CHEMICAL MANAGEMENT DEPARTMENT

SODIUM HYPOCHLORITE PLANT OPERATION

Document Code: HEI-IMS-CHEM-SOP10 Page: 1 of 8

Sodium Hypochlorite plant Operation

(Clause 8.1, 8.5 of ISO 9001:2015, 8.1, 8.2 of ISO 45001:2018)

Lead OPS Plant Plant

Chemist Manager Manager Manager
Issued for HEI HEI QATPL HEI
00 Jan 2019
Implementation Muhammad Mehdi
Ashar Muhammad
Akhtar Hassan
Ishfaq Khan Janhanzeb
Bhatti

Rev Issue Date Description Prepared by Checked by Checked by Approved by

 CHEMICAL MANAGEMENT DEPARTMENT

SODIUM HYPOCHLORITE PLANT OPERATION

Document Code: HEI-IMS-CHEM-SOP10 Page: 2 of 8

1.0 DOCUMENT HISTORY

2.0 PURPOSE

3.0 SCOPE

4.0 RESPONSIBILITIES

5.0 PROCEDURE

5.0 RELATED DOCUMENTS

 CHEMICAL MANAGEMENT DEPARTMENT

SODIUM HYPOCHLORITE PLANT OPERATION

Document Code: HEI-IMS-CHEM-SOP10 Page: 3 of 8

DOCUMENT HISTORY
REV. # DATE PAGE # SECTION DCR# NATURE OF AMENDMENT

* All changes made in the document are notified in the Document History. For details of amendments,
please refer to relevant DCR (Doc. Change Request).
 CHEMICAL MANAGEMENT DEPARTMENT

SODIUM HYPOCHLORITE PLANT OPERATION

Document Code: HEI-IMS-CHEM-SOP10 Page: 4 of 8

1. PURPOSE
The purpose of this document is to provide instructions, determines pre-requisites, identifies
precautions, details the sequential steps and assigns responsibilities for operating the Sodium
Hypochlorite plant.

2. SCOPE

This procedure applies to the operation of sodium hypochlorite plant, determines pre-requisites,
identifies precautions details the sequential steps and assigns responsibilities for operating the
plant.

3. RESPONSIBILITIES

3.1. Plant Manager

Plant Manager ensures that the proper procedures, as detailed below, are followed for
operating sodium hypochlorite plant.

3.2. Lead Chemist

It is the responsibility of Lead Chemist to ensure that all technical pre-requisites are
fulfilled prior to the starting for sodium hypochlorite plant. Overall responsibility for
correct operation lies with Operation Manager.

Ensuring that solution preparation is carried out correctly and according to procedure.
3.3. Assistant Chemist
Responsible for operating the plant as per instructions provided in this procedure and
also for proper solution preparation of chemicals.
3.4. Department heads

Maintenance Department Heads will manage to maintain the tanks pumps and other
equipment as per PM schedule.

4 PROCEDURE

4.1 Pre-requisites for Starting of DAF System.

 PTW & LOTO has been cancelled and system is ready for startup.
 Hypo plant MCC panel should be energized.
 Hypo plant Rectifier should be energized.
 All the breakers should be racked in and auto.
 All pressures and temp must be normal.
 All valves should be in normal position.
 CHEMICAL MANAGEMENT DEPARTMENT

SODIUM HYPOCHLORITE PLANT OPERATION

Document Code: HEI-IMS-CHEM-SOP10 Page: 5 of 8

 All level transmitter should be calibrated and working normal.

 Thick salt water tank level should be greater than 0.5 M.
 Clear water tank level should be 2.2 M.
 Dilute salt water tank level should be 2.2 M.
 Flow of service water in heat exchanger should be greater than 20 M3/h.
 H2 concentration should be less than 50 LEL.
 All online instruments should be in service.
 Back Flushing line of Heat exchanger should be close
4.2 General Precautions

 Check and clear all the alarms.

 Never operate critical valves during operation.
 Carefully observe the leakage of the Generator and all pumps discharge lines.
 Dilute brine solution should be in range 2.8 to 3.2%.
 Never close MOV during pump running.
 Never close hand valve during production.

4.3 Hypo Plant Start-up and Storage Sequence

Before the start of the system the operation mode of plant should be cleared by the operator,
according to the process correct valve position/state should be made. The valve with salt
related system, cooling system, electrolytic system and dosing system should be in Open
position and pickling system valves should be in close position. In addition, all the valves before
the pressure gauge (pump outlet, the generator) should be open.

 Dilute salt water tank level should be greater 2.2 M.

 Open the brine circulation valve.
 Brine storage valve should close.
 Isolation valves of pump should be open.
 Drain valve of Generator should be close.
 Start dilute salt water pump.
 Start the blower.
 After 20 sec start the Rectifier and adjust the current.
 After 60 Minutes circulation, 1st open the brine storage valve then Close the brine
circulation valve.
 Open brine circulation valve, when Dilute salt water tank level decreased up to 0.25 M, then
close brine storage valve.
 CHEMICAL MANAGEMENT DEPARTMENT

SODIUM HYPOCHLORITE PLANT OPERATION

Document Code: HEI-IMS-CHEM-SOP10 Page: 6 of 8

 Open the thick salt water tank valve and inlet valve of dilute salt water tank.
 Start clear water pump and then start Thick salt water pump.
 When level of dilute salt water tank reached at 2.2 M then stop the clear water pump and
thick salt water pump.
 Close valve of thick salt water tank and inlet valve of dilute salt water tank.

4.4 Normal operating conditions

 Observe Generator Temperature, should be less than 40 oC.

 Voltage of Rectifier should be 96 to 106 V.
 Current of Rectifier should be less than 2950 A.
 Flow of dilute salt water after Generator should be greater than 40 M3/h.
 Observe pressure of dilute salt water after Electrolyzer, should be greater than 0.07 Mpa.
 H2 concentration should be less than 50 LEL.
 Dilute brine solution should be in range 2.8 to 3.2%.
 Sodium Hypochlorite concentration should be 0.7 to 0.8%.

4.5 Shutdown

 First of all, rotate the current knob counterclockwise to zero then turn off the Rectifier.
 Stop the dilute salt water pump.
 Before stop the air blower ensure H2 concentration should be less than 10 LEL.
 close the brine tank inlet valve and open the Generator service water inlet flushing valve.
 Open the elctrolyzer dump valve and make sure electrolzer is cleaned with service water.
 Open the generator drain valve to drain the water from generator.
 Close the Generator service water inlet and close the Generator dump valve.
 Open the brine tank inlet valve.
 Perform back washing of Heat exchanger after every shut down.

4.6 Back washing of Heat Exchanger

 Open the heat exchanger back flush valve.

 Open the Heat exchanger brine solution side inlet and outlet butterfly valves.
 Open the service water underground valve and close, heat exchanger service water side,
service water valve 90%.
 CHEMICAL MANAGEMENT DEPARTMENT

SODIUM HYPOCHLORITE PLANT OPERATION

Document Code: HEI-IMS-CHEM-SOP10 Page: 7 of 8

 Open the heat exchanger brine solution side service water globe valve until water will come
clean from back flushing line.
 Repeat same procedure with 2nd heat exchanger.

4.7 CIP of sodium hypochlorite Generator

 Open the generator Acid water inlet globe valve and outlet globe valve.
 Close the generator outlet production and circulation hand valves.
 Fill half acid Tank with service water.
 Open the inlet and outlet isolation valve of acid water circulation pump.
 Start the acid pump and circulate the water then stop the pump.
 Prepared the 5 to 8% hydro chloric acid solution by adding HCL in Acid cleaning tank.
 Start Acid mist absorber.
 Open the globe valve of acid tank circulation line and close the main inlet valve of generator
then start pump to circulate for proper mixing.
 close the globe valve of acid tank circulation line and open the main inlet valve of generator
to circulate the solution from generator to acid tank for one hour.
 Stop the pump and drain the solution and add again fresh water to rinse the generator.

4.8 Check List

CIP
Stand
Description KKS Circulation Production
by
Thick salt water Close Close Open Close
pound outlet valve

Sodium Close Open Open Close

Hypochlorite
Generator

Thick salt water Y0PBE03AP001~AP002 Close Close Open Close

pump

Clear water tank Close Close Open Close

inlet valve

Clear water pump Y0PBE02AP001~AP002 Close Close Open Close

Dilute water tank Close Close Open Close
inlet valve
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SODIUM HYPOCHLORITE PLANT OPERATION

Document Code: HEI-IMS-CHEM-SOP10 Page: 8 of 8

Air Blower Y0PBE07AN001~AN002 Close Open Open Close

Dilute salt water Y0PBE05AP001~AP004 Close Open Open Close
pump

Brine circulation Open Open Close Close

valve

Brine storage valve Close Close Open Close

Acid cleaning pump Y0PBE13AP001~AP002 Close Close Close Open
Acid fume absorber Y0PBE14AK001 Close Close Close Open
Continuous dosing Y0PBE09AP001~AP003 Close Close Close Close
pump

Shock dosing pump Y0PBE10AP001~AP002 Close Close Close Close

Chemical Y0PBE11AP001~AP002 Close Close Close Close
preparation dosing
pump