Anagold Sulfide Operations
Mainstream Control Room Operations Competency
This Competency provides the guidelines for Control Room Operators/Engineers for assessment of the key criteria for DCS operation of the POX
Mainstream Circuit. The competency is composed of:
1. General Knowledge
2. Performance of Main Activities
3. Troubleshooting Exercises
Competency Elements and Perfomance Criteria
General Knowledge
Competency Element
1. Mainstream process and flowsheet
Perfomance Criteria
This is what they must do
 Can describe the process from
acidulation feed to CCD.
 Can describe the reagents used in the
circuit (Oxygen, Sulfuric Acid, Floculant,
Caustic), the requirements and control of
these.
 Can describe what field operators do
during the process. (monitor, sample)
 Can describe where the mainstream
areas are and when to start the flow of
reagents
 Can describe what is the use of specific
chemical used in process and why it is
Skills and Knowledge
This is what they must know
 Should know which elements and
equipments are used in the process
 Should know which type of reagent is
used in the process (where and when)
 Should be familiar with routine work of
field operators
 Should know importance of lime stone
and how it effects iron/arsenic tank
 Should know density parameters
(thickener to underflow surge tank)
 Should know when and why to use steam
in the process
 Should know how to interpret

2. Process Control Loops
3. Permissives and Interlocks
4. Safety and Risks
5. Bridges and Forces
important
 Can describe the connection of process
between upstream and mainstream
 Can describe the usage of steam
generator
 Can describe the reason why equipments
are used and how maintenance of
equipments help for smooth process
 Can describe what field operators do
during thickening process and
importance of feedback from operators
 Able to draw process flow from the start
of circuit till the end
 Able to read and interpret P&IDs
 Can describe Proportional (Gain),
Integral, and Derivative functions
 Can describe the difference between
Automatic and Manual Control
 Can describe Remote (Cascade) and ratio
control
 Can describe the purpose and function of
permissives and interlocks
 Can refer to MS WRAC document
 Can explain why some actions/activities
are not done properly to field operators
because of safety/risk
 Can demonstrate the Anagold procedure
for placing a bridge or force.
 Can demonstrate when a function or
input is bridged.
 Correctly logs bridges and takes required
actions to rectify issues that required the
data/parameter which are given by field
operators and shown in DCS
 Should know the terms/symbols/codes
which are shown in P&ID
 Should know the difference between
feedback and feedforward control
 Should be familiar how process control
loops work
 Should know when and where to use
auto/manual/cascade controls
 Should know the difference between the
two.
 Should know and review the document
 Should refresh the knowledge about risks
of the elements/equipments/regaents
 Should know the reason bridges are
required, and the implication of having
bridges in place (same)
 Should know the procedure of getting
approval when to use bridges
 Should know the risk of certain

6. DCS Trend Configuration
7. Key Process Parameters for POX Area
8. Hazards associated with the Mainstream
Area
9. HIS System
bridge being placed.
 Can describe when to use bridge
(troubleshooting or operational
requirements)
 Can describe how the force is put in
place and when to use
 Can describe parameters from the
equipment (thousands)
 Can describe the limits to configure DCS
 Can change the time duration of trends
where it is necessary
 Can desribe the key parameters such as
temperature, pressure, level of slurry
and the reason why parameters are
important
 Can describe the limits of parameters
and if parameters are not in limits
 Can determine troubleshooting actions
to get back those parameters into ideal
range
 Can describe what are the hazards (high
temp, high pressure, reagents,
radioactive materials)
 Can explain the emergency response
protocol
 Can describe what equipments can’t
bypass (interlocks)
parameters during bridge
 Should interpret what happens during
the trend changes
 Should know what the trends meaning
for the operation
 Should know how operations will be
affected by key process parameters
 Should know critical parameters (density,
temperature, pressure)
 Should know the consequences of
deviation in the critical parameters
 Should know the worst case scenarios
possible in Autoclave & POX area
 Should know the EPRP procedure and
what action should be taken by DCS
 Should know the changes/indicators in
the field or DCS where incident might
happen (sound, vibration, leakage)
 Should know the reason how HIS system
works and shouldn’t change in this part
without approval
 Should know which HIS system is
activated in which area
 10. Mainstream Area Lab Analysis and
relationship to area performance
11. Provide instruction and guidance to field
operators
Main Activities
Competency Element
12. POX Feed Thickener Operation Key
Parameters
 Can describe the results from lab analysis
and change the parameters accordingly
 Can explain how reagents might effect
the performance of mainstream process
 Can explain how often lab results come
and check according to set points
 Can describe the lab results for upstream
which might effect mainstream
 Can describe when to give instruction
(reading parameters and trends).
 Can describe the critical parts when field
operators need guidance to open-close
the equipment (such as christmas tree)
 Can guide operators from shutdown to
start of process or (when shutdown
happens).
 Can desribe when shutdown is necessary
(which equipments cause shutdown:
autoclave, scrubber, thickener, flash
vessel, heater) and why these
equipments are important
Perfomance Criteria
 Can describe bed level
 Can describe optimum PH level (max-2.5
pH, up to 3 pH will effect density)
 Can take action if deviation in PH level
occurs
 Can describe how parameters connect
 Should know what analysis are required
by MS area
 Should interpret of lab results and how it
can affect the process (sulphur & carbon)
 Should know what action can be taken
after interpreting results
 Should know what risks/hazards are
involved during guidance of activities
 Should know which activities are
priorities during start-up and shutdown

Skills and Knowledge
 Should know level of Density (40-45%)
 Should know when to run Floculant flow
(in auto-cascade mode)
 Should know the codes in the DCS screen
(PIC, WIC, FIC, AI, HV, DI, XV, PU, AG, LI,
NI, ZI, TI)

13. Acidulation Feed and By-pass feed
control
14. Throughput ramp up
15. Throughput ramp down
with acidulation tank
 Able to identify all parameters within
feed thickener
 Can take necessary action if the carbon
level deviates
 Can change parameter of WIC
(acidulation to pox feed tank – tph,spt)
and inform the change to field operator
 Can discuss with supervisor for the
decisions made & inform them about
parameters
 Can monitor level of pH in acidulation
tanks and agitator (vibration) level
 Can run the pump for sulfuric acid
 Can run the pump for scrubber
 Can take action to increase tph, check
heaters and increase the GEHO output
manually & inform the supervisor
 Inform ramp-up to field operator and
oxygen plant operator
 Before taking actions inform US and DS
operators about the ramp up
 Can describe the flow from POX surge
tank to autoclave
 Can describe how much amount of slurry
(tonnes per hour) should be decreased
 Upon instruction can decrease slurry in
the feed pump (pump speed) manually
 Communicate with 3rd party about ramp
down (oxygen level)
 After decreasing the level in feed pump
 Should know the troubleshooting
procedures
 Should know where the pumps are
leading and what are their speed &
current
 Should know if there is a deviation in
carbon level of surge tank,
 Should know how parameter change
effects the other parameters
 Should explain the reason when there is
a issue or upset condition
 Should know the limit of tph
 Should know the limit of oxygen plant
 Should know the differences between
auto control pump and manual control
pump
 Should know and able to explain the
connection when there is a change made
in parameters
 Should know what problems would occur
if no ramp down
 Should know & describe why we need to
ramp down (pumps, downstream,
thickener etc.) and talk with supervisor
to understand the reason
 Should know and able to explain the
connection with oxygen mass flow
spreadsheet with ramp down process
and how much you should decrease

16. POX Shutdown for Hot Stand-by
check the LT/HT levels and how the other  Should know how much oxygen gotta be
pumps (LT/HT heater) react decreased
 Decrease the pump level more (2% per
pump)
 After decreasing the pump level (5 mins)
change the Oxygen set point parameter
accordingly
 Refer to SOP No:.... (POX Shutdown for  Should know the reason for shutdown
Autoclave Hot Standby)  Should know all the procedure should be
 Communicate with the field operators done one autoclave at a time (the
and vendors(3rd party if necessary) priority depends on supervision and
 If Shutdown is 30 min above, prepare communication)
draining for HT heaters, LT heaters and  Should know and explain the connection
HT & LT flash vessels with shutdown process and flash vessel
 Prepare Autoclave level – 65-70% and  Should know when to stop all the
can describe the purpose of level auxilaries pumps (gland water
arrangement distribution, hp water pump, purge
 Venting the heaters and flash-vessels to water pump, flash trim pump)
atmospheric pressure
 Open the drain valves of HT&LT heaters
and at the same time front-end pumps
(can describe why we do this)
 Communicate with field operator to
lower the pressure by opening drain
valves HT&LT flash vessels, at the same
time depressurize the back-end pumps
 Monitor all the parameters

17. POX Start-up from Autoclave Hot
Standby
 Refer to SOP No:.... (POX Start-up from
Autoclave Hot Standby)
 Communicate with the field operators
and vendors(3rd party if necessary)
 Confirm all the equipments/elements are
 Should know all the procedure should be
done one autoclave at a time (the
priority depends on supervision and
communication)
 Should know and explain the connection

18. Autoclave heat up and start up from cold
ready and available
 Prepare a checklist for start-up process
 Refer to SOP No:.... (POX Start-up and
Heat-Up from empty state)
 There should be at least 2 DCS operators
during this period
 Communicate with the field operators
and vendors(3rd party if necessary)
 Confirm all the equipments/elements are
ready and available
 Prepare a checklist for start-up process
 Process start with boilers – make sure
you have all the parameters right (diesel,
demin water) and monitor the
parameters
 Refer to SOP No:....(Boiler start-up)
 Check autoclave pressure level (can be
close to zero)
 Communicate with field operator after
arranging Setpoint (SP) to make sure he
does check the parameters in boiler and
condensate the steam line traps
 Pressurize the steam line spargers (6) by
opening the discharge valves – make
sure the oxygen and quench water valves
are closed (can describe why these
valves would be open / interlocks)
 Communicate with field operator to
with start-up process and flash vessel
 Should know when to start all the
auxilaries pumps (gland water
distribution, hp water pump, purge
water pump, flash trim pump)
 Should know what equipments/elements
are needed for start-up
 Should know and explain when is needed
start up process (shutdown,
maintenance connected to autoclave –
scrubber, flash vessel)
 Should know how much time needed to
do heat up (16-20 hours app)
 Should know the reason of close-open
valves / While closing drain valves, you
open bleed valves (describe why we
open these valves – air will come out)
 Should know and be able to describe why
field operators open the steam line
valves gradually – start slow with 20%
(communicate with field operators
continously)
 Should know temperature increase (10C
increase per hour-why we need this slow
process) and steam pressure / steam
table excel control – kpag and
temperature connection while doing
start-up.
 Should know autoclave reach to
optimum temperature (220C) then will
check the parameters (steam flow,
boiler, temperature).
 Should know the current boiler load
 control the steam manual valve  Should know when to fill-up the heaters
accordingly directed by control room  Should know how long it will take for the
operator. reaction starts inside the autoclave
 While doing heat-up , run the agitators  Should know what is the target steam
(6) manually and check with field flow to the Autoclave and to its
operator to keep agitators run smoothly corresponding compartments.
(small valves should be open by them)  Must know the correct Autoclave level
 Ensure agitator speed at 50% prior to agitator start.
 Monitor the quench water valve flow  Should know why it needs to prime all
comes up to 0 (no water goes into Sparger (6).
autoclave discharge line) and wait
around 3 mins to make sure the line is
pressurized
 Ensure pump drain and bleed valves are
closed (communicate with field operator)
 Make sure all parameters are running
correctly before shift to auto-cascade
level
 Increase the agitator speed to 95% for
first 3 then others are to 85%
 Following the trend of autoclave
temperature (till oxygen-slurry reaction
starts)
 Ensure the levels and parameters are
within range before discharge of slurry
(opening autoclave discharge valves)
 Monitor the autoclave level to make sure
parameters are in range
 Check flash tank level and open the flash
tank level control valve (between 2
tanks).
19. POX Start-up from Power Failure.
20. POX Shutdown due to Power Failure
 Refer to SOP No:.... (POX Start-up from
Power Failure)
 Communicate with the Field operators
which equipment to be started first for
POX train start-up. (Instrumentation and
Electrical personnel must be within the
POX MCC Substation).
 Confirm all the equipments/auxilliary
pumps are ready and available.
 Prepare a checklist for start-up process
 Check if Steam Generator (Boiler is
needed to increase the Autoclave
temperature.
 Confirm to Air Liquid plant if O2 is
available after the Power Failure and
ready to supply.
 Reset all the alarm in the DCS screen,
HIS, Console and ready to go.
 Communicate with the Field operators,
Field Supervisor, Shift Engineer for
information dissemination.
 Confirmed the Emergency Diesel
Generator are running.
 Start the Agitator seal water system as
soon as possible.
 Can describe when the Autoclave need
to box-up.
 Can describe the valve position should be
during Power Failure.
 Determine what is the cause of Power
Failure and how long it takes before to
resume by informing the proper
 Should know and describe when to start
the POX from Power Failure.
 Able to explain the importance of proper
communication with Control Room
Operator and Field Operator.
 Should know the priority equipment to
start after power failure.
 Demostrate the importance of using SOP,
Equipment checklist.
 Should know if the Autoclave
temperature can sustain during POX start
without starting steam generator.
 Should know how long the Air Liquid can
supply O2 after the Power failure. (How
many hours).
 To know where to reset the Activated
INTERLOCK, HIS in the work station.
 Should be able to identify which
equipment are connected to the
Emergency Generator.
 Should be able to discuss why the
Autoclave Agitator is the most priority to
start.
 Should know what pressure,
temperature, level of the Autoclave
before to box-up.
 Define the meaning of Fill-open, Fill-
close, and Fill-last in the valve position
during loss of instrument air of loss of
power supply.
 Should know all parameters are within

21. Autoclave cool down and
depressurization to less than 100°C
22. LT feed pumps changeover
department. (Electrical, Contractor,
Deputy Manager).
 Refer to SOP No:.... (Autoclave cool down
to less than 100°C).
 Can figure out how many hours the
depressurization and cooling of
Autoclave takes until 80°C or 85°C.
 Used the steam table when cooling or
heating the Autoclave.
 Prepare the Autoclave level while cooling
down as preparation for heating-up or
dumping when External or Internal work
will carried out.
 Can provide DCS trend showing the
temperature decrease rate, pressure,
level.
 Quench water injection in each
compartment is used depending on
temperature decrease rate.
 Stop the Autoclave all 6 Agitators when
level triggered low-low level setted at
30%.
 Oxygen line (spargers) must be flush with
quench water. (Mandatory).
 Can show where LT feed pumps located.
 Speak with field operator first to confirm
if gland seal manual (on field) valve is
the limit if Power resume.
 Able to decide if heaters/flash vessels
level need to drop depending Power
availability.
 Should know the importance of using
SOP, checklist in cooling the Autoclave.
 Should know what is the cool down rate
of Autoclave should be.
 Define the importance of using the
steam table while heating or cooling the
Autoclave.
 Should know that Cooling down and
decreasing level can be done via
Autoclave venting and discharging to
High Pressure Flash vessels.
 Should know how to open and inject
Quench water to the Autoclave.
 Able to determine which Autoclave
compartments needs to inject quench
water. (Current MOC required atleast
15°C increase or decrease rate in cooling
or heating).
 Should know the effect of running
Autoclave agitator at below 30% level.
 Should know the risk of not purging
oxygen sparger with queach water after
used. (Line is pressurised with oxygen
(high concentration).
 There might be an issue with pump –
broken pump or under maintenance
 We change-decrease the LL by 30%

23. HT feed pumps changeover
open and manual drain valve is closed (force won’t be needed) – DCS operation
 Choose either manual or sequence (auto)  Preparation depends on the case
 Manual process is chosen currently (maintenance or urgency)
 Prepare LT Heater set point to 85%  Stop the LT feed pump is around 1 min
because one pump will be in stand-by  We stop one LT feed pump and start
 Open the automatic suction valve other one which operates(called online)
 Open the automatic gland seal valve  Decrease LT Heater should be gradually
(control room) and check the flow switch around 20 min.
(should be on)
 Switch from auto-cascade to manual
control (LT feed pump)
 Decrease the speed of online LT feed
pump to 30% and stop the pump
manually
 Start the stand-by LT feed pump and
open the automatic discharge valve
 Increase the speed of online pump to
85% or the flow rate is greater than 30
cubic meter – it will be arranged
manually from the control room
 Switch from manual to auto-cascade
control
 Decrease LT Heater setpoint to 77%
gradually until see no fluctuation
 Can show where HT feed pumps are  There might be an issue with pump –
 Speak with field operator first to confirm broken pump or under maintenance
if gland seal manual (on field) valve is  We change-decrease the LL by 40%
open and manual drain valve is closed (force won’t be needed) – DCS operation
 Choose either manual or sequence (auto)  Preparation depends on the case
 Manual process is chosen currently (maintenance or urgency)
 Prepare HT Heater set point to 85%  Stop the HT feed pump is around 1 min
because one group of pump will be in  We stop one HT feed pump and start
stand-by other one which operates (called online)
  Open the 2 automatic suction valves and  Decrease HT Heater should be gradually
inlet discharge valve around 20 min
 Open the 2 automatic gland seal valve
(control room) and check the flow
greater than 0.6
 Switch from auto-cascade to manual
control (HT feed pump)
 Decrease the speed of online HT feed
pump to 30% and stop the pumps
manually
 Start the stand-by HT feed pumps and
open the outlet automatic discharge
valve
 Increase the speed of online pump until
PDI shows greater than 220 or the flow
rate is greater than 20 cubic meter – it
will be arranged manually from the
control room
 Switch from manual to auto-cascade
control
 Decrease HT Heater setpoint to 77%
gradually until see no fluctuation
24. GEHO start up  Refer to SOP No:.... (GEHO Priming)  Should know the process of GEHO
 Ensure that GEHO is primed Priming and how long it would take
 Ensure front-end of the GEHO start-up  Should know what is the use of GEHO
 DCS operator can operate either in (GEHO – Autoclave feed pump (slurry))
manual or sequence (auto) (Manual  Should know the sequence during start-
process is chosen currently) up process
 Refer to SOP No:.... (GEHO Start-Up)  Should know minimum seal water flow
 Switch booster pump control from for all pumps is 0.6 m3/h
manual to auto-cascade  Should know SPT for GEHO minimum
 Set the GEHO speed to 5% and start the suction pressure 550
GEHO  Start up means maintenance is finished /

25. GEHO shutdown
26. GEHO single to parallel operation
 Increase the GEHO speed by 2%
gradually until see no fluctuation
 Refer to SOP No:.... (GEHO Shutdown)
 Decrease both GEHO speed by 2%
gradually (VSD Speed Setpoint) while
decreasing oxygen flow according to
demand (operator’s decision-checking
ratio)
 DCS should let HT & LT Heater levels
reach LL before stop the system
 Make sure oxygen flow is cut after
burning out feed in autoclave
 Should operate both in Control
shutdown (no fluctuation) or emergency
shutdown (immediate)
 Check if the priming in the field is done –
speak with operator
troubleshooting is done
 Should know GEHO’s auxiliaries
equipment and purpose (lubrication
pump, propelling liquid pump, main
motor pump)
 Should know and be able to explain what
the pumps are for and how field
operators check on the pumps (oil level,
flow level, warm-up and speed)
 Should know the parameter limits for
GEHO operation
 Should know the usage of booster pump
– supplying to GEHO (Maintenance can
be done in both GEHO and booster pump
together)
 Should know what ‘no fluctuation means’
– LT and HT feed pump flows are stable,
GEHO discharge pressure is stable
 Should know when needs shutdown
(GEHO pump might be under
maintenance, issue with the GEHO pump
or the booster pump) and how long it
will take
 Should know the affects connected to DS
and US areas (flash tanks, tailings,
autoclave)
 Choose auto or manual SPT based on the
case (system is put on auto system which
can catch up-by design)
 Shutdown can take around 30-45 min
 Single operation: One GEHO works
 Parallel operation: 2 GEHO works
 Speak with field operator first to confirm  Single to parallel: Maintenance of GEHO
if gland seal manual (on field) valve on is finished (possible reason, GEHO
the booster pump is open and manual available)
drain valve is closed  4 MS GEHO – 3 DS GEHO
 Choose either manual or sequence (auto)  Routine maintenance – 8 hours for
 Make sure seal water running (0.8 m3/h operation (from shutdown to start)
ideal) to pump before booster suction
valve is open.
 Open the automatic gland seal valve
(booster pump) and check the flow
greater than 0.6 (match with above
explanation).
 Open the 2 automatic suction valves and
inboard discharge valve (suction of
booster pump).
 Pre-start GEHO
 Switch from auto-cascade to manual
control
 Set the speed of booster pump to 30%
and start the booster pump.
 Increase the speed of booster pump until
SPT (set point) shows greater than 550 –
it will be arranged manually from the
control room (currenty LL is 150kpag).
 Switch booster pump control from
manual to auto – manual set SPT (800)
 Set the GEHO speed to 5% and start the
GEHO.
 When GEHO discharge pressure reaches
same as Autoclave pressure, open
outboard automatic valve
 Increase the GEHO speed by 2%
gradually until see no fluctuation (make

27. GEHO parallel to single operation
28. Steam injection preparation and start up
sure the GEHO speed is same for both)
 Speed up the GEHO which will be
running and decrease other one which
will shutdown
 Gradually speed up by 2% and decrease
other one by 2% (Ex: 85% SPT – 31% SPT
check both pumps level)
 Make sure no abnormalty in other
parameters (vibration etc. Field operator
control)
 When working GEHO reached certain
ideal speed level, continue decreasin
other GEHO till 5% (min.speed)
 Adjust the oxygen flow per demand
while keeping the operation stable (by
checking other parameters)
 Control stop the GEHO pump
 Make sure field operators start POX
Boiler at Low Load (SPT 7 bar)
 Drain condensate from supply header
(manual valves checked by field
operator)
 Make sure of starting pressurization at
steam blowback vessel (pressure of
steam header line and blowback vessel
should be close to each other ex. 7 to 6.9
bar)
 Block valve before steam blowback
should be open after pressure
equalization (done by DCS)
 Condensate from steam blowback vessel
(field operator)
 Maintenance or breakdown might be
reason for one GEHO to shutdown
 2 works to 1 work
 Issue with the GEHO pump or the
booster pump
 Issue with downstream area from GEHO
(flash tanks, tailings, autoclave)
 Control shutdown (no fluctuation) or
emergency shutdown (immediate)
 Steam is needed for heating-up
autoclave
 Steam is coming from POX steam-boilers
(2) / one stand-by and one on duty
(rarely both work together)
 Boiler needs air receiver and diesel day
tank to operator (demineralized water is
needed because of heavy metal usage)
 240-260C is needed for steam generation
 Demin water is put into the hotwell tank
and then it goes to boiler
 Field operators run & check the
equipments in this area and most are
automatically run
 Field operator checks hotwell tank feed
  Equalize the pressure of steam blowback
vessel and header line after blowback
 Condensate draining from the header
line after blowback
 Block valve after steam blowback should
be open after pressure equalization
(done by DCS)
 Increase the boiler SPT (pressure or load-
not fixed but according to demand – max
35 bar)
Normal operation steps:
 Control room operator bridge steam
block valve
 Cut oxygen line to specific sparger (make
sure communicated with supplier)
 Purge specific sparger with quench water
 Check with field operator that all the
manual valves for oxygen-quench water
lines are closed
 Ready for injection / check with field
operator to open hand valve and manual
valve of steam gradually till reaching the
demand required
Shutdown steps:
 No changeover between oxygen to
steam (other steps are sames as normal
operation)
29. Steam shutdown  Check all temperature are stable and
within range (autoclave compartment
220 is target)
 Ask field operator to close hand valve
and manual valve gradually
 When the valves are closed, field
water pump (3) / only one demin storage
tank
 Steam seperators (water and steam are
seperated)
 Diesel tank is needed for firing the boiler
 Operations run in 2 different cases
(complete shutdown-normal operation)
 Steam and oxygen cant be used in the
same line (same for steam and quench
water-safety reasons, flammable mix)
 Bridge is needed when there is a change
between steam to oxygen
 Gradual valve opening is needed so that
interlock system wont be triggered
 Why shutdown – no steam needed
(autoclave temperature is within the
range)
 Whenever there is a shutdown or
maintenance we need the steam for
heat-up

30. Safe changeover from Oxygen to steam
and steam to oxygen injection on same
sparger
31. Oxygen injection start up
operator opens quench water manual  Steam injection is one-time process (not
valves (communicated with DCS) continuous during normal operation)
 Purge specific sparger with quench water  Field operator should be aware of sounds
(no steam in the line) while cooling down of boiler
 Ask field operator to open oxygen
manual valves (ready for O2 injection)
 Initiate the pre-purge sequence for
steam boiler (gradual decrease and
automatic shutdown)
 Control room operator bridge steam  Most preferred sparger is number 2
block valve (because we can make steam distribution
 Cut oxygen line to specific sparger (make easily)
sure communicated with supplier)  Why using quench water? To clear
 Purge specific sparger with quench water residual oxygen from the line (that’s the
 Check with field operator that all the safe procedure)
manual valves for oxygen-quench water  Why change from oxygen to steam?
lines are closed Needed for heat-up
 Ready for injection / check with field
operator to open hand valve and manual
valve of steam gradually till reaching the
demand required
 DCS confirm oxygen plant is running and  Why oxygen injection needed? Burn the
ready to supply sulphur sulphide in autoclave
 Open the valve before oxygen outlet  Oxygen is produced by Air Liquid plant
valve (oxygen supply equilisation valve)  The pressure on the line should be low
gradually differential so that there will be no
 Pressure equalisation – Before and after issue/reaction
Oxygen outlet valve (214XV1376)
 Open the oxygen outlet valve and oxygen
goes through to blowback vessel
 Pressure equalisation – between oxygen
supply and oxygen blowback (open
bypass valve)

32. Oxygen injection shutdown
 Open the valve (143XV1977 – block valve
before oxygen blowback vessel)
 Pressure equilisation – between
blowback and oxygen line header (open
the bypass valve)
 Open the valve (143XV1986) – block
valve after blowback vessel)
 Make sure of header lines are filled with
oxygen by checking pressure transmitter
(close to blowback pressure-ideal 34 bar)
 Check with field operator if the oxygen
line and quench water lines are open /
steam lines are closed
 Manual valves are open for quench and
oxygen / proceed with purging of all
spargers
 Ready for oxygen injection
Complete shutdown scenario:  Why shutdown – autoclave shutdown
 Make sure feed is completely stopped  2 scenarios – one is complete shutdown,
(GEHO pumps). second is changeover oxygen to steam
 Make sure material in the autoclave  Autoclave depressurize – remove all the
should be burnt out. fluids from the lines / takes 16 hours (10
 Close all the oxygen block and flow degrees per hour)
valves.
 Purge all spargers with quench water (no
oxygen should be left in the lines)
Injection Shutdown in 2 different ways:
 Autoclave depressurize (depressurize
oxygen blowback and other all fluids by
closing/opening valves)
o Quench water – manual (close
quench water 2 isolation valves
and open bleed valve)

33. Oxygen blowback vessel pressurization
and depressurization
34. Oxygen and steam injection on various
spargers at the same time
o Steam – manual (close 2 isolation
valves and open bleed valve)
o Oxygen – DCS (close block valve
VX1977 before oxygen blowback)
o Inform MS field workers about
start venting oxygen blowback
(evacuation) then opening
oxygen blowback vessel valve
PV1985 gradually until pressure
reaches zero
 Autoclave box up (close all autoclave
feed line – slurry, oxygen, quench and
steam and outlet line – discharge lines)
 Refer to SOP No:.... (Oxygen blowback
vessel pressurization and
depressurization).
 Communicate with Field Personnel
(Operation, Maintenance, Contractors)
for the Pressurization activity.
 Determine that no active activity,
isolation within the Oxygen blowback
vessel and parts.
 Identify which valve need to open during
pressurization.
 Identify all the interlock in the DCS
Console and DCS Screen with regards to
Oxygen Blowback vessel.
 Communicate with Field Supervisor that
no personnel inside the POX building
during O2 blowback pressurization.
 Proper communication with Field
Operator and Field Supervisor for proper
valve line-up.
 Should know the Oxygen Hazards when
not properly handled.
(Oxygen does not burn. It is not
flammable, but it is an oxidizer. Oxygen
feeds fire, so it's dangerous to use
around something that is burning
because it will help the fire burn much
more quickly).
 Gradual pressurization in blowback
vessel is recommended via the bypass 1
inch line.
 Oxygen Automated control valve cannot
actuate if active interlock is/are active in
the DCS.
 As per SOP, nobody inside the POX
building during O2 pressurization.

 Can describe the risk/hazards when
operating steam/oxygen and quench
water.

35. Mainstream water balance control
36. Decant thickener operation key
parameters
 Ensure to flush the spargers with quench
water before introducing Oxygen.
 Ensure to flush the spargers with quench
water before introducing Steam.
 Ensure the spargers are primed with
quench water after maintenance work.
 Bridge the Steam valve when injecting
steam with approval from Shift Engineer.
 Boiler pressure vs Autoclave pressure
should be monitored.
 Boiler pressure vs Autoclave pressure
must be monitored to avoid the Interlock
to activate.
 Can described the water balance in
mainstream area.
 Can described the effect of improper
water usage in the system.
 Described the flocculant vs dilution water
ratio.
 Can describe the thickener rake
operation.
 Can describe the Auto-cascade operation
of Decant underflow pump.
(Steam and Quench water is unsafe)
(Steam and Oxygen is unsafe)
(Oxygen and Quench water is safe)
 Should know the importance of flushing
the spargers with quench water prior to
inject steam nor Oxygen.
 Should know the importance of priming
the spargers with quench water prior to
inject steam nor Oxygen specially if from
maintenance work.
 Opening the steam valve without
bridging it can result to HIS interlock of
all Spargers to close.
 Should know the PDI of boiler to
Autoclave pressure to avoid sudden
closing of Steam blowback dischage valve
due to activated interlock.
(PDI ≤300 kpag steam blowback vessel
oulet valve to close)
(Sudden pressure swing in main header
line ≥3700 kpag PSV of boiler released).
 Proper water usage in the Mainstream
contribute high efficiency in plant
operation.
 Should know that proper water balance
contribute less consumption in-terms of
reagents consumption.
 Understand the effect of over
flocculation.
 Should know the rake high limitation.
 Manage the rake mechanism movement
function: (forward-backward-down).
 Explain the function of Semi-Auto, Auto,

37. POX Shared Utilities Knowledge
38. Autoclave Agitator Seal System Start-up
39. Autoclave Agitator Seal System
Shutdown
40. POX Emergency Shutdown due to sudden
loss of oxygen
 Can balance the flow from decant
thickener overflow to acidulation tanks
and POX feed thickener overflow tanks.
 Monitoring the Thickener underflow
density.
 Describe the equipments in the POX
shared utilities.
 Communicate with Field Operator when
to start the boiler.
 Can describe the function of Steam
Generation in the POX operation.
 Can determine the level of
chemical/reagents use in Demin area.
 Communicate with Field Operator to
check the line-up of Flush/Emergency
water system, Cooling water system,
buffer fluid system.
 Ensure that seal water tank level is
enough before starting the pump.
 Advise to bleed all the compensator for
possible trap air.
 Communicate with Field Operator before
to stop Agitator seal system.
 Can initiate agitator seal system
shutdown safely.
 Notes the closing of spargers and
discharge valve of O2 blowback vessel.
 Ramps down Trains to minimum
 Advise Downstream Control Room
Operator that throughput will be ramped
down.
Manual, Local/Remote, Int/Ext, Stop.
 Understand the effect of low density and
high density in downstream area.
 Understand the requirements before to
start the Steam generator (boiler).
 Able to discuss the requirement of
demineralised water into the boiler. (ph,
conductivity).
 Know the function of Demin plant and
uses in POX operation.
 Understand the importance of
chemical/reagent in demin area.
 Understand how the seal water system
works in the Autoclave agitators.
 Understand the desired Flush seal
minimum flow on each agitators (0.28
l/min).
 Should know how the compensator
works.
 Able to describe when to stop the seal
water system.
 Know how the buffer fluid refill system
mixed. (glycerin + demi water)
 Fully understand the effect of Oxygen
loss into the autoclave with respect to
temperature and pressure.
 Can communicate effectively with Air
Liquide for proper coordination.
 Aware of the risks and hazards of venting
  Call Air Liquide to get information on the Oxygen Blowback vessel.
when the O2 supply will come back.  Knowledgeable on the purpose of
 If O2 loss is unable to come back by 10 equalizing Oxygen line and blowback
minutes, decide to shutdown both pressure.
Trains.
 Stops LT feed pumps, then stops HT feed
pumps and GEHOS on LL level interlocks.
 Monitor flash vessel level and flash trim
flow.
 Observe Autoclave level, if not holding,
box up by closing secondary MOGAS
discharge valve.
 If Blowback vessel has high pressure
>3500kPag, gradually open vent to
equalize.
 Constantly communicate with Air Liquide
for start up update.

41. POX Autoclave Discharge Line
Pressurization
 Checks that QW pumps are running with
enough pressure (at least ~300kPag
greater than autoclave pressure).
 Communicate with Field Operator to
open manual vent valve of the clave
discharge line.
 Opens the auto vent valve in the DCS.
 Ensure drain manual valve is closed.
 Force interlocks on the QW injection
valves with the MOGAS discharge valves
to allow water injection while the clave
discharge valves are in close position.
 Inject water gradually with an initial
opening of 2%. Increase opening until
flow reaches 10m3/hr.
 Can decide when there’s a need to
pressurize autoclave discharge line.
 Able to do pre-checks of the essential
valves and instruments involved prior to
pressurization.
 Understands the hazards associated
during line pressurization.
 Understands why the line should be filled
up and pressurized.
 Should be mindful enough on bridging
and removing interlocks.

42. Manage Boiler Pressure Controller
43. Scrubber system operations
44. Caldera Valve Control
 Confirm flow in the vent line.
 Once flow is confirmed coming out of the
vent line, inform Field operator to close
discharge line vent manual valve.
 Close QW auto and control valves in the
DCS.
 Remove forced interlocks.
 Communicate with Field Operator for the
desired Boiler pressure.
 Can take action immediately when
pressure abruptly increase.
 Proper monitoring of scrubber system
and the water condition in Scrubber tank
must be clear.
 Frequent stroking of the the dampener
(1 x per shift including counter weight)
 Correct water flow setpoint in rod deck
and venturi.
 Can take action immediately when
pressure increase in the Scrubbers.
 Can describes the power drive of Caldera
valve.
 Can take action immediately when valve
is in stuck position.
 Can shows the Caldera valve trend in
DCS.
 Able to set pressure controller based on
Autoclave pressure.
 Understand how the pressure control
valve works.
 Should know the limitation of pressure
controller based on PRV rated capacity.
 Aware of the pressure limitation in
dampener to avoid shut of Oxygen flow
valves.
 Understand the function of venturi
scrubber.
 Understand the function of Safery
scrubber.
 Understand the Manual and Automatic
operation of Caldera valve.
 Can describe if the Caldera is working
normal based in Output and valve
Feedback.
 Understand the importance of Caldera
valve in the POX system and the severity
of damage during mis-operation.
 Caldera valve operation is always in Auto
mode.

45. Agitator Mechanical Seal System
46. POX Ekato agitator system knowledge
 Ability to check the mechanical seal
temperature in the DCS.
 Can describe the purpose of agitator
mechanical seal system and its
subsystem (buffer fluid,flush/emergency
and cooling).
 Can identify the importance and safety
issues of the agitator mechanical seal
system and its subsystem
 Manage the level of seal water tanks.
 Proper monitoring of seal flows in each
agitators.
 Can take action if agitator HIGH vibration
switch activited.
 Can describe the function of POX Ekato
agitator system.
 Can identify the importance and safety
issues of POX Ekato agitator system and
its subsystem (buffer
fluid,flush/emergency and cooling).
 Understand the Caldera profile if the
plug is passing or broken.
 Should know the impact in Operation
when Mechanical seals damaged.
 Should know and understand the
indication of mechanical seal failure.
 Should know the potential effect on the
agitators.
 Should know how to respond,
troubleshoot and interpret the alarm
fault of agitator mechanical seal system
and its subsystem associated with the
procedures.

 Understand the Rated power of 6
agitators.
 Should know the flow too-low limit of
flush water in the agitators.
 Understand the purpose of Agitator in
Autoclave operation.
 Understand the all the Interlocks and HIS
of Agitator.
 Should understand the start up,
operational and shutdwon procedures of
Ekato agitator system.
 Should know how to interpret the alarms
on level switches associated with
vendor’s manual.
 Should understand how pressure
compensator works especially during
autoclave pressure fluctuations.

Trouble Shooting Activities
Competency Element
47. React immediately, properly make
decisions, and stabilize on sudden upset
condition on heaters, autoclave and flash
vessels to prevent shutdown
48. Abrupt decrease in GEHO HP Air
Compressor Pressure
49. Sudden Loss of GEHO HP Air Compressor
Pressure
Performance Criteria
 Information dissemination to Field
Operator of sudden upset.
 Can take action immediately when
sudden upset happen and stabilise the
system.
 Identify immediately the cause of upset.
 Knowledgeable how to control the
Oxygen pressure while starting the
system.
 Immediately inform the Field Operator
for decreasing HP air compressor and
check the main HP Compressor.
 Identify the cause of decreasing pressure
in compressor.
 Immediately inform the Field
Operator/Maintenance personnel for
sudden loss of HP air compressor.
 Prepare to happen that Geho’s will trip
due to Compressor pressure low
interlock.
 Immediately start the system after
compressor pressure resume.
 Should know when to use the manual fill
up through hand pump operation.
Skills and Knowledge
 Able to start the the system safely.
 Able to identify the safe pressure settings
of heaters, autoclave and flash vessel.
 Able to identify the safe temperature
settings of Autoclave.
 Able to identify the correct heaters level
in starting the pumps to avoid low level
activated.
 Understand the effect of high Oxygen
concentration in the Autoclave and its
hazards.
 Understand the function of air
compressor in Geho pumps.
 Able to check the level transmitter in
suction/discharge air vessel of Gehos.
 Should know the interlock for pressure
low limit of HP air compressor for
tripping of gehos.
 Able to manage the Autoclave pressure
and temperature.
 Able to manage the pressure of
heaters/flash vessels safely.
 Able to manage the temperature of
Autoclave after tripping of gehos.
 Understand the Compressor and
Autoclave differential pressure interlock
  Inform Field Operator to check the valve
line-up to Gehos.
 Inform Field Operator to check the
Compressor for any alarm and reset.
50. Tripping of GEHO  Stabilize Heater levels by decreasing SP
ato avoid HH levels or by gradual
increase of the other running GEHO.
 Decrease of O2 injection as required.
 Inform Aır Liquide.
 Inform Field operator of the trip.
 Advise field operator to check alarms in
the PLC.
 Investigate thru DCS trends the reason
for upset.
 As soon as root cause is identified and is
safe to retart GEHO, advise field
operator.
 Restart GEHO and adjust O2 injection
accrdingly as required.
51. Sudden closing of Autoclave discharge Outboard A valve:
valve  Attempt to reopen the valve.
 If unable to open, inform field operator
and instrumentation.
 Start ramping down GEHOs to minimum
speed; adjust O2 accordingly.
 Inform Air Liquide.
 If autoclave level gets to 86% and valve is
still unable to open, initiate shutting
down of feed.
Inboard B valve:
 Do not attempt to reopen the valve after
activation.
 Able to react immediately with presence
of mind to able to do the first step when
GEHO trips.
 Able to manage Heaters level during the
upset.
 Able to identify the root cause prior on
restarting GEHO.
 Able to efectively communicate with
field operator and Air Liquide during the
upset.
 Able to know the reason behind the
importance of pressurizing discharge line
prior to opening the inboard valve.
 Able to react and decide on ramping
down during the upset.
 Able to manage Heater levels and
pressures during the ramp down.
 Able to communicate effectively with the
field operator, instrumentation
personnel, and Air Liquide during the
upset.
 Able to independently decide when to
shutdown the feed to the autoclave.

52. Sudden tripping of POX Thickener rake
53. Sudden tripping of Decant Thickener rake
initial closing.
 Close the outboard valve and HP caldera.
 Inform field operator to prime discharge
line.
 Ramp down GEHOs to minimum.
 After discharge line is pressurized,
attempt to open the valve. Note that
instrumentation should be around during
the reopening.
 If unable to open, initiate feed shutdown
when level gets to 86%.
 Advise field operator and  Knows how to operate the rake in
Instrumentation to check alarms in the manual thru DCS panel.
PLC.  Knows the torque settings of the rake.
 Gradually ramp down feed and wash to  Knows the operating set point of the
the thickener. rake.
 After field and instrumentation advise,  Knows the purpose of the auxilliaries of
attempt to raise the rake to maximum if the rake.
accessible in DCS, otherwise, have field  Acknowledge the different scenarios
operator to raise it via PLC. when rake can be bogged.
 If unable to raise, stop feed to the
thickener.
 If raised, attempt to restart the rake.
 Check the DCS trend of the rake for  Knows how to operate the rake in
possible cause of trip. manual thru DCS panel.
 Advise field operator and  Knows the torque settings of the rake.
Instrumentation to check alarms in the  Knows the operating set point of the
PLC. rake.
 After field and instrumentation advise,  Knows the purpose of the auxilliaries of
attempt to raise the rake to maximum if the rake.
accessible in DCS, otherwise, have field  Acknowledge the different scenarios
operator to raise it via PLC. when rake can be bogged.
 If unable to raise, stop feed to the

54. Sudden tripping of Autoclave Agitator
55. Tripping of Double Pumps
thickener by stoping the feed from the
Autoclave by the approval of Managers.
 If raised, attempt to restart the rake.
 Inform Field Operator to check the actual
condition of agitator prior to start.
 Identify the reason for tripping of
Agitator.
 Can show the trend of flush water flow
and vibration indicator in the DCS.
 Restart the Agitator if no issue found.
 Identify interlock that may have caused
the trip of double pumps wether it is
high or low LT/HT level, pump problem
like VSD fault, valve switch or low
flowrate, etc.
 Decrease the LT feed pumps speed or LT
level to prevent high level trip of LT
 Restart the double pumps
 Communicate with field operator if any
abnormalities were observed ex.
(leakage, cut v-belts, leak at mechanical
seal) and contact Mechanical team
 Communicate with Instrumentation for
any transmitter or valve
 Communicate with Electrical team for
VSD fault or tripped feedback alarms
 If any leakage is observed or unable to
restart, changeover to standby double
pumps
 Check if HP seal water pumps have
enough pressure and flowrates
 Ramp down the Geho speeds to slow
 Able to monitor the pressure of
Autoclave when agitator tripped while
Oxygen is injected.
 Knows all the interlock/HIS related to
Autoclave agitators.
 Able to check the seal water supply
system, all parameters within normal
condition.
 Know the interlocks that will be activated
as an effect when double pumps trip
 Know the required pressure and
flowrates of HP seal water pumps
 Know how to changeover double pumps
as per SOP
 Able to identify possible double pumps
problems through trends and monitoring
 Able to react quickly on upset condition
and adjust the correct paramater
 Able to manage heater levels
 Ability to decide when Geho needs to
shutdown
 Knows which departments should be
informed or communicated in relation to
the upset condition (Electrical,
Mechanical, Instrumentation, Air Liquide)
 Able to set the Autoclave within
parameters despite the upset condition

56. Tripping of LT Feed Pumps
down the decrease of HT level
 Shutdown may be necessary if heater
levels are too low
 Adjust Autoclave accordingly but at the
same time ensure temperature and
pressure are within parameters
 Check if any HIS alarms are activated and
reset
 HT pressure may increase due to Geho
ramp down, increase bleed as necessary
 If HT pressure is decreasing too fast,
decrease bleed
 Communicate with Airliquide on the
sudden decrease of oxygen consumption
 Identify interlock that may have caused  Through proper monitoring of trends,
the trip of LT Feed pumps wether it is able to detect if there are abnormalities
high or low LT level, pump problem like of the pumps through parameters
VSD fault, valve or low flowrate. monitoring like currents and speed
 Quickly analyze if it is necessary to ramp  Able to stabilize heater levels on upset
down Geho speeds and adjust oxygen to condition
Autoclave accordingly while observing  Know the effect to autoclave on sudden
temperature and pressure reduced feed
 Changeover to standby LT feed pump if  Troubleshoot the problem and prevent
necessary shutdown
 Decrease HT level set point to decrease  Know the interlocks that will be activated
the speed of double pumps thus slowing as an effect when LT feed pumps trip
down the decrease of LT level  Know the HIS system and interlocks
 Check if any HIS has been activated and  Able to stabilize the Autoclave on sudden
reset ramp down of feed and oxygen
 Communicate with field operator for any  Able to changeover LT feed pumps based
abnormalities at the field ex. (leakage, on SOP
instrument air leakage on valves)  Ability to decide when shutdown is
 Communicate with designated necessary

57. High pressure for HT and HP vessels
58. High Pressure for LT and LP vessels
department if instrument or equipment
problem like VSD fault (Electrical)
 Decide whether Geho shutdown is
necessary
 Analyse the cause of high pressure in HT
Heater and HP Flash vessel.
 Can show the trend of Autoclave
pressure, HT Heaters, Flash vessel.
 Check the Autoclave discharge caldera
valve position as a source of pressure
swing in the system.
 Check the LP Flash vessel Caldera valve
setpoint and valve feedback should be
the same.
 Communicate to the Field Operator for
any abnormalities in field.
 Can able to detect and respond any LT
Heater and LP Flash Vessel high pressure
condition as quick as possible.
 Can able to determine the possible cause
of the upset condition.
 Can able to direct Field Operator to
conduct field verification regarding
pressure transmitter readings, actual
scrubber rod deck dampener opening,
actual condition of vent scrubber.
 Can able to direct field operator to
conduct dampener stroking, to prevent
any scale build up in scrubber
dampeners.
 Can able to troubleshoot and regain
situation back within operating range by
 Should know the limitation of pressure in
the heaters/flash vessels.
 Know how to stabilize the pressure in the
system including levels of heaters.
 Able to check the performance of the
double pumps, Autoclave feed pumps.
 Able to check the design pressure
setpoint in the system.
 Able to check the pressure transmitter
both in heaters/flash vessels must
working properly.
 Should know LT Heater and LP Flash
Vessel normal operating range pressure.
 Should know what are the implications if
LT Heater and LP Flash Vessel pressure is
higher than normal operating range such
as interlock activation, and equipment
failure.
 Should know pressure and temperature
relationships in closed vessel system.
 Should know how pressure control works
in LT Heater and Flash Vessel.
 Should know how to determine wether
pressure indicator gives true or false
reading.

59. High difference between OP and FBK for
Caldera Vent and Level valves
60. High Scrubber Dampener differential
pressure
adjusting scrubber rod deck dampener
opening.
 Check the DCS faceplate if it is in auto or
local.
 Inform Field Operator to check the actual
opening in field.
 Advise field operator to check the alarm
in the panel and reset it.
 Ask instrumentation personnel for
calderas calibration and stroking with
minimal effects in an operation.
 Analize and check for possible line
blockage.
 Reduce tonnage if necessary for trouble
shooting.
 Check any fluctuations of parameters in
front-end, back-end and autoclave area.
 Check the trend for the abrupt increase
of pressure and if the scrubber high level
switch is activated.
 If activated, confirm to field operator the
scrubber status or condition and look for
any leakages. İf unusual and quite,
baricade the area and escalate to
supervisors.
 If confirm, Prepare for the emergency
shutdown and advise to evacuate the
area.
 If normal, advise field operator to
visiually check the actual dampener
opening and conduct dampener test.
 Ask instrumentation personnel for
 Should know the condition or status of
the calderas in normal operation (in auto
or local).
 Should know the normal opening of the
calderas for the specific tonnage.
 Ability to recognize the impact when the
calderas will suddenly close.
 Should know how to assist and advise
the instrumentation personnel for
manual calibration without stroking the
calderas.
 Should know how to operate in manual if
necessary.
 Should know how to identify and gather
the data before declaring emergency
shutdown.
 Should know the reliability of the presure
transmitters.
 Should know the operating ranges of
dampener differential pressure.
 Should anticipate the increase of
dampener pressure may lead to increase
of LT pressure thus HIS activation or
equipment failure if higher than normal
operating pressure.

61. Low level of Clean Water Tanks
62. Low EKATO cooling, flush, buffer fluid
tanks
dampener calibration and transmitter
cleaning.
 Ramp down operation and observe for
any changes of the dampener differential
pressure.
 Can able to determine and respond to
low level situation of Clean Water Tanks
before any interlock condition activates.
 Can able to distinguish the reason for
upset condition.
 Can able to direct Field Operator to
check filter system in Demin Water Plant
as a source of the water going to clean
water tank and restart the system.
 Can able to direct Field Operator to
ensure all manual valves are open,
automatic valves working properly, lines
are clear if there is no flow going to Clean
Water tanks after Demin Water Plant
Multimedia and Carbon filter is already
running.
 Can able to determine the actual
consumption of clean water vis-a-vis the
actual supply.
 Advise field operator to check the line up
and verify the level in field.
 Choose either manual or auto fill up.
 In auto fill up refer to the vendors
manual refill system;
 Refer to SOP no. ..for Buffer fluid refill
system.
 Refer to SOP no. ..for Cooling water refill
system.
 Should know clean water tank normal
operating level range, low level value and
low low level value.
 Should know the consequences once
interlock is activated because of low low
level and what is it’s implication to
eqipments.
 Should know where is clean water source
and where it will be used.
 Should know how to determine wether
level transmitter is giving correct reading
or not.
 Should be familiar the SOPs of vendor’s
manual.
 Should know the DCS operating system;
permissives, interlocks, level ranges and
alarms.
 Should aware the reliability of the level
transmitters.
 Should be familiar the line up in field
especially the additional modified pump

63. Autoclave Agitators high vibration alarms
64. Low Raw Water tank level
65. Low Raw Water transfer pumps
discharge pressure
 Refer to SOP no. ..for Flush and
Emergency refill system.
 during fill up of cooling and flushing
 Analyze the cause of alarms.
 Advise field operator to confirm in field.
 Decrease agitator speed and corrolate a
current, torque and power.
 Ask mechanical personnel for the
intensity and instrumentation personnel
for the transmitter.
 Reduce the oxygen, quench water or
steam addition in the designated sparger
line.
 Close the designated automatic sparger
valve if necessary and check any
changes.
 Stop and restart agitator if necessary to
prevent bogged.
 Check raw water transfer pumps and
well water pumps.
 Inform shift engineer and area supervisor
about the problem.
 Inform raw water users to decrease
consumption wherever possible if
troubleshooting takes time.
 Temporarily change raw water users’
supply from raw water to process water
if possible.
 Advise area supervisor to check in the
field the status of the pumps and
discharge lines.
 If no issues with the lines, advise the field
use to refill the buffer fluid tank.
 Should know what to do incase no flow
tanks due to common pipe and elevation.
 Should know the DCS operating system;
agitator permissives, interlocks, alarms
and HIS system.
 Should know how to determine the
cause of alarms and the implications if
the alarms continue.
 Should aware the reliability of the
transmitters.
 Should know the incremental increase of
oxygen, quench water or steam addition
and agitator speed in the designated
sparger line.
 Should know the utilities which are
supplying the raw water.
 Should know raw water users.
 Can lead troubleshooting of common
raw water issues in DCS such as faulty
level transmitter, high supply discharge
pressure, low raw water transfer
currents, etc.
 Should know the effect in the process
plant if cannot recover the level.
 Should know the possible causes and
effects of raw water transfer pumps low
discharge pressures.
 Should know the HH and LL limits/

66. Loss of flocculant supply for POX/Decant
Thickener
67. High bed level for POX/Decant Thickener
68. High Torque but low density for POX
thickener
operator to gradually decrease discharge
valves’ opening.
 Monitor pumps’ current while
troubleshooting is on going.
 Check the cause of the loss of flocculant
supply ( flocculant pump VFD fault, low
level of flocculant storage tanks, leak in
the line).
 Assess/estimate how long the flocculant
loss will be.
 If the loss of flocculant takes time,
decrease to stop feeding into the
thickener.
 Adjust underflow rates accordingly.
 Confirm with the field operator’s bed
level reading.
 Check torque, bed pressure, and
densities reading.
 Increase underflow rate if bed pressure,
torque, and density are increasing.
 If torque and density are decreasing,
decrease feed flow and increase
flocculant.
 Inform field operator to check the bed
level.
 Check the flocculant ratio.
 Inform the Field Supervisor if the
flocculant plant is working normal.
 Inform Field operator to check the
turbidity of overflow.
 Check the Free-acid in the mixing tank.
 Check the ore feed analysis and inform
interlocks setting of the raw water
pumps discharge pressure.
 Should be familiar with the common
causes of the loss of flocculant.
 Should know the importance of
flocculant in the thickener.
 Should be able to assess, react and
decide accordingly with the time
duration of the flocculant loss.
 Should know the normal operating bed
level of the thickener.
 Should know how to corollate the
torque, bed pressure and densities,
 Should be familiar with mass balance
approach.
 Should know the operating parameters
of thickener rake mechanism and its
limitation.
 Able to discuss the effect of low density
and high density in the POX operation.
 Should know the immediate action for
the issue.
 Know the mass balance of the thickener.
(Feed tph vs Drawout tph).

69. POX operations during carry over
Shift engineer in-charge.
 Check the underflow pumps flowrate and
the density meter if same as the sample
density result.
 Decrease the feed rate until the torque
back to normal while stabilising the
underflow density.
 Frequent ask Field operator for the
feedback of thickener condition.
 Check the level of heaters and flash  Should know the operating parameters
vessels. of heaters and flash vessels.
 Advise field operator to check the clarity  Should know the Heaters and Flash
of water in the scrubber tank. vessels transmitters and calderas are
 Advise field operator to distinguish the working properly.
carry over either oxidized or non-  Should be certain that the carry over is
oxidized. oxidized or non oxidized.
 İf non oxidized, divert sump pumps and  Should know how to troubleshoot the
seal water return of double pumps to issue.
decant.  Should know the consequences of the
 İf oxidized, increase choke flow ratio and carry over in scrubber system.
trim flow ratio.
 Reduce tonnages
 Monitor the carry over frequently.
Competency Assessment

Competency Element C NY Mentor Incumbent

C
1. Mainstream process and flowsheet
2. Process Control Loops
3. Permissives and Interlocks
4. Bridges and Forces
5. DCS Trend Configuration
6. Key Process Parameters for POX Area
7. Hazards associated with the
Mainstream Area
8. HIS System
9. Mainstream Area Lab Analysis and
relationship to area performance
10. Provide instruction and guidance to
field operators
11. POX Feed Thickener Operation Key
Parameters
12. POX Feed Thickener Operation Key
Parameters
13. Acidulation Feed and By-pass feed
control
14. Throughput ramp up
15. Throughput ramp down
16. POX Start-up from Autoclave Hot
Standby
17. POX Shutdown to Autoclave Hot
Standby
18. Autoclave start up and heat up from
cold
19. POX Start-up from Power Failure
20. POX Shutdown due to Power Failure
21. Autoclave cool down and
depressurization to less than 100°C
22. LT feed pumps changeover
23. HT feed pumps changeover
24. GEHO start up
25. GEHO shutdown
26. GEHO single to parallel operation
27. GEHO parallel to single operation
28. Steam injection preparation and
start up
29. Steam shutdown
30. Safe changeover from Oxygen to
steam and steam to oxygen injection
on same sparger
31. Oxygen injection start up
32. Oxygen injection shutdown
33. Oxygen blowback vessel
pressurization and depressurization
34. Oxygen and steam injection on
various spargers at the same time
35. Mainstream water balance control
36. Decant thickener operation key
parameters
37. POX Shared Utilities Knowledge
38. Autoclave Agitator Seal System Start-
up
39. Autoclave Agitator Seal System
Shutdown
40. POX Emergency Shutdown due to
sudden loss of oxygen
41. POX Autoclave Discharge Line
Pressurization
42. Manage Boiler Pressure Controller
43. Scrubber system operations
44. Caldera Valve Control
45. Agiataor Mechanical Seal System
46. POX Ekato agitator system
knowledge
47. React immediately, properly make
decisions, and stabilize on sudden
upset condition on heaters,
autoclave and flash vessels to
prevent shutdown
48. Abrupt decrease in GEHO HP Air
Compressor Pressure
49. Sudden Loss of GEHO HP Air
Compressor Pressure
50. Tripping of GEHO

51. Sudden closing of Autoclave

discharge valve
52. Sudden tripping of POX Thickener
rake
53. Sudden tripping of Decant Thickener
rake
54. Sudden tripping of Autoclave
Agitator
55. Tripping of Double Pumps

56. Tripping of LT Feed Pumps

57. High pressure for HT and HP vessels

58. High Pressure for LT and LP vessels

59. High difference between OP and FBK
for Caldera Vent and Level valves
60. High Scrubber Dampener differential
pressure
61. Low level of Clean Water Tanks

62. Low EKATO cooling, flush, buffer fluid

tanks
63. Autoclave Agitators high vibration
alarms
64. Low Raw Water tank level

65. Low Raw Water transfer pumps

discharge pressure
66. Loss of flocculant supply for
POX/Decant Thickener
67. High bed level for POX/Decant
Thickener
68. High Torque but low density for POX
thickener
69. POX operations during carry over