ITC LIMITED AGRI BUSINESS DIVISION ILTD

GLT

STANDARD OPERATING PROCEDURE

OPERATION OF UTILITIES

APPROVED BY FACTORY MANAGER SOP NO. E 03
ISSUED BY FACTORY ENGINEER ISSUED DATE 01.07.2009
VERSION 1.0 PAGE Page 1 of 6

SCOPE: Procedure for Operation of Utilities


ACTIVITY:
1. Boiler Operation
2. DG Operation
3. Water System
4. ETP Operation


PROCEDURE:


1.0. BOILER OPERATION:


i. Boiler is operated and maintained by operators and supervisor. All the Boiler
technicians are First class Boiler Operators certified under Section 6 of Indian
Boiler Regulations

ii. There shall be atleast 2 operators in a shift with one operator positioned as
Boiler operator and the other as DM operator.

iii. Boiler operator shall be responsible for operation of Boiler with adherence to
checking and logging of parameters

iv. DM operator shall be responsible to ensure availability of De-mineralised water
in quality and quantity for Boiler operation

v. Boiler operation involves the following steps:

a) Fuel preparation b) Bed preparation c) DM plant operation

d) Start up e) Steam production

vi. Feed water quality shall be tested and recorded on an hourly basis in the DM
plant.

vii. Time taken for regeneration process stage wise shall be recorded in a register
in DM plant as and when regeneration takes place.

viii. The feed water for Boiler consists of condensate return from the plant and
make up water from DM plant.

ix. Ensure that feed water storage tanks are full.

x. Ensure that water level in the steam drum is atleast 40%.
ITC LIMITED AGRI BUSINESS DIVISION ILTD
GLT

STANDARD OPERATING PROCEDURE

OPERATION OF UTILITIES

APPROVED BY FACTORY MANAGER SOP NO. E 03
ISSUED BY FACTORY ENGINEER ISSUED DATE 01.07.2009
VERSION 1.0 PAGE Page 2 of 6


xi. The following important parameters shall be monitored and logged in the
register on an hourly basis:

I. Steam pressure
II. Drum water level
III. Bed temperatures (
0
C)
IV. Feed water pH
V. Chlorides in Feed water


1.1. Annual Inspection:

i. The following are inspected as part of Annual inspection by Boiler inspector:
i. Open inspection
ii. Hydraulic testing.

ii. All stop valves will be closed, safety valves are dummied and boiler is subjected
to 1.5 times its working pressure.

iii. Boiler inspector inspects condition of tubes and whether the pressure is
maintained for atleast 10 mins.

iv. Once through, Form VI will be issued by Boiler inspector for use of in steam
generation.


2.0. OPERATION OF DIESEL GENERATORS


2.1. Operation of DG Set:

i. Procedure related to operation of DG Set and Power change over from Grid to
DG Power supply is detailed in the Work Instruction No. WI ENGDG.001

ii. During continuous operation of DG Set, Fuel level in day tanks shall be
monitored visually.

iii. Day tanks shall be filled using centrifuge pump and procedure related to
operation of centrifuge pump is detailed in Work Instruction No. WI ENGDG.003


2.2. Synchronization of DG Sets:

Procedure related to operation of DG Set is detailed in the Work Instruction
No. WI ENGDG.004

ITC LIMITED AGRI BUSINESS DIVISION ILTD
GLT

STANDARD OPERATING PROCEDURE

OPERATION OF UTILITIES

APPROVED BY FACTORY MANAGER SOP NO. E 03
ISSUED BY FACTORY ENGINEER ISSUED DATE 01.07.2009
VERSION 1.0 PAGE Page 3 of 6

3.0. MONITORING, RECORDING & REPORTING OF WATER

3.1. WATER CONSUMPTION MONITORING:

The following is the procedure for monitoring of water consumption in the unit:

i. Water drawn for Domestic, Industrial and Process for the previous month shall
be recorded and submitted to EHS department who in turn report to Pollution
Control Board on or before 5
th
of every month.

3.1.1. WATER DRAWN FOR INDUSTRIAL USE:


i. Water for Industrial use comprises of consumption for Boiler, Process
Cylinders, Lamina Redriers and DG Cooling Towers.

ii. Sum of the Meter readings at the above points shall be recorded on daily basis
and monthly consumption shall to be arrived at.


3.1.2. WATER DRAWN FOR DOMESTIC USE:


i. Water for domestic use comprises of consumption at Canteen, Labour shed,
Bungalow compound, drinking & toilets etc.,

ii. Water used for domestic purpose is mainly drawn from designated wells.

iii. Readings of the above meters provided at the wells are to be recorded on a
daily basis and monthly consumption has to be arrived at.


3.2. RECORDING & REPORTING

1) The DG Supervisor shall update records showing the water drawn for
industrial & domestic consumption on a daily basis.

2) Water drawn for Domestic, Industrial and Process for the previous
month shall be recorded and submitted to EHS department who in
turn report to Pollution Control Board on or before 5
th
of every month.

3.3. EFFLUENT WATER SYSTEM
i. Effluent water collected from Industrial and domestic sources is
adequately treated and reused to comply with APPCB Norms.

ii. Effluent water to ETP shall be metered at its inlet and outlet and recorded
on a daily basis.
ITC LIMITED AGRI BUSINESS DIVISION ILTD
GLT

STANDARD OPERATING PROCEDURE

OPERATION OF UTILITIES

APPROVED BY FACTORY MANAGER SOP NO. E 03
ISSUED BY FACTORY ENGINEER ISSUED DATE 01.07.2009
VERSION 1.0 PAGE Page 4 of 6


iii. Details of metering on monthly basis shall be sent to EHS Department for
submission to Pollution control board.

iv. Treated water quality shall be tested on monthly basis.



4.0. OPERATION OF EFFLUENT TREATMENT PLANT

i. The following are the areas from which effluents are generated:

1. DM plant.
2. Boiler blowdown.
3. DG cooling towers blowdown.
4. Canteen and main office.
5. Southern bungalow compound.
6. Toilets

ii. All the effluents are collected in a mixed condition in a intermittent equalization
tank.

iii. Effluent after getting screened in Bar screen chamber is pumped from
equalisation tank into FAB reactors.

iv. In FAB reactors, the action of bacteria under aerated condition treats effluent.
FAB reactors contain media, which help in holding the bacteria.

v. After treatment, water enters Tube settlers where suspended solids are trapped
and removed by draining.

vi. FAB reactors have to be drained on a weekly basis. Tube settlers are to be
drained once in 4 hours.

vii. The drained sludge is collected in sludge drying beds, where it is subjected to
evaporation.

viii. Treated water is then pumped from final storage tanks through to an
intermediate storage tank for distribution.

ix. ETP is metered at its inlet and outlet water lines and records of incoming and
treated water are maintained.

x. The incoming water pH is checked on an hourly basis and recorded. It should
not be less than 6.5.

ITC LIMITED AGRI BUSINESS DIVISION ILTD
GLT

STANDARD OPERATING PROCEDURE

OPERATION OF UTILITIES

APPROVED BY FACTORY MANAGER SOP NO. E 03
ISSUED BY FACTORY ENGINEER ISSUED DATE 01.07.2009
VERSION 1.0 PAGE Page 5 of 6

xi. Monthly details of ETP treated water shall be provided to EHS department for
submission to Pollution Control Board.


xii. The following are the quality specifications of treated effluent:

S.NO PARAMETER RANGE
1 pH 5.5 to 7
2 TDS < 2100 ppm
3 Oil / grease 10 mg/ltr
4 BOD 100 mg/ltr
5 TSS 200 mg/ltr


xiii. EHS department shall carry out raw water and treated water testing on a
monthly basis through an external laboratory and records shall be maintained.

xiv. Treated water shall be used within the factory for:

1. Gardening.
2. Ash cooling and wetting.
3. Coal wetting and
4. Toilets flushing



RESPONSIBILITY:


BOILER OPERATIONS:

Operation of Boiler Manager Incharge of Boiler.

Review & control Factory Engineer.



DG OPERTIONS:

Operation of DG Sets Maintenance Engineer Electrical.

Review & Control - Factory Engineer.



ITC LIMITED AGRI BUSINESS DIVISION ILTD
GLT

STANDARD OPERATING PROCEDURE

OPERATION OF UTILITIES

APPROVED BY FACTORY MANAGER SOP NO. E 03
ISSUED BY FACTORY ENGINEER ISSUED DATE 01.07.2009
VERSION 1.0 PAGE Page 6 of 6



WATER SYSTEM:

Implementation of SOP Manager Incharge of Services

Quality testing and submission of returns to PCB EHS Manager.

Review & control Factory Engineer & EHS Manager


ETP OPERATIONS:

Implementation of SOP Maintenance Engineer - Services

Quality testing and submission of monthly reports to PCB EHS Manager

Review and control Factory Engineer.