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SCOPE

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1.0

Objective
To standardize the operating parameter and procedure for glycerine making process as to ensure
production of on spec product.

2.0

Scope
System 1600- Flows for glycerine making system.

3.0

Reference
P&ID # A1-1607, A1-1608 & A1-1609
BOG System 1600 FPG-III-710

4.0

Responsibilities
Utility Associate Engineers are responsible to monitor & operate bleacher operation according
to the procedure stated in SOG & ensure safe practices are followed.

5.0

Procedure
1.
1.1

PROCESS DESCRIPTION
Incoming glycerine from Still and Dryer A-B Receiver will be joined together before
entering E-1610 Glycerine Bleacher Pre-cooler. The temperature is controlled by TIC
P303 which regulate E-1610 bypass line control valve. Cooling water cools the
distillates in the cooler approximately (80-95) C before entering the Bleacher Feed
Tank.

1.2

Feed to bleachers is provided by P-1608 Glycerine Bleacher Feed Pump from S-1611.
Pump is running in AUTO and regulated automatically by pre-set value from FIC
P406. It feeds to a bank of four activated carbon bleachers, V-1604 A, V-1604B,V1604C and V-1604 D, operating in series. These bleachers remove traces of colour
bodies, residual odors, and other impurities.

1.3

The Glycerine Bleachers are filled with 1-2 mm diameter granular carbon which
comes from coal and is a porous material with thousands of very small pores in each
granule: macropores and micropores. Macropores are relatively large for glycerine
molecules and allow it to move freely in and out of the pores. Micropores are too
small for the glycerine, but large enough to capture the longer carbon chain
e.g. flavor, odor, and color contaminants.

1.4

Sample is taken from middle and final bleacher and analyze for certain criteria to
decide whether activated carbon need to be changed. If middle bleacher sample off,
change the lead bleacher. If final bleacher sample off, change all bleachers.
Criteria for middle/final bleacher sample failure are as below on the basis whichever
comes first :
1). Color
2). FA&E

10 Max
0.23 Max

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3). Odor
Grade 2 and Grade 1
4). Bleachers has been running 10 days Max since last bleacher carbon change.
C+
5). H2S
FAIL
1.5

Fresh carbon sacks weight about 1000 Ib each are stored at first platform of
glycerine refinery structure (top of bleachers bed) or in the warehouse A.
Forklift is used to transport these sacks from warehouse to glycerine plant and hoist
to lift it up from ground floor to second platform where it will be stored in limited
units.

1.6

The purpose of backwash is to remove very fine carbon, sulphate and air trap out of
the system. Cold water will flush out fine carbon and air trap . This process will take
minimum 1 hour or until no fine carbon is observed in the sample taken at the outlet.
Hot water wash will remove sulphate from carbon and this process will take about 1
hour. If more than one bleacher needs to be backwashed, it needs to be done
individually or one by one. This to avoid fine carbon from first bleacher goes to another
bleacher and cause longer time to come out of the system.

1.7
C

2.

Sweetening on process will flush water out of the system before system ready to
divert to analysis tank. Sweetening on process for more than one bleacher can be done
simultaneously. This will save time a bit compared to individual sweetening on.
Draw sample and analyze for Specific Gravity and filter papers test. If both meet
specification then it will be diverted to analysis tank.

CHEMICALS REACTION
Not Applicable

3.

PROCESS FLOW
Refer to Piping and Instrumentation Diagram (P&ID) page number A1-1607, A1-1608
and A1-1609.

Document No. : FPG-III-705


Revision : 12
Expiry Date : Until Superseded
Page : 4 of 21
4.

EQUIPMENT AND CONTROL


EQUIPMENT
S-1611
P-1608
V-1604 A

V-1604 B

V-1604 C

V-1604 D

E-1611

INSTRUMENTS
TI P301
LI P302
TIC P303
SC P406
LSL P368
LSH P367
PI P351
TIT P350
LSL P370
LSH P369
PI P353
TIT P352
LSL P372
LSH P371
PI P355
TIT P354
LSL P374
LSH P373
PI P357
TIT P356
FI P358

DESCRIPTION
Tank temperature indication
Tank level indication
Temperature control
Pump speed control
Level switch low
Level switch high
Pressure indication
Temperature indication
Level switch low
Level switch high
Pressure indication
Temperature indication
Level switch low
Level switch high
Pressure indication
Temperature indication
Level switch low
Level switch high
Pressure indication
Temperature indication
Mass flowmeter

FIC P406

Mass flowmeter

TIC P408

Temperature control

LOCATION

E-1610

Vessel outlet
Vessel outlet
Vessel outlet
Vessel outlet
Vessel outlet
Vessel outlet
Vessel outlet
Vessel outlet
Line to Reflux tank
at manifold station
Outlet from polish
filter
Inlet to analysis tank

5.

BLEACHER START UP

5.1

BLEACHER PRE START UP

1.

Open both 1 1/2 valves inlet and outlet from E-1610 to S-1611.

2.

Open both valves at E-1610 bypass line.

3.

Open both 2 cooling water valves inlet and outlet of E-1610.

4.

Open both 1 valves inlet and outlet from E-1611 to analysis tank.

5.

Open 3 cooling water valve outlet of E-1611.

6.

Put TIC P408 set point 52 C in Auto control.

Document No. : FPG-III-705


Revision : 12
Expiry Date : Until Superseded
Page : 5 of 21
7.

Then proceed with Still and Dryer start up. Refer to that particular equipment start up
procedure.

8.

Change all filter elements in Glycerine bleaching filter F-1601 A and F-1602A/B if
needed. Refer to procedure 6.0.

5.2

BLEACHER EMPTY START UP

1.

Set TIC P303 higher than normal but not more than 86C

2.

Follow Bleacher Backwash Procedure to do backwash for a new activated carbon.

3.

If all bleachers have been changed with new activated carbon, refer to
6.5.1 and 6.5.2 Backwash and Sweetening On Procedure for all bleacher.

4.

Build up level in S-1611 about 20% before proceed with bleacher start up.

5.

If only two bleachers has been changed with new activated carbon, follow 6.5.1 back
wash procedure for that 2 bleachers.

6.

Line up the other 2 bleachers with old activated carbon in series.

7.

Outlet from second bleacher is then connected to finish product line through polish
filter and back to S-1611.

8.

Ensure all bleeders are close.

9.

Open 2 valves from S-1611, inlet / top and outlet / bottom of the bleachers at
manifold station.

10.

Open 2 valves to finish product line and 1 valve back to S-1611

11.

Open 2 valve (bottom draw) from S-1611 to P-1608 /P-1608 B suction and 1 valve
discharge to bleaching manifold.

12.

Put FIC P406 in MANUAL 20% and start pump P-1608 /P-1608 B.

13.

Monitor for any leaks especially at manifold and bleachers top opening.

14.

Monitor differential pressure across each bleacher not exceeding PSV setting at pump
and bleacher itself before increase pump output.

15.

Keep recirculate until the other 2 bleachers are ready for sweetening on and the first 2
bleacher are hot (about normal operating temperature).

16.

With FIC P406 still in manual, stop P-1608 / P-1608 B.

Document No. : FPG-III-705


Revision : 12
Expiry Date : Until Superseded
Page : 6 of 21
17.

Isolate 2 valve from bottom outlet of the second bleacher and 2 valve to finish
product line.

18.

Open bleeder to bleed out trapped pressure in the hose before disconnects it.

19.

Connect outlet from second bleacher to the bottom of the third bleacher and outlet
from (top) third bleacher vent to release any pressure trap.

20.

With FIC P406 still in MANUAL 50% , start pump P-1608 / P-1608 B.

21.

Increase pump output gradually and monitor the pressure across bleachers.

22.

Once level switch high at third bleacher triggered, stop P-1608 / P-1608 B.

23.

Re-arrange back bleachers line up, outlet from bottom of second bleacher is fed to the
top of third bleacher and bottom outlet of third bleacher is fed to the bottom of the
fourth bleacher.

24.

Let top outlet from fourth bleacher vent to atmosphere at manifold station to release
any pressure trap.

25

Repeat steps 20-22.

26.

Re-arrange back bleachers line up, bottom from the third bleacher is fed to top inlet of
the fourth bleacher and bottom outlet from the fourth bleacher is connected to finish
product line.

27.

Line up outlet from bleachers to reflux tank at bleacher manifold.

28.

Close all bleeders and ensure 2 valves top and bottom of the bleachers are open.

29.

Open valve to reflux tank.

30.

Start P-1608 and monitor for any leaks especially at manifold and bleachers top
opening.

31.

Ensure flow is stabilize and about the same as normal running or increase pump
output gradually until it reach normal operating flow.

32.

Monitor the density meter which is measured by DI P406.

33.

It will continuously increase until reach about 1.2420 g/cc (depends on the product
temperature). This will take about slightly less than double from normal sweetening on
process for single bleacher.

34.

Grab a sample and check as per sampling plan (filter paper test and specific gravity).

35.

If all qualities are within specification, divert final outlet from bleachers to analysis
tank through polish filter. Prior to that, put P-1608 in manual.

36.

Open inlet valve to polish filter and inlet valves for both filter bags, slowly vent air trap
in the vessel (polish filter) through vent point on the top of the vessel until liquid
coming out.

37.

Close the vent valve and slowly open the outlet of the polish filter.

38.

Repeat step 36 & 37 for both filter bags.

39.

Open isolation valve to analysis tank.

40.

Monitor flow and pressure registered in TDC.

41.

After flow has been stabilized put pump FIC P406 in AUTO mode.

6.

NORMAL OPERATIONS

1.

Temperature is controlled by TIC P303 which regulate TV P303 bypass E-1610 valve
to get desired temperature. Ensure valve is operated in AUTO and temperature within
control range.

2.

In case of glycerine temperature well below control range, ON the steam condensate coil
and closely monitor the temperature. Shut it off when temperature back to normal.

3.

Tank S-1611 is nitrogen blanketed, ensure the pressure is within control range as set at
pressure control valve PCV P306.

4.

Ensure tank has enough quantity to compensate upstream system shutdown for
washing in order to run bleacher continuously otherwise it need to be recycled.

5.

Feed to bleachers is provided by P-1608 / P-1608 B Glycerine Bleacher Feed Pump


from S-1611. Pump is running in AUTO and regulated automatically by pre-set value
from FIC P406. Check regularly if pump discharge pressure is within control limit and
there is no sign of PSV lift up.

6.

Product quality need to be checked according to sampling plan and ensure all within
control range. Investigate any abnormality.

7.

Check product sample coming out from middle and final bleacher to determine if
there is a need for carbon replacement.

Replace lead bleacher if middle sample fail and all bleachers if final product fail to
meet specification. Refer to carbon replacement procedure for detail.

6.1
1.

CARBON REPLACEMENT ( EMPTY OUT )


From TDC put FIC P406 in manual mode (feed pump running in manual) at current
output. This is to avoid pressure surge in the system and cause upset especially
channelling.

st

nd

rd

th

2.

Update the online bleacher according to sequence 1 , 2 , 3 . and 4 . on the TDC.

3.

Stop P-1608 / P-1608 B and isolate that particular bleacher which needs to be replaced.

4.

In order to change line up orientation, isolate 2 valve to each bleacher at hose


manifold and open bleeder to release any trapped pressure.

5.

Line up the other 3 bleachers in series in order to run the system by bypassing bleacher
which need to be replaced. Second bleacher will be a lead bleacher.

6.

Once line up completed, with P-1608 / P-1608 B still in manual mode, start the pump.
Monitor for any leaks especially at hose manifold.

7.

Let the flow stabilize for a while before change FIC P406 to AUTO MODE (pump
running base on flow set point).

8.

On bleacher which activated carbon need to be replaced, connect 3 barg nitrogen


supply to the bleacher top / inlet and line up bottom / outlet of the bleacher to Bleacher
Feed Tank ( follow normal flow top to bottom ).

9.

Open both 2 valve inlet and outlet of the bleacher to purge remaining glycerine to
Bleacher Feed Tank.

10.

After completed, connect water hose to the bottom of the bleacher and top bleacher
with Nitrogen supply, run both sources in counter current. Before remove hoses from
manifold, open bleeder to release pressure trap.
Avoid sending too much glycerine to sump because it will contribute to very high
load to waste water.

11.

Open the 4 air operated valve, PV 182 or PV 183 respectively depends on which
carbon dumpster is empty at that time.

12.

Open Nitrogen supply to pressurize the bleacher for a while and open 4 valve to spent
carbon dumpster. This need to done carefully considering high nitrogen pressure.

13.

Bottom bleacher 2 valve which connected to the water remain in close position.

14.

Use this water if necessary to fluidize or loosen carbon bed so that easier to it dump
out of the bleacher vessel.

15.

Check discharge line from bleacher to dumpster or the amount of spent carbon
collected in the dumster to ensure all carbon has been removed. Normally it is about 4
bags.

16.

After completed, depressurize the system by bleed out trapped pressure through
bleeder at manifold station before open 10 cap on top of the bleacher.

17.

Now bleacher vessel ready to be filled with new fresh carbon and it use approximately
3 sacks which about 1000 Ib each in weight.
Before switch hose orientations make sure all associated valve are closed and line
already depressurize. Use proper PPE and extra precaution need to be considered as
the hose / line may content hot product or water.

6.2

CARBON REPLACEMENT ( CHARGING )

1.

In order to fill fresh carbon into bleacher vessel, move carbon sack using hoist on top
of the 10 bleacher cap which already open earlier.

2.

Ensure the sack chute align with bleacher vessel cap opening before lower it down
until the chute is inside bleacher vessel.

3.

Ensure all ventilation fan are running because this process will create considerable
amount of carbon dust.

4.

Open the outer rope which ties the skirt followed by inner rope to charge fresh carbon
into the bleacher.
Use proper PPE and half mask with dust cartridge when handling carbon granules

5.

Repeat the same step until complete all three sacks. Do not over fill the bleacher to
allow any expansion during running.

6.

After completed, close back 10 bleacher cap and connect 2 line clamp properly.

6.3

BLEACHER BACKWASH
a) Cold Water backwash

C
1.

Check if 10 bleacher cap is already installed properly.

2.

Connect hose from soft water as a cold water backwash to the bottom inlet to newly
change carbon bed. Connect the top outlet to rain ditch. Start the water bottom fill.
Ensure the valve is slowly open up to 75% opening to prevent sudden pressure increase
in the bed.
Once the bed is full, let it soak for 1 hour.

3.

After 1 hour, continue backwash as normal procedure. Open both 2 valve on top
inlet and bottom outlet of the bleacher. Gradually increase the cold water supply to
prevent carbon carry over. Keep monitor the water discharge to rain ditch.

4.

Maintain cold water backwash until fines carbon and air trap removed.

5.

Then stop cold water backwash and isolate both 2 valve from cold water supply and
to the bottom of the bleacher.

Note: Please monitor Soft water tank level. Stop the flushing if soft water
tank level drop too drastic.
b) Hot water backwash

CC1.

Connect hotwater to the bottom inlet to newly change carbon bed. This will take
approximately 1 hour.

2.

Drain all the water after hot water wash is complete.

Note: Please monitor Soft water tank level. Stop the flushing if soft water
tank level drop too drastic.

6.4 BLEACHER SWEETENING


a) Sweetening on bottom fill from BFT.
1.

After all backwash are complete, please ensure all the water has been drained from the
bed (until no water flow from bottom line, up to this stage, there are estimated the
carbon hold the water as the same weight as the carbon itself)

2.

Connect hose from BFT direct to new bed bottom.

3.

Start the bottom fill until the bed is full.

4.

Let it soak for 1 hour. - during this stage, online the other 3 beds as normal practice
during carbon change.

5.

After soaked for 1 hour, start sweetening on process as per normal procedure.

Before switch hose orientations make sure all associated valve are closed and line
already depressurize. Use proper PPE and extra precaution need to be considered as
the hose / line may content hot liquid. While performing the backwash, ensure the
discharge water from manifold is cleaned before diverted to the analysis tank sump.
b) Sweetening on Top fill from BFT.

1.

From TDC put FIC P406, P-1608 / P-1608 B in MANUAL at the present output and
stop the pump.

2.

Isolate all associated valves and depressurize the hoses through bleeder.

3.

Line up bleachers according to sequence, bleacher with fresh carbon at the farthest
(last bleacher before entering final cooler) and bleacher with most depleted carbon as
a lead bleacher (inlet from P-1608 / P-1608 B).

4.

At the initial stage, the valves configuration are little bit different compare to
normal running. At this time, the bed is emptied. The bottom of previous bleacher bed
is lined up through the bottom of the bleacher bed. This is to fill up the bed with
glycerine and to vent air. The top hose of the bed is lined up to the drain/manifold
station.

5.

Ensure the valves and hoses are properly line up. Start P-1608. gradually increase
the pump output and closely monitor the bleacher beds pressure. Once the Level
Switch Low is triggered, this is a sign that the glycerine is built up in the bed.
Next, the Level Switch High will trigger and this will indicate that the bed is
almost full with glycerine. Stop the P-1608 / P-1608 B, once the glycerine is
overflowing from the bed through the top hose.

6.

Reconnect back the hose to the top of the bleacher bed from the previous outlet
bleacher bed and hook up hose from the outlet of last bleacher bed to reflux tank
through finish product line at the manifold station by passing the polish filters. Make
sure valve to other places are in close position.

7.

Keep P-1608 / P-1608 B in MANUAL and start the pump.

8.

Ensure flow is stabilize and about the same as normal running.

9.

Monitor the density meter which measured by DI P406 .

10.

It suppose to increase gradually until reach about 1.2420 g/cc(depends on product


temperature). This will take about 3-5 hours.

11.

Take sample and check as per sampling plan (filter paper test and specific gravity).

12.

If all qualities are within specification, divert final outlet from bleachers to analysis
tank through polish filter. Prior to that, put P-1608 / P-1608 B in manual.

13.

Open inlet valve to polish filter, slowly vent air trap in the vessel through vent point on
the top of the vessel until liquid coming out.

14.

Close the vent valve and slowly open the outlet of the polish filter

15.

Open isolation valve to analysis tank and slowly close polish filter bypass line.

16.

Monitor flow and pressure registered in TDC.

17.

After flow is stabilized put pump in AUTO mode.

Before switch hose orientation make sure all associated valve are closed and line already
depressurize. Use proper PPE and extra precaution need to be considered as the hose / line may
content hot product or water. While doing this process, ensure the feed to the bleacher beds is
constant to eliminate burp occurs it the beds. When this happen, it will deteriorate the quality
until all parameter is stable.
6.5

IF ALL BLEACHERS NEED TO BE CHANGED

6.5.1

BACKWASH

1.

Refer to 6.1 Carbon Replacement Procedure for activated carbon replacement.

2.

Bleed any pressure trap from the line through bleeder at manifold station before
dismantle hose connection.
Connect service water supply at manifold station to first bleacher bottom and top outlet
from bleacher to sump.

3.
4.

Slowly open 2 valves inlet and outlet of the bleacher at manifold station and monitor
for any leaks.

5.

Maintain cold water flush for about 1 hour to remove fines and air trap. After 1 hour,
check sample and the process is complete when there is no fine carbon observed.

6.

Then connect hot water supply to the bottom of the bleacher to flush out sulphate. Prior
to that bleed any pressure trap from bleeder at manifold station.

7.

This will take approximately 1 hour.

8.

For second bleacher, connect service water to bottom inlet and top outlet to sump.
Connect hose at manifold station straight to the sump and secure it properly.

9.

After first bleacher hot water flushing completed, close both 2 valve from hot water
supply and outlet of the bleacher.

10.

If second bleacher cold water flushing also complete, shut off 2 valve from service
water supply and change it to hot water.

11.

Outlet from second bleacher is then connected to sump.

12.

Flush with hot water for about 1hour.

13.

After complete, close hot water supply valve.

14.

Disconnect the hose and drain out the water from bleacher.

15.

Then first 2 bleachers are ready for sweetening on process.

16.

For the next 2 bleachers backwash, repeat steps 6.5.1(1)-(15)

6.5
6.5.2

IF ALL BLEACHERS NEED TO BE CHANGED


SWEETENING ON
1.

Monitor bleacher feed tank S-1611 level.

2.

Sweetening on process can be done simultaneously for all bleachers.

3.

Prior to that bleachers need to be filled with glycerine and ensure all air trap
has been removed.

4.

Connect hose from bleacher feed tank to the bottom of the first bleacher and
top outlet is vent to atmosphere.

5.

FIC P406 in MANUAL 50% , start pump P-1608 / P-1608 B.

6.

Increase pump output gradually and monitor the pressure across bleachers.

7.

Once level switch high at first bleacher triggered, stop P-1608 / P-1608 B.

8.

Re-arrange back bleachers line up, feed to the first bleacher from the top and
outlet from the bottom is fed to bottom of the second bleacher. Top outlet
valve from the second bleacher is left open to vent out air trap.

9.

Repeat step 5-8 until all bleachers are filled with glycerine.

10.

Once the fourth bleacher is filled with glycerine, stop the pump.

11.

Re-arrange back hose line up and ensure all are correct.

12.

Feed from bleacher feed tank S-1611 is fed to the top of the first bleacher and
coming from bottom is fed to top of the second bleacher.

13.

Bottom outlet from second bleacher is then connected to the top of the third
bleacher.

14.

Bottom outlet from the third goes to the top of the fourth bleacher.

15.

Bottom outlet from fourth is then connected to finish product line and line up
to reflux tank at bleacher manifold.

16.

Open polish filter bypass valve.

17.

Ensure all bleeders are close before open 2 valves top / inlet and bottom /
outlet of each bleacher.

18.

Make sure valve to other tank are in close position.

19.

Put P-1608 / P-1608 B, FIC P406 in MANUAL and start the pump.

20.

Monitor for any leaks especially at manifold and bleachers top opening.

21.

Ensure flow is stabilize and about the same as normal running.

22

Monitor the density meter which is measured by DI P358.

23

When it reach about 1.2420g/cc(depends on product temperature), grab a


sample and check as per sampling plan (filter paper test and density).

24.

If all qualities are within specification, ensure P-1608 / P-1608B still in


MANUAL current pump Output.

25.

Open inlet valve to polish filter, slowly vent air trap in the vessel through vent
point on the top of the vessel until liquid coming out.

26.

Close the vent valve and slowly open the outlet of the polish filter

27.

Open isolation valve to analysis tank and slowly close polish filter bypass line.

28.

Polish filter need to be changed prior to this, refer to polish filter change
procedure.

29.

Ensure all lines up are correct, bleeders and bypass valve at polish filter are
closed.

30.

Monitor flow and pressure registered in TDC. Check if there is any leak
especially at polish filter.

After flow is stabilized put pump in AUTO mode.

Before switch hose orientation make sure all associated valve are closed and
line already depressurize. Use proper PPE and extra precaution need to be
considered as the hose / line may content hot liquid.
6.6
1.

CHANGING POLISH FILTER WORK INSTRUCTION


Ensure all clean filters are ready on the platform.

2.

Isolate polish filter by closing inlet and outlet valves.

3.

Purge remaining Refined Glycerin in the vessel with Nitrogen to Reflux Tank
(S-1601).

4.
5.

Open vent line to depressurize the vessel.


Open the vessel cap by losing the bolt and nuts.

6.

Remove all used filter elements into drum.

7.

If any carbon found at the bottom of the polish filter casing, use vacuum
cleaner to clean the carbon.

8.

Wash hands using 7steps hand washing with bactericidal soap at nearby sink,
and wipe dry hand with tissue paper.

9.

Put in the new filter elements.(total of 55 elements)


Material Code : 1) SMF -30AF-1PK 483
2) WF-2C30A-C

10.

Close back the vessel cap by tightening the bolts and nuts

Note : During normal running, the polish filters will be changed for every
carbon change or if differential pressure across the filter is less than 0.1 barg or
higher than 1.02 barg whichever comes first.

6.6 Changing Filter Bag

1.

Close inlet and outlet valve at the filter bag housing.

2.

Open vent valve at the top of the vessel.

3.

Drain the remaining product in the vessel by opening the drain valve at the
vessel body and also two valves under the filter room.

4.

When all of the remaining product has been drained, open the vessel cap.

5.

Remove the old filter bag. Inspect for any abnormalities, i.e: burst, amount of
carbon trapped.

6.

Insert a new filter bag, ensure the filter bag is the right one with the right
specification.
Material Code : POF-5-PO2E- 20L or 30L
Note : (20L or 30L) Packing Quantity.

7.

Close the vessel cap by tightening the nuts.

Note: Use check sheet and comply with the item during changing filter bags and
polish filter. Refer to attachment.
7.0

BLEACHER SHUTDOWN

1.

Ensure feed from Still and Dryer to Bleacher Feed Tank already shutdown.

2.

Isolate both 1 valves inlet and outlet of E-1610 and also both valve at E-1610
bypass line.

3.

Isolate both 2 cooling water valve inlet and outlet from E-1610.

4.

If bleacher Feed Tank, S-1611 needs to be emptied out, run P-1608 / P-1608 B in
manual mode until cavitate.

5.

Stop P-1608 / P-1608 B and isolate 2 valve inlet to the pump.

6.

If all bleachers need to be emptied out purge the line all the way to reflux tank.

7.

Refer to 6.1 Carbon Replacement Procedure for activated carbon replacement.

8.

EMERGENCY SHUTDOWN

1.

In case of power outage, all electrical equipment will be down including pumps and
agitators.

2.

Isolate valves outlet from S-1611 Bleacher feed tank.

3.

What need to be done is much depends on how long it will be shut down. For a long
shutdown proceed with next step.

4.

Purge the line from bleacher all the way to reflux tank until confirm it is clear.

4. Ensure at site there is no overflow from S-1611.


9.

OPERATING PARAMETER
Refer to SOP

10.

SAFETY INFORMATION

EQUIPMENT

SAFETY INSTRUMENT

S-1611

PVVV P305
6 Overflow line
24 loose cover access way
Internal relief valve
PSV P307
PSV P361 A
PSV P361 B
PSV P361 C
PSV P361 D

P-1608
V-1604 A
V-1604 B
V-1604 C
V-1604 D
11.

SETTING
( barg )
0.01 & 0.005

10.3
6.9
10.3
10.3
10.3
10.3

RELEASE TO
Atmosphere
Atmosphere
Atmosphere
Internal pump suction
Pump suction
Atmosphere
Atmosphere
Atmosphere
Atmosphere

TROUBLESHOOTING

PROBLEM
Black particle in final
product ( Especially during
sweetening on which takes
longer time )
High DP across bleacher
bed

PROBABLE CAUSES
Pressure surge in bleacher bed

Backwash is not sufficient before


proceeded with sweetening on
Outlet valves not fully open
Product too viscous

High moisture in final


product

Incoming product from dryer and


still contain high moisture
Steam coil leak

Carbon exhausted too fast

Product in feed tank out of spec.

CORRECTIVE ACTION
Check for inconsistent pump output. If
there is fluctuation run the pump in
manual and adjust the output
accordingly
Ensure water flow is sufficient by
checking pump pressure
Check valves at manifold station
Check product temperature, if too low
turn on steam coil
Counter check moisture from incoming
product
Isolate steam coil and continue monitor
moisture in final product
Counter check product quality in feed
tank, empty out if quality is off
especially FA&E

ATTACHMENT 1

Verification Checklist for Carbon Change


REFINED GLYCERIN PROCESS

C+

Originator

Verified by

Date / Time

Frequency

: whichever comes first.

Material
Code:

Shift Team Leader / Acting STL

Every 10 days or quality off,

CAL-TR

1-

Operator Attire & Hygieness:

2.1

Hair net is adequate and clean

2.2

Respirator was available

2.3

Rubber gloves is adequate and clean

2.4
2.5
2.6

Uniform (attire) is clean and no loose


item on top of the uniform (e.g pen)
Free from any illness - cough, flue,
diarrhea
No excessive odor such as perfume,
after shave or scented soap

Lot # :
Sack # :

Immediate Corrective Action If NO

2-

Check tools cleanliness:

3.1

Tools used to open the filter are adequate &


clean.

3.2

Platform and surrounding is clean

3.3

Activated Carbon are available on the platform.

3.4

Tools reconciliation :
Carbon Room:
Ratchet spanner
Spanner

3-

Inspection during opening the Bleacher


Vessel:

4.1

Any leak at Bleacher Vessel?

4.2

Any damage on the distributor triangle?

4.3

Check for Activated Carbon appearance.

4-

Inspection before Bleacher Vessel closure:

5.1

Put back the distributor triangle.

5.2

Any leak at bleacher vessel after filter online?

5.3

Ensure the number of tools after completed the


task are the same as 3.4.

Immediate Corrective Action, If 'NO'

Immediate Corrective Action, if YES.

Immediate Corrective Action, if YES.

ATTACHMENT 2

Verification Checklist for Polish Filter & Filter Bag Changing


REFINED GLYCERIN PROCESS

Originator

Verified
by

Team / Shift :

_/_

Shift Team Leader / Acting STL

Date /
:
Time
Frequency : Every Polish Filter Change
Material Code:

Lot

1)SMF -30AF-1PK 483


2)WF-2C30A-C

:_

Date /
:
Time
Frequency : Every Filter Bag Change
Material
Code:
#

POF-5-PO2E-20L or 30L
Note: (20L or 30L ) -Packing Quantity

Tasks

Batch

Immediate Corrective Action (If 'NO')

1-

Check the availability of sanitization tools:

1.1

Bacteriacidal soap supply adequacy

1.2

Water supply for cleaning activities

1.3

Tissue paper for drying

22.1
2.2
2.3

3-

Hair net is adequate and clean

2.5

Face mask and beard cover is adequate and


clean

2.6

Long sleeve apron is available

2.7

Rubber gloves is adequate and clean

2.7

Uniform (attire) is clean and no loose item on top


of the uniform (e.g pen)

2.8

Follow 7-steps hand washing

Check tools cleanliness:

3.1

Tools used to open the filter are adequate &


clean.

3.2

Platform and surrounding is clean

3.4

4-

Immediate Corrective Action If NO

No excessive odor such as perfume, after shave


or scented soap
Free from any illness - cough, flue, diarrhea
Team leader to relocate if personal not fit to
work in Polish/Bag Filter Room
Nails are short and clean. Remove watches and
jewelry such as ring & bracelet.

2.4

3.3

C+

Operator Attire & Hygieness:

Immediate Corrective Action, If 'NO'

Clean filter cartridges are available on the


platform.
Tools reconciliation :
Polish filter:
Ratchet spanner
Valve opener
Inspection during opening the polish filter:

4.1

Any leak at polish filter housing?

4.2

Any sign of contamination at polish filter?

4.3

Any sign of contamination at filter base plate?

4.4

Any sign of contamination in filter housing?

5-

Inspection before polish filter closure:

5.1

Any sign of contamination at polish filter?

Immediate Corrective Action, if "YES".

Immediate Corrective Action, if "YES".

5.2

Any sign of contamination at filter base plate?

5.3

Any sign of contamination in filter housing?

5.4
5.5
4-

Any top spring caps are missing or wrong


position?
Any leak at polish filter housing after filter
online?
Inspection during opening the filter bag:

4.1

Any leak at filter bag housing?

4.2

Any sign of contamination at filter bag?

4.3

Any sign of contamination at filter housing?

5-

Inspection before filter bag closure:

5.1

Any sign of contamination at filter bag?

5.2

Any sign of contamination in filter bag housing?

5.3

Any leak at filter bag housing after filter online?

66.1

Filter room condition:


Any sign of glycerin on the polish filter & filter
bag housing?

6.2

Any sign of glycerin on filter room wall?

6.3

Any sign of glycerin on the vacuum cleaner?

Immediate Corrective Action, if "YES".

Immediate Corrective Action, if "YES".

Immediate Corrective Action, if "YES".