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FPG CONTROLLED DOCUMENT
STANDARD OPERATING PROCEDURE (SOP)
Title:
SCOPE
-Glycerin (System 300) Process Control Strategy
-Loading/Unloading (System 1000) Process Control Strategy
-Chemicals Storage(System 1100) System Process Control Strategy
-Utilities System (System 1300) Control Strategy
APPROVAL
Signature
Date
Role
Originator:
____________________
Wong Sei Wei
Approval:
___________________
Azizi Mohamad
Operation Manager
QA Approval:
____________________
Anh Lenuhoang
QA Manager
Objective
A system to make sure Manufacturing Standard is properly followed during production. This
process control strategy covers 3 levels process control, and links manufacturing standard and
actual operation. It focuses in controlling each one of sources of variability. This range should be
narrow enough to ensure that finish product have a low level of variability and a low level defects.
2.0
Scope
-Glycerin (System 300) Process Control Strategy
-Loading/Unloading (System 1000) Process Control Strategy
-Chemicals Storage(System 1100) System Process Control Strategy
-Utilities System (System 1300) Control Strategy
3.0
References
a) Formula Cards & Raw Material Specifications
b) Process Control strategy validation report.
4.0
Definition
MPD :
E&I
:
DDS :
TFA :
SOG :
TDS :
CBM :
EO
:
FC
:
PM
:
5.0
Responsibilities
Material And Process Delivery Owner (MPD): are responsible to analyze and study the historical
data on process, propose changes to the limits in order to improve the process performance. The
MPD is the owner of the system and the document.They are responsible for documenting the change,
communicate and train Operation Associates on the changes made. E.O is conducted to confirm the
process capability to meet the changes in an on-going basis.
The Mechanical and E&I Associates: are responsible for performing the maintenance and
calibration of process instrumentation and equipment, according to the approved methods.
The Analytical Associate: is responsible for making sure the inspection and testing of the products
using the validated lab equipments and verified lab methods. They are responsible for performing
6.0
Procedure
Crude Glycerine System Process Control Strategy
Strategy
Location
Level 0 action
Level 1 action
C
C
Ensure
Crude Glycerine
Ensure pH set point is set Review in DDS
Glycerine from Reactor
for at 0.5 - 3.0.
meeting
Glycerine
Acidulation
Column
is
Hydrochloric Acid is used
acidulated
to
to acidulate the crude
remove soap and
glycerine.
form TFA
Hydrochloric
Acid
received is inspected via
COA release.
IRMS
GCAS# 95322972
Level 2 action
C
MPD to review the
monthly
quality
compliance
in
Monthly Review.
Location
Level 0 action
Level 1 action
C
Ensure TFA is Glycerine
Set the tank level at 75% Review
separated
from Reactor
for at all time for TFA to be meeting
Crude Glycerine Acidulation
removed
by
flowing
by
flowing
through
Acidulated
through
Glycerine Hydroclone and
Acidulated
continuous skimmed off
Glycerine
from Glycerine Reactor.
Hydroclone and
skimmed of from
Glycerine
Reactor.
Ensure
the
Glycerine
Reactors FRP &
Glycerine
Neutralization
Feed
Tank
integrity
are
protected.
in
Level 2 action
DDS N/A
Glycerine
Reactor
&
Glycerine
Neutralization
Feed tank.
N/A
Ensure
the Glycerine
acidulated
Neutralization
Glycerine flow is feed Tank
controlled before
sending
for
neutralization
N/A
Ensure
Crude Glycerine
Glycerine
is Neutralization
neutralized before
feeding
to
Glycerine
Evaporator.
C
Ensure pH set point is set Review
at 5.0-7.0.
meeting
in
C
DDS MPD to review the
monthly
quality
compliance
in
Monthly Review.
Sodium
Hydroxide
received is inspected via
COA release.
RMS
GCAS# 10050853.
Ensure additional Glycerine
TFA skimming is Evaporator
done
before Feed Tank
Glycerine
Evaporator
C
Ensure level is set at Review
405cm.
meeting
Skim the TFA once a
week
in
DDS N/a
Location
Level 0 action
C
Check moisture & % Review
Glycerine
meeting
Based on the above
results,
adjust
the
following :
Pot temperature
set point 98-103 OC
Vapor Pressure is
set at 70 mmHg at all
time.
Ensure
Crude Glycerine
Glycerine
is Evaporator
within the limits
before sending to
Glycerine Surge
Tank
Level 1 action
in
Level 2 action
C
DDS MPD to review the
monthly
quality
compliance
in
Monthly Review.
C
Check moisture & % Review
off-spec Operation to review
Glycerine
results in DDS # of NCR in
meeting
Monthly Review.
Based on the above
results,
adjust
the
following :
Glycerine
Evaporator
Pot
temperature set point
98-103 OC
Vapor Pressure is
set at 70 mmHg.
Check TFA.
Based on TFA result,
ensure
the
upstream
Reactor skimming is
effective as stated in PCS.
Check Ash and pH.
Based on the results,
adjust the neutralization
pH set point 5.0-7.0.
Level 2 action
C
MPD to review
Yield in Monthly
and
Quarterly
Review.
MPD to review the
monthly
quality
compliance
in
Monthly Review.
Location
Level 0 action
Level 1 action
Level 2 action
C
DDS MPD to review
Yield in Monthly
and
Quarterly
Review.
MPD to review the
monthly
quality
compliance
in
Monthly Review.
Location
Boiler 1 & 2
Multimedia
Filter
Ensure Chilled
water is treated
Ensure
to slow Zeolite
down the
resin
in
Softener
corrosion rate at
is
theprotected
equipments
using JBA water
for boiler steam
generation
Ensure
Ensure
no water
Tempered
scaling
in to
boiler
is treated
slow
down
the
corrosion rate at
the equipments
Pot feeder at
pump
Carbon Filter
discharge
Cooling
Tower
Pot feeder at
Softener to
pump
produce
discharge.
Softwater
Level 0 Action
Ensure Steam pressure
Check
Total
is
set at 10-11 barg
in
Suspended
Solid
auto
mode.
(<5ppm)
Check the following
Based for
on boiler
the result,
quality
water
:adjust the backwash
frequency. (200O-Alkalinity
500ppm)
pH
(10.5-11.5)
Check
the following
TDS
(1000-2000ppm)
quality
:
Sulphite
(20-50ppm)
Ortho PO4
(8-14ppm)
OrthoPhosphate
pH ( 7.2-8.0 ) (2040ppm)
Conductivity ( 700Silica
(100-200ppm)
1000 microsiemen
)
Total Iron ( 3.0ppm
Based
max ) on the results
above, adjust pump
stroke
of thechemicals
Based on
results
accordingly
to get
the
above, adjust
pump
dosage.
stroke of chemicals
accordingly to get the
If
TDS is out of range,
dosage.
verify
conductivity
meter
adjust the
Ensureand
temperature
is
O
set
set point
at 35 accordingly.
C max.
Ensure Chilled water
temperature is set at
Check
Free
3.5
5.0
C. Chlorine
(<0.1ppm)
Check nitrite (300Based on the result
500ppm)
above, adjust
Based
on thetheresult,
backwash
frequency.
add
nitrite accordingly.
Ensure
Tempered
Check hardness
water
temperature is
( 0.5ppm
set
at 58 max
65 O)C.
Based onnitrite
the result
Check
(300above, adjust the
500ppm)
regeneration
Based
on the result,
frequency.
add
nitrite accordingly.
Level 1 Action
CC
Review
Reviewin
inDDS
DDS
meeting
meeting
Page :8 of 23
Level 2 Action
C
MPD to
to review
review
the
Monthly
Monthly
Compliance
in
in
Monthly Review.
C
Review in DDS
meeting
C
MPD to review
the
Monthly
Compliance
in
Monthly Review.
C
CReview in DDS
Review
meetingin DDS
meeting
C
C
MPD to review
MPD
to Monthly
review
the
the
Monthly
Compliance
in
Compliance
in
Monthly Review.
Monthly Review.
CC
Review
Reviewin
inDDS
DDS
meeting
meeting
C
MPD to
to review
review
the
Monthly
Monthly
Compliance
in
in
Monthly Review.
Glycerine
ATC 040 pH CBM
Reactor
for analyzer to S-302.
Calibration
Acidulation
SAP
Glycerine
Neutralization
ATC 059
analyzer
pH CBM
Calibration
- SAP
Glycerine
Evaporator
SAP
TITC 077
Glycerine Evaporator
Reboiler temperature.
ATC212 pH
Analyzer
CBM Calibration
SAP
Note : On-line inspection shall be carried out on 6 monthly basis for all critical PCS equipments.
6.2
SAP
Ensure
the
Glycerine
Reactors FRP
&
Glycerine
Neutralization
Feed
Tank
integrity
are
protected.
Glycerine
TITC 054 - Glycerin CBMReactor
& Reactor temperature calibration
Glycerine
indicator
Neutralization
Feed Tank.
Ensure
the Glycerine
acidulated
Neutralization
Glycerine flow Feed Tank
is
controlled
before sending
for
neutralization.
N/A
SAP
Location
Equipments
Action
Tool
LITC 069
Glycerine
Evaporator feed tank
level.
CBM Calibration
SAP
Ensure
Crude Saponification
Glycerine is within Tank
the limits before
sending
to
Glycerin Still
LITK 106
Saponification Tank
A level.
CBM
Calibration
SAP
FITK 041
Glycerine transfer
flow
CBM
Calibration
SAP
CBM Calibration
SAP
FITK041- Glycerin
transfer flow
LITK 112
Saponification Tank
B level
C
CBM calibration
SAP
Units
O
Tag Number
Target
Formula
Range
TIC C044
80 max1
AIC C040
0.5-3.0
LIC C043
40-80
AIC C059
5.0-7.0
Temperature
*pH into Reactor
Acidulation Interface Level
*pH of Neutralized
Glycerine
Kg/hr
FIC C055
500
Kg/hr
FFIC C056
4C
2000
Units
Tag Number
Formula
Range
cm
LIC C069
110-410
LIC C080
40-60
*Evaporator Pressure
mmHg
PIC C078
70 fixed
TIC C077
98-103
LIC C079
40-60
* Glycerine Hotwell
pH
AICC 212
6-10
* Glycerine
pH
AICC 059
5-7
GLYCERINE EVAPORATION
Set Point Variables
*Pot Temperature
Hot Well Level
Evaporator Feed
Tank
Target
Units
Tag Number
LIC M041
Target
Formula
Range
75 95
barg
3 4.8
DEAERATOR
Set Point Variables
Units
ppb
Tag Number
Target
Formula
Range
7 Max
TI M501
105-115
Barg
PI M429
0.4 0.5
TIC M427
80-90
LIC M052
40-60
Units
Tag Number
Barg
PI M330
PI M078
9.7 -11.0
Barg
PIC M077A
9.7 -11.0
LIC M081
LI M333
55 - 65
55 65
Units
Tag Number
Target
Formula
Range
Formula
Range
TI M434
45 max
Spillback Loop
Temperature
TIC M123
90-97
LIC M110
80 min
Units
Target
Formula
Tag Number
C
100 max
barg
Barg
Range
79
PI M179
67
0.56-3.88oC
Barg
PI M155
67
Barg
PI M177
67
80-109
Barg
6.4-8.1
109 Max
Barg
0.9 min
Units
Tag Number
Barg
Formula
Range
1.72 max
Barg /PSI
Target
160 max
PSHL M174
7.86/114
LOW
Lag Compressor Pressure
Switch Setting
Barg /PSI
PSHL M175
HIGH
LOW
7.86/114
6.55/95
54.4 max
Barg
17.0 max
DOWTHERM VAPORIZER
Set Point Variables
Units
Tag Number
Target
Formula
Range
Bar A
PI M439
4.0-4.5
Deg. C
TIM192
350 Max
Delta Temperature
Deg. C
DOWDELT
+5
Bar A
PIC M191
4.0-4.5
RAW WATER
Set Point Variables
Units
Hrs
Barg
PI M023
PI M342
45
45
LICM004
92-98
Raw/Fire Water
Tank Level (S-1301)
CITY WATER
Tag Number
Target
Formula
Range
24
Units
Tag Number
Target
Formula
Range
Barg
PI M026
5-7
cm
LIC M344
2750 min
LIC M344
90-98
FIRE WATER
Set Point Variables
Units
Tag
Number
Target
Formula
Range
65 min
95 min
Barg
PI M006
10 14
S-1301 Level
LIC M004
75-100
S-1343 Level
LIC M294
75-100
Psi
PSL M555
154
Psi
PSL M555
159.5
Psi
PSL M010
143
Psi
PSL M050
132
Units
Tag Number
Target
Formula
Range
Barg
PI M219
PI M221
PI M222
3.5-4.5
3.5-4.5
3.5-4.5
TI M369
35 max
TAH 369
26.7
TAHH M369
34.0
C
C
Units
Tag Number
Barg
PI M382
Target
Formula
Range
26.6 28.2
Units
Tag Number
Supply Pressure
Barg
PI M383
Target
Formula
Range
1.5-2.0
Units
Tag Number
Supply Pressure
Barg
PI M376
Target
Formula
Range
2.2-2.6
Units
Tag Number
Supply Pressure
Barg
PI M379
PSL M374
Target
Formula
Range
8.0-10.0
TEMPERED WATER
Set Point Variables
Tempered Water Header Temperature
Units
o
Tag Number
Target
Formula
Range
TI M243
58-63
Barg
PI M242
PI M243
4.1-8.0
4.1-8.0
LIM 246
80 - 90
TIC M257
58-63
CHILLED WATER
Units
Tag Number
Target
Formula
Range
TI M245
3.5-6.0
Barg
PI M242
PI M243
4.0-8.0
LIM 238
80 - 90
TI M557
3.5-6.0
BOILER BLOWDOWN
Set Point Variables
Effluent Temperature
Blowdown Drum
Pressure
Blowdown Drum Level
Steam knock out
pressure
Level
Units
Tag Number
Target
Formula
Range
TI M428
40.6 max
Barg
PIC M425
1 2.0
LIC M426
40-60
Barg
PICM 567
1.0 - 3.0
LICM 566
40 - 60