LOTTE PAKISTAN PTA UTY Plant Operating ProcedureT-11 UTILITIES PALNT ETP plant (Revision: 01)

NameSignatureDate

AuthorMuhammad Ismail

Reviewed ByRehan Siraj

Table of Contents Page No.

1. Buffer storage Area 032. Neutralization Area 093. Feed tanks Area (A1-2504A/B/C) 134. Feed chiller Package (Z1-2578) 155. Deep shaft package (Z1-2538) 266. Deep shaft operation procedure 287. Air Compressor (C1-2527A/B) system 318. Degasser (A1-2510A/B) system 359. Clarifier (A1-2511A/B) system 3810. Tertiary treatment Package 4211. Sludge Handling Package Z1-2549 48

1. BUFFER STORAGE SYSTEM SCOPEThis 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.

2. EFFLUENT STORAGE IN BUFFER TANKS 1.1. INITIAL CHECKS1. Check all PTW are completed and duly signed off.2. Physically check all equipment for mechanical jobs completion. 3. Ensure all slip plates are in proper position and all drains are closed. 4. Check all instruments are in place and on line.5. Check availabilities of utilities like:a. Instrument air b. Seal water for transfer pumps c. Potable water supply in safety shower4. Check that FT-5001, FT-5008, FT-5021 and Ft-5024 are normal.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.

6. Checks tank is ready to take the effluent.3. NORMAL OPERATION1. 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.4. EFFLUENT COLLECTION DURING PLANT SHUT DOWN5. 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 its flushing than take the sport sample of the both streams Mother Liquor and waste water from IBCs 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.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.5. SHUT DOWN OF THE BUFFER TANKS: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/DList of the equipment to be utilized for the cleaning of the buffer tanks

S#EquipmentsQuantity

1. Crane01

2. Clamp Bucket 01

3. Dump Trucks2

List of the manpower required for the buffer cleaning purposeS#ManpowerQuantity

1Supervisor1.

2Rigger2.

3Assistant Riggers/Helper3.

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 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 PPEs 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 contractors man-hours inspection will be done in time.6. BUFFER TANK CLEANING PROCEDURE WITH CRANE1. 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.9. No sludge should fall on any person 10. Standard safety instructions for crane working must be followed.11. The loaded dumpers will be weighed as per instructions sheet PTA Management, which would be basis of sludge load calculation. Daily verification sheet be submitted along with the invoice.12. Having loaded the dumper the empty bucket to be lowered down the ground and dumper would be off loaded to desponding area.13. Inside plant the dumper speed should not to exceed 25 km / hr.14. The work site housekeeping must be carried out daily on closing the crane activity by Descon.15. Crane boom will be assembled near the PTA engineering workshop area with the assistance of PTA hydraulic crane.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.

2. Feed Neutralization System1. INTRODUCTION: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. STARTUP OF THE NUTRALIZATION SYSTEM INITIAL CHECKS:1. Check that all PTWS are signed off.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 utilitiesi. 47 % caustic soda.ii. Seal wateriii. Cooling wateriv. Instrument airv. Portable water for the Safety shower9. Check that QT-5027/28/30/31 are available and calibrated.10. Check that LT-5032 is working normal and its stroke checks completed.11. Check that G1-2503A/B area available.12. Check that overflow line towards buffer tank is de-isolated 13. Check that mother liquor line to F1-2508 is slip plated.14. Check that CRU soda ash supply is offline. 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 STARTUP1. 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 PROCEDURE1. 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 standby5. NORMAL OPERATION: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 failure6. 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.

3. Neutralized Feed Storage System1. Introduction:Neutralized and cold deep shaft feed is stored in the batch tanks A1-2504A/B/C. In A1-2504A/B/C this feed is further circulated for cooling and mixing purpose. There are three tanks in this area; each has working volume of 1350 M3. Neutralized feed is transfer in the batch tank where its sampling of the COD and pH is carried out. If COD and pH are matching the required value ( i-e, 2 mg/l, adjust the air flow using the air compressor inlet guide vanes to its correct operating value of 4581 Nm3/hr.9. Confirm the deep shaft is now circulating at its normal operating point.2. Normal operation of the deep shaft1. Check the color of the effluent in the deep shaft head tank A1-2547, if the color is blackish increase the WAS flow rate.2. Check air flow and adjust by maintaining the dissolves oxygen in the head tank A1-2547, if it is less than 2 PPM then increase air flow to deep shaft.3. Check the foam on head tank A1-2547, if excessive foam is observed then add anti- foam after asking from shift manager.4. Check the temperature of the deep shaft tank A1-2547 if it is increasing above 38 0C open fire water at deep shaft.5. When feed to deep remains off line for a longer time then increase the air to risers by100 m3/hr.6. Check the level of A1-3100, if it is higher, and then increase the RAS flow to deep shaft.7. Check the air distribution is homogeneous in the degasser A1-2510 A/B. (Air is coming from all sides) if air is not coming from effluent surface then check C1-2509 A/B discharge pressure which should be higher than 0.5 brag. Otherwise start the standby blower.8. Fortnightly change over the compressor as per plant routine document and follow the routine change over procedure.3. Shutdown of the deep shaft 1. Stop the flow of the return activated sludge to the deep shaft feed mixing box by closing the pump outlet on the RAS line.2. Reduce the RAS flow to the deep shaft and maintain the flow towards WAS.3. Open the drain valve of the RAS line into the drainage pit.4. Stop the influent flow to deep shaft; stop the feed pump G1-2505A/B/C.5. Insert the isolating stop logs in the splitter box located at the outlet of the A1-2510A/B.6. Increase the air flow rate from the compressor package to its maximum value by opening the inlet guide vanes.7. Open the riser air flow control valves FCV-5120 fully.8. Stop the flow of WAS by stopping the RAS pump (G1-2512A/B/C).9. Stop the clarifier scraper (G1-2511A/B/C) according to the SOP.9.

4. AIR COMPRESSORS (C1-2527A/B) STARTUP Initial checks1. All work permits are signed off on compressor and returned.2. Check the power is available on compressor CMC control panel3. 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 risers side is fully open. Ask Utilities DCS board man to open FCV-5120 fully. Air Compressor (C1-2527A/B) startup 1. Fill the startup check list of the compressor.2. Release emergency switches of the selected compressor.3. Switch on the controlling power and check that the pre-lube oil pump is started.4. Check the lube oil pressure it must be higher than 168 kPa.5. Check that all parameters in the C1-2527 A/B MP-3 panel are normal and compressor ready indication is appearing.6. If compressor ready indication does not appear on the MP-3 panel then check all the parameters of the compressor and identify the wrong parameter.7. Inform to shift manager and see the trouble shooting guide.8. Push the start button.9. Keep the compressor in operation on unload condition for small time then press the load soft key on CMC panel.10. Confirm the opening of inlet valve and closing of the bypass valve.11. Ask DCS Boardman to put the FCV-5120 on manual and open up to 100 %.12. Turn the flow knob of the compressor from 0% to 100% gradually. 13. Increase air flow to deep shaft by rotating knob of air flow and set at 3000 m3/hr (read at FIA-5360 A/B).14. Check the flow direction of deep shafts, if it is normal, increase the flow to 3500 and then to 4000 m3/hr, otherwise decrease the flow to zero and find the reason.15. Open the six valves of the deep shaft and check the direction of the deep shaft.16. Ask DCS Boardman to put the FCV-5120 on auto with set point 1550 to 1600 m3/hr.17. Adjust the total air flow from air compressor to 4250 to 4300 m3/hr at the FIA-5360, as per requirement.18. Check passing of stand by compressor discharge valve.5. NORMAL OPERATION OF THE COMPRESSOR (C1-2527A/B)1. Take the reading periodically of the air compressor as per log sheet.2. Check any abnormal sound from air compressor if there is any abnormality then stop/changeover the compressor and inform the shift manager about the abnormality.3. Check that air traps are working properly; check the direction of deep shaft flow.6. SHUT DOWN /CHANGEOVER OF THE ON DUTY COMPRESSOR (C1-2527A/B)1. On duty compressor can be changed over to the standby compressor 2. Compressor package is stopped completely due the some maintenance work on the compressor discharge line.3. For the compressor change over just apply the change over procedure of standby compressor4. For the compressor shutdown carry out the following steps5. Inform to DCS Boardman about compressor shutdown decrease air flow to zero by rotating the knob to zero position and then unload the compressor.6. Keep it un-load during for a few minutes and then push the stop button.7. Keep the pre-lube oil pump in service for about fifteen minutes and then switch off the control power.8. Hand over the line for the maintenance9. Stop G1-2505 A/B/C and fresh feed to deep shaft is standby compressor is not available.7. Start up of the degasser (A1-2510A/B) system 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 0C10. 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.8. Start up of the degasser standby blower C1-2509A/BBefore the startup of the blower ensure that both the standby blower and its ventilation fans are in healthy condition.1. Check all permit to work are signed off and returned.2. Check that power of the blower is on.3. Check that system is ready to be taken in service.4. Check that plant air is available on nearby utility point with air hose, and air fitting is installed on the inlet line of the degasser.5. Open the discharge valves of the selected blower (C1-2509A/B).6. Start the ventilation fan of the standby blower and ensure that it is working normal.7. Start the C1-2509A/B standby blower as per procedure.8. Check that it is working normal.9. Stop the running blower; stop the ventilation fan of this blower.10. Close the discharge valve of the stopped blower.11. Check that air bubble can be seen breaking the surface of the liquor in the degasser and that these bubbles are evenly distributed across the surface.The standby blower degasser blower has now been successfully started and lined up9. Shutdown of the Degasser (A1-2510A/B) both/one lane The degasser system will have shut down due to the following conditionsI. Maintenance of the blowerII. Air supply pipe maintenanceIII. Sparger pipe work maintenance10. Shutdown due to maintenance of C1-2509A/BFor the maintenance of the degasser blower the standby unit needs to be taken in operation to continue the treatment.1. Shut down due to Air supply pipe maintenanceFor 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. 2. Shut down due to Sparger pipe work maintenanceDegasser sparger piping maintenance requires the complete shutdown of the respective degasser A1-2510A/B. For this following procedure applies.1. Ensure that deep shaft load has been deceased.2. Stop the degasser blower C1-2509A/B and C1-2514A/B as per procedure.3. Isolated the discharge valve of the degasser blower C1-2509A/B.4. Insert the isolation stop logs in the splitter box and degasser outlet.5. Drain the degasser completely for maintenance purpose.6. Put the pneumatic pump in the degasser for completely draining it out.7. After the complete draining erect the scaffolding, remove the pipe, carry out the maintenance and installed back the sparger pipe.8. Remove the scaffolding and revert the system on normal condition.11. Normal operation of the Degasser A1-2510A/B1. During normal operation air from the duty degasser blower is continuously sparged into the two lanes of degasser.2. It is possible to run with only one operational degassing lane at normal load flow although this would only occur if one of the lanes had been shut down for maintenance.3. Ensure that regular sampling of the degasser liquor is sampled to confirm the MLSS concentration.4. Monitor the blower discharge pressure at PG-5242 and discharge temperature on TG-5244.5. Check that the duty degasser blower is in healthy condition.6. Check that a regular distribution of bubbles can be seen breaking the surface of the liquor in the degasser.7. Ensure that all the alarms are regularly monitored.(i-e,FSL-5314,etc)8. Respond to alarm condition and rectify as necessary.9. Ensure that degasser blower is running normal.12. ETP Clarifier A1-2511A/B systemThis section describes the startup, shutdown, normal operation and maximum operation of the clarifier system. Startup of the clarifier Scrapers (G1-2511A/B)1. Ensure that clarifier liquid level is at its normal operating level.2. Ensure that all clarifier conditions are normal.3. Start the clarifier scraperThe clarifier scarper is now operational. Startup of the clarifier basin1. Ensure that both stop-logs in the degasser outlet are removed.(if one clarifier is under maintenance then the stop-log of that clarifier must be left in place)2. Ensure that effluent starts to flow into the clarifier basin. This can be checked from the top of the clarifier scraper bridge.3. Check that effluent from the clarifier basins overflow the weir into the launder.The clarifier basins are now operational normally.13. Startup of the RAS pump G1-2512A/B/C Initial Checks and Startup1. Check all work permits are signed off and returned.2. Check pumps are electrically energized.3. Check the lube oil level in the sight glass.4. Check that suction isolation valves are open.5. Check that discharge valve is close.6. Check that WAS discharge valve is close.7. Ensure that deep shaft is operational and is ready to accept the RAS and that the clarifiers are full of liquid.8. Ensure that before the start-up all conditions relating to RAS pumps to be started are healthy.9. Start the selected RAS pumps (G1-2512A/B/C) after filling the startup chick list.10. The RAS pump to be run with the isolation of the WAS valve unless the MLSS concentration in the deep shaft reaches the operating level of the 5000 mg/l or sludge blanket level in the clarifiers reach up to 3 feet.11. Check that sludge centrifuge M1-2548A/B are ready to accept the WAS.12. Open the WAS valve when MLSS concentration in the deep shaft ET-10 sample reaches to operating level of 5000 mg/l.13. Open the WAS take-off valve slowly to 100%.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 314. Shut Down of one clarifier:Under normal operating condition both clarifier basin are in use. However each clarifier is sized to take all of the normal flow so that one clarifier basin can be shut down for maintenance without effecting the operation of the plant. If the plant is operating on maximum load conditions then flow must be reduced as per normal load conditions. One clarifier is mostly off lined due to the following conditions.1. For the cleaning of the clarifier basin2. The inspection of the clarifier15. Shutdown of one clarifier for cleaning1. Insert the stop -log to the clarifier basin to be shut down2. Drain the clarifier until all of the sludge has been pumped out by the RAS pumps. The decrease in the sludge blanket level can be monitored visually3. Close the under flow valves from the drained clarifier.4. Insert the blinds to prevent the back-filling from the A1-3100 coagulant mixing tank.5. Stop the clarifier scarper of the shutdown clarifier basin.6. Stop one of the duty RAS pump according to the requirement of the RAS flow.7. Drain the remaining water from the shutdown clarifier basin using a submersible pump. The water should either be pumped to the working clarifier basin or the degasser outlet.8. Put one fire water hose down to the bottom of the clarifier basin with water open for leaning purpose and pump out with the help of submersible pump.9. Continuously monitor the sludge blanket level in the working clarifier and adjust the RAS / WAS flow accordingly.10. Check that clarifier is ready for the required job.11. Carry out the necessary checks before entering the vessel.12. Clarifier basin is now ready for the maintenance job.16. Normal operation of the ClarifiersDuring normal operation:1. Ensure that samples of the deep shaft head tank liquor and the clarifier basin under flow are taken to confirm the MLSS concentration in ET-10 sample.2. RAS flow is adjusted according to the requirement of the plant.3. Ensure that all alarms are regularly monitored.4. Respond to all alarms conditions and rectify as necessary.5. Ensure that water is available for flushing when RAS pumps are stopped.Ensure RAS pumps run in accordance with the required operating instruction.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 risers 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/B6. Unavailability of the C1-2509 A/B due to maintenance work.7. Tripping of the G1-2512A/B/C

TERTIARY TREATMENT1. IntroductionThe 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. 2. SARTUP OF THE PACKAGE initial checks1. Check all PTWs are signed off2. Physically check all equipments for mechanical jobs completion 3. All spectacle plates are in appropriate position4. All slip plates are removed Check the electrical energisation of :1. G1-3100 Coagulant mixing tank agitator 2. G1-3101 flocculent tank agitator3. G1-3102 scrapper motor 4. G1-3104 A/B sludge transfer pumps5. G1-3107A/B are backwash pumps6. Z1-3110 polymer preparation package drives are electrically energized. Checks availability of :1. Treated effluent 2. Compressed air3. Tertiary polymer(Nalco-9916)4. Raw water 5. Nalco 8105/PC-306Checking of instrument and control valvesCheck stroke and close manual the following valves1. LCV-5184 level control valve in concentrate return line to deep shaft mixing box A1-2562 from concentrate transfer pumps G1-3107A/B.3. Preparation of the Polymer solution in the package Z1-3110A. POWEDER:Polymer powder is blown by the polymer powder blower C1-3115 from polymer powder hopper P1-3112 for a pre-determined time to polymer mixing tank F1-3114.In F1-3114 it is 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.0.5% W/W polymer solution batch preparation from powder of Nalco-99161. Ensure dehumidifier M1-3117 is operational in powder hopper enclosure 2. Ensure that enclosure door are closed3. Ensure raw water line isolation valve to package is open; Fire water can be used if raw water is un-available.4. Open appropriate valves of pumps and tanks to prepare package for operation5. Select the powd or liq switch on the control panel.6. Release all stop button and press emergency stop reset button on control panel.7. Check that there is polymer powder in the polymer powder hopper P1-3112.8. Move switch from OFF to Auto on control panel.(sequence will be started automatically)9. On sensing the low level of the F1-3114 batch preparation tank by LSL-5713 the polymer preparation sequence will be started as:1. The raw water supply SOV-5795 will open first.2. Tank level will increase up to 20% then agitator G1-3114 will take start.3. Now polymer screw feeder P1-3112 will take start. Screw feeder feed is adjustable from the control panel it can be increased and decreased with the help of instrument tech.4. Now polymer powder transfer blower C1-3115will take start 5. Solution preparation will be stared in F1-3114 and will stop when high level will be sensed by LSH-5713.6. Main raw water supply SOV-5795 will become close.7. Agitator will remain in service up to 30 minutes for solution preparation completion.4. Start-up of the flocculent tank agitator G1-3100 and Flocculent tank Agitator G1-31018. Open the coagulant mixing tank F1-3100 tank inlet valve in the effluent line from clarifier A1-2511A/B.T his tank receives the gravity flow from the secondary clarifier.9. Ensure that by pass line valve to the tertiary treatments is in close position.10. Establish the level in the F1-3100 tank and verify form area.11. Confirm the level of Nalco-8105 in the IBC.12. Start the F1-3100 agitator G1-3100.13. Confirm the pH analyser QIA-5171 is working normal otherwise calibrate it. It must in the range of 6-9.14. Establish the level in the A1-3101(flocculent mixing tank).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-9916.5. Dosing of Tertiary Polymer Solution: To add polymer solution prepared in the polymer preparation package Z-3110 into secondary treatment effluent in flocculent tank A1-3101.This chemical addition provides the flocculation and settling of suspended fines solids.1. Ensure that there is sufficient polymer solution of .5 % w/w concentration the polymer storage tank F1-3125.2. Ensure that F1-3100 is filled with treated effluent and agitator is in running condition.3. Open the discharge isolation valve of the F1-3125.4. Open the suction isolation valve of the G1-3116A/B selected pump.5. Ensure that valves of the standby pump are in close position.6. Open the Selected pump discharge isolation valve and check the pressure on the discharge PI-5715A/B.7. Confirm that raw water SOV-5797A/B is open condition.8. Open the raw water line isolation valve located on the downstream of the dosing pumps G1-3116A/B, control the raw water flow manually to dilute the polymer solution up 0.1% W/W .Raw water flow can be adjusted manually with the help of the rota meter .(1unit =1 m3/hr),Now its isolation valves are opened up to 60 %.9. Release all stop buttons and press emergency stop Reset button on the control.10. Turn the selector switch to Hand position.11. Start duty polymer dosing pump G1-3116A/B.12. Set required dosing rate using the manual pump speed control on the polymer package door panel.6. Start-Up of The Tertiary Clarifier Scraper G1-31021. Ensure that tertiary clarifier overflow line isolation valve is open.2. Ensure that A1-3105 is ready to receive the treated effluent from the A1-3102.3. Open the valve in the effluent line inlet to tertiary clarifier to the A1-3102.(effluent flows to the tertiary clarifier by gravity from A1-3101)4. Ensure that tertiary clarifier bypass line isolation valve is closed.5. When the tertiary clarifier A1-3102 liquid level is at its normal operating level (i.e., 50 %) then start the clarifier scraper A1-3102.6. Check that torque value is normal in area on local torque indicator XI-5173.7. Start-Up of the Sludge transfer pumps G1-3104A/BTypical sludge concentration in the A1-3102 remains 0.8 %. 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. Dont 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 pumps flushing until clean water started to come from discharge drain.15. Remove the hose, close the drain valve and refit the blank.8. NORMAL OPERATION1. Check the system against any abnormality.2. Fill are logs sheet and monitor the changes. 9. Use of tertiary bypassIf the secondary treated effluent overflowing from clarifiers A1-2511A/B meets the discharge contents then it is not necessary to use tertiary treatment stage for removal of the suspended solids and reduction in the effluent COD.1. Open the isolation valve of tertiary treatment bypass line to final effluent PIT- A1-3105.2. Close the F1-3100 inlet line isolation valve.3. Stop the Nalco -8105 dosing pump and close its three way valve.4. Stop coagulant tank A1-3100 agitator G1-3100.5. Stop the on duty polymer dosing pump G1-3116A/B and isolate it physically.6. Stop the raw water flow on the downstream of the pump.7. Stop the flocculent tank F1-3101 agitator G1-3101.8. Stop the duty sludge transfer pump G1-3104A/B.10. G1-3107 A/B operation The G1-3107 A/B are called backwash Pumps .These are installed on the A1-3106 Pit which receives effluent from the sludge centrifuge M1-2548A/B concentrate and backwash water from the sand filters. Currently sand filter are bypassed. These pumps are used to transfer this effluent to deep shaft.1. Check G1-3107A/B seal flush water valves are open.2. Check that A1-3106 is filled with liquid.3. Check that all pumps drains valves are closed and blanks are fitted.4. Open duty pump suction valve.5. Ensure that isolation valve in the suction and discharge of the standby pumps are in close position.6. Open LCV-5184 up to 20 % on manual from DCS.7. Confirm that deep shaft mixing box is ready to take the effluent and it is in operational condition.8. Start the duty by backwash pump G1-3107A/B.9. Ensure that there is kick back flow to F1-3106 through ROP-5210/5227.This spill back flow will protect the pump in case of no forward flow.10. Slowly open the pump discharge valve.11. Check the pump discharge pressure on PG-5211/12.12. Control level in the A1-3106 at required level on auto on LICA-5184.Note: both pumps can be taken in service parallel when the level inA1-3106 is high.11. To start the stand by pump G!-3107A/B1. Open the suction isolation valve of the standby pump.2. Start the standby G1-3107A/B.3. Ensure that there is spillback flow to A1-3106 through ROP -5210/27.4. Slowly open the pump discharge valve.5. Check the pump discharge pressure on PG-5211/12.6. Stop the duty pump.7. Close the Deselected pump suction and discharge valves.12. Shutdown of the clarifier A1-3102 If the Tertiary clarifiers A1-3102 need cleaning: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.

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 checks1. Check all PTWs are signed off.2. Physically check of all equipments for mechanical jobs are completed.3. All slip plates are removed. Check the electrical energisation of :1. All drives of package Z1-2549 are electrically energized.2. All drives of Package Z1-2554 are electrically energized. Checks availability of :1. Waste activated sludge (WAS)2. Backwash pit A1-31063. polymer solution (Nalco-9916)4. Raw water 5. Road dumper for sludge Checking of instrument and control valvesCheck, stroke and close on manual the following 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 Z1-25641. Ensure dehumidifier M1-3117 is operational in powder hopper enclosure.2. Ensure that enclosure door is closed.3. Ensure raw water line isolation valve to package Z1-2564 is open; Fire water can be used if raw water is un-available.4. Open appropriate valves of pumps and tanks to prepare package for operation5. Select the powd or liq switch on the control panel.Liq is not used at for the preparation of solution.6. Release all stop button and press emergency stop reset button on control panel.7. Check that there is polymer powder in the polymer powder hopper P1-25718. Check that makeup tank F1-2574 low low level not illuminated if illuminated press reset alarm button until light goes out; this puts water into the tank.9. Move switch from OFF to Auto on control panel.(sequence will be started automatically)10. On sensing the low level of the F1-2574 batch preparation tank by LSL-5703 the polymer preparation sequence will be started as 11. The raw water supply SOV-5790 will open first.12. Tank level will increase up to 20% then agitator G1-2574 will take start.13. Now polymer screw feeder P1-2571 will take start. Screw feeder feed is adjustable from the control panel it can be increased and decreased with the help of instrument tech.14. The polymer powder transfer blower C1-2567will takes start.15. Solution preparation will be started in F1-2574 and will stop at 90 %, when high level will be sensed by LSH-5703.16. 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 pumps 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.ii. Man: pump speed is set by HIC-5204 A/B.3. Set the required sludge feed to the centrifuge on FIC-5138/5189.The varying sludge flow depends uponi. The amount of WAS to be processed.ii. The torque signal from centrifuge.iii. When the torque value is on lower side then high liquid will be produced by the centrifuge, so the level in the backwash pit A1-3106 also based the flow of WAS to centrifuge.iv. Capacity of the road dumper availability or wet sludge process4. Take the round of the centrifuge to check the vibration and any abnormal sound. If any abnormal sound/vibration appears then shutdown the centrifuge and identify the fault and rectify it.5. Ask DCS Boardman to give set point of HIC-5204A/B and FIC5138/5189 of the centrifuge. Confirm that polymer pump G1-2575A/B Hic value is more than 21 % otherwise polymer pump will trip.6. Check the centrifuge PLC screen which shows centrifuge step on. The torque will increase and when it will Crosse the sediment level set point, three ways valve will opens towards local sludge carrier.7. Ensure that on local screen that sediment level is ON. The centrifuge will start to discharge it sludge to its hopper.8. Check the parameter of the centrifuge which should bre in the normal given range.9. Check the vibration of the centrifuge on the local panel on the VAH-9616A/B. This should be less than 20 Mm/sec.10. Check the level of the hopper on the local mounted LT-9623A/B, and also auto start-up of the bridge breaker and sludge discharge pump. Centrifuge has tripping on the hopper high high level.6. Normal operation of M1-2548A/B1. Check the sludge concentrate. If it contains sludge then change the value of the torque through reducing WL by 01. The relative speed of the bowl and the screw will increase, due to the high separation. Maximum relative speed must be kept upto 5.0.2. If the centrifuge tripped due to the increase in torque, then bring it to the previous setting and start to increase the polymer doing after its start-up. Some time centrifuge tripped due polymer low dosing rate and does not show any indication.3. Have the normal round of the centrifuge and check it against nay abnormality. If any abnormality appears then seek instruction from shift manager.4. Take the reading as per log sheet. Compare the reading with the previous and find the change.5. Check the level increase in the hopper of the centrifuge and also prove at least one cycle of the sludge discharge pump G1-2560A/B.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 opensii. Sludge feed valve FCV-5138/5189 closesiii. Polymer dosing pump G1-2575A/B stopsiv. High speed wash,10 minutes at 2800 RPMv. Low speed wash,500 sec at 900 RPM then water valve will close vi. Centrifuge stopsvii. 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 Bowl1. For the adjustment of the torque sensor, centrifuges 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. 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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