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FPG

Oleochemicals
FPG CONTROLLED DOCUMENT
STANDARD OPERATING PROCEDURE (SOP)
Title:

PROCESS CONTROL STRATEGY


(Level 0,1 &2) - Part IV
( GLYCERINE/UTILITIES)

Document No. : FPG-II022


Revision : 7
Expiry Date : Until
Superseeded
Page : 1 of 23

Owning Area : Operation


Created : Lim Lay Cheng

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

MPO RG/ Utilities

Approval:

___________________
Azizi Mohamad

Operation Manager

QA Approval:

____________________
Anh Lenuhoang

QA Manager

Note : Last approver forward to Standards Office.

REASON FOR ISSUE:


Schedule Review

Document No. : FPG-II-022


Revision :7
Expiry Date : Until
Superseeded
Page :2 of 23
1.0

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
:

Material And Process Delivery


Electrical and Instrumentation
Daily Direction Setting
Total Fatty Acid
Standard operating Guidelines
Total Dissolved Solids
Condition Based Maintenance
Experinmental Order
Formula Card
Preventive Maintenance

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

Document No. : FPG-II-022


Revision :7
Expiry Date : Until
Superseeded
Page :3 of 23
the calibration of the lab equipments and standardization of the reagents/solution.
The Production Planning and Logistics group: is responsible for planning and coordinating the
raw materials for productions requirements. They are responsible for making sure the raw materials
are inspected and released as per the RMS, raw materials are protected during storage and the usage
of raw materials is tracked and recorded for on-going traceability.
The Alcohol, Ester, and Utilities Associates: are responsible for executing all SOG, Process
Control Strategy (Level 0 and Level 1 action) , Recycle / Reblend and the
Startup/shutdown/Changeover as per approved procedures when operating the process.
The Team Leaders: are responsible for ensuring the operation associates are qualified to operate
under controlled conditions within the shift and ensure capability is provided to run the process to
centerline. They are also responsible for effective communication taking place within and across
shift teams.
The Operations Manager: has the overall responsibility to ensure all the above are executed and
followed in operating the process so as to achieve the desired product quality.

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.

Document No. : FPG-II-022


Revision :7
Expiry Date : Until
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Page :4 of 23
Strategy

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.

Temperature does not N/A


exceed 78 OC max which
is interlock to stop flow to
Glycerine Reactor.

N/A

Ensure
the Glycerine
acidulated
Neutralization
Glycerine flow is feed Tank
controlled before
sending
for
neutralization

Ensure level is controlled N/A


at 50% Minimum.

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

Sodium Hydroxide is used


to neutralize the Crude
Glycerine.

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

Document No. : FPG-II-022


Revision :7
Expiry Date : Until
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Page :5 of 23
Strategy

Location

Ensure moisture Glycerine


is removed from Evaporator
Crude Glycerine

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.

Document No. : FPG-II-022


Revision :7
Expiry Date : Until
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Page :6 of 23
Strategy
Ensure skimming
from
Glycerine
Reactor
is
recycled
to
recover the crude
glycerine.

Glycerine Recycle / Reblend System Process Control Strategy


Location
Level 0 action
Level 1 action
C
S1101A/B
When S1101A/B is full, Review in DDS
Soapstock
let it settle for 24 hours, meeting.
Storage Tank
then start pumping from
the bottom back to
Glycerine Reactor for
reprocessing.
The indication of addition
flowrate is determined by
the adjustment on the air
inlet valve.
Addition flowrate should
not exceed 900kg/hr.
C
Check the appearance of
the sample taken from the
S1101A/B.
When the sample shows
all TFA, stop reflux OR
When soapstock surge
tank shows high level
alarm all the time, thats
the indication of no
glycerine presence.

Level 2 action
C
MPD to review
Yield in Monthly
and
Quarterly
Review.
MPD to review the
monthly
quality
compliance
in
Monthly Review.

Document No. : FPG-II-022


Revision :7
Expiry Date : Until
Superseeded
Page :7 of 23
Strategy

Location

Ensure the ITE S1102


storage
tank
skimming
is
recycled
to
recover
the
glycerine.

Level 0 action

Level 1 action

Check the appearance of C


the sample taken from Review in
Top draw out point of
meeting.
S -1102.
If the sample shows ester
is presence, send it to
Ester Wash Column for
recovering ester.

Level 2 action

C
DDS MPD to review
Yield in Monthly
and
Quarterly
Review.
MPD to review the
monthly
quality
compliance
in
Monthly Review.

If the sample shows


glycerine is presence, send
it to Glycerine Reactor for
recovering glycerine.
Addition flowrate should
not exceed 900kg/hr.
The data which is between target and the line of 37.5% FC limits is green
The data is between the line of 37.5% FC limits and the line of 75% FC limits is yellow
The data is between the line of 75% FC limits and USL and LSL limits is red
The data is out of limits is white.
So the operation associate must be careful when the data is yellow, and take action when the data is red or white.
BOG is referred to for all the set point range of Process Parameters written in this PCS.
For all the above Ester, Alcohol, Glycerine and Utilities Systems, if the quality remains out of limits, please
refer to the Troubleshooting Guide in SOG for troubleshooting effort.

Utilities Systems Process Control Strategy

Document No. : FPG-II-022


Revision :7
Expiry Date : Until
Superseeded
Strategy
Ensure
boiler
Ensure
water quality is
suspended
solids
treated
to
is
removed at
the
prevent
boiler
incoming
(tubes water
and
source
drums)
from
corrosion
and
scaling.
This
would ensure the
Steam Cooling
quality
Ensure
generated
water
quality for
Process useusage
process
will
will not cause
not
cause
fouling/scaling
fouling/scaling,
and corrosionand
to
corrosion
equipments
algae
growthand
to
boiler
meets
its
the equipments
steam generation
capacity

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.

Document No. : FPG-II-022


Revision :7
Expiry Date : Until
Superseeded
Page :9 of 23
6.1 Crude Glycerin PCS items (Critical Equipment)
Ensure Crude
Glycerine from
Glycerine
Column
is
acidulated
to
remove
soap
and form TFA
Ensure Crude
Glycerine
is
neutralized
before feeding
to
Glycerine
Evaporator.
Ensure moisture
is removed from
Crude Glycerine

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

PITC 078 Glycerine CBM Evaporator Pressure. Calibration

SAP

TITC 077
Glycerine Evaporator
Reboiler temperature.

Ensure water is Glycerine


neutralized
Evaporator
before feeding Hotwell
to
Methanol
Conc.

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

Crude Glycerin PCS Items (Other equipments)

Document No. : FPG-II-022


Revision :7
Expiry Date : Until
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Page :10 of 23
Ensure TFA is Glycerine
separated from Reactor
Crude Glycerine
by
flowing
through
Acidulated
Glycerine
Hydroclone and
skimmed
of
from Glycerine
Reactor.

TITC 054 Glycerine CBM


Reactor temperature. Calibration

SAP

CBMLITC043 - Glycerine Calibration


Reactor level.
CBMCalibration
CBMCalibration

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.

LITC222 - Glycerine CBM


Neutralization Feed -Calibration
Tank level.

N/A

SAP

Document No. : FPG-II-022


Revision :7
Expiry Date : Until
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Page :11 of 23
Strategy

Location

Equipments

Action

Tool

Ensure additional Glycerine


TFA skimming is Evaporator
done
before Feed Tank
Glycerine
Evaporator

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

Ensure skimming S1101A/B


from
Glycerine Soapstock
Reactor is recycled Storage Tank
to recover the
crude glycerine.

FITK 041
Glycerine transfer
flow

CBM
Calibration

SAP

Ensure skimming S810 to S1102


from
KOBIs
storage tank (ester)
is recycled to
recover
either
glycerine or ester

FITK 044 Glycerine transfer


flow

CBM Calibration

SAP

Ensure the ITE S1102


storage
tank
skimming
is
recycled to recover
the glycerine.

FITK041- Glycerin
transfer flow

LITK 112
Saponification Tank
B level

C
CBM calibration

SAP

C Level 1 Action : Review in DDS meeting,


Level 2 Action : Mechanical and E&I to review PM scorecard, PM Work Order % Completion ( %
Calibration ), % Backlog and % Tolerance Compliance in the Monthly Review Meeting.
7.0
Attachment 1 Crude Glycerine Key Quality Items TFA % Glycerine

Document No. : FPG-II-022


Revision :7
Expiry Date : Until
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Page :12 of 23

Attachment 2 Basic Operating Guideline (Glycerin Acidulation and Glycerin evaporation)

Document No. : FPG-II-022


Revision :7
Expiry Date : Until
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Page :13 of 23
GLYCERINE ACIDULATION/CAUSTIC DILUTION
Set Point Variables
Acidulation Feed

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

50% Caustic Flow

Kg/hr

FIC C055

500

Process Water Flow

Kg/hr

FFIC C056

4C

2000

Units

Tag Number

Formula

Range

Feed Tank Level

cm

LIC C069

110-410

Evaporator Pot Level

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

FRP Tank Limitation

GLYCERINE EVAPORATION
Set Point Variables

*Pot Temperature
Hot Well Level

Evaporator Feed
Tank

Attachment 3 Basic Operating Guidelines - Utility System

Target

Document No. : FPG-II-022


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Expiry Date : Until
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Page :14 of 23
SOFT WATER SYSTEM
Set Point Variables
Level Soft Water Tank
P1302 A/B discharge
pressure

Units

Tag Number

LIC M041

Target

Formula

Range
75 95

barg

3 4.8

DEAERATOR
Set Point Variables

Units

Oxygen Level Out of Deaerator

ppb

Water Temperature Out of


Deaerator
Pressure in Deaerator

Tag Number

Target

Formula

Range
7 Max

TI M501

105-115

Barg

PI M429

0.4 0.5

Soft Water Temperature to


Deaerator

TIC M427

80-90

Water Level in Deaerator

LIC M052

40-60

Document No. : FPG-II-022


Revision :7
Expiry Date : Until
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Page :15 of 23
UTILITY BOILER
Set Point Variables

Units

Tag Number

Steam Header Pressure

Barg

PI M330
PI M078

9.7 -11.0

Steam Pressure at Boiler


Outlet

Barg

PIC M077A

9.7 -11.0

LIC M081
LI M333

55 - 65
55 65

Units

Tag Number

Water Level in Steam


Drum

Target

Formula

Range

PROCESS WATER SYSTEM


Target

Formula

Range

Set Point Variables


Temperature of Effluent to
Drain

TI M434

45 max

Spillback Loop
Temperature

TIC M123

90-97

Process Water Tank Level

LIC M110

80 min

Document No. : FPG-II-022


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AIR COMPRESSOR AND DRYER

Set Point Variables

Units

Instrument Air Dew Point

Target

Formula

Air Comp. Discharge Temp.


Air Comp. Discharge
Pressure
Instrument Air Header
Pressure

Tag Number
C

100 max

barg
Barg

Range

79
PI M179

67

0.56-3.88oC

Wet Air Receiver Pressure

Barg

PI M155

67

Dry Air Receiver Pressure

Barg

PI M177

67

Air End Discharge Temp.


Air Discharge Pressure
Bearing Oil Temp.
Oil Pressure

Set Point Variables


Pressure Drop Across Lube
Oil Filter
Main Motor Overload
Lead Compressor Pressure
Switch Setting
HIGH

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

Document No. : FPG-II-022


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Expiry Date : Until
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Page :17 of 23
6.55/95

LOW
Lag Compressor Pressure
Switch Setting

Barg /PSI

PSHL M175

HIGH
LOW

7.86/114
6.55/95

AIR DRYER PACKAGE


Air Inlet Temperature
Air Pressure

54.4 max

Barg

17.0 max

DOWTHERM VAPORIZER
Set Point Variables

Units

Tag Number

Target

Formula

Range

Dowtherm Header Pressure

Bar A

PI M439

4.0-4.5

Dowtherm Header Temperature

Deg. C

TIM192

350 Max

Delta Temperature

Deg. C

DOWDELT

+5

Dowtherm Pressure at Vaporizer


Outlet

Bar A

PIC M191

4.0-4.5

RAW WATER
Set Point Variables

Units

Raw Water Reserve

Hrs

Raw Water Pump P-1313


Disch. Pressure

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

Document No. : FPG-II-022


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Expiry Date : Until
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Page :18 of 23
Set Point Variables

Units

Tag Number

Target

Formula

Range

City Water Pump P-1313


Discharge Pressure

Barg

PI M026

5-7

Potable Water Reserve Level

cm

LIC M344

2750 min

City Water Tank Level

LIC M344

90-98

FIRE WATER
Set Point Variables

Units

Tag
Number

Target

Formula

Range

Fire Water Reserve S-1301

65 min

Fire Water Reserve S-1343

95 min

Fire Water Main Supply Pressure


When Fire Pumps Are Running

Barg

PI M006

10 14

S-1301 Level

LIC M004

75-100

S-1343 Level

LIC M294

75-100

Jockey Pump P-1312 Low Pressure


Start

Psi

PSL M555

154

Jockey Pump P-1312 High Pressure


Stop

Psi

PSL M555

159.5

Firewater Diesel Pump P-1311 be


activated

Psi

PSL M010

143

Firewater Diesel Pump P-1362 be


activated

Psi

PSL M050

132

Document No. : FPG-II-022


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Expiry Date : Until
Superseeded
Page :19 of 23
COOLING TOWER
Set Point Variables

Units

Tag Number

Target

Formula

Range

Cooling Water Supply


Pressure

Barg

PI M219
PI M221
PI M222

3.5-4.5
3.5-4.5
3.5-4.5

*Cooling Water Supply


Temperature

TI M369

35 max

F-1361A Start Temperature

TAH 369

26.7

F-1361B Start Temperature

TAHH M369

34.0

C
C

HIGH PRESSURE NATURAL GAS TO HYDROGEN PLANT


Set Point Variables

Units

Tag Number

Supply Pressure to Gas


Plant

Barg

PI M382

Target

Formula

Range
26.6 28.2

LOW PRESSURE NATURAL GAS TO FPG FIRED HEATERS


Set Point Variables

Units

Tag Number

Supply Pressure

Barg

PI M383

LOW PRESSURE NITROGEN HEADER

Target

Formula

Range
1.5-2.0

Document No. : FPG-II-022


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Expiry Date : Until
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Page :20 of 23
Set Point Variables

Units

Tag Number

Supply Pressure

Barg

PI M376

Target

Formula

Range
2.2-2.6

HIGH PRESSURE NITROGEN HEADER


Set Point Variables

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

Tempered Water Pump Discharge


Pressure

Barg

PI M242
PI M243

4.1-8.0
4.1-8.0

Tempered Water Expansion Tank

LIM 246

80 - 90

Tempered Water Cooler Temperature


Control

TIC M257

58-63

CHILLED WATER

Document No. : FPG-II-022


Revision :7
Expiry Date : Until
Superseeded
Page :21 of 23
Set Point Variables

Units

Chilled Water Header


Temperature

Tag Number

Target

Formula

Range

TI M245

3.5-6.0

Barg

PI M242
PI M243

4.0-8.0

Chilled Water Storage

LIM 238

80 - 90

Chilled Water Cooler


Temperature Control

TI M557

3.5-6.0

Chilled Water Pump Discharge


Pressure

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