Lime Silo Recharging Truck Loading

Work Instructions

Developer Omar Ibrahim Alkhaligy SCE 26July 2011

Reviewer M Rafi OM 26 July 2011

Approver Sunil K. Vellat PM 26 July 2011

Name Title Date Signature

Revision Date Description

01 26 July 2011 Lime Silo Recharging Truck Loading Work Instructions NE/OPR/SP-001/WI-018
00 25 May 2010 Lime Silo Recharging Truck Loading Work Instructions NE/OPR/SP-001/WI-018
Document Revision and Approval
WI No: NE/OPR/SP-001/WI-018

WI Title: Lime Silo Recharging Truck Loading Work Instructions

Uncontrolled, if printed *Refer latest version in the server / SAP *If required, print both the sides*
 Lime Silo Recharging Truck Loading Work
Instructions

Table of Contents

1. Purpose....................................................................................................................................................3
2. Scope........................................................................................................................................................3
3. Safety and Health Precautions.................................................................................................................3
4. Environmental Precautions......................................................................................................................3
5. Quality Requirements..............................................................................................................................3
6. Roles and Responsibilities........................................................................................................................3
7. Equipment/Software................................................................................................................................4
8. Terminology.............................................................................................................................................4
9. Procedure/Work Instructions...................................................................................................................4
10. Records.....................................................................................................................................................4
11. Legal Requirements and References........................................................................................................7

Uncontrolled, if printed * Refer latest version in the server / SAP * If required, print both the sides *
WI. No: NE/OPR/SP-001/WI-018 Rev: 01 Page 2 of
5
 Lime Silo Recharging Truck Loading Work
Instructions
1. Purpose
The purpose of the LIME SILO RECHARGING TRUCK LOADING is to fill a silo with new lime.

2. Scope

This work instruction shall apply to auxiliary operator and CCRO for filling silo with new
lime.

3. Safety and Health Precautions

a) Wear Eye glasses, helmet and safety shoes and chemicals protection clothes.
b) Keep eye wash in area ready and steady.
c) Chemicals handling procedure should be followed.
d) Maintain housekeeping of the area.

4. Environmental Precautions

a) Lime drain should transfer to IWWPP.

b) Don't dispose lime powder or lime milk in waste bags or on the floors.

5. Quality Requirements

1. Structural and other details for the saturator can be taken from Gd2.tp8.04 - POT
Plant Section 04

6. Roles and Responsibilities

6.1 SCE : Responsible for overall execution of the work instruction

6.2 CCRO : Responsible for checking smooth execution of the work on DCS
6.3 Auxiliary Operator : Responsible for execution of the work instruction in
field
6.4 Shift Chemist : Responsible for keeping concentration and turbidity
in range and its records.

7. Equipment/Software
7.1 Silo#1 & #2

8. Terminology

Record : Performed and signed copy of work instruction

SCE : Shift Charge Engineer
CCRO : Central control room operator
DC : Document Controller
DCS : Distributed control system
PTW : Permit to work
Uncontrolled, if printed * Refer latest version in the server / SAP * If required, print both the sides *
WI. No: NE/OPR/SP-001/WI-018 Rev: 01 Page 3 of
5
 Lime Silo Recharging Truck Loading Work
Instructions
SW : Sea water

9 Work Instructions/Procedure
9.1 Pre start up checks

a. Check the components on DCS are in normal condition.

b. Check the components in local are in normal condition.

9.2 Operation procedure

S. No. ACTIVITY REMARK

1 Select the Silo to be recharged at DCS. .

Confirm that three way pneumatic inlet valve

2 (05GKA04AA004) to be opened on Silo
05GKA05BB001
Confirm that three way pneumatic inlet valve
3 (05GKA04AA003) (for charging from bag splitter)
will be selected as closed for Silo 05GKA05BB001
When the coupling
is correctly
tightened the
contact of the local
limit switch will be
4 Connect the truck hose to the lime silo feeding line active and the
relevant command
for starting
automatic
procedure will be
active.
5 Select on DCS control panel the TRUCK loading
mode
6 Push the active button on DCS screen
7 Check DCS and confirm on field the dust trap
(05GKA05AT001) to start automatically
When the silo has
been filled an
8 Start the lime discharge from the truck alarm in DCS will
be generated (by
LI+ 05GKA05CL001
When the operator on field will open the quick
9 connection the related limit switch will be
deactivated and the dust trap will stop automatically

Uncontrolled, if printed * Refer latest version in the server / SAP * If required, print both the sides *
WI. No: NE/OPR/SP-001/WI-018 Rev: 01 Page 4 of
5
 Lime Silo Recharging Truck Loading Work
Instructions
10 Silo shall be in stand-by condition and ready to start
operation

10 Records
Retention
Record Number Record Title Responsibility
Period
LIME SILO RECHARGING TRUCK
NE/OPR/SP-001/WI-18 Document Controller
LOADING Work Instructions

11 Legal Requirements and References

For further details refer to
1. Doosan Operation Manual: Gd2.tp8.04 - POT Plant Section 04.
2. TE_REM_016 W07005-XG02-GKA-427802 P&ID for Lime Storage System.
3. TE_REM_019 W07005-XG02-GKA-427805 P&ID for Instrument air System.

Uncontrolled, if printed * Refer latest version in the server / SAP * If required, print both the sides *
WI. No: NE/OPR/SP-001/WI-018 Rev: 01 Page 5 of
5