . Due to the weight and awkward handling of sewer grates,

both Stock Prep general laborers will be utilized when
sewers are,cleaned .
2, Sturdy leather gloves should be worn when cleaning

sewers .
3 . Sewer grate hooks should always be used to remove and

replace sewer grates . Employees should never handle
sewer grates with their hands .
4 . Proper lifting procedures should be followed when removing

an .d replacing sewer grates .
5 . When sewers are being cleaned, open trench signs should

be posted and safety tape should be used to rope off the
area .
6 . Upon completion of cleaning sewers, sewer grate hooks,

safety tape, and open trench signs should be properly
stored .
c031118469
21/51-129
Cleaning Sewers i.n Stock Prep

Page Two
7 . Adhere ~to all area safety rules .
PREPARED BY J . A . Ciliberto
~ L ..
APPROVED BY
APPROVED BY
DATE 49
Z0311184i®
JOB SAFETY ANALYSIS
PARK 500 CODE :
De:partment : Production Page No : 1 of 1

Draining 18" Stock Prep Line To Flush Out Stock Prep
Draining the 18" EYE INJURY - 1. Wear approved safety glasses or

standpipe line to Liquor splashes face shields .
sewer to flush out
HAND INJURY - 1. Wear leather gloves or gloves made
Pinches of other thick material .
FOOT INJURY - 1. Always wear safety shoes .
GENERAL INJURY - 1. Ensure you have firm footing at

all times when turning valves, and
when walking on grating and steps .
2031ils-Aw 0 97 1
Originator. : _ s_ W . rha"Pl I1
D . R . Ampey
Date : _ Ort-ohP,- 2s , i qR2
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
Department : Production Page No : i nf i

Unplugging 18" Sample Valve Stock Prep
Unplugging 18" Sample EYE INJURY - 1. Wear approved safety glasses .

Valve Irritation
HAND INJURY - 1. Wear rubber gloves or gloves made of

Scrapes, Bruises heavy material .
GENERAL INJURY - 1. Wear ear protection .

Head, Fingers,
Arms, Back 2. Watch overhead clearance, it is very
low .
3. Be sure manual valve to the sample

port is closed before breaking
victaulic .
4. Watch for pinch points when disconnecting

victaulic .
5. Be extremely careful of hitting arms or

back on adjacent pipes - close quarters
catwalk level .
Z031118472
Originator : I . R . McLaughlin/
D . R . Ampey
Date : _ October 1 . 1982
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :

Bypassing Denitration Stock Prep
T SK HAZARDS SAFETY PRECAUTIONS

Bypassing Denitration EYE INJURY - 1. Wear approved safety glasses or goggles .
Redirecting flow by Irritation
opening and closing
valves HAND INJURY - 1. Wear rubber gloves, valves may be worn in
Cuts, Bruises spots and cut hands .
2. Never try to force open or close hard

valves, use a wrench .
3. Be mindful of low clearance on catwalk

level .
4. Since valves to redirect CEL flow is on

the other side of the railing, be
extremely careful not to hit head on
railing .
5. Due to switching CEL tanks periodically,

always remember to hose excess CEL not
drained to sewer .
2031118473
Originator : _ I• R . McLaughlin/
D . R . Ampey
Approved :
JOB SAFETY ANALYSIS
PARK 500 CODE :
Department : Production Page No : 14f 1

Heating DN With Raw Steam Stock Prep
Using Raw Steam to HAND INJURY - . Wear gloves made of heavy m terial
heat DN Burns, Pinches to protect hands when openi g and
closing valves .
FOOT INJURY - . Wear rubber safety boots .

Burns
. Use caution whenever you ar~ working
with steam .
HEAD INJURY - . Be aware of overhead hazard~ or

Bumps, Bruises wear a safety hard hat .
GENERAL INJURY - . Watch where you are walkinglto avoid

Trips, Falls trips and falls .
2 0 T-vk. I 18 4 7 4
Originator • Steve happell/

D . R . Ampey
Approved :
JOB SAFETY ANALYSIS
-Z
PARK 500 CODE :
Department : Production . Page No : 1 of 1

Emptying Collection Tank Stock Prep
TASKS HAZARDS SAFETY_PRECAUTIONS
Emptying Collection EYE INJURY - 1. Wear approved safety glasses or goggles

Tank Irritation due to the possibility of DNCEL splashing
in eyes .
HAND INJURY - 1. Wear rubber gloves . Valve handle could

Cuts, Bruises be worn in certain spots and could cut
hands .
2. Ensure level in collection tank has

decreased to the cone of the tank .
3. Never open valve (drain) wide open .

Slowly open valve to prevent DNCEL
from splashing .
4. After draining tank, make sure drain

valve is completely closed .
5. Clean floor area to prevent slipping

on DNCEL .
20311184'~ i
Originator : _ I . R . McLaughlin/
D . R . Ampey
Approved :

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263-ILIaLlsa `xJ s

PARK 500 CODE :

Department : Production Page No ; 1 of 1

DESCRIPTION OF OPERP_TION JOB LOCATION

T SK H__AZ ARD S SAFETY PRECAUTIONS

Washing Down Stairwell EYE INJURY - 1. Wear approved safety glasses

HAND INJURY - 1. Use gloves to prevent cuts and irritation

GENERAL INJURY - 1. Use caution when using soaps to

2. Watch for proper foot placement ; use

FOOT INJURY - 1. Always wear approved safety shoes to

NOTE : 1. Safety signs "Wet Floor" should be

Date : September 26, 1982

PARK 500 CODE :

Department : Production Page No : 1 of 1

DESCRIPTION OF OPERATION JOB LOCATION

TASKS HAZARDS SAFETY PRECAUTIONS

Shoveling up of HAND INJURY - 1. Wear rubber gloves to protect your

EYE INJURY - 1. Wear safety glasses to avoid the

3. Do not stand in the stock while shoveling .

4. Remove any obstacle in the area that

GENERAL INJURY - 1. Wear ear protection in the designated

2. Wear safety shoes that have been

Date : September 24, 1982

PARK 500 CODE :

Department • Production Page No : 1 of 1

DESCRIPTION OF OPERATION JOB LOCATION

Using ChemicaLl Drum Opening Tool Stock Prep

T SK HAZARDS SAFETY PRECAUTIONS

Opening Chemical Drum EYE INJURY - 1. Wear safety glasses/goggles whenever

HAND INJURY - 1. Wear leather or rubber gloves to protect

GENERAL INJURY - 1. Ensure proper tool is used for each

2. Apply pressure to top of tool while

3. Stand as far back from drums as possible

Originator : _ Laure E . McBride/

Date : September 21, 1982

Department : Production Page No ; 1 of 1

DESCRIPTION OF OPERATION JOB LOCATION

TASKS HAZARDS SAFETY PRECAUTIONS

GENERAL INJURY - 1 . Store ladder in its proper location

PARK 500 CODE :

Department : Production Page No ; 1 of 1

nESCRIPTION' OF OPERP_TION JOB LOCATION

TASKS HAZARDS SAFETY PRECAUTIONS

External Cleaning of EYE INJURY 1. Wear Safety glasses . (Use XL-100)

HAND INJURY - 1. Wear gloves made of rubber or leather .

FOOT INJURY - 1. Be sure to roll up water hose when

2. Be very cautious when walking on wet

3. Do not use water on electrical motors .

4. Be sure heaters are off and locked

Date : . August 16, 1982

PARK 500 CODE :

Department : Production Page No ; 1 of 1

DESCRIPTION OF OPERATION JOB LOCATION

Cleaning the Evaporator Seal Pit Stock Prep

TASKS HAZARDS SAFETY PRECAUTIONS

2. Never enter the Evaporator Seal Pit

EYE OR FACE INJURY - 1. Wear Safety Glasses when cleaning

HAND INJURY - 1. Wear Rubber gloves to avoid skin

2. Beware of sharp pieces of metal or

3. If you happen to get a cut or abrasion

GENERAL INJURY - 1. Wear approved Safety Shoes .

3. Do not jump off any of the ladder

4. Exercise caution when entering or