N-10012-4-OPM-1201-0 Operation and Maintainance Manual Liquefaction Section PDF

OPERATION AND MAINTAINANCE MANUAL
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CLIENT SECTION DOCUMENT NO. PAGE NO.
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VICENTIN
N-10012 LIQUEFACTION N-10012-4-OPM1201 0 1 OF 97 05/11/2012
S.A.I.C.
OPERATION AND MAINTENANCE MANUAL

TITLE :
LIQUEFACTION SECTION.
CLIENT : VICENTIN S.A.I.C.
140,000 OR 150,000 LITERS / DAY ANHYDROUS

PLANT :
ALCOHOL
LOCATION : AVELLANEDA, SANTA FE- ARGENTINA
PROJECT NO. : N-10012
DOCUMENT NO. : N-10012-4-OPM1201
0 05.11.2012 VMS SBG/PKR VBJ FOR EXECUTION

REV. PREPARED CHECKED APPROVED
DATE REMARKS
NO. BY BY BY
THIS DOCUMENT IS THE PROPERTY OF PRAJ INDUSTRIES LTD., INDIA AND SHOULD NOT BE REPRODUCED WITHOUT WRITTEN
CO NF I D EN T IA L CONSENT FROM,”PRAJ INDUSTRIES LTD, “PRAJ HOUSE”, BAVDHAN, PUNE 411021, INDIA
OPERATION AND MAINTAINANCE MANUAL – LIQUEFACTION SECTION

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DISCLAIMER:
The purpose of the operation and maintenance manual (O & M manual) is to establish general guidelines
for the safe and proper use and maintenance of the Process Plant (as defined in the Supply Agreement
executed between the recipient and Praj Industries Limited) supplied by Praj Industries Limited (PIL).
These instructions are submitted with the implicit understanding that:
a) They are a guide to the recipient for the operation and maintenance of the Process Plant for efficient
operation.
b) The recipient has assigned skilled & competent maintenance and operating personnel for the
functioning of the Process Plant described herein.
c) The recipient has read, understood and thoroughly examined the aforesaid instructions prior to
abiding with the requirements.
The information contained in the O & M manual is confidential, and is meant solely for the use of the
recipient only and is not for circulation. This document is not to be reported or copied or made available
to others. The information contained herein is based on:
a) the specifications and data provided by the recipient,
b) the input parameters provided by the recipient
The operating parameters and auxiliary / utility consumption mentioned in the O&M manual are to be
used as guidelines only and the same may change during Process Plant stabilisation as well as due to
change in input specification. PIL is not liable for any operational hazards or injuries caused to anybody
on account of the use of the processes mentioned in the O & M manual. During the warranty period Praj
Industries Limited shall not be liable for any claims, losses, and damages arising out of the use of the
Process Plants by the recipient on account of non-compliance with the terms of this O & M manual.
The recipient shall comply with all applicable laws while using the Process Plants with respect to which
this operation and maintenance manual is provided.
Start-up assistance or field engineering service provided by PIL during the pre commissioning and
commissioning period or thereafter on the request of the recipient shall in no way relieve the recipient of
the responsibility for the proper maintenance and use of the Process Plant.
PIL reserves the right to alter, amend and / or modify the operation and maintenance manuals from time
to time.
In no event shall PIL be liable for any damages and /or liabilities on account of any indirect, incidental,
special, consequential or any other similar losses.
The information incorporated in the O & M manual is subject to copyright and must not be used,
disseminated, copied or disclosed to third parties without the written consent of PIL.
If you are not the intended recipient you should forthwith destroy all copies and inform PIL at
info@praj.net.
© Praj Industries Limited All Rights Reserved Registered Office: Praj Industries Limited, `Praj House',
Bavdhan, Pune- 411021 Maharashtra, India

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TABLE OF CONTENT
SR.NO CONTENTS PAGE NO.
PART – I THEORETICAL ASPECTS
1.0 INTRODUCTION 06
1.0.1 Theory of Liquefaction 09
1.0.2 Process Description 16
1.0.4 Control Logic & Interlock Description 22
1.0.5 Equipment Description 23
PART – II PRESTARTUP ACTIVITIES
2.0 GENERAL INSTRUCTION 27
2.0.1 Cooling Water Loop Testing 31
2.0.1 a SOP For Establishment of Cooling Water Circuit 31
2.0.2 Water Flushing / Cold Water Trial 33
2.0.3 Vacuum Trail 40
2.0.4 Steam Trial 40
2.0.4.a SOP for charging low pressure steam header 41
2.0.5 Standard Operating Procedure (SOP) 44
2.0.5.a SOP for Liquefying Enzyme dosing system 44
2.0.5.b SOP for Viscosity Reducing Enzyme dosing system 45

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2.0.5.c SOP for Aqueous Ammonia Dosing System 46
2.0.5.d SOP for Saccharifying Enzyme dosing system 46
2.0.5.e SOP for Preparation of 3.0 % w/w caustic solution in T-1351 48
PART – III PROCESS STARTUP AND PROCESS PARAMATER
3.0.1 Normal Start-up 53
3.0.2 Process Parameter 60
3.0.3 Cleaning In Place (CIP) 63
3.0.4 Process Monitoring 73
3.0.5 Troubleshooting 76
PART – IV PROCESS SHORT SHUTDOWN & PROCESS STARTUP
4.0.1 Power Failure 80
4.0.2 Cooling Water Failure 84
4.0.3 Steam Supply Failure 87
4.0.4 Instrument Air Failure 89
4.1 Plant Short Shutdown & Start Up After Short Shutdown 92
4.1.1 Plant Short Shutdown 92
4.1.2 Plant Start Up After Short Shutdown 93

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Plant Long Duration Shutdown & Start Up After Long

4.2 94
Duration Shutdown
4.2.1 Plant long duration shut down 94
4.2.2 Plant start up after long duration shut down 97

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1.0 INTRODUCTION
This document on OPERATIONAL AND MAINTAINANCE MANUAL contains

confidential and proprietary information belonging exclusively to PRAJ INDUSTRIES
LIMITED of Pune, India. VICENTIN S.A.I.C. AVELLANEDA, SANTA FE -
ARGENTINA shall maintain confidentiality and take all necessary care to ensure that
the information shared in this document is used only by the authorized and assigned
representatives.
Under article (Secrecy and confidentiality) Process license is nonexclusive, non-

transferable, for commissioning and operation of 140,000 OR 150,000 LPD OF
ANHYDROUS ALCOHOL using Sorghum or Corn as feedstock at VICENTIN S.A.I.C.
AVELLANEDA, SANTA FE-ARGENTINA only.
All data and information submitted here in regarding design details, operation system,
processing techniques should not be divulged to others without the written consent
from PRAJ INDUSTRIES LIMITED, INDIA. Here after PRAJ INDUSTRIES
LIMITED, INDIA shall be called as PIL.
VICENTIN S.A.I.C. AVELLANEDA, SANTA FE-ARGENTINA shall be responsible for

procurement and installation of process plant according to engineering software
provided by PIL. Necessary laboratory equipment, instrument and furniture shall be
provided by VICENTIN S.A.I.C. AVELLANEDA, SANTA FE-ARGENTINA Also,
VICENTIN S.A.I.C. AVELLANEDA, SANTA FE-ARGENTINA shall be responsible for
arranging skilled operating staff for plant operation and laboratory analysis. VICENTIN
S.A.I.C. AVELLANEDA, SANTA FE-ARGENTINA shall train operating staff for plant
and personal safety and hazards under local statutory regulations before
commencement of pre-commissioning activity.

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As per of the contract, all chemicals, feedstock and utilities shall be made available by
VICENTIN S.A.I.C. AVELLANEDA, SANTA FE - ARGENTINA and shall ensure
readiness for completion of mechanical work as detailed out in contract.
VICENTIN S.A.I.C. AVELLANEDA, SANTA FE - ARGENTINA acknowledges that PIL

is providing the design of the process plant to produce 140,000 OR 150,000 LPD OF
ANHYDROUS ALCOHOL from Sorghum or Corn as feedstock and that PRAJ has not
actually constructed the Process Plant. PIL warrants that after acceptance of plant
performance parameters, process plant will have the capacity to perform in all material
respects with the performance specification. VICENTIN S.A.I.C. AVELLANEDA,
SANTA FE - ARGENTINA expressly acknowledges that the ability of the process plant
to actually perform in material compliance with the performance specifications is
conditioned upon several factors outside of the control of PIL, including but not limited
to proper construction of the process plant, proper maintenance of the plant and
machinery, use of chemicals and enzymes as per specification, availability of utility,
proper operation of the plant as per operation manual supplied by PIL.

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PART–I
THEORETICAL ASPECTS

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LIQUEFACTION SECTION
1.0.1 THEORY OF LIQUEFACTION
Ethanol is produced from starchy feedstock, which can be classified as grains and
tubers. Typical examples of grains from which ethanol is produced are Corn, wheat,
barley, sorghum, rice, rye, triticale and sometime oats. Tubers like cassava, potato,
sweet potato is also used to produce ethanol especially in Southeast Asia.
Typically grain or tubers is moisture and rest is organic and inorganic solids.
Organic solids are starch, protein, fats, and non starch polysaccharides while inorganic
solids are ash.
Typical Composition of grains (in % by wt) is
CASSAVA
PARAMETER CORN WHEAT SORGHUM RICE
CHIPS
Moisture 10 10 11 11 11
Starch 62 60 62 64 70
Protein 11 13 9 5 3
Fats 4 2 3 1 1
Fiber 2 2 2 1 2
Ash 1 2 1 1 2
Other Solids 10 11 10 17 11
Starch is a polymer of glucose units. It consists of two main constituents namely
Amylose and Amylopectin.

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Amylose: Amylose is a polymer of 500 – 1,500 glucose units joined by 1 – 4 alpha

linkages in linear form.
Amylopectin: Amylopectin is branched polymer of glucose units joined by 1 – 4 alpha

linkages in the linear section and cross-linked by 1 – 6 alpha linkages. A molecule of
Amylopectin consists typically of 500 – 40,000 glucose units.
α - 1 – 4 - link
oo o o o o o o o
o o o o o o o o
o o o o o o o o
o
o
o o
o o o
o o o
o
o
α - 1 – 6 - link
o
o
o
o
o o o o o o o o
o
o o o o o o o o
o o o o o o o o
In its native form, starch consists of microscopic, partially crystalline, granules, which
are insoluble in water and not very susceptible to enzymatic hydrolysis. When aqueous
slurry of milled starch is heated above 80 °C, these starch granules begin to swell and
rupture. The Amylose and Amylopectin molecules unfold and become soluble. This

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process is called “gelatinization” of starch. During this stage, the viscosity of the slurry
rises dramatically. If the gelatinized slurry is allowed to cool, it would set to a gel and
some of the linear Amylose molecules would form a precipitate called retrograded
starch. It is very difficult to re-dissolve a set gel and virtually impossible to hydrolyse
retrograded starch.
Gelatinized starch, being in solution, can be broken down to smaller units (dextrins) by
the action of certain enzymes.
Apart from starch there are other nonstarch polysaccharides and fibers which comprises
of cellulose and hemicellulose components like pentosans (comprising of xylan,
arabinan, mannan etc.), uronic acid which contributes to rise in viscosity while
processing starch. To minimize this viscosity reducing enzymes are added. If nonstarch
polysaccharides are not degraded, can affect slop recycle in liquefaction as well as
alcohol concentration in fermented mash.
Proteins are solubilised to peptides and other amino acids by proteases which act as
FAN (free assimilable nitrogen) for yeast multiplication in fermentation process. High
protein contents my cause scaling problem for evaporators.
Other components present are like phytates and phytic acid which sequesters Ca2+ ions
and makes calcium deficiency for liquefying enzyme where it acts as enzyme stabilizer.
Tannins are color components which inhibit alpha amylase activity.

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Enzymes are biological catalysts, which bring about or accelerate a reaction without
themselves being changed during the reaction. Two types of enzymes are normally
employed in this process.
Liquefying Enzyme (Alpha Amylase)

Alpha amylases are commercially produced from microorganisms. Like Bacillus
lichenformis (heat labile alpha amylase); Bacillus subtilis (heat stable alpha amylase)
and are available in various concentrations. It is important to know the enzyme strength
in order to calculate the correct amount of enzymes to be used. Ca-ions acts as
stabilizers for the enzymes therefore, earlier calcium chloride was added. But with
recent advances in biotechnology, it is not required for new generation Enzymes.
Enzymes are very specific for their action and have optimum range for temperature and
pH-values. Liquefying enzyme hydrolyses starch (especially alpha 1-6 linkage) into
dextrins under optimum temperature and pH condition.
Saccharifying Enzyme (Amyloglucosidase)

This enzyme hydrolyses 1 – 4 and 1 – 6 alpha linkages from the non-reducing end of
starch and dextrin molecules and produces single glucose molecules. This process step
is called “Saccharification”.
Saccharifying enzyme is commercially produced from a mold Asperigillus niger and is

available in various concentrations. As for alpha amylase, the enzyme strength must be
known to calculate the correct amount to be added.

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Saccharifying enzyme has different optimum values for temperature and pH than alpha
amylase. It breaks down dextrins to glucose during the fermentation. It is important to
know that a small amount of starch is bound with other non starch polysaccharide
which cannot be broken by these enzymes. This unconverted portion is called
“Residual Starch”, and for this reason a 100 % theoretical yield cannot be achieved.
Enzyme Optimum pH Optimum Temp.
Liquefying Enzyme (Alpha Amylase) 5.5 - 6.0 85-90 0 C *
Saccharifying Enzyme (Amyloglucosidase) 3.5 – 4.75 34-60 ° C *

Note: * Optimum Temp may vary as per vendor specification.

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Hydrolysis of a 1 – 4 Alpha Glucosidic Bond
CH2OH CH2OH Hydrolysis CH2OH CH2OH

o o o o
O + H 2O +
HO OH OH
OH HO OH OH HO OH OH
Condensation
OH OH OH OH
α - 1,4 - Glucoside Bond α - D Glucose α - D Glucose
Stoichometry for Starch Hydrolysis
H (C6H10O5)n OH Hydrolysis n(C6H12O6)

901 kg (901*180/162=1000)
(162)n 180

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Process Block Diagram for Typical Grain to Ethanol Process
GRAIN HANDLING & STORAGE
GRAIN CLEANING & MILLING
RECYCLE STEAMS, SLURRY PREPARATION &

LOW PRESSURE LIQUEFACTION
STEAM, ENZYME
SACCHARIFCATION &
YEAST & ENZYME FERMENTATION CO2
DISTILLATION & DEHYDRATION

STEAM ETHANOL
DECANTATION WET CAKE
THIN STILLAGE
EVAPORATION
PROCESS CONDENSATE
TREATMENT PLANT
SLUDGE

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1.0.2 PROCESS DESCRIPTION

In Liquefaction process, convertible starch in flour is converted into dextrins by using
liquefying enzyme. Saccharifying enzyme further converts dextrin into glucose during
fermentation process.
Before liquefaction process, the Receiving Hopper in the Grain Milling Section receives
the Corn OR Sorghum. Pre-cleaned Corn OR Sorghum is fed at a controlled rate to the
Hammer Mill. In this unit operation, Corn OR Sorghum is broken down into small
particles (flour). Flour from the hammer mill discharged in the Flour Hopper and then
fed to the Pre-masher at a controlled rate from a sealing screw conveyer. Oversized
particles are segregated with the help of Vibratory Screen. They are then recycled back
to the Hammer Mill through the Coarse Bin. In slurry preparation section flour is mixed
with recycle streams along with enzyme. Starch rapidly takes up water and gets
gelatinized. Thus, it is converted from an insoluble to a soluble form. Gelatinized starch
is also called “Dextrins”.
PID No.: N-10012-1-PID1201: RECYCLE STREAM COLLECTION TANK

Recycle Stream Collection Tank (T-1211) is provided to collect recycle streams before
feeding it to Slurry Mixing Tank. Steam Condensate from CIP solution Preheater, UF
Permeate from Process Condensate Treatment Plant, Fresh Water and spent lees from
Exhaust Column bottom from Distillation Section is collected in Recycle Stream
Collection Tank (T-1211). The liquid from Recycle Stream Collection Tank (T-1211) is
pumped by Recycle Stream Transfer Pump (P-1211A/B) and liquid at 60 - 65 Deg. C is
fed to Premasher (E-1201).

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PID No.: N-10012-1-PID1202: SLURRY PREPARATION

Corn OR Sorghum Flour from milling section is weighed and continuously discharged
by gravity to Premasher (E-1201) through Seal conveyer (E-1202).
In Pre-Masher, flour is mixed with dilution stream from Recycle Stream Collection Tank
(T-1211), Thin Stillage from Decantation section and part of Liquefying Enzyme as per
specification (Alpha Amylase) is added to form a lump free slurry or paste with
optimum dry solids concentration. The mixing in Premasher occurs in a short time,
where the flour is thoroughly blend with the recycle streams to form slurry.
The slurry is then taken to the Slurry Mixing Tank (T-1201). Slurry Mixing Tank
temperature is maintained between 85–87 Deg. C. The slurry pH is maintained between
of 5.5 - 6.0 by addition of Aqueous Ammonia continuously through Aqueous Ammonia
Dosing System (U-1243).
In Slurry Mixing Tank, slurry is continuously agitated with top entry Agitator (A-1201)
and kept in circulation by Slurry Mixing Tank Pump (P-1201 A/B) to keep solids in
suspension. Level Controller LIC-120201 controls the level of the Slurry Mixing Tank
(T-1201). Residence time for slurry in the Slurry Mixing Tank (T-1201) is 1 Hour.
Steam injector (N-1201) is provided to Slurry Mixing Tank (T-1201). Steam is supplied
to the tank to maintain the temperature of slurry. The pH of the Slurry is measured and
recorded by pH controller AIC-120203 and adjusted by adding Aqueous Ammonia.
Flow of Aqueous Ammonia is controlled by flow control valve (ACV-120203). In case of
Sorghum as feed stock, addition of Viscosity reduction enzyme is provided for
Premasher and Slurry Mixing Tank.
CIP solution is provided through cleaning nozzle for cleaning of Slurry Mixing Tank.

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PID No.: N-10012-1-PID1203: JET COOKER AND FLASH TANK

The slurry from Slurry Mixing Tank (T-1201) is continuously transferred to Jet Cooker
(J-1201). At the outlet of Jet Cooker, temperature will be maintained around 110-115
Deg. C. The Jet Cooker is equipment, where the slurry is instantly heated by jet of steam
that sterilizes the slurry.
The sterilization process kills most bacteria that inhibit fermentation.
It also sheers and unravels the long chain starch molecules, making them accessible to
the alpha amylase enzymes in the liquefaction tanks.
The Delta P on the Jet Cooker should be around 40 psig for optimum sheering.
The Delta P can be adjusted by moving the combining tube back or forward in the Jet
Cooker.
For more details of Jet Cooker operation Refer Operation manual of Jet Cooker which is
provided by Vendor. Any adjustments should be done slowly.
This is a direct contact process, where each kilogram of steam used dilutes the starch
slurry mixture and will require evaporation capacity to remove the water later.
In Jet Cooker, the slurry is cooked by using high pressure steam (pressure 88 psig). The
temperature for slurry is controlled by temperature controller TIC-120301.
The Cooked Slurry is retained in the Cook Tube (T-1213) for 5 to 7 minutes. The slurry
is fed in the bottom and exits from the top of Cook Tube (T-1213). Back pressure in the
Cook Tube (T-1213) is maintained by using pressure control valve PCV-120301.
The Cooked Slurry is then flashed in the Flash Tank (T-1212) for reducing the
temperature of the Slurry. The Flash Tank (T-1212) is operated under vacuum and is
maintained by pressure control valve (PCV-120302). Due to pressure drop the
temperature of slurry is reduced. Flashed Steam from this tank, is used as a source of
energy to Exhaust Column (C-1462) in Distillation Section. The temperature in flash

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Tank (T-1212) is maintained around 84 - 85 Deg. C. Thereafter, the Slurry is fed to the
Initial Liquefaction Tank (T-1202) by using Flash Tank Transfer Pump (P-1212A/B). In
case of any upset, there is provision to take the slurry back to Slurry Mixing Tank (T-
1201).
PID No.: N-10012-1-PID1204: LIQUEFACTION TANK

In the Initial Liquefaction Tank (T-1202), temperature of slurry is maintained at 85 to 87
Deg. C. Balance quantity of Liquefying Enzyme as per specification (Alpha Amylase) is
added prior to slurry feeding to Initial Liquefaction Tank (T-1202). The slurry is
continuously agitated with the Agitator (A-1202) provided to Initial Liquefaction Tank
(T-1202) and slurry is kept in circulation by the Initial Liquefaction Tank Pump (P-1202
A/B) to keep solids in suspension. Level controller LIC-120401 controls the level of
Initial Liquefaction Tank (T-1202). Retention time for the Slurry in the Initial
Liquefaction Tank is 1 hour. The Liquefied Slurry from the Initial Liquefaction Tank (T-
1202) is transferred to the Final Liquefaction Tank (T-1203) by using Initial Liquefaction
Tank Transfer Pump (P-1202A/B).
In the Final Liquefaction Tank (T-1203), the Liquefied Slurry is constantly agitated with
the Agitator for Final Liquefaction Tank (A-1203) and slurry is kept in circulation by
using the Final Liquefaction Tank Pump (P-1203A/B) to keep solids in suspension.
Level controller LIC-120402 controls the level of the Final Liquefaction Tank. Retention
time for Liquefied Slurry in the Final Liquefaction Tank is 1 hour.
CIP solution is provided through cleaning nozzle for cleaning of Initial and Final
Liquefaction Tank.

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PID No.: N-10012-1-PID1205: SLURRY COOLING

The Liquefied Slurry is cooled in two stages. In first stage it is cooled by preheating
Fermented Mash from Fermentation Section in Mash Preheater (H-1211 A/B) and in
second stage it is cooled in Slurry Cooler (H-1212A/B) by using cooling water on other
side to maintain slurry temperature at 32- 34 Deg. C. The liquefied slurry at 32 – 34 Deg.
C temperature is fed to Fermentation section. The heat exchangers provided are of plate
type heat exchangers and with standby. CIP connections are also provided for these
heat exchangers.
PID No.: N-10012-1-PID1206: ENZYME DOSING SYSTEM:

Liquefying Enzyme Dosing System (U-1241)
Alfa Amylase is liquefying enzyme and is stored in Liquefying Enzyme dosing Tank
(U-1241) and is pumped by Dosing Pump to process. Alfa Amylase enzyme is used in
Liquefaction section.
Saccharifying Enzyme Dosing System (U-1344)

Gluco Amylase is saccharifying enzyme and is stored in saccharifying enzyme Dosing
Tank and is pumped by Saccharifying enzyme Dosing Pump to process. Gluco Amylase
enzyme is used in Fermentation section.
Viscosity Reducing Enzyme Dosing System (U-1242)
Viscosity Reducing Enzyme is stored in Viscosity Reducing Enzyme dosing Tank (U-
1242) and is pumped by Dosing Pump to process. Viscosity reducing enzyme is used in
Liquefaction section.

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Aqueous Ammonia Dosing System (U-1243)

Aqueous Ammonia (25%w/w conc.) is stored in Aqua Ammonia Dosing System (U-
1243). It is used to maintain optimum pH in liquefaction section. Aqua Ammonia comes
in the liquid form. One can smell Ammonia at 5 ppm.
Ammonia draws heat to vaporize and will draw the heat and moisture out of your skin,
eyes or lungs and will instantly freeze your body tissue. Aqua Ammonia chemical
formula is NH4OH. It has a basic pH (high pH) and it is added into the Slurry tank for
pH control. Using Ammonia for pH control will also create free nitrogen (an essential
nutrient for the yeast).
Read the MSDS before handling chemicals and always wear proper PPE when working
in this area.

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1.0.4 CONTROL LOGIC & INTERLOCK DESCRIPTION

Refer control logic & interlock description document N-10012-3-ILD1201 for
liquefaction section.

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1.0.5 EQUIPMENT DESCRIPTION
QUANTITY
TAG NO. DESCRIPTION TECHNICAL DETAILS
OP. S/B
Agitator for Slurry Mixing
A-1201 1 0 Type: Top Entry
Tank with Motor
A-1202 Agitator for Initial
1 0 Type: Top Entry
Liquefaction Tank with Motor
Agitator for Final
A-1203
Liquefaction Tank with 1 0 Type: Top Entry
Motor
Type: Ribbon Mixer with
E-1201 Premasher with Motor 1 -
Paddles
E-1202 Seal Conveyer with Motor 1 - Type: Screw Conveyer
Type: Plate Heat
H-1211 A/B Mash Preheater 1 1
Exchanger
Type: Plate Heat
H-1212 A/B Slurry Cooler 1 1
Exchanger
J-1201 Jet Cooker 1 0 Type: Hydro heater
Steam Injector for Slurry
N-1201 1 0 Type: Ejector
Mixing Tank
Slurry Transfer Pump with Type: Centrifugal
P-1201 A/B 1 1
Motor Capacity: 52 m3/hr
Initial Liquefaction Tank Type: Centrifugal
P-1202 A/B 1 1
Transfer Pump with Motor Capacity: 52 m3/hr
Final Liquefaction Tank Type: Centrifugal
P-1203 A/B 1 1
Transfer Pump with Motor Capacity: 52 m3/hr
Recycle Stream Transfer Type: Centrifugal
P-1211A/B 1 1
Pump with Motor Capacity: 40 m3/hr
Flash Tank Transfer Pump Type: Centrifugal
P-1212 A/B 1 1
with motor Capacity: 52 m3/hr
Type: Cylindrical
/Vertical Shell with
T-1201 Slurry Mixing Tank 1 0 Conical Top and Conical
Bottom
Capacity: 60 m3

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QUANTITY
OP. S/B
Type: Cylindrical
T-1202 Initial Liquefaction Tank 1 0 Conical Top and Conical
Bottom
Capacity: 60 m3
Type: Cylindrical
T-1203 Final Liquefaction Tank 1 0 Conical Top and Conical
Bottom
Capacity: 60 m3
Type: Cylindrical
Recycle Stream Collection
T-1211 1 0 Conical Top and Sloping
Tank
Bottom
Capacity:25 m3
Type: Cylindrical
T-1213 Cook Tube 1 0
Dished Ends
Capacity: 12 m3
Type: Cylindrical
T-1212 Flash Tank 1 0
Dished Ends
Capacity: 16 m3
Liquefying Enzyme Dosing Type: Metering, Capacity :
U-1241 1 0
System 15LPH
Viscosity Reducing Enzyme Type: Metering, Capacity :
U-1242 1 0
Dosing System 9LPH
Aqueous Ammonia Dosing Type: Metering, Capacity :
U-1243 1 0
System 25LPH
Saccharifying Enzyme Dosing Type: Metering, Capacity :
U-1344 1 0
System 25LPH
Cleaning Nozzle for Slurry Self Operated with 3600
Y-1201A/B 2 0
Mixing Tank rotation
Y-1202A/B Cleaning Nozzle for Initial 2 0 Self Operated with 3600

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QUANTITY
OP. S/B
Liquefaction Tank rotation
Cleaning Nozzle for Final Self Operated with 3600
Y-1203A/B 2 0
Liquefaction Tank rotation

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PART–II
PRESTARTUP ACTIVITIES

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2.0 GENERAL INSTRUCTIONS

Operator must read and understand these instructions before operating the plant.
(1) The procedures and operating conditions listed here are guidelines only and may be
modified on start-up. The control system must be flexible enough to accommodate
these changes.
(2) This does not cover peripheral equipment, which may affect the plant operation.
(3) It is expected that the operator may be required to take some decisions and actions
not covered by this manual. The operator will be expected to monitor the system
during operation, and may need to intervene to assure safe operation of the plant as
and when required. The control system must be flexible enough to allow operator
intervention when necessary.
(4) Operator should read the bought-out items operation manual / safety procedures
received from respective vendors and follow the instructions as mentioned in their
manual before starting / stopping the respective item.
(5) Operating personnel should follow the safety regulations as per factory rules as well
as factory acts and regulations.

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A. Inspection and cleaning of Equipment

Inspection is nothing but PID audit. It is necessary to conduct PID audit to ensure that
plant erection is done as per the recommended design. Audit report should be made
and if in case any work is pending it should be brought to notice of project engineer and
should be completed considering pre-start-up and start-up schedule.
All instruments should be mounted at respective locations, tested, calibrated and ready
for use. Ensure that all the equipment and instruments are properly tagged and
respective tag numbers and nameplates are visible to operators to avoid any confusion
during operation. Pipes should be colored and coded for proper identification and ease
of operation as per the codes prescribed by local legal body.
Once PID audit is completed and system is ready in all respects carry out internal
inspection of all equipment. Ensure that there should not be any foreign material inside.
It should be free from all debris. Note that external process area is equally important
and it should be neat and clean. There should not be any machinery lying inside the
process area, which may create obstacle in operation.
Once physical inspection of all the equipment is completed open bottom most nozzles
of it for flushing purpose. Make temporary arrangements for putting water from top of
the all equipment for flushing it. Remember that these temporary arrangements made
should be removed after water flushing. Flush all the equipment till you get clear water
from bottom nozzles of the respective equipment.
B. Flushing of Piping
During erection there are chances that metal pieces, welding rod pieces, cotton balls etc.
may trap inside pipelines. It is necessary to flush piping to avoid problems like
chocking, damaging of instruments, and pumps during pre-start-up and start-up.
Liquid lines can be flushed with water. Steam lines flushed with steam and airlines can

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be flushed with air. But remember that one end of the line should be open to
atmosphere and other end should be connected to flushing media. During flushing
consider safety aspects of it too.
C. Pressure Safety Valve & Pressure vacuum Relief Valves

All PSV should be tested for their accurate set pressures and proper functioning. It can
be tested at site if facilities are available or should get tested from outside agency with
its certification.
D. Box up of System
Once equipment’s inspection, cleaning and piping flushing is completed; box up the
total system. Ensure that all pipe lines are properly connected in place. All manholes /
man-ways, drains, vents should be closed properly and system should be made ready
for use.
E. Control valve Stroke Checking

It is very important conduct stroke trials of all control valves before putting them in
actual use and process and instrumentation person should witness this. During stroke
trial it is necessary to match valve opening on control panel with valve opening in field.
After complete stroke checking its formal report should be made and problems faced
should be reported and rectified.

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F. Interlock testing
All interlocks should be tested before putting system on line. For interlock test methods
refer to instrumentation instruction manual. Process person should witness this test and
joint report should be made.
G. Utility and Allied System Checks

It is necessary to know readiness of the utilities and allied systems otherwise it may
create nuisance during pre start-up and start-up. In utilities and allied system check
following systems should be ready and designed to supply required inputs to the main
plant and designed to accept outputs from the main plant.
1. Power supply
2. Instrument air supply
3. Steam supply
4. Cooling water supply
5. Fresh Water supply
6. Sealing fluid supply
7. Process Condensate treatment plant.
8. Feed Stock handling section
Its Inspection report should be made and if any lacuna is there it should be brought to
the notice of project engineer to furnish it.

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2.0.1 COOLING WATER LOOP TESTING
2.0.1 (A) SOP FOR ESTABLISHMENT OF COOLING WATER CIRCUIT:

Cooling water system is most important considering plant performance. Cooling water
should be available with desired flow and desired pressure at respective user. Ensure
that cooling water, which is being used, meets all specifications like hardness, pH,
phosphate, turbidity, alkalinity, etc. Its report should be made. Note that analysis of
cooling water should be made on regular basis. Based on analysis reports we can decide
chemical doses required and blow down rates. Better quality of cooling water supply
(CWS) definitely ensures better life of the exchangers and less maintenance cost.
Ensure cooling tower basin is properly cleaned and filled with specified quality and
quantity of makeup water. Makeup water supply system should be available on
continuous basis. Before starting cooling water pumps make sure that all vents on CW
lines are open to vent out the air. Vent at top most point should be open to ensure
complete removal of air from the CW circuit. Then start cooling water supply pumps.
After venting out air and once continuous supply of water starts close vents and
establish the desired flows through respective users with sufficient control valve
opening in MAN mode. Check the CWS pressure on respective header and it should be
sufficient enough to fulfil the requirement. Run the complete cooling water circuit for at
least eight hours to ensure better performance. Make its formal report.
During initial start up of cooling water circuit it is necessary to flush the cooling water
headers. In order to avoid the unwanted material to feed back to the cooling tower, it is
necessary to drain the cooling water return headers before cooling tower. A temporary
arrangement is required to do the same. After ensuring the flushing of the cooling water

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headers, divert the cooling water return header to Cooling Tower and establish the
cooling water circuit.
LIST OF HEAT EXCHANGERS THAT USE COOLING TOWER WATER IN
1. Fermented Mash Preheater (H-1211 A)
2. Fermented Mash Preheater (H-1211 B)
3. Slurry Cooler (H-1212A)
4. Slurry Cooler (H-1212B)
1. Ensure all vents on cooling water supply and return lines are open. Cooling water
vents are provided in order to vent the air from the cooling water lines. This vent is
provided at cooling water return header.
2. Ensure complete venting of air from all high points in the piping around the plant
and close air vent valves.
3. Ensure the flow of cooling water through individual user after complete
establishment of the cooling water circuit in liquefaction section

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2.0.2 WATER FLUSHING /COLD WATER TRIAL

Water Flushing is nothing but cleaning the equipment and arresting the leakages. It is
very important to test plant on water first to see its performance so as not to face any
problem during actual plant operation. During water trial itself it is important to tune-
up all the instruments and observe the performance of rotating equipment too.
Before starting actual water trial ensure there is sufficient Fresh Water stock available.
Following are the equipment to be tested on water along with allied rotating
accessories.
a. Recycle Stream Collection Tank (T-1211)
b. Slurry Mixing Tank (T-1201)
c. Flash tank (T-1212)
d. Initial Liquefaction Tank (T-1202).
e. Final Liquefaction Tank (T-1203).
Before starting actual water trial ensure availability of Fresh Water and other utilities.
All motors, pumps, agitators are to be operated remotely in coordination with field
personnel.
It is presumed that instrument air line flushing, control valve stroking of all control
valves and instrumentation continuity has already been done. Vacuum Trials have been
completed. Flushing of Sealing Water Header and utility headers has been done
thoroughly.
Ensure flow of sealing water to the required pumps.
Water Flushing – Liquefaction Section
1. Close valves on all outgoing lines from Fresh Water Header. Start the Fresh Water
Pump. Check Fresh Water Header pressure.

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2. Ensure that all manual valves on incoming lines to Recycle Stream Collection Tank
(T-1211) are completely closed. Ensure that the manual valve on drain line at outlet
of Recycle Stream Collection Tank (T-1211) is closed.
3. Start Fresh Water supply to Recycle Stream Collection Tank (T-1211) by opening
manual valve on Fresh Water line and by opening LCV-120101 in MAN mode.
4. Open the manual drain valve at suction of P-1211A/B. Drain the water till clear
water starts flowing out. Close the drain valve. Calibrate LT 120101 on Recycle
Stream Collection Tank (T-1211).
5. After achieving 30% level in Recycle Stream Collection Tank (T-1211) start P-
1211A/B and open valve on recycle line and start recirculating water to Recycle
6. Open manual valves on P-1211A/B discharge to Premasher (E-1201) by opening
manual valve and FCV-120102.
7. Ensure that all manual valves on incoming lines to Slurry Mixing Tank (T-1201) are
completely closed. Ensure that the manual valve on drain line at outlet of Slurry
Mixing Tank (T-1201) is closed. Ensure that the suction valves of the Slurry Mixing
Tank Pumps P-1201 A/B are completely closed.
8. Process Water will overflow from Premasher (E-1201) to Slurry Mixing Tank (T-
1201).
9. Calibrate FIT-120102 based on level drop of Recycle Stream Collection Tank (T-1211)
and take LCV-120101 in AUTO mode. After calibration of FIT-120102 take Recycle
Stream Collection Tank (T-1211) level controller LIC- 120101 in AUTO mode with
50% set point.

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10. Open the manual drain valve at suction of Slurry Mixing Tank Pumps (P-1201A/B).
Drain the water till clear water starts flowing out. Close the drain valve. Calibrate
LT -120201 on the Slurry Mixing Tank (T-1201).
11. As level of Slurry Mixing Tank (T-1201) is up to 30% (Variable), start the agitator A-
1201 remotely. Ensure mixing profile of the agitator.
12. Once 60% level is achieved in Slurry Mixing Tank T-1201, open the suction valves of
the Slurry Mixing Tank Pumps (P-1201A/B). Start Slurry Mixing Tank Pump
(P-1201A/B). Open butterfly Valve on re-circulation line of Slurry Mixing Tank (T-
1201). Water will start re-circulating back to Slurry Mixing Tank (T-1201). Check the
performance of the Pump. Open LCV-120202.
13. Open PCV-120301 and PCV-120302 in MAN mode while filling Cook Tube with
water in order to avoid the pressurization.
14. Ensure flow to Jet Cooker (J-1201). When level in Slurry Mixing Tank (T-1201)
reaches up to 85%, take LCV-120202 in AUTO mode with 80 % set point.
15. Close valve on re-circulation line to Slurry Mixing Tank (T-1201). Water will start
flowing to Jet Cooker (J-1201). Ensure the proper flow indication on FIT-120301.
16. Open drain valve on outlet of Jet Cooker (J-1201) to Cook Tube (T-1213). Drain water
to gutter until clear water is observed. Close drain valve. Water will start flowing to
Cook Tube (T-1213).
17. Once Cook Tube is filled, open drain valve on outlet of Jet Cooker (J-1201) to Cook
Tube (T-1213). Drain water to gutter. Level in Cook Tube (T-1213) will start falling
slowly. Stop water supply to Jet Cooker (J-1201). Ensure clear process water from
Cook Tube (T-1213) and close the drain valve later.

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18. Ensure that the Drain Valve at outlet of Flash Tank (T-1212) and Flash Tank Bottom
Transfer Pump (P-1212A/B) is completely closed. Close suction valves of Flash Tank
Bottom Transfer Pump (P-1212A/B).
19. Allow overflow from Cook Tube (T-1213) to flow in to Flash Tank (T-1212).
20. Open drain valve at outlet of Flash Tank (T-1212). Drain water to gutter till clear
water begins to flow out. Close the drain valve. Level in the Flash Tank (T-1212) will
start to rise.
21. Calibrate LT-120303 on the Flash Tank (T-1212).
22. Once Flash Tank is filled up to 70%, open suction valve of (P-1212A/B). Open LCV-
120303 in MAN mode and start Flash Tank Bottom Transfer Pump (P-1212A/B).
Check performance of the Pump. Water will start flowing to Initial Liquefaction
Tank (T-1202). Take LCV-120303 in AUTO mode with 60 % set point.
23. Ensure that the drain valve at the outlet of Initial Liquefaction Tank (T-1202) is
closed. Suction Valves of Initial Liquefaction Tank Transfer Pump (P-1202A/B)
closed. Discharge Valves of Initial Liquefaction Tank Transfer Pump (P-1202A/B)
closed.
24. Level in Initial Liquefaction Tank (T-1202) will start rising. Open drain valve at the
outlet of Initial Liquefaction Tank (T-1202). Drain water to gutter till clear water
begins to flow out. Close the drain valve.
25. Open the suction valves of (P-1202A/B). Close LCV-120401 completely by operating
it in MAN mode from the Control Panel. Open the Butterfly Valve on re-circulation
line of Initial Liquefaction Tank (T-1202) manually.
26. Calibrate LT 120401 on the Initial Liquefaction Tank (T-1202).

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27. Once 30% (variable) level is achieved in Initial Liquefaction Tank (T-1202), start the
Agitator for Initial Liquefaction Tank (A-1202) remotely. Check the performance of
the agitator.
28. Once level in the Initial Liquefaction Tank (T-1202) reaches to 60%, start P-1202A/B.
Check the performance of the pump. Ensure that water flows to the Initial
Liquefaction Tank (T-1202) through the re-circulation line.
29. Close circulation valve and open LCV-120401 in MAN mode. Water will start
flowing to Final Liquefaction Tank (T-1203). Also check P-1202A/B discharge line to
Final Liquefaction Tank (T-1203).
30. Once level of water in Initial Liquefaction Tank (T-1202) rises to 85%, switchover
LIC-120401 to AUTO mode. Give Set Point at 80%.
31. Open drain valve on Final Liquefaction Tank Transfer Pump (P-1203A/B). Drain
water to gutter till clear water begins to flow out. Close the drain valve. Level in the
Final Liquefaction Tank will start rising. Open suction valve of Final Liquefaction
32. Close LCV-120402 completely by operating it in manual mode from the Control
Panel. Open the Butterfly Valve on re-circulation line of Final Liquefaction Tank (T-
1203) manually.
33. Calibrate LT-120402 on the Final Liquefaction Tank (T-1203).
34. Once 30% level is achieved in Final Liquefaction Tank (T-1203), start the Agitator for
Final Liquefaction Tank (A-1203) remotely. Check the performance of the agitator.
35. Start P-1203A/B. Check the performance of the pump. Ensure that water flows to
the Final Liquefaction Tank (T-1203) through the re-circulation line.

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36. Once level of water in Final Liquefaction Tank (T-1203) rises to 85%, switchover
LIC-120402 to AUTO mode with 80% set point. Close the manual valve on the
re-circulation line of the Final Liquefaction Tank (T-1203).
37. Open manual valves, so that Fermented Mash Preheater (H-1211A) & Slurry Cooler
(H-1212 A) will be on line. Open vents on PHE outlet to vent the air. Close the vents
after removing entrapped air.
38. Open manual valves so that Fermented Mash Preheater (H-1211B) & Slurry Cooler
(H-1212 B) will be on line and close manual valves so that (H-1211 A) & (H-1212 A)
will be off line.
39. Open valve on Fresh Water to Aqueous Ammonia dosing system (U-1243). Open U-
1243 bottom drain valve. Close the drain valve after observing the clear water from
the drain. Level of the tank will start rising. Fill the tank up to 80% level. Stop water
make up to the tank. Start pump and open tank circulation valve. Close circulation
valve and open valves on line going to Slurry Mixing Tank (T-1201). Ensure the flow
to Slurry Mixing Tank (T-1201). Stop the pump after empty out the tank.
40. Open valve on Fresh Water to Liquefying Enzyme dosing system (U-1241). Open U-
1241 bottom valve and drain valve. Close the drain valve after observing the clear
water from the drain. Level of the tank will start rising. Fill the tank up to 80 % level.
Stop water make up to the tank. Start pump and open tank circulation valve. Close
circulation valve and open valves on line going to Slurry Mixing Tank (T-1201)
through FIT120601 and Initial Liquefaction Tank (T-1202) through FIT120602.
Ensure the flow to Recycle Stream Collection Tank (T-1201) and Initial Liquefaction
Tank (T-1202). Stop the pump after empty out the tank.
41. Open valve on Fresh Water to Saccharifying Enzyme dosing system (U-1344). Open
U-1344 bottom valve and drain valve. Close the drain valve after observing the clear

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water from the drain. Level of the tank will start rising. Fill the tank up to 80 % level.
circulation valve and open valves on line going to Fermentation Section. Ensure the
flow to Fermentation Section. Stop the pump after empty out the tank.
42. Open valve on Fresh Water to Viscosity Reducing Enzyme dosing system (U-1242).
Open U-1242 bottom drain valve. Close the drain valve after observing the clear
water from the drain. Level of the tank will start rising. Fill the tank up to 80% level.
circulation valve and open valves on line going to Slurry Mixing Tank (T-1201).
Ensure the flow to Slurry Mixing Tank (T-1201). Stop the pump after empty out the
tank.

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2.0.3 VACUUM TRIAL
Vacuum Trials is required for Flash Tank (T-1212) and is to be taken at the time of
vacuum trial for Distillation section.
Vacuum trial for liquefaction section to be carried out after completion of water
flushing:
1. Close PCV-120301 completely by Operating PIC-120301 in Manual mode. This will
ensure that the Cook Tube (T-1213) will not be subjected to Vacuum.
2. Ensure that the flash tank bottom manual butterfly valve is completely closed.
3. After ensuring vacuum in C-1462 slowly open PCV-120302 in manual mode.
4. Once maximum possible Vacuum is attained and the corresponding Pressure is
indicated by PIT-120302, arrest the leakages if any.
5. Ensure that rate of drop in vacuum does not exceed 20 ~ 25 mm of mercury per
Hour as indicated by PIT-120302 after closing PCV-120302.
2.0.4 STEAM TRIAL

The purpose of steam trial is to ensure the line up, leakages, instruments healthiness.
Steam trial is to be carried out in coordination with boiler house.
It is presumed that instrument air line flushing, control valve stroking of all control
valves and instrumentation continuity has already been done. Vacuum Trials have been
completed as well. Flushing of all utility headers has been done thoroughly. PSV tested
and installed at its place.

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2.0.4.a SOP for charging low pressure steam header

1. Ensure all steam trap inlet valves closed and steam trap bypass valves full open.
2. Ensure all valves on steam header are closed.
3. Slowly open steam main isolation valve (B/L) to the plant.
4. Allow steam / condensate to drain from steam trap bypass valves.
5. Ensure there are no leakages, increase steam pressure set point to the plant (B/L)
slowly in stepwise manner (2-3 psig per 10 min) to 18 psig.
6. Ensure the 100 % isolation of all valves on steam header.
7. Ensure complete draining of steam condensate from the steam header, take steam
traps TST-400206 and TST-400204 on low pressure steam header on line. In order to
take a steam trap on line, close steam trap bypass valve and open steam trap inlet
and outlet manual valves.
8. Ensure healthiness of PI-400203 & TI-400202. Ensure steam is saturated based on PI-
400203 & TI-400202 reading.
9. Ensure healthiness of TST-400206 and TST-400204. Steam trap must be able drain the
steam condensate as soon as it gets accumulated in steam header. Faulty operation
of steam trap may result in accumulation of steam condensate in steam header
followed by steam hammering.
10. While opening the isolation valves on steam header to respective user, open the
valve gradually and allow the condensate to drain from respective steam trap of the
user. Take steam trap on line after ensuring complete removal of steam condensate.

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Steam trial for liquefaction section

1. Ensure low pressure steam header is charged as per SOP. Refer 2.0.4.1
2. Ensure the water flow circuit is established in liquefaction. Refer 2.0.1.(A)
3. Ensure inlet valve before FIT-130901 closed.
4. Open slowly steam header isolation valve on steam line going to CIP Solution Pre
Heater H-1351.
5. Take FIT-130901 on line after ensuring no steam condensate in the line and ensure
its healthiness.
6. Ensure flow of water through tube side of CIP Solution Pre Heater H-1351.
7. Slowly open valve on steam header to Slurry Mixing Tank (T-1201). Open TST-
400204 bypass valve. Close the bypass valve after ensuring the complete draining of
condensate. Take TST-400204 on line and ensure its healthiness.
8. Ensure Slurry Mixing Tank (T-1201) having 30 – 50% level and under circulation.
Open manual inlet and outlet valve of FCV-120201. Open FCV-120201 5% in MAN
mode. Slowly increase the valve opening and ensure the healthiness of FIT-120201
and TIC-120201. TIC-120201 will slowly goes on increasing. When Slurry Mixing
Tank (T-1201) temperature reaches 850 C, take TIC-120201 in AUTO mode with 850C
set point and take FQIC-120201 in CAS mode.
9. Ensure the flow of water through Jet Cooker (J-1201). Ensure the availability of high
pressure steam. Ensure TST-400201 is in line and all steam condensate from the line
is already drained by using bypass line.
10. Open 5% manual valve on steam line to Jet Cooker (J-1201). Slowly increase valve
opening and ensure healthiness of FIT-120301, PI-120304, and TI-120302.
11. Take TIC-120301 in AUTO mode, which controls the outlet temperature of Jet
Cooker (J-1201).

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12. Open the manual valves 5 – 10 % approximately of steam header to service tapping
and flush the lines accordingly. (Note – Proper care should be taken while flushing
the flexible hoses in order to avoid its displacement)
13. After completion of the steam trial inform boiler house regarding the stoppage of
steam to the plant. Slowly start reducing the steam to individual users. Close all
isolation / control valves after closing main steam supply valve (B/L) to the plant.
Note – After completion of water and steam trial stop all pumps. Ensure all
control valves and isolation valves are closed. Drain all tanks and lines.

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2.0.5 STANDARD OPERATING PROCEDURE

2.0.5. a SOP for Liquefying Enzyme dosing system
Alfa Amylase is liquefying enzyme and is stored in Alfa Amylase dosing system (U-
1243) and is pumped by Alfa Amylase metering Pump to process. Alfa Amylase
enzyme is used in Liquefaction section.
1. Ensure water flushing of alfa amylase dosing system is completed.
2. Physically check the tank before loading of alfa amylase to (U-1243).
3. Ensure tank drain valve is closed.
4. Use all required PPE’s and follow safe operating practices.
5. Ensure the alfa amylase quality.
6. Start loading alfa amylase to Alfa Amylase dosing system (U-1243). Keep watch on
level indication on LI-120603.
7. Stop alfa amylase filling to Alfa Amylase dosing system (U-1243) at 80% level.
8. Open metering pump suction and discharge manual valves. Open manual valve on
alfa amylase line to Slurry Mixing Tank T-1201. Start metering pump. Ensure the
flow through FI-120601. Open manual valve on alfa amylase line to P-1212A/B
suction and ensure the flow through FI-120602.
9. Stop metering pump after dosing and close the manual valves.
10. Alfa amylase dosing is batch mode of operation.

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2.0.5.b SOP for Viscosity Reducing Enzyme dosing system

Viscosity Reducing Enzyme is stored in Viscosity Reducing Enzyme dosing system (U-
1242) and is pumped by Viscosity Reducing Enzyme metering Pump to process.
Viscosity Reducing Enzyme is used in Liquefaction section.
1. Ensure water flushing of Viscosity Reducing Enzyme dosing system (U-1242) is
completed.
2. Physically check the tank before loading of Enzyme.
5. Ensure the Viscosity Reducing Enzyme quality.
6. Start loading Viscosity Reducing Enzyme to Viscosity Reducing Enzyme dosing
system (U-1242). Keep watch on level indication on LI-120603.
7. Stop Viscosity Reducing Enzyme filling to Viscosity Reducing Enzyme dosing
system (U-1242) at 80% level.
Viscosity Reducing Enzyme line to Slurry Mixing Tank T-1201. Start metering
pump. Ensure the flow. Stop metering pump after dosing and close the manual
valves.
9. Viscosity Reducing Enzyme dosing is batch mode of operation.

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2.0.5.c SOP for Aqueous Ammonia Dosing System

Aqueous Ammonia (25%w/w conc.) is stored in Aqua Ammonia Dosing System (U-
1243). It is used to maintain optimum pH in liquefaction section.
1. Ensure water flushing of aqua ammonia dosing system is completed.
2. Physically check the tank before loading of aqueous ammonia to U-1243.
4. Start loading aqueous ammonia to U-1243. Keep watch on local level indication LI-
120603.
5. Stop aqua ammonia filling to U-1243 at 80% level in U-1243.
6. Line out aqueous ammonia to Slurry Mixing Tank (T-1201) by taking AIC-120203 in
AUTO mode. Open manual valve on pump suction and discharge line. Ensure ACV-
120203 and manual isolation valve of ACV-120203 and start the pump.
7. Aqueous ammonia dosing is continuous mode of operation.

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2.0.5.d SOP for Saccharifying Enzyme dosing system

Gluco Amylase is saccharifying enzyme and is stored in saccharifying enzyme dosing
system (U-1344) and is pumped by metering Pump to process. Gluco Amylase enzyme
is used in Fermentation section.
1. Ensure water flushing of gluco amylase dosing system is completed.
2. Physically check the tank before loading of gluco amylase to saccharifying enzyme
dosing system (U-1344).
5. Ensure the gluco amylase quality.
6. Start loading gluco amylase to saccharifying enzyme dosing system (U-1344). Keep
watch on level indication on LI-120603.
7. Stop gluco amylase filling to saccharifying enzyme dosing system (U-1344) at 80%
level.
gluco amylase line to Fermentation section. Start metering pump. Ensure the flow to
Yeast Activation Vessel. Open manual valve on gluco amylase line and line out till
fermentor.
9. Stop metering pump after dosing and close the manual valves.
10. Gluco amylase dosing is batch mode of operation.

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2.0.5.e SOP for Preparation of 3.0 % w/w caustic solution in T-1351
1. Ensure CIP Tank T-1351 vent line is clear and open.

2. Ensure the tank T-1351 is empty.
3. Ensure T-1351 drain valve is closed.
4. Open valve on water supply line and fill the required quantity of Fresh Water 1 in
the tank (Check against level of the tank). During normal operation of the plant
evaporation condensate to be used instead of Fresh Water1.
5. Close valve on water supply line and confirm level in the tank.
6. Open valve on P-1351A/B suction and Start P-1351A/B and start circulation
through H-1351 by opening manual inlet and outlet valve of H-1351.
7. Ensure caustic lye stock (50% w/w) in Caustic Solution Storage Tank (T-351).
8. Ensure manual valve on caustic lye line to U-343 is closed. Open P-351 suction
manual valve and start the pump.
9. Open manual valve on caustic lye supply line to T-1351 and add required quantity
caustic lye (Check against level of the tank).
10. Close valve on caustic lye supply line and stop P-351. Keep caustic solution under
circulation for half hour.
11. Ensure and confirm the caustic solution concentration of the tank (Standard
Titration with dilute HCL – 0.1N).
12. Ensure T-214 is ready to accept steam condensate from H-1351.
13. Open manual valve on low pressure steam to H-1351.
14. Open FST-3237 steam trap bypass valve.
15. Ensure the T-1351 is in circulation through H-1351, open FCV-3175 on low pressure
steam line to H-1351 5% in MAN mode. Take steam trap FST-3227 on line by

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opening steam trap inlet and outlet valve and close trap bypass valve. Steam
condensate will start flowing to T-214.
16. Take FIQC-3175 in AUTO mode and gradually increase the set point to 12000 lb/hr.
17. Keep watch on T-1351 temperature on TI-3175. When temperature of T-1351 reaches
170-175 oF, close FCV-3175 on low pressure steam line to H-1351 in MAN mode.
18. Hot CIP solution is ready for CIP.

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PART–III
PROCESS START UP
AND
PROCESS PARAMETER

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Operator must read and understand these instructions before operating the plant.
(1) The procedures and operating conditions listed here are guidelines only and may be
modified on start-up. The control system must be flexible enough to accommodate
these changes.
(2) This does not cover peripheral equipment, which may affect the plant operation.
(3) It is expected that the operator may be required to take some decisions and actions
not covered by this manual. The operator will be expected to monitor the system
during operation, and may need to intervene to assure safe operation of the plant as
and when required. The control system must be flexible enough to allow operator
intervention when necessary.
(4) Operator should read the bought-out items operation manual / safety procedures
received from respective vendors and follow the instructions as mentioned in their
manual before starting / stopping the respective item.
(5) Operating personnel should follow the safety regulations as per factory rules as well
as factory acts and regulations.
(6) Before plant start it is necessary to make detailed schedule so as to understand
sequence of start-up of individual sections and their synchronization.

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Safety Notes
1. This is a hardhat and safety glasses area.
2. Never attempt to repair or replace the equipment in this area without prior
consent from authorized plant personnel. Never attempt to repair or replace any
equipment in this area without following Lockout-Tag out (LOTO) procedure
3. Good housekeeping is required, keep the area clean and free of debris.
4. Grain dust is explosive. Use adequate ventilation and follow cleaning practices
for any safe hot work practices.
5. Be cautious from rotary / moving equipment like conveyors.
6. No Smoking Zone.
7. Carbon Dioxide is toxic.
8. Use safety goggle, gloves and follow safe practices while handling chemicals like
concentrated sulphuric acid, nitric acid, urea, aqua ammonia, enzymes and active
dry yeast.
9. High temperature steam / mash use PPE.

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NOTE – REFER ‘OPM PRE-STARTUP ACTIVITIES’ FOR DETAILED PROCEDURE
OF TAKING ANY EQUIPMENT ON LINE AND FOR SOP.
3.0.1 NORMAL START UP
1. Assure all work is completed; permits returned and visually inspect all equipment.
2. Before starting this section, ensure that the Milling Section is ready to start.
3. Analyse corn and sorghum flour for sieve analysis, moisture content, total solids,
starch and other components. Refer Praj Analytical Manual.
4. Ensure that in auxiliaries respective enzymes are filled in enzyme dosing system as
per the specification and approved by Quality Control laboratory.
5. Ensure that aqueous ammonia has been charged in aqueous ammonia dosing
system as per the specification. Caustic addition provision is also given to Aqueous
Ammonia Dosing System.
6. Ensure that the suction and discharge valve of all pumps are closed.
7. Close all the drain valves of all tanks in Liquefaction Section.
8. Start Air Compressor and ensure that the auxiliaries and utilities sections are in
ready condition.
9. Ensure availability of Low Pressure Steam, Fresh Water, Cooling Water, High
Pressure steam and instrument air at rated pressure.
10. Ensure that the drain valve on the suction line of the Slurry Transfer Pump (P-
1201A/B) is completely closed.
11. Ensure that Fresh Water is available for sealing of pumps.
12. Ensure vacuum is applied to distillation section and is ready to accept vapors from
Flash Tank.

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13. Open manual valve on Fresh Water line to Recycle Stream Collection Tank (T-1211).
Open LCV-120101 in MAN mode.
14. When Evaporation section is working, UF Permeate will be transferred to Recycle
Stream Collection Tank (T-1211), thus reducing fresh water consumption.
15. After distillation section is started, spent lees from Exhaust Column C-1462 will be
transferred to Recycle Stream Collection Tank (T-1211), thus reducing fresh water
consumption.
16. Steam condensate from CIP solution Preheater will also be transferred to Recycle
17. Once 70% (variable) level is achieved in the Recycle Stream Collection Tank (T-1211),
take LIC-120101 in AUTO mode with 70% (variable) set point.
18. Open Recycle Stream Transfer pump (P-1211A/B) suction and discharge manual
valve and start the pump. Open manual valve after FCV-120102 on Recycle stream
water to Premasher with motor (E-1201). Open FCV-120102 in MAN mode. Ensure
flow of water through FCV-120102.
19. Take FCV-120102 in AUTO mode with 20,200/24540/31929 LPH set point for Corn
/ Sorghum without Tannin / Sorghum with Tannin respectively.
Note – While starting steam to any user, pressure of steam header to be monitored
in order to avoid the sudden fluctuations.
20. Once water is fed to the Premasher (E-1201), it will start flowing into the Slurry
Mixing Tank (T-1201).
21. Start the motor of the Premasher (E-1201).
22. Start feeding Thin Stillage from Decantation section to Premasher (E-1201)
immediately after start-up of Decantation section. Recycle Stream water to be used
initially on higher rate as per requirement. After availability of Thin Stillage, Recycle

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Stream water to be decreased accordingly. If water boiling in distillation is going on,

the water can be recycled through Thin stillage line and water will be replaced by
thin stillage after feeding fermented mash to Mash Column. (Note – thin stillage
addition will change the temperature and lower the pH of Slurry Mixing Tank)
23. When 15 to 20% level is achieved in the Slurry Mixing Tank (T-1201), open the
suction valve on Slurry Transfer Pump (P-1201A/B) after confirmation from
maintenance regarding which pump to be used. Ensure that LCV120202 is closed.
Start Pump and gradually open the discharge valve of the Pump. Open Slurry
Mixing Tank (T-1201) circulation valve 100% and ensure tank is in circulation.
24. Once the 30% (variable) level is achieved in the Slurry Mixing Tank, start the
agitator A-1201.
25. Viscosity Reducing Enzyme may also be used for Sorghum case.
26. Maintain the temperature of the Slurry Mixing Tank (T-1201) at 850C by sparging
steam through the sparger N-1201. Take TIC-120201 in AUTO mode with 850C set
point and FQIC-120201 in CAS mode.
27. Ensure distillation system under vacuum. Take PI-120302 in AUTO mode with 0.58
bar (a) as set point.
28. Set the downstream pressure control valve PCV-120301 about 25 -50% open.
29. Open LCV-120202 in MAN mode with 43,240 LPH flow of water to Cook Tube (T-
1213) through FIT-120301.
Note: – Monitor PT-120301 and PT-120302 continuously during the initial start up.
If pressure gets to high it can rupture safety disc PSV 120301 and PSV-120302.
30. Allow Recycle Stream water to pass through the Cook Tube (T-1213).
31. Recycle Stream water coming out of the Cook Tube (T-1213) will depressurise in the
Flash Tank (T-1212).

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32. Lined out Recycle Stream water from Flash Tank back to Slurry Mixing Tank by
opening Auto valve XV 120301 on discharge to Flash Tank. Ensure manual valve on
P-1212A/B discharge to Initial Liquefaction Tank (T-1202)) & Final Liquefaction
Tank (T-1203) is closed.
33. Start P-1212A/B and maintain level in Flash Tank about 20% (variable) by taking
LIC-120303 in AUTO mode with 20% (variable) set point.
Note – While starting steam to any user, pressure of steam header to be monitored
in order to avoid the sudden fluctuations.
For Jet Cooker it is important that slurry and steam should be with constant
pressure to achieve desired temperature at the outlet. Do not adjust combining
tube on Jet Cooker from the factory setting unless advised by vendor.
34. Adjust the steam flow rate to the Jet Cooker so as to maintain the temperature at the
outlet of Jet Cooker at 110-115 oC. Control back pressure manually by controlling
PCV-120301. Start building pressure in Cook Tube (T-1213) by reducing PCV-120301
in MAN mode. Take PIC-120301 in AUTO mode with 2.8 bar (A) set point.
35. Flashed vapours are fed to Exhaust Column C-1462.
Note: As flashed vapours are fed to Exhaust Column C-1462 it will heat up.
36. Maintain optimum pH of the slurry by adding aqueous ammonia in the Slurry
Mixing Tank (T-1201). Take pH controller AIC-120203 in AUTO mode with 6.5 set
point.
37. Once Slurry Mixing Tank (T-1201) temperature reaches 850C, Start Seal Conveyor (E-
1202).
38. Start Hammer mill Section (Refer SOP for grain milling section) and begin feeding
Corn/Sorghum Flour to the Premasher (E-1201) slowly. Corn OR Sorghum flour
will get mixed with hot water to generate slurry.

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39. Start liquefying enzyme supply to Premasher (E-1201) with reference to starch
analysis in the laboratory. About 1/3rd of the total liquefying enzyme is added to
Slurry Mixing Tank by starting metering pump.
Note: Operator must monitor slurry solids after start of flour.
40. Ensure optimum DS (dry solids) of slurry by controlling flow rate of hot water/
flour.
41. Adjust the steam flow rate to maintain the temperature at the outlet of Jet Cooker at
110 ~ 115oC. Start building pressure in Cook Tube T-1213 by reducing PCV-120301
in MAN mode. Take PIC-2030 in AUTO mode with 25.7 psia set point.
42. Flashed vapours are fed to Exhaust Column C-1462.
Note: As flashed vapours are fed to Exhaust Column C-1462 it will heat up.
43. Once temperature at the outlet of Jet Cooker is achieved to 1100C, line out the slurry
to Initial Liquefaction Tank (T-1202) by opening manual valve on slurry to Initial
Liquefaction Tank (T-1202). Close auto valve on slurry circulation Line to Slurry
44. Start Liquefying Enzyme Dosing at measured flow rate through FIT-120602 to P-
1212A/B suction at the same time when slurry starts transferring to Initial
Liquefaction Tank (T- 1202). About 2/3rd of the total liquefying enzyme is added to
Initial liquefaction Tank (T-1202) through P-1212A/B suction by starting metering
pump.
45. Open the suction valve of Initial Liquefaction Tank Transfer Pump (P-1202A/B) and
start the pump. Open the tank circulation valve gradually.
46. Once 30% level is achieved in the Initial Liquefaction Tank T-1202, start the Agitator
for Initial Liquefaction Tank A-1202.

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47. Allow Slurry Mixing Tank (T-1201) level to increase. Take LIC-120201 in AUTO
mode after achieving 80% (variable) level with 80% set point.
48. Take Initial Liquefaction Tank T-1202 LIC-120401 in AUTO mode with 80 % set
point.
49. Take sample of Liquefied Slurry from outlet of Initial Liquefaction Tank T-1202 for
analysis of `Dry Solid (DS)’ contents. It should be maintained to 25 - 30 % w/w by
adjusting hot Fresh Water flow rate.
50. Allow Liquefied Slurry to flow to the Final Liquefaction Tank (T-1203).
51. After achieving the 30% (variable) Level in the Final Liquefaction tank (T-1203), start
the Agitator for Final Liquefaction Tank A-1203.
52. Open the suction valve of the Final Liquefaction Tank Transfer Pump (P-1203A/B)
and start the pump. Gradually open the tank circulation valve.
53. Take sample of Liquefied Slurry from outlet of Final Liquefaction Tank (T-1203) for
analysis of `Residual Starch’ by `Iodine Test’. Iodine test should be negative after
final liquefaction tank. If starch has not been converted to dextrins, iodine test will
turn slurry sample to violet. If it remains colourless it indicates negative test. Take
LIC-120402 in AUTO mode with 80% set point.
54. Ensure that the valves on the Cooling Water inlet and outlet line to the Slurry Cooler
H-1212 A/B are open. Line out liquefied slurry to Yeast Activation Vessel R-
1321A/B through Fermented Mash Preheater H-1211A/B and Slurry Cooler H-
1212A/B by opening respective manual valves. Part of heat from liquefied slurry is
used for preheating the fermented mash to feed to Mash Column in Fermented
Mash Preheater H-1211 A/B and remaining heat will be removed in Slurry Cooler
H-1212 A/B. (CIP of Fermented Mash Preheater (H-1211 A/B) and H-1212 A/B

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should be followed after not getting the desired heat exchange from the respective
heat exchanger)
55. Maintain all parameters as mentioned in the Operating Parameters Section.
56. After ensuring the stabilisation of liquefaction process start increasing feeding to
Slurry Mixing Tank (T-1201) till the flow rate of liquefied slurry to fermentation
section reaches desired capacity.

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3.0.2 PROCESS PARAMETER

3.0.2. (A) FLOW PARAMETER FOR CORN
SR.NO. PARAMETER TAG NO. UNIT VALUE

Fresh Water 1 to Recycle stream
1 FQI-120101 LPH 3580
Collection Tank (T-1211)
Recycle Stream Water to
2 FQIC-120102 LPH 20200
Premasher (E-1201)
UF Permeate to Recycle stream
3 FQIC-120103 LPH 6860
Thin Stillage to Premasher (E-
4 FQIC-120204 LPH 9730
1201)
Low Pressure Steam to Slurry
5 FQIC-120201 Kg/Hr 1680
Mixing Tank (T-1201)
High Pressure Steam to Jet
6 FQI-120301 Kg/Hr 1645
Cooker
7 Grain Slurry to Jet Cooker FI-120301 LPH 43240
Dilute Liquefying Enzyme to
8 FI-120601 LPH 5.5
Slurry mixing tank / Premasher
Dilute Liquefying Enzyme to P-
9 FI-120602 LPH 3.5
1212A/B suction
3.0.2. (B) FLOW PARAMETER FOR SORGHUM WITHOUT TANNIN

1 FQI-120101 LPH 0
2 FQIC-120102 LPH 24540
Premasher (E-1201)
3 FQIC-120103 LPH 14480
4 Thin Stillage to Premasher (E-1201) FQIC-120204 LPH 8175

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5 FQIC-120201 Kg/Hr 1505
6 High Pressure Steam to Jet Cooker FQI-120301 Kg/Hr 1505

8 FI-120601 LPH 5
9 FI-120602 LPH 3
1212A/B suction
3.0.2. (C) FLOW PARAMETER FOR SORGHUM WITH TANNIN

1 FQI-120101 LPH 0
2 FQIC-120102 LPH 31925
Premasher (E-1201)
3 FQIC-120103 LPH 21925
4 Thin Stillage to Premasher (E-1201) FQIC-120204 LPH 0
5 FQIC-120201 Kg/Hr 1530
6 High Pressure Steam to Jet Cooker FQI-120301 Kg/Hr 1670

8 FI-120601 LPH 5
9 FI-120602 LPH 3
1212A/B suction

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TEMPERATURE

Recycle Stream Collection Tank(T- oC
1 TI-120101 75
1211)
2 Slurry Mixing Tank (T-1201) TIC-120201 oC 85
3 Liquefied Mash to Fermentation TIC-120504 oC 35
4 Slurry from Jet Cooker TIC-120301 oC 110

High Pressure Steam Temperature oC
5 TIC-120302 165
to Jet Cooker
6 Flash Tank Temperature TIC-120303 oC 84.5
7 Initial Liquefaction Tank TI-120401 oC 85
8 Final Liquefaction Tank TI-120402 oC 85
9 Fermented Mash out H-1212 A/B TI-120502 oC 34
PRESSURE

1 Cook Tube PIC-120301 Bar(a) 2.8
2 Flash Tank PIC-120302 Bar(a) 0.58

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LEVEL

Recycle Stream Collection Tank
1 LIC-120101 % 80
level
2 Slurry Mixing Tank level LIC-120201 % 80
3 Flash Tank level LIC-120303 % 30
4 Initial Liquefaction Tank LIC-120401 % 80
5 Final Liquefaction Tank LIC-120402 % 80
pH

1 Slurry Mixing Tank AIC-120203 - 6.5

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3.0.3 CLEANING IN PLACE (CIP)

Cleaning in Liquefaction section to be carried out immediately after shut down.
SOP for CIP of liquefaction section with Recycle Stream water after shutdown –
1. Start Recycle stream transfer pump (P-1211A/B); open FCV-120102 in MAN mode.
Recycle Stream water will start flowing to Slurry Mixing Tank (T-1201) through
Premasher (E-1201).
2. Start electrical motor for Premasher (E-1201).
3. At 30% level in Slurry Mixing Tank (T-1201) start agitator (A-1201) and stop Recycle
Stream Transfer Pump (P-1211A/B) and electrical motor for Premasher.
4. Take PCV-120302 and PCV-120301 in MAN mode.
5. Start Slurry Transfer Pump (P-1201A/B) and open LCV-120202 in MAN mode so
that required flow will start flowing to Cook Tube (T-1213) through Jet Cooker (J-
1201).
6. Divert Recycle Stream Water back to Slurry Mixing Tank (T-1201) by opening Auto
valve XV-120301. Close manual valve on discharge to Initial Liquefaction Tank (T-
1202).
7. Keep Slurry Mixing Tank (T-1201) in circulation through Jet Cooker, Cook Tube and
Flash Tank for 30 minutes.
8. After 30 minutes, start Flash Tank Transfer Pump (P-1212A/B) and take LIC-120303
in AUTO mode, divert Flash Tank Transfer Pump (P-1212A/B) discharge to Initial
Liquefaction Tank (T-1202) by opening respective manual valve and close XV-
120301 valve on discharge to Slurry Mixing Tank (T-1201).
9. Level in Slurry Mixing Tank (T-1201) will start decreasing. At low level in Slurry
Mixing Tank T-1201, Agitator A-1201 will stop automatically. Transfer water from

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Slurry Mixing Tank (T-1201) to Cook Tube (T-1213). Stop Slurry Transfer Pump (P-
1201A/B) and close LCV-120202.
10. Open manual valve at Cook Tube bottom to Flash Tank Bottom Transfer Pump (P-
1212A/B) suction and close manual valve at Flash Tank (T-1212) bottom to Flash
Tank Bottom Transfer Pump (P-1212A/B). Empty out Cook Tube (T-1213)
completely to Initial Liquefaction Tank (T-1202).
11. Open manual valve on Flash Tank (T-1212) bottom to Flash Tank Bottom Transfer
Pump (P-1212A/B) and close manual valve on Cook Tube (T-1213) bottom to Flash
Tank Bottom Transfer Pump (P-1212A/B). Take PCV-120302 in MAN mode with
15% opening. Empty out Flash Tank (T-1212) to Initial Liquefaction Tank (T-1202).
Close PCV-120302 and stop Flash Tank Bottom Transfer Pump (P-1212 A/B).
12. Drain out the balance water level from Slurry Mixing Tank (T-1201), Cook Tube (T-
1213) and Flash Tank (T-1212) to respective drain lines.
Safety Note – Hot fluid, use PPE.
13. Ensure the sufficient level in Initial Liquefaction Tank (T-1202). Start Initial
Liquefaction Tank Transfer Pump (P-1202A/B) and transfer all water from Initial
Liquefaction Tank (T-1202) to Final Liquefaction Tank (T-1203) by opening LCV-
120401 in MAN mode. Stop Initial Liquefaction Tank Transfer Pump (P-1202A/B)
after complete transfer of Initial Liquefaction Tank (T-1202).
14. Ensure the sufficient level in Final Liquefaction Tank (T-1203). Start Final
Liquefaction Tank Transfer Pump (P-1203A/B) and start circulation in Final
Liquefaction Tank (T-1203). The water from Final Liquefaction Tank (T-1203) to be
transferred to fermentation section after shut down of fermentation section. Stop
Final Liquefaction Tank Transfer Pump (P-1203A/B) after transferring water to

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fermentation section through Fermented Mash Preheater (H-1211 A/B) and Slurry
Cooler (H-1212A/B).
15. Drain remaining water level from Initial Liquefaction Tank (T-1202) and Final
Liquefaction Tank (T-1203) by opening respective drain valves.
16. Carry out CIP for Fermented Mash Preheater (H-1211 A/B) and Slurry Cooler (H-
1212A/B). Refer SOP for CIP for Fermented Mash Preheater (H-1211 A/B) and
Slurry Cooler (H-1212A/B).
17. During short shutdown of more than 4 hours perform the CIP of Slurry Mixing Tank
(T-1201), Initial Liquefaction Tank (T-1202), Final Liquefaction Tank (T-1203) using
CIP cleaning nozzle and transfer slurry to Beerwell.
SOP for Changeover and CIP to Fermented Mash Preheater (H-1211 A/B) & Slurry
Cooler (H-1212 A/B)
The operator should always be aware of what the Delta T and Delta P normally run on
the heat exchangers.
Flush liquefied slurry out of exchangers A.S.A.P. (Never let it sit longer than necessary)
Ensure that 2.5-3.0 %w/w Caustic solution (CIP) solution has been prepared in CIP
Tank (T-1351).
1. Ensure CIP solution is ready in CIP Tank (T-1351).
2. Ensure CIP Pump (P- 1351A/B) is running.
3. Ensure valve on LP steam to CIP Solution Pre Heater (H-1351) is closed, open
manual valve on CIP Pump (P- 1351A/B) discharge. Throttle CIP tank (T-1351)
circulation valve.
4. Stop CIP Pump (P- 1351A/B) after CIP.

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Note –
At the time of Fermented Mash Preheater (H-1211 A/B) changeover, keep fermented
mash to Mash Column FCV-140103 in MAN mode in order to avoid sudden
fluctuation and control the mash flow manually. Continuous monitoring is
necessary. After stabilization of flow take FCV-140103 in AUTO mode.
SOP for Changeover of Fermented Mash Preheater (H-1211A) to (H-1211B)
a. Ensure Fermented Mash Preheater (H-1211 B) is CIP’d and ready for operation.
b. Ensure Fermented Mash Preheater (H-1211 B) drains and vents closed.
c. Ensure manual valves of CIP closed.
d. Open 100BF120502 & 100BF120515.
e. Open 100BF120523 & 100BF120519.
f. Close 100BF120503 &100BF120505.
g. Close 100BF120513 & 100BF120508.
h. Ensure flow through Fermented Mash Preheater (H-1211 B).
i. Fermented Mash Preheater (H-1211 A) is ready for CIP.
SOP for CIP of Fermented Mash Preheater H-1211A
1. Ensure Fermented Mash Preheater (H-1211 A) is ready for CIP.

2. Open manual valve on UF Permeate /Fresh Water to CIP Tank.
3. Close manual valve at CIP Tank (T-1351) bottom to CIP Pump (P- 1351A/B).

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4. Open 80BF120504, 80BF120510 and 80BF120507 and close 100BF120505,

100BF120503, 100BF120513 and 100BF120508. Flush the slurry side of H-1211A back
to Beerwell for 5 minute (variable).
5. Open manual valve at CIP Tank (T-1351) bottom to CIP Pump (P- 1351A/B) suction
and close manual valve on UF Permeate /Fresh Water to CIP Pump (P- 1351A/B).
6. Circulate CIP solution through PHE and back to CIP Tank for 15 minutes (variable).
7. After 15 minutes (variable), open manual valve on Fresh Water to CIP Pump (P-
1351A/B) suction and close manual valve at CIP Tank (T-1351) bottom to CIP Pump
(P- 1351A/B).
8. Flush both sides of PHE with Fresh Water for 5 minutes.
9. After flushing of H-1211A with Fresh Water, stop CIP Pump (P- 1351A/B). Close
discharge valve and close manual valve on Fresh Water to CIP Pump (P- 1351A/B)
suction.
10. Close 80BF120504, 80BF120510 and 80BF120507.
11. Drain H-1211 A completely by opening PHE drain valves.
12. Close PHE drain valves after ensuring complete draining of PHE.
13. H-1211 A is ready for operation.
SOP for Changeover of Fermented Mash Preheater H-1211 B to Fermented Mash
Preheater H-1211A
1. Ensure H-1211 A is CIP’d and ready for operation.
2. Ensure H-1211 A drains and vents closed.
3. Ensure 80BF120504, 80BF120510 & 80BF120507 closed.
4. Open 100BF120508 & 100BF120513.
5. Open 100BF120503 & 100BF120505.
6. Close 100BF120519 & 100BF120523.

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7. Close 100BF120502 & 80BF120515.

8. Ensure flow through H-1211A.
9. H-1211 B is ready for CIP.
SOP for CIP of Fermented Mash Preheater H-1211B
1. Ensure Fermented Mash Preheater (H-1211 B) is ready for CIP.
3. Close manual valve at CIP Tank (T-1351) bottom to CIP Pump (P- 1351A/B).
4. Open 80BF120514, 80BF120521 and 80BF120518 and close 100BF120515,
100BF120502, 100BF120523 and 100BF120519. Flush the slurry side of H-1211 B back
to Beerwell for 5 minute (variable).
5. Open manual valve at CIP Tank (T-1351) bottom to CIP Pump (P- 1351A/B) suction
and close manual valve on UF Permeate /Fresh Water to CIP Pump (P- 1351A/B).
(P- 1351A/B).
8. Flush both sides of PHE with Fresh Water for 5 minutes (variable).
9. After flushing of H-1211 B with Fresh Water, stop CIP Pump (P- 1351A/B). Close
suction.
10. Close 80BF120514, 80BF120521 & 80BF120518.
11. Drain H-1211 B completely by opening PHE drain valves.
13. H-1211 B is ready for operation.

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SOP for Changeover of Slurry Cooler H-1212A to Slurry Cooler H-1212B

1. Ensure H-1212 B is ready for operation.
2. Ensure H-1212B drains and vents closed.
3. Ensure 80BF120538 & 80BF120545 closed.
4. Open CWS & CWR manual valves of H-1212B.
5. Open 100BF120535 & 100BF120539.
6. Close 100BF120526 & 100BF120528.
7. Ensure flow through H-1212B.
8. Close CWS & CWR manual valves of H-1212A.
9. H-1212A is ready for CIP.
SOP for CIP of Slurry Cooler H-1212A

1. Ensure H-1212A is ready for CIP.
2. Close manual valve at CIP Tank (T-1351) bottom to CIP Pump (P-1351).
4. Open 80BF120527 & 80BF120531 and flush slurry side of PHE for 5 minute (variable)
and transfer the material to Beerwell.
5. After 5 minute (variable), open manual valve at CIP Tank (T-1351) bottom to CIP
Pump (P-1351) and close manual valve on UF Permeate /Fresh Water to CIP Pump
(P-1351) suction.
(P- 1351A/B).
8. Flush slurry side of PHE with Fresh Water for 5 minutes (variable).

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9. After flushing of H-1212A with Fresh Water, stop CIP Pump (P- 1351A/B). Close
suction.
10. Close 80BF120527 & 80BF120531.
11. Drain H-1212A totally by opening PHE drain valves.
13. H-1212A is ready for operation.
SOP for Changeover of Slurry Cooler H-1212B to Slurry Cooler H-1212A

1. Ensure H-1212A is ready for operation.
2. Ensure H-1212A drains and vents closed.
3. Ensure 80BF120527 & 80BF120531 closed.
4. Open CWS & CWR manual valves of H-1212A.
5. Open 100BF120526 & 100BF120528.
6. Close 100BF120535 & 100BF120539.
7. Ensure flow through H-1212A.
8. Close CWS & CWR manual valves of H-1212B.
9. H-1212B is ready for CIP.
SOP for CIP of Slurry Cooler H-1212B

1. Ensure H-1212B is ready for CIP.
2. Close manual valve at CIP Tank (T-1351) bottom to CIP Pump (P-1351).
4. Open 80BF120538 & 80BF120545 and flush slurry side of PHE for 5 minute (variable)
and transfer the material to Beerwell.

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5. After 5 minute (variable), open manual valve at CIP Tank (T-1351) bottom to CIP
Pump (P-1351) and close manual valve on UF Permeate /Fresh Water to CIP Pump
(P-1351) suction.
(P- 1351A/B).
8. Flush slurry side of PHE with Fresh Water for 5 minutes (variable).
9. After flushing of H-1212B with Fresh Water, stop CIP Pump (P-1351A/B). Close
suction.
10. Close 80BF120538 & 80BF120545.
11. Drain H-1212B totally by opening PHE drain valves.
13. H-1212B is ready for operation.

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3.0.4 PROCESS MONITORING

Process plant incorporates necessary flexibility of operation modes and operating
parameters, so that the plant can be operated with desired results, even if the
composition of feedstock and other inputs vary to some extent. While using this
operational flexibility, on-line analysis of inputs and process kinetics helps in receiving
feedback on variations. This helps in maintaining desired operating parameters and
conditions.
Following are the various parameters required for monitoring of liquefaction process.
The significance of the variation in parameter is also discussed subsequently. The
parameter is monitored by the analytical tools or procedure given in Praj’s Analysis
Manual.
Dry Solids
Indirectly, it shows the total solids present in slurry mixing tank. Increase in DS than
the normally observed figure may be due to either of the following reasons.
Inadequate flow of Recycle Streamed water.
Addition of excess feed than the rated flow.
Improper agitation.
Improper temperature control.
Low retention time.
Low activity of enzyme.
PH
The pH must be favourable to the activity of enzyme.

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Temperature
Temperature is critical parameter in liquefaction which is to be maintained for
favourable condition for enzyme activity.
Residual Starch and DE

The rise in residual starch & DE is because of reduction in enzyme activity, retention
time, and unfavourable process parameters etc. resulting in loss of starch, dextrin.
SR. Significance of
Section Description Analysis
NO. analysis
1 Feedstock This section comprises 1) Over all quality 1) Over all raw
Handling of following sections. checking material Quality
Cleaning & 2) Particle Size maintenance
Milling 1) Feedstock storage. distribution 2) Determination of
2) Feedstock Cleaning 3) Raw material yield,
system, analysis for Starch, 3) Fermentation
3) Milling Moisture, Fats, efficiency, Final
4) Weighing Proteins, Ash ethanol
content, crude fibre, concentration.
other solids 4) Residence Time
2 Feedstock This section consists of 1) pH 1) Optimum pH for
Processing followings, 2) Viscosity enzymatic
1) Slurry mixing 3) DE hydrolysis of starch
2) Initial liquefaction 2) Viscosity is
3) Jet Cooking and important from
final liquefaction flow ability of
slurry
3) DE is to check
the extent of
hydrolysis

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Frequency of Routine Analysis
Parameters Frequency of analysis
A Milling Section
1 Particle size analysis Twice a day
2 Moisture analysis Once a day
3 Total solids Once a day
4 Moisture Once a day
5 Starch Once a day
6 Proteins Once a day
7 Fats Once a day
8 Fibres Once a day
9 Ash Content Once a day
B Liquefaction Section
1 pH All Tanks every 2 hr
2 Total Solids Every two hrs for Slurry Mixing Tank
3 DE Once in a shift in Final Liquefaction Tank
4 Iodine Test Final Liquefaction Tank every 2 hr

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3.0.5 TROUBLE SHOOTING

The following table summarizes the commonly faced problems, their causes and the
corrective actions required.
It should be noted that the same problems may not arise during the course of Plant
operation.
It should be remembered that Process Troubleshooting depends greatly on
Experience and Technical Knowledge.
Vigilant Data Collection and Process Monitoring are handy tools in identifying
Problems and their Causes.
In this section some common cases were considered which guides the operating personnel to
arrive at the solution; troubles apart from the mentioned cases may also occur, operator has to
take appropriate action accordingly.
TROUBLE CAUSES CORRECTIVE ACTIONS

DS of Slurry is More. Check and maintain proper DS.
Check and maintain temperature at
High temp. of slurry 85oC by adjusting water temperature
based on enzyme addition.
Quality of Enzyme Check activity and if found low use
Slurry Viscosity is high
(old Stock) more dosage or fresh enzyme
in Slurry Mixing Tank
Ensure that enzyme dosing pumps
T-1201 Inadequate enzyme
are in operation. Check and adjust
dosing
supply of enzyme.
Check and maintain pH by dosing
pH low or high
Aqua Ammonia.

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Slurry level in tank
Maintain working level in tank
high
Adjust flow rate of water to slurry
Water quantity less
preparation
Lumps observed in Aqueous Ammonia
Check dilution and pH of slurry.
Slurry Mixing Tank conc. is high
T-1201 Agitation improper Check functioning of the agitator
Temperature of slurry Check and adjust the temperature
in tank high/low of slurry in tank
Improper enzyme Supply Enzyme as per
supply requirement.
Improper discharge
Open discharge valve 100% and
head for the slurry
No Slurry Flow through ensure discharge pressure.
pump
Jet Cooker
Position of Jet Cooker Ensure alignment of mark on
combining tube sliding body & heater body
Ensure upstream steam supply
No Steam Flowing Partial opening of
valve and NRV/check/SV valve is
through Jet Cooker steam supply valve
fully open.
Caution : Make sure Raise set point of temperature
liquid flow is controller to open Jet Cooker
established prior to steam stem to allow steam flow.
opening of Jet Cooker Verify stem position on actuator
Steam stem yoke.
Purge out steam condensate.
Presence of
Install steam trap with a shut off
Steam condensate
valve
Flashing of slurry Raise Jet Cooker discharge
Rough Operation
inside Jet Cooker pressure, Retune controller.
Low slurry flow rate Maintain optimum flow rate,
with reference to Jet pressure of slurry. Maintain
Cooker model adequate back pressure

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Maintain adequate discharge

Flashing of slurry
pressure at Jet Cooker outlet
Stoppage of slurry flow
Ensure operations in the plant
rate gut continuation of
meticulously
steam supply
Excess steam
condensate in steam Ensure healthiness of steam trap.
Noise & Vibration supply
Dissolve air or other
gases vaporize and
implode in against wall Install air eliminator
of combining tube and
discharge pipe
Swings in discharge
Retune control loop
temperature
Steam pressure is low. Maintain steam pressure @ 88 psia
Slurry temperature is Maintain slurry temperature in
low. Slurry Tank
Jet CookerJ-1201 Slurry
Steam flow rate is low. Increase and adjust steam flow.
outlet temperature is
low. More flow rate of Adjust slurry flow rate at required
slurry. value.
Back pressure of Cook Adjust and maintain back pressure
Tube is low of Cook Tube.
PCV-120301 is closed /
Open and adjust the valve.
throttled.
Stop slurry flow to Jet Cooker J-
Choking in Cook Tube. 1201. Flush out the Cook Tube
Cook Tube (T-1213)
T-1213 with steam.
pressure high
Steam inlet pressure
Maintain proper steam pressure
high.
Malfunctioning of Check and tune the working of
pressure control loop pressure control loop

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PART–IV
PROCESS SHUTDOWN
AND
PROCESS START UP

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Short duration shutdown happens because of some breakdown or some emergency or
failure of any input to the system like steam, cooling water, power, instrumental air,
Fresh Water 1 etc. Logic is that after short duration shutdown it is necessary to go upon
normal capacity and stabilize the process in short time. Better shutdown planning can
optimise the breakdown time and increasing productivity.
It may not be possible to cover all the possibilities of short duration shutdown here but
it is operator’s skill and emergency planning technique to handle the situation and
recover fast and safe. Operator must give highest priority to ‘SAFETY’.
In this section procedure for Emergency Shut Down is explained.
4.0.1 POWER FAILURE

1. Close steam inlet valve to Jet Cooker (J-1201).
2. Take jet cooker temperature controller TIC-120301 in MAN mode and close to zero.
3. Close steam to Slurry Mixing Tank FCV-120201 in MAN mode.
4. Close ACV-120203 aqueous ammonia to Slurry Mixing Tank (T-1201) in MAN
mode.
5. Close LCV-120202 Slurry Mixing Tank (T-1201) level control in MAN mode.
6. Close FCV-120204 thin stillage to Premasher in MAN mode.
7. Close FCV-120102 Recycle Stream water to Premasher in MAN mode.
8. Close FCV-120103 UF Permeate to Recycle Stream Collection Tank (T-1211) in MAN
mode.
9. Monitor all tank levels.

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10. Based on emergency power availability, start the critical equipment to which
emergency power is provided. Critical agitators and circulation pumps to be started
in order to avoid the settling of solids and for easy restart up accordingly.
(Refer document – N-10012-4-INF1006 - Emergency Power for Critical Equipment)
Restart up after resumption of power
1. When restarting after resumption power, all agitators and pumps must be switched
on normal power again before supply of flour and process water to slurry mixing
tank.
2. Ensure electrical power OK.
3. Ensure DCS OK.
4. Ensure Air Compressor and the auxiliaries and utilities sections are in ready
condition.
5. Establish Fresh Water and cooling water circuit.
6. Start Agitator A-1201 and pump P-1201A/B of Slurry Mixing Tank T-1201.
7. Close manual valve on pump Initial Liquefaction Tank transfer pump (P-1212A/B)
discharge to Initial Liquefaction Tank (T-1202) and open the XV-120301 valve to
Slurry Mixing Tank (T-1201).
8. Ensure the vacuum pumps in Distillation section are running and the system is in
vacuum.
9. Start Flash Tank Bottom Transfer Pump (P-1212A/B).
10. Open LCV-120202 gradually in MAN mode and set up required flow through FIT-
120301 to Jet Cooker.
11. Monitor PIC-120301 & PIC-120302.
12. Keep liquefaction section under total circulation.

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13. Start Agitator for Initial Liquefaction Tank (A-1202) & Agitator for Final
Liquefaction Tank (A-1203).
14. Start Initial Liquefaction Tank Transfer pump (P-1202A/B) & Final Liquefaction
Tank Transfer pump (P-1203A/B).
15. Keep Initial Liquefaction Tank (T-1202) & Final Liquefaction Tank (T-1203) under
total circulation.
16. Charge steam header.
17. Open manual valve on steam to Jet Cooker.
18. Gradually open steam to Jet Cooker (J-1201), TIC-120301 in MAN mode as per
requirement.
19. Take TIC-120301 in AUTO mode.
20. Open steam FCV-120201 to Slurry Mixing Tank (T-1201) gradually. Take TIC-120201
in AUTO mode after achieving temperature of Slurry Mixing Tank T-1201.
21. Take AIC-120203 in AUTO mode and start aqueous ammonia metering pump.
23. Start Recycle Stream Transfer Pump (P-1211A/B).
24. Open FCV-120102 in MAN mode with required flow rate.
25. Ensure UF Permeate is available with required flow rate.
26. Ensure decantation section is restarted and thin stillage is available.
27. Start seal conveyer (E-1202).
28. Start grain milling section with 50% capacity.
29. Start metering pump, start feeding alpha amylase to Premasher.
30. Ensure all temperature profile at Jet Cooker TIC-120301 gets stabilised, open Flash
Tank Bottom Transfer pump (P-1212A/B) discharge valve to Initial Liquefaction
Tank (T-1202) and close slurry discharge to Slurry Mixing Tank (T-1201).

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31. Ensure fermented Mash Preheater (H-1211 A/B) and Slurry Cooler (H-1212 A/B) set
up.
32. Ensure respective manual valves at Final Liquefaction Tank Transfer pump (P-
1203A/B) discharge to fermentation section are open.
33. Start metering pump and ensure alpha amylase dosing to Flash Tank Bottom
Transfer pump (P-1212A/B) suction.
34. Take Slurry Mixing Tank (T-1201) level LIC-120201 in AUTO mode.
35. Based on fermentation readiness, increase feed to slurry mixing tank (T-1201).
36. Maintain all the process parameters as per standard process parameters.

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4.0.2 COOLING WATER FAILURE

1. At the time of cooling water failure, the vacuum in distillation will get disturbed.
Accordingly the vacuum at Flash Tank (T-1212) will also get affected.
2. Inform boiler house regarding the stoppage of steam in all sections of the plant.
3. Open XV-120301 valve to Slurry Mixing Tank (T-1201) and close manual valve on
Flash Tank Bottom Transfer pump (P-1212A/B) discharge to Initial Liquefaction
Tank (T-1202).
4. Take Jet Cooker (J-1201) TIC-120301 in MAN mode and force to zero.
5. Take steam to Slurry Mixing Tank (T-1201) TIC-120201 in MAN mode and gradually
start reducing steam. Close FCV-120201.
6. Close manual valve on steam to Jet Cooker
7. Take Slurry Mixing Tank (T-1201) level controller LIC-120201 in MAN mode and set
up the flow of slurry to jet cooker at required flow rate.
8. Stop grain milling section.
9. After 10 minutes of stopping grain milling section, stop Seal conveyer (E-1202).
11. Close FCV-120102 Recycle stream water to Premasher in MAN mode.
mode.
14. Stop Premasher (E-1201) after ensuring the stoppage of grain flour.
15. Stop alpha amylase metering pump.

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Start up after resumption of cooling water

1. Ensure cooling water circuit is established.
2. Ensure the stabilisation of vacuum in Distillation section.
3. Charge steam header.
5. Gradually open steam to jet cooker TIC-120301 in MAN mode as per requirement.
6. Take Jet Cooker (J-1201) outlet temperature TIC-120301 in AUTO mode.
7. Open steam FCV-120201 to Slurry Mixing Tank (T-1201) gradually. Take TIC-
120201in AUTO mode after achieving temperature of Slurry Mixing Tank (T-1201).
9. Ensure UF permeate availability to Recycle Stream Collection Tank (T-1211) and
take FQIC-120103 in AUTO mode.
10. Start Seal Conveyer (E-1202).
Tank Bottom Transfer pump (P-1212A/B) discharge valve to Liquefaction Tank (T-
1202) and close Flash Tank Bottom Transfer pump (P-1212A/B) discharge to Slurry
14. Ensure Fermented Mash Preheater (H-1211 A/B) and Slurry Cooler (H-1212 A/B)
set up.
15. Ensure respective valves at Final Liquefaction Tank Transfer pump (P-1203A/B)
discharge in fermentation section are open.

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17. Take Slurry Mixing Tank (T-1201), LIC-120201 in AUTO mode.

18. Based on fermentation readiness, increase feed to slurry mixing tank.

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4.0.3 STEAM SUPPLY FAILURE

1. Close manual valve on steam to Jet Cooker.
2. Open manual valve on Flash Tank Bottom Transfer pump (P-1212A/B) discharge to
Slurry Mixing Tank (T-1201) and close manual valve on Flash Tank Bottom Transfer
pump (P-1212A/B) discharge to Initial Liquefaction Tank T-1202.
3. Take Jet Cooker (J-1201) TIC-120301 in MAN mode and force to zero.
4. Take steam to Slurry Mixing Tank (T-1201), TIC-120201in MAN mode and close
FCV-120201.
5. Take Slurry Mixing Tank (T-1201) level controller LIC-120201 in MAN mode and set
up the flow of slurry to jet cooker at required rate.
7. After 10 minutes of stopping grain milling section, stop (E-1202).
9. Close FCV-120102 recycle stream water to Premasher in MAN mode.
mode.
13. Stop alpha amylase pump metering pump
Start up after resumption of steam

1. Ensure steam header is charged.
3. Gradually open Jet Cooker steam TIC-120301 in MAN mode as per requirement.

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4. Take Jet Cooker (J-1201) TIC-120301 in AUTO mode after establishment of J-1201
outlet temperature.
in AUTO mode after achieving temperature of Slurry Mixing Tank (T-1201).
7. Ensure thin stillage is available.
8. Start seal conveyor (E-1202).
Tank Bottom Transfer pump (P-1212A/B) discharge valve to Initial Liquefaction
Tank (T-1202) and close Flash Tank Bottom Transfer pump (P-1212A/B) discharge to
Slurry Mixing Tank T-1201.
12. Ensure Fermented Mash Preheater H-1211 A/B and Slurry Cooler H-1212 A/B set
up.
13. Ensure respective valves at P-1203A/B discharge in fermentation section are open.
15. Take Slurry Mixing Tank (T-1201) LIC-120201 in AUTO mode.

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4.0.4 INSTRUMENT AIR FAILURE

During instrument air failure condition all on-off and control valve should go to air
failure position as mentioned with instruments on P&ID (FO: AIR FAIL TO OPEN, FC:
AIR FAIL TO CLOSE).
Operator and shift engineer has to ensure air fail position of control / solenoid valves
during instrument air failure. Based on temperature requirement, manual valves on
cooling water return lines of exchangers to be adjusted if required.
Due to failure of control valves steam to plant will get stopped. Boiler house operator
has to take actions accordingly.
If instrument air failure will be expected for more than 20 minutes, take total plant shut
down as per short shut down procedure.
1. Stop Slurry Transfer Pump (P-1201 A/B).
2. Stop aqueous ammonia pump. Close ACV-120203 in MAN mode.
3. Stop alpha amylase metering pump.
5. Stop Seal conveyor (E-1202).
6. Ensure manual valve on steam to Jet Cooker gets closed.
7. Take Jet Cooker (J-1201) TIC-120301 in MAN mode and force to zero position.
8. Take steam to Slurry Mixing Tank (T-1201) TIC-120201 in MAN mode and close
FCV-120201.
9. Take Slurry Mixing Tank (T-1201) level controller LIC-120201 in MAN mode and
close to zero.
11. Close FCV-120102 recycle stream water to Premasher in MAN mode.
12. Close FCV-120103 on UF Permeate line to Recycle Stream Collection tank (T-1211).

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15. Open manual valve on Flash Tank Bottom Transfer pump (P-1212A/B) discharge to
Slurry Mixing Tank (T-1201) and close manual valve on Flash Tank Bottom Transfer
pump (P-1212A/B) discharge to Initial Liquefaction Tank (T-1202). Establish re-
circulation after resumption of instrument air.
16. Keep PIC-120301 & PIC-120302 in AUTO mode.
17. Monitor Cook Tube (T-1213) pressure at PT-120301 & Flash Tank (T-1212) pressure
at PT-120302.
18. Close LCV-120401 and LCV-120402 for Initial Liquefaction Tank T-1202 & Final
Liquefaction Tank (T-1203) in MAN mode. Keep Initial Liquefaction Tank T-1202 &
Final Liquefaction Tank (T-1203) under circulation.
19. Keep Recycle Stream Collection Tank (T-1211) under circulation.
Start up after resumption of instrument air

1. Ensure instrument air header is charged.
2. Ensure steam header is charged.
3. Ensure vacuum system is established.
4. Open LCV-120202 in MAN mode and set required flow to Jet Cooker (J-1201).
5. Establish Flash Tank Bottom Transfer pump (P-1212A/B) discharge flow back to
Slurry Mixing Tank (T-1201).
7. Gradually open steam to jet cooker TIC-120301 in MAN mode.
in AUTO mode after achieving temperature of Slurry Mixing Tank T-1201.

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9. Take TIC-120301 in AUTO mode after establishment of Jet Cooker (J-1201) outlet
temperature.
11. Take FIQC-120103 in AUTO mode on evaporation condensate line to Stream
Collection tank (T-1211).
12. Open ACV-120203 in MAN mode and start metering pump. Take AIC-120203 in
AUTO mode.
13. Ensure thin stillage is available.
14. Start seal conveyor (E-1202).
17. Ensure all temperature profile at Jet Cooker TIC-120301 gets stabilised, open P-
1212A/B discharge valve to Initial Liquefaction Tank (T-1202) and close Flash Tank
Bottom Transfer pump (P-1212A/B) discharge to Slurry Mixing Tank (T-1201).
19. Ensure Fermented Mash Preheater (H-1211 A/B) and Slurry Cooler (H-1212 A/B)
set up.
20. Ensure respective valves at Final Liquefaction Tank (P-1203A/B) discharge in
fermentation section are open.
21. Take Slurry Mixing Tank (T-1201) LIC-120201 in AUTO mode.
22. Take LCV-120401 and LCV-120402 for Initial Liquefaction Tank (T-1202) & Final
Liquefaction Tank (T-1203) in AUTO mode.

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4.1 PLANT SHORT SHUTDOWN & START UP AFTER SHORT SHUTDOWN
4.1.1 PLANT SHORT SHUTDOWN
Apart from emergency shut down like power failure, cooling water failure, steam
failure and instrument air failure as mentioned earlier, there are ‘n’ number of factors,
which may lead to pre planned plant shut down for short duration till the affecting
factor will get re-normalized.
It is assumed that power, cooling water, steam and instrument air and other necessary
utilities are available for safe short shut down of the plant. It is also assumed that the
shutdown is not more than 8 hrs. If the shutdown is more than 8 hrs, follow normal
plant shut down procedure.
Based on the leading factor for plant shut down, operator has to take appropriate and
safe actions accordingly.
1. Stop Liquefaction section by stopping the Flour, Recycle Stream, Enzymes.
2. Keep cooling water available for Liquefaction section.
3. STOP Liquefied slurry transfer to Fermentation Section and keep the Tanks under
circulation.
4. If based on Time cycle, the Tanks are filled then keep the all Tanks under normal
process condition of agitation and recirculation. The use of Flour for starting next
batch of Liquefaction after shutdown will depend upon the status of all Tanks at the
time of shut down and duration of shutdown.
5. Stop Final Liquefaction Tank transfer pump (P-1203A/B).
6. Stop Fermented Mash to Fermentation section.
7. Keep respective agitators and circulation pumps in running condition.

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4.1.2 PLANT START UP AFTER SHORT SHUTDOWN

1. Ensure plant inventory suitable for start up of Liquefaction section.
2. Ensure power is ok.
3. Ensure instrument air ok.
4. Ensure cooling water circuit established.
5. Ensure steam header charged.
6. Ensure all other required utilities are ready to start Liquefaction section.
7. Ensure respective Tanks are under circulation.
8. Ensure agitator for all Tanks are running. (Based on level).
9. Ensure availability of all Enzymes.

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4.2 PLANT LONG DURATION SHUTDOWN & START UP AFTER LONG

DURATION SHUTDOWN
4.2.1 PLANT LONG DURATION SHUTDOWN / MORE THAN 24 HRS
Long duration shutdown is generally a planned shutdown for any reason. There are
some planned maintenance jobs, which are to be carried out during shutdown, jobs
like hot jobs, vessel entries, and cold jobs too.
1. Stop Fresh Water to Recycle Stream Collection Tank (T-1211) by closing LCV-120101
in MAN mode. Level in Recycle Stream Collection Tank (T-1211) will start
decreasing. At 25% level indication at LT-120101 take LIC-120101 in AUTO mode
with 25% set point. This will ensure the low level in Recycle Stream Collection Tank
(T-1211) at the end of shut down of liquefaction section.
2. Stop Rotor Feeder. Corn/Sorghum flour flow to liquefaction section will stop after
10-15 min after stopping Rotor Feeders.
3. Stop milling section as per SOP. Refer SOP for long duration shutdown for grain
milling.
4. Stop Seal Conveyor (E-1202) after stopping grain milling section.
5. Stop alpha amylase to E-1201/T-1201 by stopping metering pump. Close respective
manual valves. Stop Aqueous Ammonia Dosing Pump and close ACV-120203 in
MAN mode after stopping the pump.
6. Take LCV-120202 in MAN mode to maintain continuous feeding to Jet Cooker (J-
1201) at required rate.
7. Stop thin stillage flow to Premasher (E-1201) by closing FCV-120204. Keep Recycle
Stream water to Premasher (E-1201) for next 15-20 minutes for flushing of

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Premasher. Allow slurry in Slurry Mixing Tank (T-1201) gets diluted for next 15-20
minutes. Level in Slurry Mixing Tank (T-1201) will start decreasing.
8. Stop Recycle Stream water to Premasher (E-1201) by closing FCV-120102 in MAN
mode. Stop electrical motor of Premasher after 5-10 minutes of stopping Premasher.
9. Stop Recycle Stream Collection Tank Transfer Pump (P-1211A/B). Close LCV-
120101 by taking in MAN mode.
10. At low level of Slurry Mixing Tank (T-1201), agitator for Slurry Mixing Tank (T-
1201) will stop automatically.
11. Completely empty out Slurry Mixing Tank (T-1201). Stop Slurry Transfer Pump (P-
1201A/B) after ensuring the complete transfer of slurry.
12. Take level controllers for Initial Liquefaction Tank (T-1202) and Final Liquefaction
Tank (T-1203) in MAN mode so that required flow is maintained continuously to
fermentation section.
13. Open manual valve on Cook Tube (T-1213) bottom to Flash Tank Transfer Pump (P-
1212A/B) and close manual valve at Flash Tank (T-1212) bottom to Flash Tank
Transfer Pump (P-1212A/B). Empty out Cook Tube (T-1213) completely to Initial
Liquefaction Tank (T-1202).
14. Open manual valve on Flash Tank (T-1212) bottom to Flash Tank Transfer Pump (P-
1212A/B) and close manual valve at Cook Tube (T-1213) bottom to Flash Tank
Transfer Pump (P-1212A/B).
15. Take PCV-120302 in MAN mode with 15% opening and empty out the Flash Tank
(T-1212) to Initial Liquefaction Tank (T-1202) by taking LCV-120303 in MAN mode.
After ensuring complete transfer of Flash Tank (T-1212) stop Flash Tank Transfer
Pump (P-1212A/B) and close PCV-120302 and LCV-120303.

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16. Level in Initial Liquefaction Tank (T-1202) and Final Liquefaction Tank (T-1203) will
start decreasing after stopping Flash Tank Transfer Pump (P-1212A/B).
17. At low level of Initial Liquefaction Tank (T-1202) and Final Liquefaction Tank (T-
1203), agitators A-1202 and A-1203 will stop automatically.
18. Empty out Initial Liquefaction Tank (T-1202) completely and stop Initial
Liquefaction Tank Transfer Pump (P-1202A/B).
Note – While stopping liquefied slurry feed to Mash Preheater H-1211 A/B,
coordinate between liquefaction and distillation DCS operators. Feed to Distillation
section to be reduced accordingly.
19. Empty out Final Liquefaction Tank (T-1203) completely and stop Initial Liquefaction
Notes –
Ensure all tanks / PHEs / lines empty out completely.

It is necessary to take water flushing and CIP of the plant after plant shutdown.
Isolate all equipment by manual valves.
If the plant shutdown is planned more than 1 month it is advisable to drain
cooling water side of heat exchangers by opening dummy flanges.
All safety norms to be followed before starting any hot / cold job after plant
shutdown.
Maintenance activities if any of mechanical activities to be carried out during long
shutdown.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
4.2.2 PLANT START UP AFTER LONG DURATION SHUTDOWN.

1. Ensure plant inventory suitable for start up of fermentation section.
2. Ensure power is ok.
3. Ensure instrument air ok.
4. Ensure cooling water circuit established as per Pre start up activity
5. Ensure water flushing is completed as per Pre start up activity
6. Ensure cleaning in place is completed
7. Inform boiler house regarding plant start up.
8. Ensure all other required utilities are ready to start Liquefaction section.

N-10012-4-OPM-1201-0 Operation and Maintainance Manual Liquefaction Section PDF

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OPERATION AND MAINTAINANCE MANUAL

PROJECT REV. ISSUE

OPERATION AND MAINTENANCE MANUAL

CLIENT : VICENTIN S.A.I.C.

140,000 OR 150,000 LITERS / DAY ANHYDROUS

LOCATION : AVELLANEDA, SANTA FE- ARGENTINA

PROJECT NO. : N-10012

DOCUMENT NO. : N-10012-4-OPM1201

0 05.11.2012 VMS SBG/PKR VBJ FOR EXECUTION

OPERATION AND MAINTAINANCE MANUAL – LIQUEFACTION SECTION

OPERATION AND MAINTAINANCE MANUAL – LIQUEFACTION SECTION

SR.NO CONTENTS PAGE NO.

PART – I THEORETICAL ASPECTS

1.0.1 Theory of Liquefaction 09

1.0.2 Process Description 16

1.0.4 Control Logic & Interlock Description 22

1.0.5 Equipment Description 23

PART – II PRESTARTUP ACTIVITIES

2.0 GENERAL INSTRUCTION 27

2.0.1 Cooling Water Loop Testing 31

2.0.1 a SOP For Establishment of Cooling Water Circuit 31

2.0.2 Water Flushing / Cold Water Trial 33

2.0.3 Vacuum Trail 40

2.0.4 Steam Trial 40

2.0.4.a SOP for charging low pressure steam header 41

2.0.5 Standard Operating Procedure (SOP) 44

2.0.5.a SOP for Liquefying Enzyme dosing system 44

2.0.5.b SOP for Viscosity Reducing Enzyme dosing system 45

OPERATION AND MAINTAINANCE MANUAL – LIQUEFACTION SECTION

2.0.5.c SOP for Aqueous Ammonia Dosing System 46

2.0.5.d SOP for Saccharifying Enzyme dosing system 46

2.0.5.e SOP for Preparation of 3.0 % w/w caustic solution in T-1351 48

PART – III PROCESS STARTUP AND PROCESS PARAMATER

3.0 GENERAL INSTRUCTION 51

3.0.1 Normal Start-up 53

3.0.2 Process Parameter 60

3.0.3 Cleaning In Place (CIP) 63

3.0.4 Process Monitoring 73

PART – IV PROCESS SHORT SHUTDOWN & PROCESS STARTUP

4.0 GENERAL INSTRUCTION 80

4.0.1 Power Failure 80

4.0.2 Cooling Water Failure 84

4.0.3 Steam Supply Failure 87

4.0.4 Instrument Air Failure 89

4.1 Plant Short Shutdown & Start Up After Short Shutdown 92

4.1.1 Plant Short Shutdown 92

4.1.2 Plant Start Up After Short Shutdown 93

OPERATION AND MAINTAINANCE MANUAL – LIQUEFACTION SECTION

Plant Long Duration Shutdown & Start Up After Long

4.2.1 Plant long duration shut down 94

4.2.2 Plant start up after long duration shut down 97

OPERATION AND MAINTAINANCE MANUAL – LIQUEFACTION SECTION

This document on OPERATIONAL AND MAINTAINANCE MANUAL contains

Under article (Secrecy and confidentiality) Process license is nonexclusive, non-

VICENTIN S.A.I.C. AVELLANEDA, SANTA FE-ARGENTINA shall be responsible for

OPERATION AND MAINTAINANCE MANUAL – LIQUEFACTION SECTION

VICENTIN S.A.I.C. AVELLANEDA, SANTA FE - ARGENTINA acknowledges that PIL

OPERATION AND MAINTAINANCE MANUAL – LIQUEFACTION SECTION

OPERATION AND MAINTAINANCE MANUAL – LIQUEFACTION SECTION

OPERATION AND MAINTAINANCE MANUAL – LIQUEFACTION SECTION

Amylose: Amylose is a polymer of 500 – 1,500 glucose units joined by 1 – 4 alpha

Amylopectin: Amylopectin is branched polymer of glucose units joined by 1 – 4 alpha

OPERATION AND MAINTAINANCE MANUAL – LIQUEFACTION SECTION