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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
This instruction describes the effluent storage in buffer tanks A1-2500A/B/C/D.It covers the intial lining
up of the effluet in the buffer tanks,shutdown and normal operation of the buffer tanks and the effluent
feed pumps G1-2501A/B/C/D.
1. INTRODUCTION:
Plant effluent from core and non-core plants is collected for treatment in buffer tanks; A1-
2500A/B/C/D. Contaminated water run-off from non-core areas is collected in drainage pits and
pumped over to the buffer storage tanks A1-2500 A or C. The general effluent drainage of the
effluent from core plant is collected in the core pit A1-850 and is pumped to effluent plant as waste
water via G1-851A/B .Waste water stream is cooled by E1-2526 a plate and frame type heat
exchanger with bypass. Waste water steam is mainly acidic in nature due to high percentage of the
PTA, CTA, and ACETIC ACID etc. Sometimes it becomes basic due to the excessive caustic wash at
the core plant. The buffer storage also receives direct discharge of mother liquor by diversion of its
normal flow to the neutralization by manual isolation valve now this is not applicable.
3. Ensure all slip plates are in proper position and all drains are closed.
a. Instrument air
5. Check instrument air supply to LT-5012, LT-5013, LT-5014 and LT-5015 (buffer tank A1-
2500A/B/C/D tank level transmitters) bubbler type.
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
3. NORMAL OPERATION
1. Mother liquor is not to be diverted to neutralization plant even mother liquor filter M1-1603 is in-
service or not .It is due to the reason that pH probes of the both F1-2508 and F1-2519 may be
damaged due to the high temperature of the mother liquor.
2. Effluent of the plant to be lined up in the buffer storage tanks and changeover the mother liquor and
waste water accordingly.
3. Quality-wise the effluents of the plant to be lined up in the buffer storage tanks and divert the waste
water or mother liquor accordingly.
4. Physically check the level of the buffer tanks and update the DCS board man .In order to avoid the
overflowing the buffers due to malfunction of the level transmitters.
5. To increase the flow of effluent from the buffer storage tank or to take effluent from another buffer
tank FCV-5001/5008/5021/5024 should not open more than 5% at -a -time. This is due to avoid the
entrainment of the PTA powder to neutralization section and feed storage tanks A1-2504A/B/C/D.
6. Disturbance in the oxidation plant, i-e, M1-1603 by passing causes high COD effluent flow to the
buffer storage section, due to this lineup the mother liquor to the dedicated buffer. High COD
effluent will reduce the total hydraulic load of the deep shaft, so buffers management will be
required.
7. When waste water flow from the G1-851 A/B start to decrease than open the bypass valve of the
E1-2526 and check the flow, if it become normal, inform to the shift manager for chocking of inlet
strainer of E1-2526. The PTA in effluent causes chocking of E1-2625 inlet strainer.
8. Check that all pumps G1-2501A/B/C/D are available in healthy condtion and can be taken in
service.
5. Select one buffer storage tank A1-2500 A/B/C/D before one week of the plant shutdown in order to
accommodate the plant flush effluent. Plant effluent may contain the metals which are toxic for the
bacteria.
6. Take maximum flow from this buffer storage tank during the week. It should not keep on filling.
Level need to be decreased up to minimum.
7. As the core plant put on flush after shutdown, then stop taking effluent from this buffer and lock
close the buffer outlet valve and stop the transfer pump G1-2501A/B/C/D.
8. Shift both waste water and mother liquor streams to this buffer storage tank, in order to collect the
effluent in one buffer.
9. Monitor the level of this buffer via DCS and also from area in order to avoid the overflowing of
effluent in other buffer storage tanks.
10. When core plant completes it’s flushing than take the sport sample of the both streams Mother
Liquor and waste water from IBC’s sample point and check the cobalt and manganese result.
11. Line up the effluent in some other buffer storage tank if the result of the metals is normal.
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
12. Put the buffer in which contaminated effluent is collected on settling for 24 hours then take the
sample for metals and carry out test, if metals found normal then line up this buffer for feed
preparation otherwise inform to shift manager.
There is no shutdown in the effluent collection section, the effluent collection stop which is only for
the time being. Buffer storage pumps remain in service on kickback if required otherwise can be
stopped only feed to neutralization will is to be stopped by closing the FCV-
5001/5008/5021/5024.from DCS. For the cleaning of the buffers storage isolate the valves of this
buffer storage tank and carryout the necessary preparation for cleaning as per given procedure.
1.2. Procedure for the PTA Sludge removal From Buffer Tanks A1-2500A/B/C/D
List of the equipment to be utilized for the cleaning of the buffer tanks
S# Equipments Quantity
1. Crane 01
2. Clamp Bucket 01
3. Dump Trucks 2
S Manpower Quantity
#
1 Supervisor 1.
2 Rigger 2.
3 Assistant Riggers/Helper 3.
1. PTW will be issued for seven days and re-validate it daily in the morning. However job will be
started daily at 08:00 hrs till sunset and will continue on Sunday and gazetted holidays.PTW
revalidation will be done at site to avoid any delay in the job.
2. Safety signs would be displayed for crane and dumpers activity.
3. No entry signs to be posted for restriction of entry of unauthorized persons/traffic to avoid any
safety incident.
4. The crane and dumpers activity area to be hard barricaded with an entry gate. A crane and only
one dumper will be parked inside barricaded area. The other waiting dumper to be parked
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
outside the barrication. PTA will provide scaffolding team and material, while Descon will give
the exact requirement of scaffolding.
5. Tanker cleaning activity to be carried out during daylight only.
6. A scaffolding platform along with ladder on the tank to be erected by PTA scaffolding team
with plant scaffolding material.
7. Bucket movement will be controlled through a tie-rope by a rigger to avoid its hitting the tanks
walls or other surfaces.
8. The tank cleaning staff will wear proper PPE’s including splash goggles, PVC gloves and
rubber boots.
9. Dump truck water arrangement will be made at working site and working staff will be changed
after every 60 minutes.
10. A resting area i.e. tank with bench/chairs will be provided near work area but outside the
barrication.
11. Immediately reported any safety incident to PTA plant area operator, who will report the matter
to Utilities shift manager.
12. All standard safety instructions and operating procedures must be followed at work site.
13. Dispensation for hot work permits for crane to be arranged by PTA (if needed).
14. Descon will explain the job method and give task instructions to their workforce before starting
the job.
15. Bucket will be inspected at least once a week. Inspection will be arranged by PTA planning, to
avoid the wastage of contractor’s man-hours inspection will be done in time.
1. Park the crane inside the barricaded area where it will be operated.
2. The crane weight will be taken on outer riggers (jacks) with no load on wheels to ensure
balanced operation of the crane.
3. In order to ensure that crane bucket is not touching with tanker bottom. The crane bucket rope
will be marked up to 6000 mm (including basket height) and this mark should be clearly visible
and must remain outside the top surface of the PTA sludge.
4. The tank will be prepared for the entry and it will be handed over to maintenance staff before
starting cleaning operation.
5. Once dumper is parked for loading sludge. Its engine must be switched off and driver should go
to the tent. No one will enter the work site without proper PPE.
6. The rope tied up with the bucket will be held by a rigger positioned at scaffolding platform; the
rope will further be knotted with scaffolding pipes. When the bucket is at height the rigger will
loose the rope slowly in such a manner that it will not hit the tank surface or sidewalls.
7. Another rigger must be positioned at scaffolding platform who will direct the crane driver
regarding bucket movement; He will watch the depth of bucket inside the sludge tank and will
ensure the depth mark on the bucket rope that it does not touch the sludge tank top surface.
8. The site supervisor must ensure that no person is doing any activity under the crane operation.
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
7. Job method for the Leak Repair or Lining in Buffer Tank With Man riding basket
1. Crane Man riding Basket, Safety Harness, Ropes & Lifting Gear to be Inspected/Checked by
PPTA Rigging Supervisor.
2. Two trained experienced persons of Man riding Basket can do the job at-a-time.
3. Area barrication and sign posting must be done prior commencing the job.
4. Two guy ropes (Tag line) must attach with the Man riding Basket to prevent the unnecessary
swing.
5. Attached the harness with crane hook separately all the time and do not attach it with the man
riding basket.
6. The whole activity must be supervisor by the designated mechanical supervisor and job will be
audited time to time by SHE Department.
7. In case of any abnormality the activity shall be stopped immediately.
8. The maintenance staff shall secure their Tools/ equipment with a rope to prevent the equipment
falling in the pit.
9. The crane operator, with the help of a banks man shall keep the movement of the basket to the
minimum possible to avoid the basket from hitting the pit wall or lining and crane operator will
be in their cabin during the activity.
10. The whole activity to be carried out in daylight 8:00 to 18:30 hrs.
11. Instructed PPE for the job are clear L.E.P, Helmet with chin guard ,one Radio set and rubber
boots. ( If required )
8.
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
Effluent from the buffers storage is transfer to the first neutralization tank F1-2508 via G1-2501
A/B/C/D under flow control via FCV-5001/5008/5021/5024, with an option of taking mother liquor and
CRU spent soda ash effluent into it. Caustic soda is added in to it in the form of 5% and 47% for pH
controlling purpose between5.5 to 6.0.
Effluent from F1-2508 overflows into second neutralization tank A1-2519.Caustic and HCL can be
added to this tank (depend upon pH) but due to the presence of the acid mostly pH remains in the acidic
range so HCL tank is now relocated and lines are slip plated in this neutralization tank. The pH is
maintained between 6.0 to 6.5.The effluent overflows into outlet chamber A1-2502 from where this
effluent is supplied to feed storage tanks A1-2504 A/B/C via feed cooler E1-2518 A/B.
Feed storage tanks A1-2504 A/B/C receive the neutralized effluent for final flow to biological reactor in
secondary treatment section of effluent treatment plant. Feed flow is controlled via FCV-5068
accordingly to COD load on deep shaft.
2. Ensure all slip plates are in proper position and all drains are closed.
3. Check all mechanical jobs are completed and system is ready to take the effluent.
4. Check the effluent level in the buffer storage tanks A1-2500A/B/C/D is sufficient.
5. Check that G1-2501A/B/C/D are available.
6. Check that FCV-5008/5001/5021/5024 are working normal.
7. Check that G1-2508 and G1-2519 are electrically energized.
8. Check the availability of the following utilities
i. 47 % caustic soda.
ii. Seal water
iii. Cooling water
iv. Instrument air
v. Portable water for the Safety shower
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
STARTUP
1. For the cold startup open fire water in the F1-2508 and fill the tank up to 20 %.
2. Line up the buffer storage effluent via G1-2501A/B/C/D.
3. Fill the tank and overflow this in the A1-2519.
4. Check the pH of the effluent via QT-5027/28 and calibrate them if required.
5. Start the agitator of the G1-2508 when it level reaches up 75 %.
6. Fill the A1-2519 and take the G1-2519 in service.
7. Check the pH of the effluent via QT-5030/31 and calibrate them if required.
8. Complete fill the A1-2502 and lineup 47% caustic to maintain the pH.
9. Check any abnormal sound in the G1-2508 & G1-2519 and inform to shifty manager about
abnormality.(if any)
10. When the effluent is completely neutralized and downstream system is ready to take the
neutralized effluent then take the G1-2503A/B in service as per given startup procedure.
3. G1-2503A/B NUTRALIZATION PUMP STARTUP
1. Check all PTWS are signed off.
2. Check the system for the completion of all mechanical jobs.
3. Check that pumps G1-2503A/B are electrically energized.
4. Check that seal water line isolation valve is open and its pressure is normal on the local PG.
5. Check that sufficient liquid level is available in the A1-2502.
6. Check that E1-2518A&B are ready to take the effluent.
7. Check that E1-2518 A&B cooling water is lineup.
8. Check that feed storage tank A1-2504A/B/C is ready to take the effluent.
9. Confirm that feed tank ZCV-5040/5045/5050 is operational.
10. Check that pump kick back line is minimum 10 % open.
11. Open the suction and discharge valve of the elected G1-2503A/B.
12. Check that LCV-5032 is 50% open.
13. Pull emergency stop button and push the start button.
14. Check the pump for any abnormal sound.
15. Pressure on the discharge PG-5038/5033 must be 3.5 to 4.0 barg.
16. Confirm that suction and discharge isolation valves of the standby pump are isolated.
4. G1-2503A/B CHANGEOVER PROCEDURE
1. Ensure that seal water is lineup to the standby pump G1-2503SA/B.
2. Open suction and discharge valve of the standby pump.
3. Ensure that spill back line valve is minimum 10 % open.
4. Pull emergency stop button and push the start button.
5. Check the pump for any abnormal sound.
6. Pressure on the discharge PG-5038/5033 must be 3.5 to 4.0 barg.
7. Press emergency stop button of the running pump.
8. Isolate suction and discharge valves and put the pump on standby
5. NORMAL OPERATION:
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
1. Physically check the level of the F1-2508 and F1-2519 should be full upto the overflow because
low level can damaged the agitator.
2. Physical check any abnormal sound from the agitator of the all neutralization tanks, i-e, G1-2508
and G1-2519.
3. Switch off /stop the agitator if any abnormality is observed from them and inform to shift manager.
4. To increase the flow or start taking effluent from buffer storage FCV-5001/5008/5021/5024 to be
opened slowly not more than 5% at a time.
5. Check any abnormality in the pH at DCS (in the Process value and set point).
6. Mother liquor not to be lined up in the F1-2508 neutralization tank even M1-1603 is (mother liquor
filter) in service or not. It must remain line up in buffer storage tanks.
7. When there is low pH problem then check the acetic acid concentration in the buffers and also
check the buffers tank level physically.
8. When pH value in the A1-2519 is lower than 6 then do not forward this batch to the feed tanks F1-
2504A/B.
9. When pH become low then reduce the flow from buffers and increase QT-5027 /5030 pH set
point.
6. EMERGENCIES:
In normal operation of the neutralization systems following emergencies can occur.
1. High or low pH disturbance due to the powder in the feed from the buffer tanks.
2. High or low pH issue due the malfunction of the QT-5027/5030.
3. Gear box problem of the G1-2508 & G1-2519.
4. Actuator failure of the LCV-5032.
5. Power failure
6. MCC# 22 power failure or any other issue on the MCC#22.
7. 47% caustic header leakage or G1-2621A/B failure.
8. G1-2503A/B duty pump failure while standby is under maintenance.
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
6. Check E1-2518A&B discharge temperature on TIA-5067. It should be <45 0C.At-a- time both
E1-2518 A & B can be taken in service but one E1-2518A/B is enough for the maximum flow
of effluent.
7. Confirm LT-5041/5046/5051of the select feed tank working normal and cross check it from the
area.
3. Start up of the feed pump G1-2505 A/B/C:
1. Check all PTWS are signed off.
2. Check the system for the completion of all mechanical jobs.
3. Check that pumps G1-2505A/B/C are electrically energized.
4. Check that feed storage tank A1-2504A, B & C any two are filled with neutralized effluent.
5. Check that seal water line isolation valve is open and its pressure is normal on the local PG.
6. Check that sufficient liquid level is available in the A1-2504A/B/C.
7. Check that E1-2582 is ready to take the effluent.
8. Check that E1-2582 chilled water is lineup.
9. Check that G1-2583 chilled water pump is in service.
10. Check that deep shaft package is ready to take the effluent.
11. Check that chiller package is ready to be taken in service.
12. Check that pump kick back line is 100% open.
13. Check that each pump feed diverge line to buffer storage area is fully isolated.
14. Open the suction and discharge valve of the elected G1-2504 A/B/C.
15. Check that FCV-5068 is fully close.
16. Pull emergency stop button and push the start button.
17. Check the pump for any abnormal sound.
18. Pressure on the discharge PG-5055/5058/5061 is normal.
4. NORMAL OPERATION:
1. Take the reading as per log sheet.
2. Check if any abnormality is in the parameters.
3. Check any abnormal sound from the pumps and inform to shift manager.
4. Before line up of any feed tank on forward ask board man about the COD and pH result. Its
COD must be < 8000 PPM and pH =6-9.
5. Purge the QT-5056, 5059 and 5062 once the in the shift.
6. Divert the feed back to buffer storage tan if the pH and COD are out of order.
7. The feed flow to the deep shaft should not be less than 50 m 3/hr because absorption chiller will
tripped on 50m3/hr as per logic.
5. EMERGENCIES:
Following emergencies can be occurred on this plant
1. Power failure.
2. FCV-5068 mal function.
3. Feed Quality (if it is out of order then transfer this to the buffer storage are via divergent line).
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
NOTE: Don’t open purge valve of condenser in any case while the absorption chiller is in service.
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
1. The purge tank to be purge when the pressure exceeds 60 mmHg. The purge tank will be
evacuated until tank pressure is reduced to 30 mmHg.
2. The Micropanel should be set to operate in the manual purge mode.
3. Operate purge pump G1-2596 for 10 minutes to warm up oil with gas ballast open, leak rate
valve open and all purge system valves closed.
4. Check that the purge pump G1-2596 is capable of pulling down to at least 3 mm Hg by opening
manual valves slowly and reading the purge pump pressure on the vacuum indicator gauge.
5. Slowly open purge tank valve to read the purge tank pressure on the vacuum indicator gauge. If
the pressure exceeds 30 mm Hg absolute, the purge tank may be purged although it is not
necessary unless the tank pressure is equal to or exceeds 60 mm Hg absolute.
6. Slowly open purge tank valve. Watch the purge tank pressure. When it is lowered to 30 mm Hg
absolute, close the valves.
7. Run purge pump for 10 minutes more to clean up oil.
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
1. Initial checks:
1. All jobs are completed and PTW are signed off.
2. Check that chiller Z1-2580A/B/C main motor and auxiliaries’ power is on.
3. Check G1-2583 is in service.
4. Check that oil level in the sight glass is normal.
5. Check that oil reservoir temperature is > 60 0C or it must be refrigerant temperature plus 50 oC.
6. Check chilled water inlet and outlet isolation valves are fully opened
7. Check cooling water inlet and outlet valves are fully opened.
8. Check parameters and set points of chiller from the local panel (comfort screen) as
press“MENU from (“CCN”,” LOCAL” RESET”,” MENU”) keys.
9. Then Press “STAUS” KEY
10. Bring the cursor to “STATUS O1” by pressing “PREVIOUS” or ”NEXT” key then press
“SELECT”KEY. The screen will start showing the status of all parameters on that condition and
respective keys will change to “NEXT”,”SELECT”,”EXIT”,
11. After checking all the parameter press “EXIT ” KEY twice to come at first screen.
12. To check the set points press the “MENU” KEY and then press “SET POINT”key. The screen
will show the set points as
i. Base demand limit 100 %
ii. LCW set point 9.0 oC
iii. ECW set point 18 oC
iv. Ice build set point 4.4 oC
13. Bring the first screen by pressing the “ENTER” and then “EXIT “key.
2. STARUP OF THE C1-2580A/B/C
1. LOCAL STARTUP (MANUAL STRATUP):
i. Local startup is initiated by pressing “LOCAL “menu soft key on comfort screen. Local
start-up can proceed when the chiller schedule indicates that the current time and date
have been established as a run time and date, and after the internal 15-minute start-to-
start and the 1-minute stop-to-start inhibit timers have expired. The timer must expire
before the chiller will start.
ii. Once local start-up begins, chiller; control system performs a series of pre-start tests to
verify that all pre-start alerts and safeties (i.e. number of starts , bearing temperature,
motor temperature, compressor discharge temperature, evaporator refrigerant
temperature, oil sump temperature, condenser pressure and line voltage) are within the
limits then control reads “PRESTART” otherwise the startup will be delayed or aboard.
iii. If chiller reads” PRESTART” then the following sequence will start.
a. The chilled water relay energizes, and the “MAINSTAT” screen line now reads
STARTUP.
b. After Five seconds, the cooling water relay energizes.
c. After point “b” (minimum 30 seconds to maximum 5 minutes) the control system
monitors the flow of chilled water and cooling water by the PDS-5230/32/5234 &
PDS-5229/31/5233 respectively.
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
d. Now control system will check the chilled water temperatures against set point. If
temperature will be below or equal to the set point plus ½ chilled water dead
band then sequence will not proceed and if the chilled water temperature is high
enough, then start-up sequence continues.
e. Now control will check the guide vane position. If the guide vanes are more than
4% open, the start-up waits until the control system closes the vanes.
f. If the vanes are closed and the oil pump pressure is less than 4 psi (28 kPa), the oil
pump relay energizes. The control system then waits until the oil pressure reaches
a maximum of 18 psi (124 kPa). Oil pressure verified (15 seconds minimum, 300
seconds maximum after point ‘e’.)
g. After oil pressure is verified, the control system waits for 40 seconds, and the
compressor start relay (1CR) energizes to start the compressor.
3. NORMAL OPERATION OF C1-2580 A/B/C
1. Take the reading as per log sheet.
2. Check the Running System — After the compressor starts, the operator should monitor the
control screen display and observe the parameters for normal operating conditions.
3. The oil reservoir temperature should be above 120 F (49 C) during shutdown.
4. The bearing oil temperature accessed on the COMPRESS table should be 120 to 165 F (49 to
74 C). If the bearing temperature reads more than 180 F (83 C) with the oil pump running, stop
the chiller and determine the cause of the high temperature. Do not restart the chiller until
corrected.
5. The oil level should be visible anywhere in one of the two sight glasses. Foaming oil is
acceptable as long as the oil pressure and temperature are within limits.
6. The oil pressure should be between 18 and 30 psid (124 to 207 kPad) differential, as seen on the
control panel default screen. Typically the reading will be 18 to 25 psid (124 to 172 kPad) at
initial start-up.
7. The moisture indicator sight glass on the refrigerant motor cooling line should indicate
refrigerant flow and a dry condition.
8. The condenser pressure and temperature varies with the chiller design conditions. Typically the
pressure will range between 60 and 135 psig (390 to 950 kPa) with a corresponding
temperature range of 60 to 105 F (15 to 41 C). The condenser entering water temperature
should be controlled below the specified design entering water temperature to save on
compressor kilowatt requirements.
9. Cooler pressure and temperature also will vary with the design conditions. Typical pressure
range will be between 60 and 80 psig (410 and 550 kPa), with temperature ranging between 34
and 45 F (1 and 8 C).
10. Check the chiller for any abnormal sound and inform to shift manger about the abnormality.
11. Check G1-2583 for any abnormal sound and the cavitation of the pump.
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LOTTE PAKISTAN PTA UTY Plant Operating Procedure
T-11 UTILITIES PALNT ETP plant (Revision: 01)
12. Check any external leakage in E1-2582 (large quantity of the makeup water indicates that there
is some leakage of the chilled water inside the circuit this continuous makeup water will not
give the required cooling).
13. If two chillers are parallel in service and chilled water entering temperature reaches to the 16 0C
then stop one of the chillers in order to run one chiller on maximum load.
14. Start the second chiller when the chilled water entering temperature is 22 to 23 0C.
4. SHUTDOWN OF THE C1-2580A/B/C:
In normal operation there is no shutdown of the chillers, it is only stopped when there is low heating
load at the chiller, the feed flow to deep shaft is below than 5o m 3/hr or any maintenance is required.
Chiller shutdown begins if any of the following condition occurs:
1. The STOP button is pressed for at least one second (the alarm light blinks once to confirm the
stop command)
2. A recycle condition is activated
3. The time schedule has gone into unoccupied mode
4. The chiller protective limit has been reached and chiller is in alarm
5. The start/stop status is overridden to stop from the control network.
a. When a stop signal occurs, the shutdown sequence first stops the compressor by deactivating
the start relay (1CR). Status message of “SHUTDOWN IN PROGRESS, COMPRESSOR
DEENERGIZED” is displayed, and the compressor on time and service on time stop.
b. The guide vanes are then brought to the closed position.
c. The oil pump relay and the chilled water pump relay shut down 60 seconds after the
compressor stops.
d. The condenser water pump shuts down at the same time if the ENTERING CONDENSER
WATER temperature is greater than or equal to 115 F (46.1 C) and the CONDENSER
REFRIGRANT TEMP is greater than the CONDENSER FREEZE POINT plus 5 F (–150C).
e. The stop-to-start timer now begins to count down. If the start-to-start timer value is still
greater than the value of the start-to-stop timer then this time displays on the control logic
display screen.
*Certain conditions that occur during shutdown can change this sequence.
f. If the AVERAGE LINE CURRENT is greater than 5% after shutdown, or the starter contacts
remain energized, the oil pump and chilled water pump remain energized and the alarm is
displayed.
g. The condenser pump shuts down when the CONDENSER PRESSURE is less than the COND
PRESS OVERRIDE threshold minus 3.5 psi (24.1 kPa) and the CONDENSER REFRIG
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TEMP is less than or equal to the ENTERING CONDENSER WATER temperature plus 3° F
(–1.6 °C).
h. If the chiller shuts down due to low refrigerant temperature, the chilled water pump continues
to run until the LEAVING CHILLED WATER temperature is greater than the CONTROL
POINT temperature, plus 5° F (3 °C).
1. Confirm evaporator bottom valve which is used for the refrigerant charging is close.
2. Remove the plug of the refrigerant charging line slowly.
3. Fit the Gas charging adaptor at the place of plug .
4. Fit charging manifold at adopter.
5. Slightly open the gas charging valve then manifold valve to remove the air from the manifold
pipes.(air purging is carried out to avoid air mixing with the refrigerant)
6. Fit manifold middle pipe at the cylinder valve and keep this valve with minimum opening,
slightly open the manifold valve, as some refrigerant starts coming from this then tight manifold
pipe.
7. Keep cylinder valve open in downward direction and open the cylinder valve then manifold
valve and start the refrigerant charging in the chiller.
8. Manual Guide Vane Operation:
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It is possible to manually operate the guide vanes in order to check control operation or to
control the guide vanes in an emergency. Manual operation is possible by overriding the target
guide vane position.
1. Access the COMPRESS screen on the control screen and scroll down to highlight TARGET
GUIDE VANE POS.
2. To control the position, use the INCREASE or DECRESE soft key to adjust to the percentage of
guide vane opening that is desired.
3. 0% is fully closed and 100% is fully open. To release the guide vanes to automatic control, press
the RELEASE soft key.
NOTE: Manual control overrides the configured pull down rate during start-up and permits the guide
vanes to open at a faster rate. Motor current above the electrical demand setting, capacity overrides,
and chilled water temperature below the control point override the manual target and close the guide
vanes.
9. EMERGENCIES:
a) Feed is not available for deep shaft due to high pH and high COD in A1-2504A/B/C and the level of
the feed tanks is full.
1. Stop all chillers and divert 50 % feed tank in buffer A/C.
2. Add high pH effluent in this feed tank and check the pH from the lab and also calibrate the pH
analyzer of this feed tank.
3. When pH is in the normal range, then open feed to deep shaft at the minimum flow rate of 55 m 3/ hr
via FCV- 5068 and start the chiller.
4. If the FCV-5068 close stuck then all chillers need to stopped, as there is no bypass available for
FCV-5068.
5. Heavy leakage in the cooling water circuit.
6. Heavy leakage in the chilled water circuit..
7. Failure of the G1-2583.
8. Heavy leakage in the E1-2582.
9. Fault in the MCC#21 & 22 the chiller trips.
10. Power failure
11. Chiller control mal operation.
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1. INTRODUCTION:
The Deep shaft effluent treatment package (Z1-2538) treats effluent from PTA plant. The objective of the
deep shaft is to reduce the chemical oxygen demand and concentrates the suspended solids in order to
achieve the discharge effluent quality.
The PTA plant deep shaft package (Z1-2538) consists of the mixing box (A1-2562), deep shaft head tank
(A1-2547), deep shaft (A1-2507), Degasser (A1-2510A/B), degasser blower package consists of the two
degasser blowers (C1-2509A/B) with two degasser ventilation fans (C1-2514 A/B),clarifier basins (A1-
2511A/B) with clarifier scrapers (G1-2511 A/B), RAS pumps (G1-2512A/B/C) and air compressor
package consisting of two Air compressor (C1-2527A/B) with auxiliaries equipment.
The mixing box (A1-2562) receives the effluent from the three areas of the effluent treatment plant. The
main flow is aqueous effluent from PTA plant which has been neutralized and then cooled by the chiller
package Z1-2578.The remaining flow consists centrifuge concentrate return via G1-3107A/B and
tertiary clarifier A1-3102 sludge transfer pumps G1-3104 A/B.These effluents are mixed with the return
activated sludge from the clarifier basin A1-2511A/B coming through the RAS pumps (G1-2512 A/B/C).
These influents are fed continuously via an underground side pipe to the down comer side of the deep
shaft (A1-2507) which dilutes the large volume of the liquor recirculating with in the deep shaft. In deep
shat the effluent is contacted with the biomass and oxygen to biochemically oxidize the organic
pollutants. The oxygen for the biochemical reaction is provided by air compressor package (C1-
2527A/B).Air is injected in the deep shaft via six down comers and six risers sparge pipes. The treated
effluent liquor overflows form deep shaft head tank to the integral off-take channel to A1-2510A/B
degasser. Degassing is achieved from the bubbling air through the liquor via a system of sparge pipe
situated on the floor of the degasser. Air for degassing is supplied by C1-2509 A/B. This degassed liquid
is transferred to the clarifier A1-2511A/B via underground pipes under the gravity flow. The settled
sludge is transferred to the deep shaft via G1-2512A/B/C (Return Activated sludge pumps) and
remaining fluid is bleed off to sludge centrifuge M1-2548 A/B as WAS (waste activated sludge).The
overflow of the clarifier is mixed with coagulant and then flocculent then it moves to the A1-3102
tertiary clarifier. The sludge of A1-3102 is transfer to deep shaft via G1-3104A/B and the treated effluent
is drained to outfall.
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NORMAL OPERATION
This condition refers to plant operating at process feed flow sheet of combined influent of 213.6
m3/hr and a COD load of up to 18.4 te /day. Under this regime normally both degasser and both
clarifier basins are operational. However it is possible to run the plant with one degasser lane and
one clarifier. During the normal plant operation one degasser and one clarifier can be handed over
for maintenance.
MAXIMUM OPERATION
This condition refers to the plant operating at process feed flow rates of combined influent between
213.6 m3/hr to 322.6 m3/hr with COD load between 18.4 te /day to 26.5 te/day. Under this regime
both degasser lanes (A1-2510A/B) and clarifiers (A1-2511A/B) must be operational.
TICKOVER OPEARTION
Deep shaft is designed to operate continuously. During the period of plant shutdown the deep shaft is
operated at low flow which is called tickover (to run the plant at low COD load without any major
change) operation.
Under above described conditions the plant must be left on tickover to prevent anaerobic condition
occurring in the process. This requires one compressor, one degasser blower, both clarifiers scarpers
and at least two RAS pumps in service. In this condition one clarifier can be taken offline. It is
necessary to reduce the MLSS concentration in the deep shaft during tickover to prevent excessively
low F/M (How much food a single pound of organisms will eat every day) ratio which loads to
the long sludge age. Long sludge age may lead to nitrification in the clarifier basins. This in turn can
lead to sludge floatation as the nitrogen attaches itself to the flocs.
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NOTE: only applicable for initial start up of deep shaft or when deep shaft is completely drained out
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After these changes one degasser and clarifier can be handed over for maintenance job
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Initial checks
1. All work permits are signed off on compressor and returned.
2. Check the power is available on compressor CMC control panel
3. Check the availability of the instrument air.
4. Check that cooling water valves (inlet and outlet) are fully opened.
5. Check that air outlet manual valve of the compressor is fully opened.
6. Open air bleeding valves of the stage cooler for a short time for removing the trapped air in cooling
water circuit then close.
7. Check that seal air valve is fully open. Logically compressor pre-lube oil will not take start without
seal air availability, in order to avoid the ingression of oil in the inter stage coolers.
8. Check that air knob is at zero, to start the compressor with no flow to deep shaft.
9. Check that the compressor is on un-load condition.
10. Check that down comer individual valves at the inlet of the each down comer are completely de-
isolated.
11. Check that the main isolation valve on the riser’s side is fully open. Ask Utilities DCS board man to
open FCV-5120 fully.
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17. Adjust the total air flow from air compressor to 4250 to 4300 m 3/hr at the FIA-5360, as per
requirement.
18. Check passing of stand by compressor discharge valve.
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Initial Startup
1. Check that splitter box, degasser and degasser outlet tank are full of liquid to the normal operating
level.
2. Confirm that isolation stop-log in the splitter box and degasser outlet line is free to take in service.
3. Check the clarifier is ready to take the effluent.
4. Check that C1-2509A/B are ready to be taken in service.
5. Check that G1-2514 A/B ventilation fan is in healthy condition.
6. Select the degasser blower to be taken in service, start the ventilation fan of that blower and
confirm that it is working normal.
7. Start the selected duty blower (C1-2509 A/B) as per startup procedure, and confirm that it is
normal in service.
8. Check that air bubble can be seen breaking the surface of the liquor in the degasser.
9. Check the discharge temperature of the blower at the TG-5244 it should be less than 100 0C
10. Check the discharge pressure of the blower at the PG-5242 and it must be less than .5 barg.
Degasser (A1-2510A/B) system is now operating normally.
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For the maintenance of the air supply pipe work the degasser system must be completely shutdown.
If the maintenance period is likely to increase beyond 24 hrs and temporary plant air hose cannot
meet the requirement of the degasser then it is recommended to pump out the degasser and the
clarifier and put the deep shaft on just aeration. For shorter maintenance period it is not necessary to
pump out and flush the system.
Degasser sparger piping maintenance requires the complete shutdown of the respective degasser
A1-2510A/B. For this following procedure applies.
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14. Increase the RAS pump discharge flow on FI-5130 by adjusting the opening of the pneumatic
air to the PCV-5213 located on the RAS line to its normal operating rate before opening the
WAS valve.
15. Daily monitor the concentration of the MLSS in the deep shaft and adjust the RAS flow to
maintain it accordingly.
The RAS pumps are operating normally 2 out of 3
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5. Ensure that water is available for flushing when RAS pumps are stopped.
Ensure RAS pumps run in accordance with the required operating instruction.
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17. EMERGENCIES:
1. Air compressor may trip due to any reason, e.g. due to power dip, power failure, tripping of
MCC# 21, or any compressor internal FAULT.
2. Start up air compressor as per procedure.
3. Mal operation of FCV-5120 can reduce the deep shaft riser’s flow to zero. Due to which the deep
shaft may rotate in reverse direction.
4. Rectify FCV-5120 mal operation and start the deep shaft as per procedure.
5. Tripping of the C1-2509A/B
6. Unavailability of the C1-2509 A/B due to maintenance work.
7. Tripping of the G1-2512A/B/C
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TERTIARY TREATMENT
1. Introduction
The tertiary treatment stage of the effluent treatment plant operates when the clarifier effluent from
A1-2511A/B does not meet the discharge effluent quality .To polish the effluent by the removal of
residual suspended solid and subsequent reduction in COD. The effluent gravitates through
conditioning (coagulant and flocculent dosing) clarification and filtration stages before discharge
from site outfall to the Sea.
When the effluent from A1-2511A/B dose meet discharge quality then tertiary treatment stage can be
bypassed and effluent sent directly to final effluent pit A1-3105.
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mixed with a known volume of the filtered water to make a batch of 0.5% W/W polymer
solution. The batch is transferred to polymer stock tank F1-3125 by the polymer solution
transfer pump G1-3123 for 30 minutes .After transfer a new batch is immediately prepared in
F1-3114 and subsequently transfer to F1-3125 on low level in F1-3125.
B. Liquid
Polymer liquid system is not being used at plant, but its option is available in the polymer
preparation package. The sequence will be started automatically by sensing low level and will
continue until stopped. We are not using this on the plant.
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15. Confirm that sufficient level up to 50% is available in the F1-3101(tank fills with effluent
under flowing coagulant mixing tank A1-3100).
16. Start the G1-3101 Flocculent tank agitator.
17. Confirm the dosing rate of the Nalco-9916.
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1. Check pumps G1-3104A/B seal flush valves are open and confirm the seal water pressure
on PG-5177/78.
2. Ensure that tertiary clarifier is full with liquid.
3. Ensure that pumps suction and discharge drain valves are fully close and drains blanks are
fitted.
4. Open the suction and discharge isolation valves of the duty pump. Don’t start the G1-
3104A with close isolation valve.
5. Ensure that suction and discharge valves of the standby pumps are fully closed.
6. Ensure that PG-5176 and 5179 is working normal.
7. Ensure that A1-2562 is operational and is ready to receive the effluent.
8. Start the duty sludge transfer pump G1-3104A/B.
9. To start the stand by pump, open the suction and discharge isolation valve of the pump.
10. Start the pump and check against any abnormal sound.
11. Stop the de-selected pump.
12. Close the deselected pump suction and discharge valve.
13. Remove the blanks and drain pump.
14. Connect the water hose with the suction and flush the pump with water. Carry out the
pump’s flushing until clean water started to come from discharge drain.
15. Remove the hose, close the drain valve and refit the blank.
8. NORMAL OPERATION
1. Check the system against any abnormality.
2. Fill are logs sheet and monitor the changes.
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8. Empty the tertiary clarifier until all the sludge has been removed via G1-3104A/B.
9. Stop the clarifier when basin is empty.
10. Clean the clarifier with fire water.
11. On complete emptying of the clarifier stop and isolate the G1-3104A/B.
12. Carry out the clearing of the clarifier.
Note: after complete cleaning of the A1-3102 take this in service as per start-up procedure.
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Sludge Handling.
1. Introduction:
There are two “Guinard” centrifuges at effluent treatment plant. It uses centrifugal force to
separate the component of the mixture with different densities ‘clarification is carried out by the
rotating horizontal bowl. The bowl of the centrifuge decanter has cylindrical and conical
sections. The sludge enters the decanter through a feed tube and enters the bowl through a
distribution chamber. As the bowl rotates the solid rapidly settles against the walls of the
spinning bowl. A screw conveyor rotating slightly lower speed than the bowl moves the solid
through the conical to the solid discharge section. At the same time the liquid effluent flow
flows through the cylindrical section to the liquid discharge.
Each centrifuge can process 11.2-27.4 M3/hr sludge contains 0.2 tons/hr of dry solid maximum.
The sludge is feed to the centrifuge from discharge header of the return activated sludge pumps
G!-2512A/B/C. The feed is under flow control. One unit is sufficient at full load of effluent
treatment plant.
Polymer is injected with the feed to the centrifuge in proportional to sludge flow. Normally it is
cationic polymer, diluted to 0.1 % W/W, for addition to centrifuge. The sludge from the outlet of
the centrifuge is transferred to the road dumper by the dedicated sludge transfer pump G1-2560
A/B with bridge breaker P1-2565 A/B. Speed of these two machines can be vary via gearbox
manual variation, provided flow range of 0.5 to 2.5 m3/hr at 6 barg pressure. The centrate water
goes to backwash pit A1-3106, from where it is send back to the deep shaft.
2. SARTUP
INITIAL CHECKS
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Checks availability of :
1. Waste activated sludge (WAS)
2. Backwash pit A1-3106
3. polymer solution (Nalco-9916)
4. Raw water
5. Road dumper for sludge
Checking of instrument and control valves
1. FCV-5189 flow control valve in sludge feed water line to sludge centrifuge M1-2548 A from
RAS pumps G1-2512 A/B/C.
2. FCV-5138 flow control valve in sludge feed water line to sludge centrifuge M1-2548 B from
RAS pumps G1-2512 A/B/C.
3. ZCV-5236 in raw water line to sludge feed line of M1-2548A.
4. ZCV-5235 in raw water line to sludge feed line of M1-2548B.
5. ZCV-5238 three ways valve in dewatered line to sludge road dumper of M1-2548A.
6. ZCV-5237 three ways valve in dewatered line to sludge road dumper of M1-2548B.
3. Polymer solution Nalco-9916 preparation in package Z1-2564
0.2 W/W solution is prepared in batches from powder in solution preparation package Z1-2564
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16. Then solution will be transferred via G1-2572 to the solution feed tank F1-2568, when low
level 10 % will be sensed on LS-5701.
17. The solution transfer pump G1-2572 will be stopped at high level 90% indication on LS-5701
.this switch will stop the pump automatically.
4. Start-up of sludge centrifuge M1-2548 A/B
Start up initial checks.
1. Check that sludge inlet isolation valve of the centrifuge M1-2548 is open.
2. Open the raw water isolation valve to the centrifuge M1-2548 A/B.
3. Open the manual isolation valve in the polymer and sludge feed line to the duty
centrifuge. Normally one centrifuge remains in service, one standby. Polymer should
be fed to the feed inlet line of the centrifuge M1-2548A/B. The second injection valve
is located on the main inlet line of the sludge centrifuge. It should always be locked
closed.
4. Ensure that duty two RAS pumps G1-2512A/B/C are in service and WAS (waste
activated sludge) discharge valve towards M1-2548 A/B is in open condition.
5. Ensure polymer preparation package Z1-2564 is on auto preparation condition and
solution tank is > 80%.
6. G1-2575 A/B is on auto and mode and pump’s suction and discharge valves are open.
7. Check that seal water supply to the G1-2560 A/B is open and water is coming from
the drain.
8. Ensure that backwash pit pump G1-3107 A/B should be in the service and LICA-
5184 is set to control the level in the A1-3106 pit at 40% on auto. This is used to
transfer the concentrate back to deep shaft.
9. Ensure that road dumper is in place for the collection of the wet sludge.
10. Start the M1-2548 A/B duty centrifuge. Ensure that all emergency stop buttons are
released.
5. M1-2548A/B start up:
1. Press the ‘starts cycle’ button on the panel in the PLC room. Green light indicates
“ON” and following automatic timed operating sequence will start.
i. Centrifuge starts, speed increases up 2800 RPM in 200 seconds.
ii. Polymer dosing pump G1-2575 A/B starts.
iii. Sludge feed valve FCV-5138/5189 opens.
iv. Sludge transfer pumps G1-2560 A/B and bridge breaker (lump breaker) P1-
2565 A/B starts.
2. Set the required polymer feed to the centrifuge at DCS. The pump speed can be
control on auto and manual.
i. Auto: the pump speed is linked to WAS flow to the centrifuge through
FFY-5138/5189 ration control.
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6. Check that P1-2665A/B started normal with G1-2560A/B respectively. Otherwise centrifuge will trip
on hopper high level.
7. Check that G1-2540A/B grease pumps are on auto. To confirm that bearing are properly
greased.
8. Check that batches of the polymer are properly consumed. To check the proper
consumption of the chemical Nalco-9916.
9. Check the dehumidifier of the polymer package is in service and is controlling the
humidity. Its failure will cause the lump formation of polymer powder.
7. M1-2548A/B shut down:
Note: Always stop the centrifuge after running wash cycle in order to avoid the chocking of
the centrifuge.
4. Press the ‘wash stop’ button on the panel in the PLC room, This sequence will also
happens automatically if a lack of torque is detected for any specific length of the
time. The following automatic timed operating sequence will be initiated and
centrifuge will be washed.
i. Wash water solenoid valve ZCV-5235/5236 opens
ii. Sludge feed valve FCV-5138/5189 closes
iii. Polymer dosing pump G1-2575A/B stops
iv. High speed wash,10 minutes at 2800 RPM
v. Low speed wash,500 sec at 900 RPM then water valve will close
vi. Centrifuge stops
vii. Sludge transfer pump G1-2560 a/B and lump (bridge) breaker P1-
2565A/B stop on low level (after the draining of the centrifuge)
12. Start the standby centrifuge if it is required when the duty centrifuge is on wash
cycle.
8. Working instruction for running the M1-2548A/B without Bowl
1. For the adjustment of the torque sensor, centrifuge’s bowl hood removal is
required.
2. After initial adjustment of the torque, it is required to run the machine without the
reinstallation of hood in order to verify the accuracy of the torque sensors
adjustment.
3. Torque adjustment PTW will be hold by the SM-UTY before start-up of the
machine, and no job will be done on the said machine jest before energisation of
the machine and the tie when machine is running.
4. Before running the machine without hood, area will be tape barricaded and no one
will be allowed to stay in the barricaded area.
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5. After having the observation during the first run of the centrifuge, if instrument
team will be in need to proceed with further adjustment, the centrifuge will be
stopped and isolated again before the re-initiation of the job.
6. For further test run, instruction mentioned in step (3) and (4) will be followed.
7. The permission for said job will be given by the Plant manager Utilities plant.
9. M1-2548A/B Emergencies:
8. CentrifugeM1-2548A/B vent on wash cycle without any indication. Restart the
centrifuge and check all the parameter, and find out the reason.
9. Centrifuge trips on high high level, first check the sludge level in the hopper if is
actual then start the sludge discharge pump on manually form local panel and open
the local drain of the sludge discharge line and provide a water hose. Secondly
check the bridge breaker P1-2565A/B is rotating or not .If it is not rotating then
stop sludge pump and inform to shift manager for the replacement of the bridge
breaker pin.
10. If the bridge beaker is ok and a fault indication is appearing on the panel then clean
the sensor with the help of the shift instrument teach and take the centrifuge in
service.
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