A Initial Check (Start) - EPV - 0202

B Deareate and purging by Nitrogen

Raw material selection and Charging by

C Pump EPP-0202
 Process Steps

1. Check pretank EPV-0202 condition- for temp (TE-V2021, TE-V2022 < 80 C) and ,
pressure (PT-V2021< 0.2 barg), level (LT-V2021 ~ 0%)
2. All auto valves HXYV-V20211, HXYV-V2023, HXYV-V20212, HXYV-V2024, HXV-
V20213, HXV-V2021, HXYV-V2028, HXV-V2026, HXYV-V2029, HXYV-V2025, HXV-
V2027 , HXV-V20210 are closed

1. Check intital vessel pressure 0.2 > PT-V2021 < 0.3 barg on EPV-0202
(if high vent through PCV-V2021 by opening HXV-V20213,)
2. Start Vacuum Pump (This vacuum pump is in manual mode and not part of DCS
graphics)
3. Open Auto valve HXV-V2021 on vacuum line (VAC-207101-80-B1)
4. Pull Vacuum 600 to 650 mmHG on EPV-0202
5. Close HXV-V2021 on Vacuum line (VAC-207101-80-B1)
6. Stop vacuum Pump (This vacuum pump is in manual mode and not part of DCS
graphics)
7. Open HXYV-V20212 (N-207103-25-B1) and HXV-V2027 on (N-207102-50-B1)
8. Break vacuum EPV-0202 by Nitrogen till Pressure (PT-V2021) reaches to 0.2 barg
9.Close HXYV-V20212 (N-207103-25-B1) and HXV-V2027 on (N-207102-50-B1)

1. Do positioning and hose connection on raw material drum

2. Open HXYV-V2023 on RM charging line (PR-207106-40-B1)
3. Open HXV-V20213 and control valve V-2021 100% manualy
4. Open compressed Air valve on AODD pump EPP-0202
5. Start Charging
6. Check LT-V2021 and FIQ-V2021 for the level and feed rate
7. Complete Charging
8. Close compressed Air valve on AODD pump EPP-0202
9. Flush charging line by opening manual nitrogen valve on discharge of EPP-202 line
10. Close HXV-V20213 and control valve V-2021 100% manualy
11. Close HXYV-V2023 on RM charging line (PR-207106-40-B1)
 Valve
Alarm
1. PA-V2021 = 1.75 H, 1.8 HH (Kg/cm2 g)
2. PIAY-V2021B = 7 H, 7.5 HH Kg/cm2g (on
outlet of PSV)
4. TIAY-V2021 = 175 C H, 180 C HH
6. LTA-V2021 = 85 % H, 90 % HH
8. LIAS-V2022 = 15 % LL , 20 % L
7. PIAY-V2027 = 8 H, 8.5 HH, 1.5 L, 1 LL
(Kg/cm2g)
A Initial Check (Start) - R - 106

Collect Material from pre vessel V-202

B to REACTOR R-106

Test - Oxygen measurement

Not ok

ok

D Check Addtion Type

 Reactant 1 pre-addition to R -106

E1

TEST

Not ok

ok
 Reactant 1 Addition to R -106

E2

Reactant 2 pre-addition to R -106

F1
F1

TEST

Not ok

ok

F2 Reactant 2 Addition to R -106

Stabilisation of Batch (This is standing

F condition of reactor for 10 to 15 min
after Reactant 1 or Reactant 2 addition

G Sample from R-106

 TEST

Not ok

ok
 Process Steps
1. Check REACTOR R-106 condition- for temp (TE-R1061, ≤ 80 C) and , pressure ( PT-R1062< 0.2 barg),
level (LT-R1061 ~ 0%)
2. All auto valves HXV-R1019, HXV-R1016, HXV-R106, HXV-R1062, are closed

Put PCV-V2025 and PCV-V2021 in auto mode & add Set pressure of 1.2 kg/cm2 in PIC V-2021.
1. Open HXV-V20212 (N-207103-25-B1) and HXV-V2027 on (N-207102-50-B1) on pre tank V-202
2. take nitrogen pressure PT-V2021> 1 barg in pre tank (V-202)
3.Close HXV-V20212 (N-207103-25-B1) and HXV-V2027
4. Open HXV-R10622 and HXV-R10621
6. Close HXV-R10622 and HXV-R10621
7. Open HXV-10620, HXV-V20210, HXV-V2026
8. Transfer all pretank material to R-106
9. Check levle in LT-R1061,
10. Start agitator RAG-106 at 50 rpm (VFD ~ 50%)

1. OpenHXV-R10623 and HXV-R10612

2. Check oxygen
3. Close HXV-R10623 and HXV-R10612

Test - If oxygen is ≥ 1 ppm go to step C or go to step D

Check Addtion type

1. Go to step 5A for Reactant 1 addtion
2. Go to 5B for Reactant 2 addition
1. Check ST-0302 for TE-T3021/3022 ≤ 20 C, PT-T3021/3022 for ≥ 3.5 Kg/cm2g, LT-T3021/3022 ≥ 15 %
2. Increase agitator output to 100% (speed to 100 rpm)
3. Check PT-R1067/1068 > 3.5 Kg/cm2g
4. Open nitrogen valve HXV-R1065/10617 and HXV-R10618 and take 1 Kg/cm2 pressure in REACTOR R-
106
5. Close nitrogen valve HXV-R1065/10617 and HXV-R10618
6. Put PCV-R1061 and PCV-R1062 in auto mode
8. Put FICQ-R1063 in manual mode and put set Reactant 2int of 100 Kg/hr for totallizer of 50 Kg
9. Put FICQ-R1063 in auto mode
10. Put PIC-R1061 at 3.5 Kg/cm2g in auto mode
11. Put TIC-R1061 at 175 C in auto mode
12. Put Ratio controller RC-R1063 in manual mode with set Reactant 2int of ----------
13. Open HXV-R10632 and HXV-R1061
14. Open HXV-R10616/10619
Open HXV-P3033 on E-0303 (discharge side) with PIC_P3032 at SP of 4 kg/cm2 in auto mode
15. Start Reactant 1 addition
16. Check rise of PT-R1061/1062/1063 and TE-R1061/1062/1063
17. Close HXV-R10632 and HXV-R1061
18. Close HXV-P3033 with PIC-P3032 in manual mode with 100% opening.
19. Repeat step 3 to 11 for one more time

Confirm test and go to step E2 or go back to step E1

1. Put FICQ-R1063 in manual mode and put set Reactant 2int of XXX Kg/hr for totallizer of
Reactant 1 based on SOP quantity
2. Put FICQ-R1063 in auto mode
3. Put PIC-R1061 at 3.5 Kg/cm2g in auto mode
4. Put TIC-R1061 at 175 C in auto mode
5. Put Ratio controller RC-R1063 in manual mode with set Reactant 2int of xxx (this is require
during simaltanReactant 1us addition of Reactant 1 & Reactant 2)
6. Open HXV-R10632 and HXV-R1061
7. Open HXV-R10616/10619
Open HXV-P3033 on EPP-0303 (discharge side) with PIC_P3032 at SP of 4 kg/cm2 in auto mode

8. Start Reactant 1 addition

9. Put TCV-R1061B in auto mode
10. Open cooling water valve HXV-R10610/1067
11. Check rise of PT-R1061/1062/1063 and TE-R1061/1062/1063
12. Close HXV-R10632 and HXV-R1061 & stop Reactant 1 addition
13. Close HXV-R10616/10619
Close HXV-P3033 with PIC-P3032 in manual mode with 100% opening.

1. Check ST-0303 for TE-T3031/3032 ≤ 10 C, PT-T3031/3032 for ≤ 1 Kg/cm2g, LT-T3031/3032 ≥ 15 %

2. Increase agitator speed to 100 rpm
3. Check PT-R1065/1066 > 3.5 Kg/cm2g
4. Open nitrogen valve HXV-R1065/10617 and HXV-R10618 and take 1 Kg/cm2
pressure in REACTOR R-106 (take PIC-V1061 in auto mode during Nitrogen addition)
5. Close nitrogen valve HXV-R1065/10617 and HXV-R10618
7. Put DPIAS-R1062 in auto mode with set Reactant 2int of XX Kg/cm2g
8. Put FICQ-R1062 in manual mode and put set Reactant 2int of 100 Kg/hr for totallizer of 50 Kg
9. Put FICQ-R1062 in auto mode
10. Put PIC-R1061 at 3.5 Kg/cm2g in auto mode
11. Put TIC-R1061 at 155 C in auto mode
12. Put Ratio controller RC-R1063 in manual mode (this loop only use during simaltanReactant 1us
addition of Reactant 1 & Reactant 2 with set Reactant 2int of ----------
13. Open HXV-R10632 and HXV-R1062
14. Open HXV-R10630/10631
Open HXV-P3033 on EPP-0303 (discharge side) with PIC_P3032 at SP of 4 kg/cm2 in auto mode
15. Start Reactant 2 addition
16. Check rise of PT-R1061/1062/1063 and TE-R1061/1062/1063
17. Close HXV-R10632 and HXV-R1062
18. Close HXV-R10630/10631
Close HXV-P3033 with PIC-P3032 in manual mode with 100% opening.
19. Repeat step 3 to 18 for one more time
 Confirm test and go to step F2 or go back to step F1

1. Put FICQ-R1062 in manual mode and put set Reactant 2int of 800 Kg/hr for totallizer of
Reactant 2 based on SOP quantity
2. Put FICQ-R1062 in auto mode
3. Put PIC-R1061 at 3.5 Kg/cm2g in auto mode
4. Put TIC-R1061 at 155 C in auto mode
5. Put Ratio controller RC-R1063 in manual mode with set Reactant 2int of ----------
6. Open HXV-R10632 and HXV-R1062
7. Open HXV-R10630/10631
Open HXV-P3033 on EPP-0303 (discharge side) with PIC_P3032 at SP of 4 kg/cm2 in auto mode
8. Start Reactant 2 addition
9. Put TCV-R1061B in auto mode
10. Open cooling water valve HXV-R10610/1067
11. Check rise of PT-R1061/1062/1063 and TE-R1061/1062/1063
12. Close HXV-R10632 and HXV-R1062
13. Close HXV-R10630/10631
Close HXV-P3033 with PIC-P3032 in manual mode with 100% opening.

1. Check reaction pressure and temperature

2. Check reduction of pressure PT-R1061/1062/1063 upto 1.5 Kg/cm2g

1. Put bottol or tin in sample box

2. Open manual Nitrogen valve on jet ejector of sample box
3. Open HXV-R10633
4. Collect sample
5. close HXV-R10633
If not ok go for step EA or EB
jgjhgjh
 Alarm
1. TIA-R1061 (H, HH, L, LL)
2. LIAS-R1062 (HH)
3. LICAY-R1061 (H, HH)
4. PIA-R1069 (H, HH)
5. PIAS-R1062/1063 (H, HH, L, LL)