Shut Down Standard Operating Procedure

Prepared by: Reviewed by: Approved by:

Name: Reggab Abdelkader Zouad Zoubir Daoudi Adlane

THU Project Operations General
Position:
Supervisor Manager Manager
Signatur
e:

Doc. No. Issue/Rev. Issue/Rev. Date: Sheets

ES-ALG-THU-PR-03 02/00 15-03-2016 1 OF 7
1. Purpose:

This procedure is direct to the personnel responsible for starting and operating the Thermal Unit (THU).

2. Scope:

This procedure is to define the sequence of events and the actions to be taken in THU site when all power to
the Thermal Unit (THU) is interrupted, when the Emergency Stop button on the plant control panel is pressed
and when the Emergency Stop button on the Hauck burner control panel is pressed.

3. Responsibilities:

3.1 Project Supervisor:

The Project Supervisor is responsible for all actions, which need to be taken in the Control Trailer. As soon as
the emergency condition is brought under control the supervisor is responsible for determining the status of all
personnel on location.

3.2 Senior Operator:

The Senior Operator is responsible for confirming that the emergency water sprays are on and the Drum is
being turned slowly by the Gas air motor.

3.3 Junior Operator:

The Junior Coordinator is responsible for ensuring that the drum is turning and that the emergency water is
turned on. The Coordinator also directs the other personnel in the quenching of any vapors that escape the
system.

3.4 Coordinator:

The Coordinator will ensure that the emergency water pump is running. The Coordinator
Is to assist in the quenching of any vapors from the system.

Doc. No. Issue/Rev. Issue/Rev. Date: Sheets

ES-ALG-THU-PR-03 02/00 15-03-2016 2 OF 7
3.5 Technician:

The Technician immediately starts second generator and air compressor. If the emergency shutdown has
resulted from the stoppage of the main power first generator, it is the responsibility of the Plant Mechanic to
determine the cause of the stoppage and restart the second generator as quickly as possible.

3.6 Technician Helper:

The Technician helper is responsible for assisting the Technician in locating and supplying the tools and
equipment that are needed to determine and remedy the cause of the shutdown.

3.7 Laborers:

The Laborers will help in the quenching of any vapors that are coming from the system.

4. Definitions and Abbreviations:

4.1 THU: Thermal Unit

4.2 ES : Environnemental Solutions.
4.3 IDF : Induced Draft Fan

5. Procedure:

5.1 Loss of Mains Power to the Unit:

When power is lost from Generator N°1, the second generator activated immediately.
Start local IDF at 100% to evacuate the vapor from the drum, start the air compressor for supplying the air to
knife gate thus the discharge auger, than rotate the Dryer Drum slowly. These features of the Thermal Unit
(THU) are designed to protect the drum and quenching the volatile steams those escape from the drum seals.
It is essential to ensure that the Emergency Shutdown System is functioning properly & immediately.
If a loss of power occurs at the plant, then each individual has assigned duties and should be familiar with
their duties and ready to react quickly. These duties will be carried out simultaneously, and in the order listed
for each classification.

5.2 Project Supervisor:

5.2.1 The Project Supervisor will make certain that all duties are performed correctly and quickly.
5.2.2 The Project Supervisor will then assist in any area that may require assistance.

Doc. No. Issue/Rev. Issue/Rev. Date: Sheets

ES-ALG-THU-PR-03 02/00 15-03-2016 3 OF 7
5.3 Operators:

5.3.1 The Operator will ensure that the second generator operated and the power done, before starting any
other task. Next the Operator will ensure that the switches are in the correct position to maintain air
and water if the power is restored.
5.3.2 The Operator will place the Discharge End Seal Spray Solenoid Valve switch in the “on” position.
5.3.3 Place the Feed End Seal Spray Solenoid Valve switch in the “on” position.
5.3.4 Place the Emergency Water Solenoid Valve switch in the “on “position.
5.3.5 Place the Drum Air Motor Solenoid Valve switch in the “on” position.
5.3.6 If it becomes necessary to stop the drum or the emergency water, then a manual valve in the air lines
can be used to shut off the air to either or both pieces of equipment.
5.3.7 The Operator will follow the following steps until the power is resumed.
5.3.8 Continue spraying water over the drum seals, as needed.
5.3.9 Continue running the drum at low speed.
5.3.10 When the Drum shell temperature is below 300 F, stop the drum by closing the manual valve on the
air to the drum air motor drive.
5.3.11 Stop the water spray over the drum seals by closing the manual valve on the air to the emergency
water supply diaphragm pump.
5.3.12 When power is restored and the problem has be fixed, the startup of the plant will begin.
5.3.13 Before restarting the (THU) System after power is restored, make certain that the manual valves are in
the correct open position.
5.3.14 Place the Discharge End Seal Spray Solenoid Valve switch in the “off’ position.
5.3.15 Place the Feed End Seal Spray Solenoid Valve switch in the “off” position.
5.3.16 Place the Emergency Water Solenoid Valve switch in the “off “position.
5.3.17 Place the Drum Air Motor Solenoid Valve switch in the “off” position.
5.3.18 Stop the diesel powered air compressor.
5.3.19 To resume operation, use the normal Start-up Procedure.
5.3.20 Pressing the Emergency Stop Button on the Control Panel.
5.3.21 Pressing the Emergency Stop button on control panel causes the circuit breaker to trip “off”. This
removes all power. All motors will stop. The control panel and the Hauck burner control panel will
remain energized. All burners will be extinguished. All inside and outside lighting will remain on. The
emergency water system and the air driven drum rolling system will be activated immediately. The
above procedures will be followed.
5.3.22 Once the emergency has been remedied reset the Emergency Stop button.
5.3.23 The Start-up Procedure will be used to restart the plant.
5.3.24 Pressing the Emergency stop Button on the Hauck Burner Control panel.

Doc. No. Issue/Rev. Issue/Rev. Date: Sheets

ES-ALG-THU-PR-03 02/00 15-03-2016 4 OF 7
5.3.25 Pressing the Emergency stop Button on the Hauck Burner Control panel removes all power from the
panel. All burners will be extinguished. If it is desired to shut down the plant follow the normal shut
down procedure.
5.3.26 If it is desired to restart, the plant reset the Emergency Stop button.
5.3.27 Relight the burners according to the Start-Up Procedure.

5.4 Coordinator:

5.4.1 The Coordinator will first ensure that the drum is rotating and the motor is functioning properly.
5.4.2 Next he must ensure that the emergency water sprays are working.
5.4.3 Then he controls the spraying of the vapors from the system.

5.5 Technician:

5.5.1 The technician immediate response to the power failure is to start the air compressor.
5.5.2 Next the Technician turns his attention to starting the generator.

5.6 Technician Helper:

5.6.1 The Technician Helper will assist the Technician with his responsibilities.
5.6.2 The Helper will carry out instructions given him by the Technician or the Supervisor.

5.7 Laborers:

5.7.1 In case of power failure, the laborers will immediately man the water hoses at the dryer.
5.7.2 The laborers will quench any steams as directed by the Coordinator, the Operator or the Supervisor.
5.7.3 The laborers will perform any other duties as directed by the Supervisor.
Notes:

These steps are a guideline for the emergency shutdown in case of a loss of power and
should be followed. Conditions may change requiring actions other than those in this
Procedure, and the Supervisor will direct the personnel in these changes. It should be
remembered that this is an emergency situation and that there is a potential harm to
personnel and equipment if the Emergency Air and Water Systems are not maintained and
working properly.
5.9. Training:
Establish and train employees on standard procedures for:

Doc. No. Issue/Rev. Issue/Rev. Date: Sheets

ES-ALG-THU-PR-03 02/00 15-03-2016 5 OF 7
  The Thermal Technology /THU Unit Training Courses.
 Hydraulic Basic Program.
 Fire Fighting Courses.
 Lifting Operation Courses.
6. Forms:

Form No. Description File

N/A N/A N/A

7. References:

 ISO 9001/2015
 ISO 14001/2015
 OHSAS 18001/2007
 Process Flow drawing C11610
 Equipment Location drawing C13987
 P&I drawing C13984
 Control Console Layout drawing C12806-29
 Interlock System drawing C12806-28
 IDM drawing 48258E20 and 48258E21
 EPCON drawing D-545-010
 Hauck Burner Management System Description Volume 3, Section H, Hauck, Panel

List of Amendments

Doc. No. Issue/Rev. Issue/Rev. Date: Sheets

ES-ALG-THU-PR-03 02/00 15-03-2016 6 OF 7
 MODIFICATIONS, CHANGES AND
Sr. Date Page
ADDITIONS

10

Doc. No. Issue/Rev. Issue/Rev. Date: Sheets

ES-ALG-THU-PR-03 02/00 15-03-2016 7 OF 7