N-10012-4-OPM-1501-0 Operation and Maintenance Manual Evaporation Section PDF

OPERATION AND MAINTENANCE MANUAL
PROJECT REV. ISSUE

CLIENT SECTION DOCUMENT NO. PAGE NO.
NO. NO. DATE
VICENTIN
N-10012 EVAPORATION N-10012-4-OPM1501 0 1 OF 149 05.11.2012
S.A.I.C.

TITLE :
EVAPORATION 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-OPM1501
0 05.11..2012 SSK/SAJ PKR/SBG VBJ FOR EXCECUTION

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 NFI D E N TI A L CONSENT FROM,”PRAJ INDUSTRIES LTD, “PRAJ HOUSE”, BAVDHAN, PUNE 411021, INDIA
OPERATION AND MAINTENANCE MANUAL EVAPORATION SECTION.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
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.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
TABLE OF CONTENT
SR.NO. CONTENTS PAGE NO.
PART – I THEORETICAL ASPECTS
1.0 INTRODUCTION 07
1.0.1 Theory of Evaporation 09
1.0.2 Process Description 16
1.0.3 Control Logic & Interlock Description 34
1.0.4 Equipment Description 35
1.0.5 List of Pressure Safety Valves 41
PART–II PRE-START-UP ACTIVITIES
2.0 GENERAL INSTRUCTIONS 43
2.0.1 SOP for establishment of cooling water circuit 47
2.0.2 SOP for charging low-pressure steam 48
2.0.3 Water Flushing/Cold Water Trial 49
2.0.4 Vacuum Trial 60
2.0.5 Steam Trial 67
PART – III PROCESS START-UP AND PROCESS PARAMETERS
3.0.1 Safety Notes 84
3.0.2 Normal Start-up 85

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
TABLE OF CONTENT
3.0.3 Process Parameters 88
3.0.4 Cleaning in Place (CIP) 95
3.0.4 a SOP for Preparation of 3-5 % w/w Nitric acid solution in CIP 95
Tank T-1506
3.0.4 b SOP for Preparation of 3-5 % w/w caustic solution in CIP Tank 96
T-1351
3.0.4.c SOP for CIP of Falling Film Effect – I (H-1501) 97
3.0.4 d SOP for CIP of Falling Film Effect – II (H-1502) 99
3.0.4 e SOP for CIP of Falling Film Effect – III (H-1503) 102
3.0.4 f SOP for CIP of Falling Film Standby Effect (H-1504) 104
3.0.4 g SOP for CIP of Forced Circulation Effect – I (H-1505) 106
3.0.4 h SOP for CIP of Forced Circulation Effect – II (H-1506) 108
3.0.4 i SOP for CIP of Forced Circulation Standby Effect (H-1507) 110
3.0.5 Process Monitoring 112
3.0.6 Frequency of Routine Analysis 113
3.0.7 Troubleshooting 115
PART – IV PROCESS SHUTDOWN & PROCESS START-UP

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
TABLE OF CONTENT
4.0.1 Power Failure 121
4.0.2 Cooling Water Failure 125
4.0.3 Steam Supply Failure 129
4.0.4 Instrument Air Failure 133
4.1 Plant Short Shutdown & Start-up after Short Shutdown 138
4.1.1 Plant Short Shutdown 138
4.1.2 Plant Start-up after Short Shutdown 140
4.2 Plant Long Duration Shutdown & Start-up after Long 143
Duration Shutdown
4.2.1 Plant Long Duration Shutdown 143
4.2.2 Plant Start-up after Long Duration Shutdown 146

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
PART–I
THEORETICAL ASPECTS

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
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.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
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.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
1.0.1 THEORY OF EVAPORATION
All steam heated evaporator bodies, no matter what their configuration, have the
following standard components –
HEAT EXCHANGER - contains tubes, tube sheets, and shell enclosing the tubes along
with tube sheets.
LIQUID BOXES - serve as channels to distribute feed to all of the tubes.
VAPOR LIQUID SEPARATOR - serves as separation chamber to release vapour from

boiling liquid.
MIST ELIMINATOR - serves to remove fine, small particles of liquid from vapours
released from vapour liquid separator.
VAPOR PIPE - direct released vapours from vapour liquid separator to condenser.
RECIRCULATION PIPE - recirculation piping transfer the liquid from vapour liquid
separator to heat exchanger.
RECIRCULATION PUMP - recirculation pump transfer the liquid from vapour liquid
separator to heat exchanger.
CONDENSATE PIPE - outlet piping removes condensate from the heating element
shell to a condensate tank, thus removing the condensate from the evaporator system.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
NONCONDENSIBLE VENT PIPE - allows removal of non-condensable gases to

prevent them from accumulating inside the heating element shell and blanking off the
heating surface.
VAPOR INLET
HEAT
EXCHANGER
SHELL
SECTION
NON-CONDENSIBLE
GAS OUTLET
CONDENSATE
VAPOR OUTLET OUTLET
VAPOR-LIQUID
SEPARATOR
(VLS)
FEED INLET
CIRCULATING VINASSE OUTLET

PIPING CIRCULATING
PUMP

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Vapor Out
Steam / Vapour in
Concensate Out
Feed In
Conc. Product Out
HEATING ELEMENT – Heat Exchangers

The heating element is made up of a tube bundle enclosed by a cylindrical shell installed
in the vertical / horizontal position. The heating element shell is in Stainless Steel. The
tubes are expanded into the tube sheets.
The tube sheets are circular plates, with holes drilled to match the specific tube pattern
required for the evaporator. The tube sheets are made up of solid stainless steel. The
heating element shell contains several internal tube support baffles to reduce tube
vibration and for tube breakage potentials. These internal tube support baffles also serve
to channel and distribute the vapours more evenly through the tube bundle.
The vapour condensate falls by gravity, is collected on the lower portion of the shell, and
leaves the heating element through the condensate outlet nozzle.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
The heating element is provided with a non-condensable vent gas outlet connection. One
non-condensable gas vent is located near the top of the shell section and one non-
condensable gas vent is located near the bottom of the shell section. These locations
along with the internal tube support baffle arrangement allows for the vapours to be
directed through the total length of the tube bundle.
DISTRIBUTION BOX
The top main liquid box of the falling film evaporator bodies is an extension of the heater
shell above the top tube sheet. The top liquid box contains the spray shower distribution
nozzles which are located above the top tube sheet to provide even distribution of liquid
to all of the tubes. The top liquid box contains four (4) spray shower distributor nozzles.
The large volume of circulating Thin Stillage causes a liquid level to build on the plate
which serves to provide an even flow of Thin Stillage to all of the tubes.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
VAPOR-LIQUID SEPARATOR – VLS

In the evaporators the Thin Stillage is carried through the tubes by the high velocity
vapor. Without some type of separation devices, the Thin Stillage would be carried over
with the vapor to the next effect. To prevent this "carry-over," the evaporator is provided
with two parts to separate the liquid from the vapor.
The VLS serves as a "wide spot in the line" of the vapor flow path between the effects.
Because the flow area of the vapor body is significantly larger than the flow area of the
tubes, the velocity of the vapor and liquid mixture is greatly reduced. With this large
reduction in velocity, any large particles of liquid or foam that are carried along with the
vapor will be slowed enough to lose their momentum and will fall downward by gravity
back to the sump of the VLS.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Vapor Out
Mist Eliminator
Feed In
Recirculation In
Recirculation Out

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
MIST ELIMINATOR
After the larger liquid particles fall out of the vapour, a "polishing" device, called a Mist
eliminator is used to remove the smaller particles from the vapour. These smaller liquid
particles can resemble a mist or a fog. A wire mesh type mist eliminator is provided in
the upper section of the vapour body to remove the smaller liquid particles. A wire mesh
type mist eliminator uses both impingement and change of direction to provide
extremely low pressure drops. This type is designed for vertical vapour flow and is of
the self-draining type.
Vapor
Flow

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
1.0.2 PROCESS DESCRIPTION
GENERAL
The Evaporation plant is designed to operate with three Cases
Case-I – Feedstock Corn.
Case II – Feedstock Sorghum without Tannin with Recycle of Thin Stillage.
Case III – Feedstock Sorghum with Tannin without Recycle of Thin Stillage.
In order to have energy saving, there is thermal integration of Evaporation section with
Mash Column (C-1401) in Distillation section.
The Evaporation plant consists of two sections. The First section consist of three effect
Falling Film Evaporators operating on principle of multi-effect evaporation. One
common standby evaporator is also provided to have continuous operation of the plant
during cleaning in place (CIP) of any Falling Film evaporator. Hence at any time three
evaporator bodies will be in operation.
The position of the Falling Film evaporator in multiple effect system is mentioned in
below table.
Mode of
Under CIP First Effect Second Effect Third Effect
Operation
Mode A H-1501 H-1502 H-1503 H-1504
Mode B H-1502 H-1501 H-1503 H-1504
Mode C H-1503 H-1501 H-1502 H-1504
Mode D H-1504 H-1501 H-1502 H-1503

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Thus H-1501 will always act as First Effect whenever in operation, Falling Film Effect
– II (H-1502) can operate as First Effect or Second effect, Falling Film Effect – III (H-
1503) can operate as Second effect or Third effect, and Falling Film Standby Effect (H-
1504) will always operate as Third effect.
The Second section consists of two effect Forced Circulation evaporators operating on
principle of multi-effect evaporation. One common standby evaporator is also provided
to have continuous operation of the plant during cleaning in place (CIP) of any Forced
Circulation evaporator. Hence at any time two evaporator bodies will be in operation.
Second Section will be operative only with Case II and Case III with sorghum as feed
stock.
The position of the Forced Circulation evaporator in multiple effect system is

mentioned in below table.
Mode of
Under CIP First Effect Second Effect
Operation
Mode P H-1505 H-1506 H-1507
Mode Q H-1506 H-1505 H-1507
Mode R H-1507 H-1505 H-1506
Thus Forced Circulation Effect – I (H-1505) will always act as First Effect whenever in
operation, Forced Circulation Effect – II (H-1506) can operate as First Effect or Second
effect and Forced Circulation Standby Effect (H-1507) will always operate as Second
effect.
(Refer: Control & Interlock Descriptive Logic N-10012-4-ILD 1501, section “N-
Changeover Modes for falling film evaporators and forced circulation evaporators’)

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
A) Case-I – Feedstock Corn.
3 EFFECT FALLING FILM SYSTEM ON STEAM

In case of corn as feed stock, only Falling Film section shall be in operation. Thin Stillage
from Decantation section along with waste CIP solution of Evaporation and
Fermentation will be preheated with steam condensate in Thin Stillage Preheater (H-
1509A/B) and then fed to Falling Film Effect -I. Steam will be used as heat source for
Falling Film Effect - I. Steam condensate from shell of Falling Film Effect - I will be
collected in Steam Condensate Tank (T-1504). Thin Stillage vapors generated from
Falling Film Effect - I will be used as heating source for Falling Film Effect - II. Partially
Concentrated Thin Stillage from Falling Film Effect - I will be fed to Falling Film Effect -
II. Thin Stillage vapors generated in Falling Film Effect - II will be used as heating source
for Falling Film Effect - III and partial vapors shall be send to Mash Column (C-1401) as
heating source. Partially Concentrated Syrup from Falling Film Effect - II will be fed to
the Falling Film Effect - III.
Thin Stillage vapors generated in Falling Film Effect - III will be condensed in Surface
Condenser (H-1508). Concentrated Syrup (34.00% w/w to 35.00% w/w) will be send to
Concentrated Syrup Tank (T-1505).
Process Condensate generated in Surface condensers will be collected in Process

Condensate tank –2 (T-1503). This condensate will be pumped to Process Condensate
tank –1 (T-1502).
Process Condensate generated from Falling Film Effect - II and Falling Film Effect - III
will be collected in Process Condensate Tank – 1 (T-1502). This Process Condensate will

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
be used for preheating the Treated Process Condensate in Treated Process Condensate
Preheater (H-1510) and then will be sent to Process Condensate Treatment Plant.
Necessary vacuum required will be generated by Water Ring Vacuum Pump (P-
1513A/B). Concentrated Syrup from Falling Film Effect - III will be collected in
Concentrated Syrup Tank (T-1505) and then will be sent for storage.
B) Case II – Feedstock Sorghum without Tannin with Recycle of Thin Stillage.
3 EFFECT FALLING FILM SYSTEM ON STEAM + 2 EFFECT FORCED

CIRCULATION SYSTEM ON STEAM
Evaporation plant consists of two sections. First section will consist of three effects
Falling Film Evaporators which will be operating on steam. Second section will consist
of two Effect Forced Circulation Evaporators which will also be operating on steam.
There will be a common standby for 3 operating Falling Film Evaporators and there will
be a common Force Circulation standby for 2 Forced Circulation Evaporators. Standby
Evaporators shall be in operation when any regular effect shall be in CIP. Thus plant
shall operate without stoppage during CIP operation.
Section I (3 Effect Falling Film System):

Thin Stillage from Decantation section along with waste CIP solution of Evaporation and
1509A/B) and then fed to Falling Film Effect - I. Steam will be used as heat source for

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Concentrated Thin Stillage from Falling Film Effect - I will be fed to Falling Film Effect -
II. Thin Stillage vapors generated in Falling Film Effect - II will be used as heating source
for Falling Film Effect - III. Partially Concentrated Syrup from Falling Film Effect - II will
be fed to the Falling Film Effect - III.
Thin Stillage vapors generated in Falling Film Effect - III will be partially used as a heat
source for Mash Column (C-1401) in Distillation Section and remaining vapors will be
condensed in Process Condenser (H-1511). And partially Concentrated Syrup (29.00%
w/w to 30.00% w/w) will be fed to the second section.
Section II (2 Effect Forced Circulation):

Partially Concentrated Syrup from the first section will be fed to Forced Circulation
Effect–I in second section. Steam will be used as heating medium for the first effect and
vapors generated in Forced Circulation Effect –I will be used as a heat source for Forced
Circulation Effect –II.
Partially Concentrated Syrup will be fed to Forced Circulation Effect –II where it will be
concentrated up to 35% w/w. Steam condensate generated will be collected in Steam
Condensate Tank (T-1504). After that it will be recycled to boiler section after preheating
Thin Stillage in Thin Stillage Preheater (H-1509A/B).
Thin Stillage Vapors generated in Forced Circulation Effect –II will be totally condensed
in Surface Condenser (H-1508). Process condensate generated from Surface
Condenser(H-1508), Process Condenser (H-1511) and Forced Circulation Effect –II of
second section will be collected in Process Condensate Tank – 2 (T-1503) and will be

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
further transferred to Process Condensate Tank-1(T-1502). Similarly Process Condensate

generated from Falling Film Effect–II and Falling Film Effect-III will be collected in
Process Condensate Tank – 1(T-1502). This Process Condensate will be used for
preheating the Treated Process Condensate in Treated Process Condensate Preheater (H-
1510) and then will be sent to Process Condensate Treatment Plant.
1513A/B). Concentrated Syrup from Forced Circulation Effect –II will be collected in
C) Case III – Feedstock Sorghum with Tannin without Recycle of Thin Stillage.
3 EFFECT FALLING FILM SYSTEM ON STEAM + 2 EFFECT FORCED

CIRCULATION SYSTEM ON STEAM
Evaporation plant consists of two sections. First section will consist of 3 Effects Falling
Film Evaporators which will be operating on steam. Second section will consist of 2
Effect Forced Circulation Evaporators which will also be operating on steam. There will
be a common standby for 3 operating Falling Film Evaporators and there will be a
common Force Circulation standby for 2 Forced Circulation Evaporators. Standby
Evaporators shall be in operation when any regular effect shall go under CIP. Thus plant
shall operate without stoppage during CIP operation.
Section I (3 Effect Falling Film):

Thin Stillage from Decantation section along with waste CIP solution of Evaporation and
1509A/B) and then fed to Falling Film Effect-I. Steam will be used as heat source for

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Concentrated Syrup from Falling Film Effect - I will be fed to Falling Film Effect - II. Thin
Stillage vapors generated in Falling Film Effect - II will be used as heating source for
Falling Film Effect - III. Partially Concentrated Syrup from Falling Film Effect - II will be
fed to the Falling Film Effect - III.
Thin Stillage vapors generated in Falling Film Effect - III will be partially used as a heat
source for Mash Column (C-1401) in Distillation section and remaining vapors will be
condensed in Process Condenser (H-1511). And partially Concentrated Syrup (29.00%
w/w to 30.00% w/w) will be fed to the second section.
Section II (2 Effect Forced Circulation):

Partially Concentrated Syrup from the first section will be fed to Forced Circulation
Effect -I in second section. Steam will be used as heating medium for the 1st Effect forced
Circulation Evaporator and vapors generated in Forced Circulation Effect -I will be used
as a heat source for Forced Circulation Effect -II.
Partially Concentrated Syrup will be fed to Forced Circulation Effect -II where it will be
concentrated up to 35% w/w. Steam condensate generated will be collected in Steam
Condensate Tank (T-1504). After that it will be recycled to boiler section after preheating
Thin Stillage in Thin Stillage Preheater (H-1509A/B).

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Thin Stillage Vapors generated in Forced Circulation Effect -II will be totally condensed
in Surface Condenser (H-1508). Process condensate generated from Surface Condenser
(H-1508), Process Condenser (H-1511) and Forced Circulation Effect –II of second section
will be collected in Process Condensate Tank – 2 (T-1503) and will be transferred to
Process Condensate Tank -1 (T-1502). Similarly Process Condensate generated from
Falling Film Effect – II and Falling Film Effect - III will be collected in Process
Condensate Tank – 1 (T-1502). This Process Condensate will be used for preheating the
Treated Process Condensate in Treated Process Condensate Preheater (H-1510) and then
will be sent to Process Condensate Treatment Plant.
1513A/B). Concentrated Syrup from Forced Circulation Effect -II will be collected in

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
P&ID No.: N-10012-1-P&ID1501: P&I DIAGRAM FOR FALLING FILM EFFECT -I
FALLING FILM EFFECT -I (H-1501)

First section consists of 3 Effect Falling Film Heat Exchanger along with Vapour
Liquid Separator (VLS) and Recirculation pumps. Each Falling Film body is provided
with 980 tubes of 50.8 mm OD and all Effect operate under vacuum.
Preheated Thin Stillage is pumped to Falling Film Effect – I (H-1501) based on level in
Vapor Liquid Separator for FF Effect – I (V-1501) and recirculated through Recirculation
Pump for FF Effect – I (P-1501). A partially concentrated Thin Stillage is transferred to
Vapor Liquid Separator for FF Effect – II (V-1502) based on liquid level control.
Saturated steam is used as heating media for this Falling Film Effect – I (H-1501).
Steam condensate from Falling Film Effect – I (H-1501) is collected in Steam
Condensate Tank (T-1504). This steam condensate is used to preheat the Thin Stillage
feed.
The Thin Stillage Vapors from Falling Film Effect – I (H-1501) is used as heating media
for Falling Film Effect – II (H-1502). Level of Vapor Liquid Separator for FF Effect – I
(V-1501) is controlled by level indicator and controller LIC-150101 through level
control valve (LCV-150101).
P&ID No.: N-10012-1-P&ID1502: P&I DIAGRAM FOR FALLING FILM EFFECT-II
FALLING FILM EFFECT –II (H-1502)

Thin Stillage from Falling Film Effect – I (H-1501) is pumped to Falling Film Effect –II
(H-1502) based on level in Vapor Liquid Separator for FF Effect – II (V-1502) and
recirculated through Recirculation Pump for FF Effect – II (P-1502). A partially

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
concentrated Thin Stillage is transferred to Vapor Liquid Separator for FF Effect – III (V-
1503) based on liquid level control and recirculated through Recirculation Pump for FF
Effect – III (P-1503).
In Sorghum case, Vapours generated in Falling Film effect –II will be used as heating
media for Falling Film Effect – III.
In Corn case, Vapors generated in Falling Film effect –II will be used partially as
heating media for Mash Column in Distillation section and Falling Film Effect – III.
Level of Vapor Liquid Separator for FF Effect – II (V-1502) is controlled by level
indicator and controller LIC-150201 through level control valve (LCV-150201).
P&ID No.: N-10012-1-P&ID1503: P&I DIAGRAM FOR FALLING FILM EFFECT -III
FALLING FILM EFFECT -III (H-1503)

In Sorghum case, Partially Concentrated Thin Stillage from Falling Film Effect – II is
pumped to Falling Film Effect –III (H-1503) based on level in Vapor Liquid Separator for
FF Effect – III (V-1503) and recirculated through Recirculation Pump for FF Effect – III
(P-1503). A partially concentrated Thin Stillage is transferred to Vapor Liquid Separator
for FC Effect – I (V-1505) based on liquid level control and recirculated through
Recirculation Pump for FC Effect – I (P-1505). Vapors generated in Falling Film Effect –
III will be used as heating media for Mash Column (C-1401) in Distillation Section and
remaining vapors will be condensed in Process Condenser (H-1511).
In Corn case, Partially Concentrated Thin Stillage from Falling Film Effect – II is pumped
to Falling Film Effect –III (H-1503) based on level in Vapor Liquid Separator for FF Effect
– III (V-1503) and recirculated through Recirculation Pump for FF Effect – III (P-1503),
where it is concentrated up to 34%w/w to 35%w/w. This concentrated syrup is

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
transferred through Concentrated Syrup Transfer Pump (P-1512) to Concentrated Syrup

Tank (T-1505). Vapors generated in Falling Film Effect – III will be condensed in Surface
Condenser (H-1508). Level of Vapor Liquid Separator for FF Effect – III (V-1503) is
controlled by level indicator and controller LIC-150301 through level control valve
(LCV-150301).
P&ID No.: N-10012-1-P&ID1504: P&I DIAGRAM FOR FALLING FILM STANDBY

EFFECT
FALLING FILM STANDBY EFFECT (H-1504)

In Sorghum case, During CIP of regular Falling Film Effects, partially concentrated
Thin Stillage from previous effect is transferred to Falling Film Standby Effect (H-1504)
based on level in Vapor Liquid Separator for FF Standby Effect (V-1504) and recirculated
through Recirculation Pump for FF Standby Effect (P-1504). A partially concentrated
Thin Stillage is transferred to Vapor Liquid Separator for FC Effect – I (V-1505) based on
liquid level control and recirculated through Recirculation Pump for FC Effect – I (P-
1505). Vapors generated in Falling Film Standby Effect (H-1504) will be used as heating
media for Mash Column (C-1401) in Distillation Section and remaining vapors will be
condensed in Process Condenser (H-1511).
In Corn case, During CIP of regular Falling Film Effects, Partially Concentrated syrup
from previous Falling Film Effect is pumped to Falling Film Standby Effect (H-1504)
based on level in Vapor Liquid Separator for FF Standby Effect (V-1504) and recirculated
through Recirculation Pump for FF Standby Effect (P-1504), where it is concentrated up
to 34%w/w to 35%w/w. This concentrated syrup is transferred through Concentrated
Syrup Transfer Pump (P-1512) to Concentrated Syrup Tank (T-1505). Vapors generated

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
in Falling Film Standby Effect (H-1504) will be condensed in Surface Condenser (H-
1508). Level of Vapor Liquid Separator for FF Standby Effect (V-1504) is controlled by
level indicator and controller LIC-150401 through level control valve (LCV-150401).
P&ID No.: N-10012-1-P&ID1505: P&I DIAGRAM FOR FORCED CIRCULATION

EFFECT -I
FORCED CIRCULATION EFFECT -I (H-1505)

Second section consists of 2 Effect Forced Circulation Evaporators along with Vapour
Liquid Separator (VLS) and recirculation pumps. Each Forced Circulation body is
provided with 152 tubes of 38.1 mm OD and the Effect operate under vacuum.
Second section will operate during Sorghum case only.
Partially concentrated Thin Stillage from first section is pumped to Forced Circulation
Effect – I (H-1505) based on level in Vapor Liquid Separator for FC Effect – I (V-1505)
and recirculated through Recirculation Pump for FC Effect – I (P-1505). A partially
concentrated Thin Stillage is transferred to Vapor Liquid Separator for FC Effect – II (V-
1506) based on liquid level control.
Saturated steam is used as heating media for this Forced Circulation Effect – I (H-
1505). Steam condensate from Forced Circulation Effect – I (H-1505) is collected in
Steam Condensate Tank (T-1504). This steam condensate is used to preheat the Thin
Stillage feed.
Thin Stillage Vapors from Forced Circulation Effect – I (H-1505) is used as heating
media for Forced Circulation Effect – II (H-1506). Level of Vapor Liquid Separator for
FC Effect – I (V-1505) is controlled by level indicator and controller LIC-150501
through level control valve (LCV-150501).

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.

EFFECT -II
FORCED CIRCULATION EFFECT -II (H-1506)

Thin Stillage from Forced Circulation Effect – I (H-1505) is pumped to Forced Circulation
Effect – II (H-1506) based on level in Vapor Liquid Separator for FC Effect – II (V-1506)
and recirculated through Recirculation Pump for FC Effect – II (P-1506) where it is
concentrated up to 34%w/w to 35%w/w. This Concentrated Syrup is transferred
through Concentrated Syrup Transfer Pump (P-1512) to Concentrated Syrup Tank (T-
1505).
Vapours generated in Forced Circulation Effect – II (H-1506) will be condensed in
Surface Condenser (H-1508).
Level of Vapor Liquid Separator for FC Effect – II (V-1506) is controlled by level
indicator and controller LIC-150601 through level control valve (LCV-150601).
The density of concentrated syrup is controlled by density indicator and controller DIC-
150601 based on the control logic selection. The density controller (DIC-15601) is in
cascade with low pressure steam flow totaliser indicator controller FQIC-150501 and
FQIC-150901, which ultimately control the concentration of Concentrated Syrup.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.

STANDBY EFFECT
FORCED CIRCULATION STANDBY EFFECT (H-1507)

During CIP of Forced Circulation Effect – I or II, partially concentrated Thin Stillage
from previous effect is transferred to Forced Circulation Standby Effect (H-1507) based
on level in Vapor Liquid Separator for FC Standby Effect (V-1507) and recirculated
through Recirculation Pump for FC Standby Effect (P-1507). Concentrated Syrup is
transferred through Concentrated Syrup Transfer Pump (P-1512) to Concentrated Syrup
Tank (T-1505).
Vapors generated in Forced Circulation Standby Effect (H-1507) will be condensed in
Surface Condenser (H-1508). Level of Vapor Liquid Separator for FC Standby Effect (V-
1507) is controlled by level indicator and controller LIC-150701 through level control
valve (LCV-150701).
P&ID No.: N-10012-1-P&ID1508: P&I DIAGRAM FOR CONDENSERS
SURFACE CONDENSER AND PROCESS CONDENSER (H-1508, H-1511)

In Sorghum case, Thin Stillage Vapors from Forced Circulation Effect –II (H-1506) or
Forced Circulation Standby Effect (H-1507) are condensed in Surface Condenser (H-
1508). Thin Stillage Vapors from Falling Film Effect – III (H-1503) or Falling Film
Standby Effect (H-1504) are used as heat source for Mash Column (C-1401) in
Distillation section and remaining vapors are condensed in Process Condenser (H-
1511).

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
In Corn Case, Thin Stillage Vapors from Falling Film Effect – III (H-1503) or Falling
Film Standby Effect (H-1504) are condensed in Surface Condenser (H-1508).
Evaporation condensate from Falling Film Effect – II (H-1502), Falling Film Effect – III
(H-1503) & Falling Film standby Effect (H-1504) is collected in Process Condensate
Tank - 1 (T-1502).
Evaporation Condensate from Forced Circulation Effect – II (H-1506) & Forced
Circulation Standby Effect (H-1507), Surface Condenser (H-1508) and Process
Condenser (H-1511) is collected in Process Condensate Tank – 2 (T-1503). Level of
Process Condensate Tank – 2 (T-1503) is controlled by level indicator and controller
LIC-150801 through level control valve (LCV-150801). The process condensate from
Process Condensate Tank – 2 (T-1503) is transferred to Process Condensate Tank – 1
(T-1502) based on liquid level control through Flow Totalizer and Indicator (FQI-
150801).
1513A/B). The required vacuum is controlled by pressure indicator and controller
PIC-150801 through pressure control valve (PCV-150801).
P&ID No.: N-10012-1-P&ID1509: P&I DIAGRAM FOR THIN STILLAGE

PREHEATER
STEAM CONDENSATE TANK AND THIN STILLAGE PREHEATER (T-1504 & H-

1509A/B)
Steam Condensate generated from Falling Film Effect – I (H-1501) or Falling Film
Effect – II (H-1502), Forced Circulation Effect – I (H-1505) or Forced Circulation Effect
–II (H-1506) is collected in Steam Condensate Tank (T-1504). Steam condensate is

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
transferred through Steam Condensate Pump (P-1511) and used to preheat Thin
Stillage in Thin Stillage Preheater (H-1509A/B).
P&ID No.: N-10012-1-P&ID1510: P&I DIAGRAM FOR TREATED PROCESS

CONDENSATE PREHEATER
PROCESS CONDENSATE TANK-1 AND TREATED PROCESS CONDENSATE

PREHEATER (T-1502 & H-1510)
Process Condensate from Process Condensate Tank – 2 (T-1503), Falling Film Effect –
II (H-1502), Falling Film Effect –III (H-1503) / Falling Film Standby Effect (H-1504) are
collected in Process Condensate Tank – 1 (T-1502). Process Condensate from Process
Condensate Tank – 1 (T-1502) is transferred through Process Condensate Pump – 1 (P-
1509) and is used to preheat UF permeate in Treated Process Condensate Preheater
(H-1510). Some of the process condensate from Process Condensate Pump – 1 (P-1509)
is also used to clean respective mist eliminators of Falling Film effect, Vapor Liquid
separator for FF effect & Vapor Liquid separator for FC effect in Evaporation section.
Condensate from Process Condensate Tank - 1 (T-1502) also serves for emergency
flow of water to Falling Film Effect in case of recirculation pump failure.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
P&ID No.: N-10012-1-P&ID1511: P&I DIAGRAM FOR FEED AND PRODUCT

TANK
THIN STILLAGE FEED TANK AND CONCENTRATED SYRUP TANK (T-1501 &
T-1505)
The concentrated syrup from evaporation section is stored in Concentrated Syrup
Tank (T-1505). The concentrated syrup is pumped through Concentrated Syrup Pump
(P-1514A/B) is transferred to Storage Tank. Thin Stillage from Decantation is collected
in Thin Stillage Feed Tank (T-1501), from where it is transferred to evaporation section
through Thin Stillage Feed Pump (P-1508A/B).
Level of Concentrated Syrup Tank (T-1505) is controlled by level indicator and
controller LIC-151101 through level control valve (LCV-151101).
P&ID No.: N-10012-1-P&ID1512: P&I DIAGRAM FOR CIP TANK
CIP TANK (T-1506)

The evaporation plant is designed such that at a time any one Falling Film effect out of
four Falling Film Evaporators and any one Forced Circulation Effect out of three Forced
Circulation Evaporators can be taken for C.I.P. While other will be taking care of
evaporation capacity. After taking out any heat exchanger for C.I.P. It will be first
drained by using CIP Drain Pump (P-1516). Hold up will be collected in CIP Tank (T-
1506). Then water will be circulated in it. Water will be followed by concentrated nitric
acid solution (3 to 5%) circulation and then caustic solution circulation. The exhaust
solutions will be transferred to B/L.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Concentrated Nitric Acid solution is to be prepared in CIP Tank (T-1506) and will be
transferred by CIP Transfer Pump (P-1515) to the effect under CIP. Measured quantity of
Concentrated Nitric Acid is to be taken in CIP Tank (T-1506) through FQI - 151201.
P&ID No.: N-10012-1-P&ID1513: P&I DIAGRAM FOR VACUUM PUMPS

EVAPORATION VACUUM PUMP (P-1513A/B)
In Sorghum case, Vapours generated from H-1503/H-1504 will be condensed in
Process condenser (H-1511) and Vapours generated from H-1506/H-1507 will be
condensed in Surface Condenser (H-1508) and necessary vacuum will be generated by
Evaporation Vacuum Pump (P-1513A/B).
In Corn case, Vapors generated from H-1503/H-1504 will be condensed in Process
condenser (H-1511) and necessary vacuum will be generated by Evaporation Vacuum
Pump (P-1513A/B).

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
1.0.3 CONTROL LOGIC & INTERLOCK DESCRIPTION

Refer “Control Logic & Interlock Description document (N-10012-4-ILD1501)” for
Evaporation section.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
1.0.4 EQUIPMENT DESCRIPTION

QUANTITY
TAG NO. DESCRIPTION TECHNICAL DETAILS
OP. S/B.
Type: Falling Film,
H-1501 Falling Film Effect – I 1 0
Vertical
Type: Falling Film,
H -1502 Falling Film Effect – II 1 0
Vertical
Type: Falling Film,
H -1503 Falling Film Effect – III 1 0
Vertical
Type: Falling Film,
H -1504 Falling Film Standby Effect 0 1
Vertical
Type: Forced circulation,
H -1505 Forced Circulation Effect - I 1 0
Horizontal
H-1506 Forced Circulation Effect - II 1 0
Horizontal
Forced Circulation Standby Type: Forced circulation,
H-1507 0 1
Effect Horizontal
H-1508 Surface Condenser 1 0
Horizontal
H-
Thin Stillage Preheater 1 1 Plate Heat Exchanger
1509A/B
Treated Process Condensate

H-1510 1 0 Plate Heat Exchanger
Preheater

H-1511 Process Condenser 1 0
Vertical
Type: Cylindrical /
vertical shell with
K-1501 Condensate Pot - 1 1 0
Dished ends
Capacity : 0.37 m3

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
QUANTITY
OP. S/B.
Type: Cylindrical /
vertical shell with
K-1502 Condensate Pot – 2 1 0 Dished ends
Capacity : 0.37 m3
N-
Spray Nozzle For FF Effect - I 2 0 Full cone spray
1501A/B
N-
Spray Nozzle For FF Effect - II 2 0 Full cone spray
1502A/B
N-1503
Spray Nozzle For FF Effect - III 4 0 Full cone spray
A/B/C/D
N-1504 Spray Nozzle For FF Standby
0 4 Full cone spray
A/B/C/D Effect
N-1505 Spray Nozzle For FC Effect - I 1 0 Full cone spray
N-1506 Spray Nozzle For FC Effect - II 1 0 Full cone spray
Spray Nozzle For FC Standby

N-1507 0 1 Full cone spray
Effect
Recirculation Pump for FF Type: Centrifugal Pump
P-1501 1 0
Effect – I with Motor Capacity :375 m3/hr
P-1502 1 0
Effect - II with Motor Capacity :375 m3/hr
P-1503 1 0
Effect - III with Motor Capacity :350 m3/hr
P-1504 0 1
Standby Effect with Motor Capacity :350 m3/hr
Recirculation Pump for FC Type: Centrifugal Pump
P-1505 1 0
Effect - I with Motor Capacity :250 m3/hr

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
QUANTITY
OP. S/B.
P-1506 1 0
Effect - II with Motor Capacity :250 m3/hr
P-1507 0 1
Standby Effect with Motor Capacity :250 m3/hr
Thin Stillage Feed Pump with Type: Centrifugal Pump
P-1508A/B 1 1
Motor Capacity :51 m3/hr
Process Condensate Pump – 1 Type: Centrifugal Pump
P-1509 1 0
with Motor Capacity :35 m3/hr
Process Condensate Pump – 2 Type: Centrifugal Pump
P-1510 1 0
with Motor Capacity :5 m3/hr
Steam Condensate Pump with Type: Centrifugal Pump
P-1511 1 0
Motor with Motor Capacity :20 m3/hr
Concentrated Syrup Transfer Type: Centrifugal Pump
P-1512 1 0
Pump with Motor Capacity :12 m3/hr
Evaporation Vacuum Pump Water Ring Vacuum
P-1513A/B 1 1
with Motor Pump
Concentrated Syrup Pump with Type: Centrifugal Pump
P-1514A/B 1 1
Motor Capacity :12 m3/hr
Type: Centrifugal Pump
P-1515 CIP Transfer Pump with Motor 1 0
Capacity :35 m3/hr
Type: Centrifugal Pump
P-1516 CIP Drain Pump with Motor 1 0
Capacity :35 m3/hr
Type: Cylindrical /
Vertical Shell with
T-1501 Thin Stillage Feed Tank 1 0 Conical Top & Slopping
Bottom.
Capacity : 30 m3

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
QUANTITY
OP. S/B.
Type: Cylindrical /
Horizontal Shell with
T-1502 Process Condensate Tank – 1 1 0 Dished Ends
Capacity : 5 m3
Type: Cylindrical /
T-1503 Process Condensate Tank – 2 1 0 Dished Ends
Capacity : 3 m3
Type: Cylindrical /
T-1504 Steam Condensate Tank 1 0
Dished Ends
Capacity : 3 m3
Type: Cylindrical /
Vertical Shell with
T-1505 Concentrated Syrup Tank 1 0
Dished Ends
Capacity : 2 m3
Type: Cylindrical /
Vertical Shell with
T-1506 CIP Tank 1 0 Dished Ends.
Capacity: 15 m3
Type: Cylindrical /
Vertical Shell with
Vapor Liquid Separator for FF
V-1501 1 0 Conical Top & Dished
Effect - I
Bottom.
Capacity : 35 m3
Type: Cylindrical /
Vertical Shell with
Vapor Liquid Separator for FF Conical Top & Dished
V-1502 1 0
Effect - II Bottom.
Capacity : 35 m3

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
QUANTITY
OP. S/B.
Type: Cylindrical /
Vertical Shell with
Vapor Liquid Separator for FF Conical Top & Dished
V-1503 1 0
Effect - III Bottom.
Capacity : 35 m3
Type: Cylindrical /
Vertical Shell with
Vapor Liquid Separator for FF
V-1504 0 1 Conical Top & Dished
Standby Effect
Bottom.
Capacity : 35 m3
Type: Cylindrical /
Vapor Liquid Separator for FC Vertical Shell with
V-1505 1 0 Dished Top & Bottom.
Effect - I
Capacity : 2.8 m3
Type: Cylindrical /
V-1506 1 0
Effect - II Dished Top & Bottom.
Capacity : 2.8 m3
Type: Cylindrical /
V-1507 0 1
Standby Effect Dished Top & Bottom.
Capacity : 2.8 m3
Y-1501 Mist Eliminator for FF Effect -I 1 0 Wire Mesh Type
Mist Eliminator for FF
Y-1502 1 0 Wire Mesh Type
Effect–II
Mist Eliminator for FF
Effect–III
Mist Eliminator for FF Standby
Effect

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
QUANTITY
OP. S/B.
Y-1505 Mist Eliminator for FC Effect -I 1 0 Wire Mesh Type
Y-1506 Mist Eliminator for FC Effect -II 1 0 Wire Mesh Type
Mist Eliminator for FC Standby
Effect

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
1.0.5 LIST OF PRESSURE SAFETY VALVES
SET PRESSURE
TAG NO. DESCRIPTION
bar (g)
PSV-150801 PSV on Process Condensate Tank–2 (T-1503) 1.0
PSV-150901 PSV on Steam Condensate Tank (T-1504) 1.0
PSV-151001 PSV on Process Condensate Tank–1 (T-1502) 1.0

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
PART–II
PRE-START-UP ACTIVITIES

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
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. These instructions do 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.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
A. Inspection and cleaning of Equipment
Inspection is nothing but P&ID & Layout audit. It is necessary to conduct P&ID &
Layout 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 P&ID & Layout 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 equipment is completed open bottom most nozzles for
flushing purpose. Make temporary arrangements for putting water from top of the all
equipment for flushing. 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.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
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 be flushed with air. Please remember that one end of the line should be open to
atmosphere and other end should be connected to flushing media. During flushing
please follow safety aspects also.
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 is completed 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 to conduct stroke trials of all control valves before putting them in
actual use, Process and Instrumentation person should witness the stroke checking
trial of all control valves. During stroke trial it is necessary to match valve opening on

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
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.
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 star-up and start-up. In utilities and allied system check
followings should be ready and designed to supply required inputs to the main plant
and 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. Effluent treatment plant
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.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
2.0.1 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. Better quality of cooling water supply (CWS)
definitely ensures better life of the exchangers and less maintenance cost. Before
starting cooling water pumps, be sure that all vents on Cooling water lines are open to
vent out the air. Vent at top most point should be open to ensure complete removal of
air from the Cooling water circuit. 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 Cooling water supply
pressure on respective header and it should be sufficient enough to fulfil the
requirement. Run the complete cooling water circuit to ensure better performance.
1. Ensure Cooling water supply is available. Open inlet cooling water supply manual
valve of Surface Condenser (H-1508). Ensure complete venting of air through vent
valve. After complete Venting of air, open cooling water return manual valve on
Surface Condenser (H-1508)
2. Open inlet cooling water supply manual valve on Process Condenser (H-1511).
Ensure complete venting of air through vent valve. After complete Venting of air,
open cooling water return manual valve on Process Condenser (H-1511).
3. Open cooling water inlet and outlet valves on PHE of Evaporation Vacuum pump
unit (P-1513A/B).
4. Note – During initial start-up of cooling water circuit it is necessary to flush the
cooling water headers in order to avoid the unwanted material transfer to
particular user.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
5. Ensure establishment of cooling water circuit for Evaporation section. Ensure the
performance of temperature transmitters on cooling water lines.
2.0.2 SOP FOR CHARGING LOW-PRESSURE STEAM
1 Ensure all valves on Low pressure Steam header are closed.

2 Slowly open Low pressure Steam main isolation valve to the Evaporation section.
3 Steam flow going to Falling Film Evaporator section is controlled by Flow
Indicator & Controller (FQIC-150901) using Flow control valve (FCV-150901). Flow
Indicator & Controller is provided with High and Low alarms.
4 Gradually open steam to Falling Film Evaporator section by opening Flow control
valve (FCV-150901) 10% in MAN mode.
5 Ensure there are no leakages.

6 Open the isolation valves on steam to falling film effect-I (H-1501) and falling film
effect-II (H-1502)
7 Once the flow rate reaches near set point of Flow Indicator & Controller (FQIC-
150901), put Flow Indicator & Controller (FQIC-150901) in AUTO mode.
8 After completion of the steam trial inform plant operator on stoppage of the 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 (FCV-150901) to the Evaporation section.
Note – After completion of water and steam trial stop all pumps. Ensure
all control valve and isolation valves are closed.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
2.0.3 WATER FLUSHING/ COLD WATER TRIAL
Water Flushing/cold water trail is nothing but cleaning of equipment and arresting
the leakage. 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. Before starting actual water trial ensure there is sufficient Process water
stock available. Following are the equipment to be tested on water along with allied
rotating accessories and pipelines:
a. Falling Film Effect - I (H-1501)
b. Vapour Liquid Separators for FF Effect - I (V-1501)
c. Falling Film Effect - II (H-1502)
d. Vapour Liquid Separators for FF Effect - II (V-1502)
e. Falling Film Effect - III (H-1503)
f. Vapour Liquid Separators for FF Effect - III (V-1503)
g. Falling Film Standby Effect (H-1504)
h. Vapor Liquid Separator for FF Standby Effect (V-1504)
i. Forced Circulation Effect – I (H-1505)
j. Vapor Liquid Separator for FC Effect – I (V-1505)
k. Forced Circulation Effect – II (H-1506)
l. Vapor Liquid Separator for FC Effect – II (V-1506)
m. Forced Circulation Standby Effect (H-1507)

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
n. Vapor Liquid Separator for FC Standby Effect (V-1507)
o. Thin Stillage Preheater (H-1509A/B)
p. Treated Process Condensate Preheater (H-1510)
q. Surface Condenser (H-1508) & Process Condenser (H-1511)
r. Thin Stillage Feed Tank (T-1501)
s. Process Condensate Tank – 1 (T-1502)
t. Process Condensate Tank – 2 (T-1503)
u. Steam Condensate Tank (T-1504)
v. Concentrated Syrup Tank (T-1505)
w. CIP Tank (T-1506)
x. Pumps
y. Condensate pots
z. CIP loop consisting CIP Tank (T-1506) and Pumps (P-1515, P-1516)
Before starting actual water flushing ensure availability of process water and other
utilities.
All motors, pumps, are to be operated remotely/ manual with in coordination with
field personnel. It is presumed that instrument airline flushing, control valve stroking
of all control valves and instrumentation continuity has already been done. Flushing
of Sealing Water Header and utility headers has been done thoroughly.
Ensure flow of sealing water to the required pumps.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
1. Ensure sufficient fresh water stock available, and all solenoid valves in
evaporation sections are closed.
2. Open manual valve on fresh water line to CIP Tank (T-1506). Water will start
flowing to CIP Tank (T-1506). Open CIP Transfer Pump (P-1515) suction valve and
drain valve; close the drain valve after clear water is observed. CIP Tank (T-1506)
level starts increasing. Calibrate LIT-151201. When CIP Tank (T-1506) level reaches
50% (variable), Start CIP Transfer Pump (P-1515). Open pump discharge valve and
CIP Tank (T-1506) circulation valve.
3. Ensure the performance of CIP Transfer Pump (P-1515). When CIP Tank (T-1506)
level reaches 60-70% (Variable), close CIP Tank (T-1506) circulation valve and open
CIP solution inlet manual valve (100BF151137) on Thin Stillage Feed Tank (T-
1501). Water will start flowing to Thin Stillage Feed Tank (T-1501). Open Thin
Stillage Feed Pump (P-1508A/B) suction valve and drain valve; close the drain
valve after clear water is observed. Thin Stillage Feed Tank (T-1501) level starts
increasing. Calibrate LIT-151102. When Thin Stillage Feed Tank (T-1501) level
reaches 50% (variable), Start Thin Stillage Feed Pump (P-1508A/B). Open Thin
Stillage Feed Pump (P-1508A/B) discharge valve and Thin Stillage Feed Tank (T-
1501) recirculation valve. Ensure the performance of Thin Stillage Feed Pump (P-
1508A/B).
Note: While filling water to evaporators keep vent on respective evaporator

open in order to avoid pressurization.
When Thin Stillage Feed Tank (T-1501) level reaches 60-70% (Variable), close Thin
Stillage Feed Tank (T-1501) recirculation valve and open manual valves across
Thin Stillage Preheater (H-1509A/B), XV-150102 and Level Control Valve (LCV-
150101) of Vapor Liquid Separator for FF Effect - I (V-1501) 10 % (Variable) in

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
MAN mode. Water will start flowing to Vapor Liquid Separator for FF Effect – I
(V-1501) through Thin Stillage Preheater (H-1509A/B).
4. Level in Vapor Liquid Separator for FF Effect – I (V-1501) will start rising.
Calibrate LIT-150101. When Level in Vapor Liquid Separator for FF Effect – I (V-
1501) reaches 30% (variable), open CIP drain valve of Vapor Liquid Separator for
FF Effect – I (V-1501). Open CIP Drain Pump (P-1516) suction header blind flange
to drain the flushing liquid. Close CIP drain valve after observing clear liquid.
When Vapor Liquid Separator for FF Effect – I (V-1501) level reaches 40%
(Variable), open Recirculation Pump for FF Effect – I (P-1501) suction valve and
start Recirculation Pump for FF Effect – I (P-1501). Open the pump discharge valve
gradually as per the current on performance curve adjusts the circulation valve.
Pump must not be started if discharge valve of Recirculation Pump for FF Effect – I
(P-1501) is open. Due to circulation Vapor Liquid Separator for FF Effect – I (V-
1501) level will come down little bit. Take Level Control Valve (LCV-150101) of
Vapor Liquid Separator for FF Effect – I (V-1501) in AUTO mode with 40%
(Variable) set point. Ensure the flow pattern of falling liquid from Falling Film
Effect – I (H-1501) to Vapor Liquid Separator for FF Effect – I (V-1501). Ensure the
performance of Recirculation Pump for FF Effect – I (P-1501).
5. Open XV-150203/XV-150202 and Level Control Valve (LCV-150201) of Vapor
Liquid Separator for FF Effect – II (V-1502) in MAN mode. Water will start flowing
from Recirculation Pump for FF Effect – I (P-1501) discharge to Vapor Liquid
Separator for FF Effect – II (V-1502). Level in Vapor Liquid Separator for FF Effect
– II (V-1502) will start rising. Calibrate LIT-150201. When Level in Vapor Liquid
Separator for FF Effect – II (V-1502) reaches 30% (variable), Open CIP drain valve
of Vapor Liquid Separator for FF Effect – II (V-1502). Close CIP drain valve after

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
observing clear liquid. When Vapor Liquid Separator for FF Effect – II (V-1502)
level reaches 40% (Variable), open Recirculation Pump for FF Effect – II (P-1502)
suction valve and start Recirculation Pump for FF Effect – II (P-1502). Open the
pump discharge valve gradually as per the current on performance curve adjusts
the circulation valve. Pump must not be started if discharge valve of Recirculation
Pump for FF Effect – II (P-1502) is open. Due to circulation Vapor Liquid Separator
for FF Effect – II (V-1502) level will come down little bit. Take Level Control Valve
(LCV-150201) of Vapor Liquid Separator for FF Effect – II (V-1502) in AUTO mode
with 40% (Variable) set point. Ensure the flow pattern of falling liquid from Falling
Film Effect – II (H-1502) to Vapor Liquid Separator for FF Effect – II (V-1502).
Ensure the performance of Recirculation Pump for FF Effect – II (P-1502).
Liquid Separator for FF Effect – III (V-1503) in MAN mode. Water will start
flowing from Recirculation Pump for FF Effect – II (P-1502) discharge to Vapor
Liquid Separator for FF Effect – III (V-1503). Level in Vapor Liquid Separator for
FF Effect – III (V-1503) will start rising. Calibrate LIT-150301. When Level in Vapor
Liquid Separator for FF Effect – III (V-1503) reaches 30% (variable), Open CIP drain
valve of Vapor Liquid Separator for FF Effect – III (V-1503). Close CIP drain valve
after observing clear liquid. When Vapor Liquid Separator for FF Effect – III (V-
1503) level reaches 40% (Variable), open Recirculation Pump for FF Effect – III (P-
1503) suction valve and start Recirculation Pump for FF Effect – III (P-1503). Open
the pump discharge valve gradually as per the current on performance curve
adjusts the circulation valve. Pump must not be started if discharge valve of
Recirculation Pump for FF Effect – III (P-1503) is open. Due to circulation Vapor
Liquid Separator for FF Effect – III (V-1503) level will come down little bit. Take

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Level Control Valve (LCV-150301) of Vapor Liquid Separator for FF Effect – III (V-
1503) in AUTO mode with 40% (Variable) set point. Ensure the flow pattern of
falling liquid from Falling Film Effect – III (H-1503) to Vapor Liquid Separator for
FF Effect – III (V-1503). Ensure the performance of Recirculation Pump for FF
Effect – III (P-1503).
Liquid Separator for FF Standby Effect (V-1504) in MAN mode. Water will start
flowing from Recirculation Pump for FF Effect – III (P-1503) discharge to Vapor
Liquid Separator for FF Standby Effect (V-1504). Level in Vapor Liquid Separator
for FF Standby Effect (V-1504) will start rising. Calibrate LIT-150401. When Level
in Vapor Liquid Separator for FF Standby Effect (V-1504) reaches 30% (variable),
Open CIP drain valve of Vapor Liquid Separator for FF Standby Effect (V-1504).
Close CIP drain valve after observing clear liquid. When Vapor Liquid Separator
for FF Standby Effect (V-1504) level reaches 40% (Variable), open Recirculation
Pump for FF standby Effect (P-1504) suction valve and start Recirculation Pump
for FF standby Effect (P-1504). Open the pump discharge valve gradually as per
the current on performance curve adjusts the circulation valve. Pump must not be
started if discharge valve of Recirculation Pump for FF Standby Effect (P-1504) is
open. Due to circulation Vapor Liquid Separator for FF Standby Effect (V-1504)
level will come down little bit. Take Level Control Valve (LCV-150401) of Vapor
Liquid Separator for FF Standby Effect (V-1504) in AUTO mode with 40%
(Variable) set point. Ensure the flow pattern of falling liquid from Falling Film
Standby Effect (H-1504) to Vapor Liquid Separator for FF Standby Effect (V-1504).
Ensure the performance of Recirculation Pump for FF Standby Effect (P-1504).

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
8. Open XV-150502 and Level Control Valve (LCV-150501) of Vapor Liquid Separator
for FC Effect - I (V-1505) in MAN mode. Water will start flowing from P-1503/P-
1504 discharge to Vapor Liquid Separator for FC Effect - I (V-1505). Level in Vapor
Liquid Separator for FC Effect - I (V-1505) will start rising. Calibrate LIT-150501.
When Level in Vapor Liquid Separator for FC Effect - I (V-1505) reaches 30%
(variable), open CIP drain valve of Vapor Liquid Separator for FC Effect - I (V-
1505). Close CIP drain valve after observing clear liquid. When Vapor Liquid
Separator for FC Effect - I (V-1505) level reaches 40% (Variable), open Recirculation
Pump for FC Effect - I (P-1505) suction valve and start Recirculation Pump for FC
Effect - I (P-1505). Open the pump discharge valve gradually as per the current on
performance curve adjusts the circulation valve. Pump must not be started if
discharge valve of Recirculation Pump for FC Effect - I (P-1505) is open. Due to
circulation Vapor Liquid Separator for FC Effect - I (V-1505) level will come down
little bit. Take Level Control Valve (LCV-150501) of Vapor Liquid Separator for FC
Effect - I (V-1505) in AUTO mode with 40% (Variable) set point. Ensure the flow
pattern from Vapor Liquid Separator for FC Effect – I (V-1505) to Forced
Circulation Effect – I (H-1505). Ensure the performance of Recirculation Pump for
FC Effect - I (P-1505).
Liquid Separator for FC Effect - II (V-1506). in MAN mode. Water will start
flowing from Recirculation Pump for FC Effect - I (P-1505) discharge to Vapor
Liquid Separator for FC Effect - II (V-1506). Level in Vapor Liquid Separator for FC
Effect - II (V-1506) will start rising. Calibrate LIT-150601. When Level in Vapor
Liquid Separator for FC Effect - II (V-1506) reaches 30% (variable), open CIP drain
valve of Vapor Liquid Separator for FC Effect - II (V-1506). Close CIP drain valve

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
after observing clear liquid. When Vapor Liquid Separator for FC Effect - II (V-
1506) level reaches 40% (Variable), open Recirculation Pump for FC Effect - II (P-
1506) suction valve and start Recirculation Pump for FC Effect - II (P-1506). Open
the pump discharge valve gradually as per the current on performance curve
adjusts the circulation valve. Pump must not be started if discharge valve of
Recirculation Pump for FC Effect - II (P-1506) is open. Due to circulation Vapor
Liquid Separator for FC Effect - II (V-1506) level will come down little bit. Take
Level Control Valve (LCV-150601) of Vapor Liquid Separator for FC Effect - II (V-
1506) in AUTO mode with 40% (Variable) set point. Ensure the flow pattern from
Vapor Liquid Separator for FC Effect–II (V-1506) to Forced Circulation Effect–II
(H-1506). Ensure the performance of Recirculation Pump for FC Effect - II (P-1506).
10. Open XV-150701/XV-15702 and Level Control Valve (LCV-150701) for Vapor
Liquid Separator for FC Standby Effect (V-1507). in MAN mode. Water will start
flowing from P-1505/P-1506 discharge to Level in Vapor Liquid Separator for FC
standby Effect (V-1507). Level in Vapor Liquid Separator for FC standby Effect (V-
1507) will start rising. Calibrate LIT-150701. When Level in Vapor Liquid Separator
for FC Standby Effect (V-1507) reaches 30% (variable), Open CIP drain valve of
Vapor Liquid Separator for FC Standby Effect (V-1507). Close CIP drain valve after
observing clear liquid. When Vapor Liquid Separator for FC Standby Effect (V-
1507) level reaches 40% (Variable), open suction valve of Recirculation Pump for
FC Standby Effect (P-1507) and start Recirculation Pump for FC Standby Effect (P-
1507). Open the pump discharge valve gradually as per the current on
performance curve adjusts the circulation valve. Pump must not be started if
discharge valve of Recirculation Pump for FC Standby Effect (P-1507) is open. Due
to circulation Vapor Liquid Separator for FC Standby Effect (V-1507) level will

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
come down little bit. Take Level Control Valve (LCV-150701) for Vapor Liquid
Separator for FC Standby Effect (V-1507) in AUTO mode with 40% (Variable) set
point. Ensure the flow pattern from Vapor Liquid Separator for FC Standby Effect
(V-1507) to Forced Circulation Standby Effect (H-1507). Ensure the performance of
Recirculation Pump for FC Standby Effect (P-1507).
11. Close CIP Drain Pump (P-1516) suction header blind flange.
12. Open manual valve on CIP Drain Pump (P-1516) suction. Open CIP Drain Pump
(P-1516) suction drain valve till clear water observed. Start CIP Drain Pump (P-
1516). Open CIP Drain Pump (P-1516) discharge manual valve (100BF15216) to
Concentrated Syrup Tank (T-1505). Water will start flowing to Concentrated
Syrup Tank (T-1505). Level in Concentrated Syrup Tank (T-1505) will start rising.
Calibrate LIT-151101. When Level in Concentrated Syrup Tank (T-1505) reaches
30% (variable), Open suction valve and drain valve of Concentrated Syrup Pump
(P-1514A/B). Close CIP drain valve after observing clear liquid. When
Concentrated Syrup Tank (T-1505) level reaches 40% (Variable), Start Concentrated
Syrup Pump (P-1514A/B) and flush the line from Concentrated Syrup Pump (P-
1514A/B) to syrup storage station by opening respective manual valve. Also flush
the recirculation lines. Ensure the performance of Concentrated Syrup Pump (P-
1514A/B).
13. After ensuring the line flushing, stop Concentrated Syrup Pump (P-1514A/B) and
close manual CIP drain valves.
14. Make temporary connection of fresh water for Process Condensate Tank - 2 (T-
1503) flushing. Start fresh water to Process Condensate Tank - 2 (T-1503). Open
Process Condensate Pump - 2 (P-1510) suction valve and drain valve. Close the
drain valve after observing clear water from the drain. Level in Process

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Condensate Tank - 2 (T-1503) will start rising. Calibrate LIT-150801. When Process
Condensate Tank - 2 (T-1503) level reaches 50% (Variable), start Condensate Pump
- 2 (P-1510). Take Level Control Valve (LCV-150801) of Process Condensate Tank -
2 (T-1503) in MAN mode and flush the discharge line to Process Condensate Tank–
1 (T-1502). After ensuring the line flushing close the valve to Process Condensate
Tank – 1 (T-1502). Ensure the flow through FIT-150801. Ensure the performance of
Process Condensate Pump - 2 (P-1510).
15. Open the manual valves on process condensate line from H-1506 / H-1507 Forced
Circulation effect II and Forced Circulation Standby effect to Process Condensate
Tank – 2 (T-1503) one by one and flush the respective lines. Close the manual
valves on respective process condensate line after flushing.
16. Take fresh water from Process Condensate Tank – 2 (T-1503) to Process
Condensate Tank - 1 (T-1502) for flushing through Process Condensate Pump – 2
(P-1510). Open Process Condensate Pump - 1 (P-1509) suction valve and drain
drain valve. Close the drain valve after observing clear water from the drain. Level
in Process Condensate Tank - 1 (T-1502) will start rising. Calibrate LIT-151001.
When Process Condensate Tank - 1 (T-1502) level reaches 50% (Variable), start
Process Condensate Pump - 1 (P-1509). Open Process Condensate Pump - 1 (P-
1509) discharge valve and flush the discharge line up to treatment plant through
Treated Process Condensate Preheater (H-1510). After flushing the discharge line
up to treatment plant, flush the discharge line routed for cleaning of Vapor Liquid
Separators of Falling film effect and Forced Circulation effect one by one. Also
flush line to Thin Stillage Tank (T-1801). Flush the emergency process condensate
supply line to all falling film Effect and forced circulation effect. After ensuring the

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
line flushing closes the valve and open valve to Process Condensate Treatment
section. Ensure the performance of Process Condensate Pump - 1 (P-1509).
17. Open the manual valves on process condensate line from respective Falling Film
effect to Process Condensate Tank – 1 (T-1502) and flush the respective lines. Close
the manual valves on respective process condensate line after flushing.
18. Make temporary connection of fresh water for Steam Condensate Tank (T-1504)
flushing. Start fresh water to Steam Condensate Tank (T-1504). Open Steam
Condensate Pump (P-1511) suction valve and drain valve. Close the drain valve
after observing clear water from the drain. Level in Steam Condensate Tank (T-
1504) will start rising. Calibrate LIT-150901. When Steam Condensate Tank (T-
1504) level reaches 50% (Variable), start Steam Condensate Pump (P-1511). Open
Steam Condensate Pump (P-1511) discharge valve and flush the discharge line to
Thin Stillage Preheater (H-1509A/B) by opening manual valves. After ensuring the
line flushing closes the valve. Ensure the performance of Steam Condensate Pump
(P-1511).
19. Open the manual valves on steam condensate line from respective Falling Film
effect and Forced circulation effect to Steam Condensate Tank (T-1504) one by one
and flush the respective lines. Close the manual valves on respective steam
condensate line after flushing.
20. Close all manual valves as well as solenoid valves in Evaporation sections after
water trial.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
2.0.4 VACUUM TRIAL
Vacuum test has to be carried out for all the equipment, which is subjected to vacuum
condition during the plant operation. Vacuum trial is to be carried out to detect air
leakage in the system.
Before staring the vacuum trials vacuum pump should be tested and its performance
should be monitored.
• Ensure cooling water is available for the vacuum pump PHE.
• Ensure the required pressure of fresh water is available for Vacuum Pumps.
• Check the Vacuum Pumps for free rotation, direction of rotation and lubrication.
• Check the suction and discharge piping of Vacuum Pumps. Put wire mesh in
suction line of the pump to avoid any foreign material entering in pump and
further damage of it.
• Ensure water flushing of soft water line to Vacuum Pump and vacuum pump
discharge chamber flushing completed.
Once these preliminary checks are over, read the operation manual of the vacuum
pump supplier and follow the instructions given therein to start the pump. Before
starting the pump ensure that air bleed valve is completely open and then start the
pump. Note the current. Check for unusual sound and vibration. If the pump
performance is satisfactory, run it continuously for one hour. After satisfactory
operation for one hour check standby pumps in a same manner.
ALWAYS REFER VACUUM PUMP SUPPLIER’S OPERATING AND
MAINTENANCE MANUAL FOR START-UP.
Isolate the system in such a way so that nothing should come in or nothing should go
out only it should be connected to vacuum system. Close all drains, vents, and
manholes.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Ensure vacuum trial for Distillation section is completed. Ensure vacuum pumps are
in running condition.
Following equipment will be under vacuum in Evaporation Section.
a. Vapour Liquid Separators for FF Effect - I (V-1501)
b. Tube side of Falling Film Effect – I (H-1501)
c. Shell & Tube side of Falling Film Effect – II (H-1502)
d. Vapour Liquid Separators for FF Effect - II (V-1502)
e. Shell & Tube side of Falling Film Effect – III (H-1503)
f. Vapour Liquid Separators for FF Effect – III (V-1503)
g. Shell & Tube side of Falling Film Standby Effect (H-1504)
h. Vapour Liquid Separators for FF Standby Effect (V-1504)
i. Tube side of Forced Circulation Effect – I (H-1505)
j. Vapour Liquid Separators for FC Effect – I (V-1505)
k. Shell & Tube side of Forced Circulation Effect – II (H-1506)
l. Vapour Liquid Separators for FC Effect – II (V-1506)
m. Shell & Tube side of Forced Circulation Standby Effect (H-1507)
n. Vapour Liquid Separators for FC Standby Effect (V-1507)
o. Shell side of Surface Condenser (H-1508) and Process Condenser (H-
1511)
p. Process Condensate Tank - 1 (T-1502)
q. Process Condensate Tank - 2 (T-1503)
r. Condensate pots (K-1501 & K-1502).
s. All related process pipeline connected to equipment.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
1. Ensure following isolation & solenoid valves position in addition to the list as
given in vacuum trial for Evaporation section.
1. Manual valve 350BF150125 on suction of Recirculation Pump for FF Effect – I
(P-1501) – CLOSED.
2. Manual valve 250BF150112 on discharge of Recirculation Pump for FF Effect – I
(P-1501) – CLOSED.
3. Manual valve 350BF150222 on suction of Recirculation Pump for FF Effect – II
(P-1502) – CLOSED.
4. Manual valve 250BF150217 on discharge of Recirculation Pump for FF Effect –
II (P-1502) – CLOSED.
5. Manual valve 350BF150332 on suction of Recirculation Pump for FF Effect – III
(P-1503) – CLOSED.
6. Manual valve 250BF150327 on discharge of Recirculation Pump for FF Effect –
III (P-1503) – CLOSED.
7. Manual valve 350BF150409 on suction of Recirculation Pump for FF Standby
Effect (P-1504) – CLOSED.
8. Manual valve 250BF150425 on discharge of Recirculation Pump for FF Standby
9. Manual valve 200BF150530 on suction of Recirculation Pump for FC Effect – I
(P-1505) – CLOSED.
10. Manual valve 250BF150524 on discharge of Recirculation Pump for FC Effect - I
(P-1505) – CLOSED.
11. Manual valve 200BF150627 on suction of Recirculation Pump for FC Effect – II
(P-1506) – CLOSED.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
12. Manual valve 250BF150624 on discharge of Recirculation Pump for FC Effect -

II (P-1506) – CLOSED.
13. Manual valve 100BF150638 on suction of Concentrated Syrup Transfer Pump
(P-1512) – CLOSED.
14. Manual valve 200BF150725 on suction of Recirculation Pump for FC Standby
15. Manual valve 250BF150723 on discharge of Recirculation Pump for FC Standby
16. Manual valves on vapor line to Mash Column (C-1401) – CLOSED.
17. Manual drain valve of CIP outlet 150BF150120 on Vapor Liquid Separator for
FF Effect - I (V-1501) circulation line – CLOSED.
FF Effect - II (V-1502) circulation line – CLOSED.
19. Manual valve of CIP outlet 150BF150334 on Vapor Liquid Separator for FF
Effect - III (V-1503) circulation line – CLOSED.
FF Standby Effect (V-1504) circulation line – CLOSED.
FC Effect - I (V-1505) circulation line – CLOSED.
FC Effect - II (V-1506) circulation line – CLOSED.
FC Standby Effect (V-1507) circulation line – CLOSED.
24. Solenoid valve XV-150101 on process condensate line to Vapor Liquid
Separator for FF Effect – I (V-1501) – CLOSED.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.

Separator for FF Effect – II (V-1502) – CLOSED.
Separator for FF Effect – III (V-1503) – CLOSED.
Separator for FF Standby Effect (V-1504) – CLOSED.
28. Manual valve 50BF150533 on process condensate line to Vapor Liquid
Separator for FC Effect - I (V-1505) – CLOSED.
Separator for FC Effect - II (V-1506) – CLOSED.
Separator for FC Standby Effect (V-1507) – CLOSED.
31. Manual valves on CIP solution inlet on Vapor Liquid Separator for FF Effect – I
(V-1501), Vapor Liquid Separator for FF Effect – II (V-1502), Vapor Liquid
Separator for FF Effect – III (V-1503), Vapor Liquid Separator for FF Standby
Effect (V-1504), Vapor Liquid Separator for FC Effect – I (V-1505), Vapor Liquid
Separator for FC Effect – II (V-1506) and Vapor Liquid Separator for FC
Standby Effect (V-1507) – CLOSED.
32. Manual valve 80BF150833 on Process Condensate Pump - 2 (P-1510) suction –
CLOSED.
33. Manual valve 150BF151018 on Process Condensate Pump - 1 (P-1509) suction –
CLOSED.
34. Level Control Valve for Vapor Liquid Separator V-1501 (LCV-150101), Level
Control Valve for Vapor Liquid Separator V-1502 (LCV-150201), Level Control
Valve for Vapor Liquid Separator V-1503 (LCV-150301), Level Control Valve

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
for Vapor Liquid Separator V-1504 (LCV-150401), Level Control Valve for
Vapor Liquid Separator V-1505 (LCV-150501), Level Control Valve for Vapor
Liquid Separator V-1506 (LCV-150601), Level Control Valve for Vapor Liquid
Separator V-1507 (LCV-150701), Process Condensate Tank - 2 (T-1503) Level
Control Valve (LCV-150801), Process Condensate Tank – 1 (T-1502) Level
Control Valve (LCV-151001). - CLOSED.
35. Manual valves of air bleed & Thin Stillage Vapor bleed for Vapor Liquid
Separators for FF Effect - I (V-1501), Vapor Liquid Separators for FF Effect - II
(V-1502), Vapor Liquid Separators for FF Effect - III (V-1503), Vapor Liquid
Separators for FF Standby Effect (V-1504), Vapor Liquid Separators for FC
Effect - I (V-1505), Vapor Liquid Separators for FC Effect - II (V-1506) and
Vapor Liquid Separators for FC Standby Effect (V-1507) – CLOSED.
36. Manual valve on process condensate line to Process Condensate Tank - 1 (T-
1502) and Process Condensate Tank – 2 (T-1503) – CLOSED.
37. All drains, vents, bleed and sample points valves – CLOSED.
38. All pressure / vacuum gauges valves – OPEN.
39. All valves on utility and process condensate lines for sight glass cleaning –
CLOSED.
2. Ensure healthiness of tight shutoff of solenoid valves while taking vacuum trial in
evaporation section. If any solenoid valve passes, the vacuum will be generated for
that particular effect which to be observed from local gauges and to be rectified
accordingly.
3. Open solenoid valve (XV-151301 and XV-151302) on the line which is connected to
suction line of vacuum pump (P-1513 A/B). Start Vacuum Pumps (P-1513A/B) by
referring operation and maintenance manual of Vacuum Pumps.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
4. Open respective manual valves across Shell side of Surface Condenser (H-1508)
and Process Condenser (H-1511), Forced Circulation Standby Effect (H-1507),
Forced Circulation Effect – II (H-1506), Falling Film Standby Effect (H-1504),
Falling Film Effect – III (H-1503), Falling Film Effect – II (H-1502) connected to
Vacuum system.
5. Open respective manual valves on Thin Stillage Vapor outlet from Vapour Liquid
Separators for FC Standby Effect (V-1507), Vapour Liquid Separators for FC Effect
– II (V-1506), Vapour Liquid Separators for FC Effect – I (V-1505)
6. Stop vacuum pumps after desired vacuum is achieved.
7. Observe the drop in vacuum and note down the vacuum drop w.r.t. time. If
vacuum drop is less than 40 mm Hg per hour then vacuum trial is acceptable. If
vacuum drop is more than 40 mmHg per hour then rectify the leakage and attend
it to reduce vacuum drop.
8. Once vacuum trial is OK release vacuum by opening the vent valves or, keep the
vacuum and start evaporation or water boiling as planned.
9. Now take distillation and evaporation system as a single system under vacuum for
trial. Open interconnecting manual valve 600BF150407/600BF150408 from
Evaporation section to Distillation section. Once the air leakages are arrested,
isolate the whole system by closing the valve on the suction line of the Vacuum
pump and stop the vacuum pump.
10. Check the rate of drop in vacuum and it should not be more than 40 mm of
mercury per hour.
11. This will confirm the vacuum test. Make formal report for evaporation vacuum
trial.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
2.0.5 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 airline 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. Steam trial is nothing but running plant without Thin
Stillage. 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.
During steam trial all motors, pumps 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, water flushing, vacuum trial has already been
done. Flushing of Sealing Water Header and utility headers has been done
thoroughly. Ensure flow of sealing water to the required pumps. Ensure following
systems are ready up to respective user’s isolation point –
1. Power supply
2. Instrument air supply
3. Steam supply
4. Cooling water
5. Fresh water supply
6. Sealing water supply

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
1. Establish the cooling water circuit as described.

2. Establish the Low pressure steam header with Low pressure steam as described.
3. Establish the fresh water flow circuit as described in water flushing part of
evaporation section.
4. Ensure any one Vacuum Pumps (P-1513 A/B) running evaporation as a single
system under vacuum with PIC-150801 in AUTO mode with 0 .2 kg/cm2 (a) set
point. Refer vacuum trial part.
5. Ensure Distillation section is ready to accept vapor from Evaporation (Refer steam
trial for distillation in document “N-10012-4-OPM-1401Operation and
Maintenance Manual Distillation Section”)
6. Ensure solenoid valves in evaporation section are in AUTO mode. Select Falling
Film Effect – I (H-1501), Falling Film Effect – II (H-1502), Falling Film Effect – III
(H-1503), Falling Film Standby Effect (H-1504), Forced Circulation Effect – I (H-
1505), Forced Circulation Effect – II (H-1506), Forced Circulation Standby Effect
(H-1507) based on mode selected for operation.
7. Ensure following status of each and every equipment.
A. H-1501 & V-1501
LIC-150101 in AUTO mode.
Tube side of Falling Film Effect – I (H-1501) & Vapor Liquid Separator for
FF Effect – I (V-1501) under vacuum condition.
Recirculation Pump for FF Effect – I (P-1501) is running and recirculation
rate adjusted.
Recirculation Pump for FF Effect – I (P-1501) discharge line out to Vapour
Liquid Separator for FF Effect – II (V-1502) or Vapour Liquid Separator for
FF Effect – III (V-1503).

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Manual valves on steam line, steam condensate line, Thin Stillage Vapor
line and Thin Stillage line -OPEN.
Isolation valve on steam to Evaporation section 1 - CLOSED.
Falling Film Effect – I (H-1501) non condensable manual valves – OPEN.
Falling Film Effect – I (H-1501) steam condensate line out to Steam
Condensate Tank (T-1504).
B. H-1502 & V-1502

Shell and Tube side of Falling Film Effect – II (H-1502) under vacuum
condition.
Vapour Liquid Separator for FF Effect – II (V-1502) under vacuum
condition.
Recirculation Pump for FF Effect – II (P-1502) operating and circulation rate
adjusted.
Recirculation Pump for FF Effect – II (P-1502) discharge line out to Vapour
Liquid Separator for FF Effect – III (V-1503) or Vapor Liquid Separator for
FF Standby Effect (V-1504).
Open Manual valves on steam line, steam condensate line, Thin Stillage
Vapor line and Thin Stillage line.
Isolation valve on steam to Falling Film Effect – II (H-1502) - CLOSED.
Falling Film Effect – II (H-1502) non condensable manual valves – OPEN.
Falling Film Effect – II (H-1502) process condensate line to Condensate Pot-1
(K-1501) - OPEN.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Falling Film Effect – II (H-1502) steam condensate line to Steam Condensate

Tank (T-1504) - CLOSED.
C. H-1503 & V-1503

Shell & Tube side of Falling Film Effect – III (H-1503) under vacuum
condition.
Vapour Liquid Separator for FF Effect - III (V-1503) under vacuum
condition.
Recirculation Pump for FF Effect – III (P-1503) running and circulation rate
adjusted.
Recirculation Pump for FF Effect – III (P-1503) discharge line out to Vapour
Liquid Separator for FF Standby Effect (V-1504) or Vapor Liquid Separator
for FC Effect – I (V-1505).
Falling Film Effect – III (H-1503) non condensable manual valves – OPEN.
Falling Film Effect - III (H-1503) process condensate line out to Condensate
Pot – 1 (K-1501).
D. H-1504 & V-1504

Shell & Tube side of Falling Film Standby Effect (H-1504) under vacuum
condition.
Vapour Liquid Separator for FF Standby Effect (V-1504) under vacuum
condition.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Recirculation Pump for FF Standby Effect (P-1504) running and circulation

rate adjusted.
Recirculation Pump for FF Standby Effect (P-1504) discharge line out to
Vapour Liquid Separator for FC Effect - I (V-1505) or Vapor Liquid
Separator for FC Effect – II (V-1506).
Falling Film Standby Effect (H-1504) non condensable manual valves –
OPEN.
Falling Film Standby Effect (H-1504) process condensate line out to
Condensate Pot – 2 (K-1502).
E. H-1505 & V-1505

Tube side of Forced Circulation Effect – I (H-1505) under vacuum condition.
Vapour Liquid Separator for FC Effect - I (V-1505) under vacuum condition.
Recirculation Pump for FC Effect - I (P-1505) running and circulation rate
adjusted.
Recirculation Pump for FC Effect - I (P-1505) discharge line out to Vapour
Liquid Separator for FC Effect – II (V-1506) or Vapor Liquid Separator for
FC Standby Effect (V-1507).
Open Manual valves on steam line, steam condensate line, Thin Stillage
Vapor line and Thin Stillage line.
Isolation valve on steam to Forced Circulation Effect – I (H-1505) - OPEN.
Forced Circulation Effect – I (H-1505) non condensable manual valves -
OPEN.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Forced Circulation Effect – I (H-1505) steam condensate line out to steam

Condensate Tank (T-1504).
F. H-1506 & V-1506

Shell & Tube side of Forced Circulation Effect – II (H-1506) under vacuum
condition.
Vapour Liquid Separator for FC Effect - II (V-1506) under vacuum
condition.
Recirculation Pump for FC Effect - II (P-1506) running and circulation rate
adjusted.
Recirculation Pump for FC Effect - II (P-1506) discharge line out to Vapour
Liquid Separator for FC Standby Effect (V-1507).
Recirculation Pump for FC Effect - II (P-1506) suction line out to
Concentrated Syrup Transfer Pump (P-1512).
Close Manual valves on steam line, steam condensate line, and open Thin
Stillage Vapor line and Thin Stillage line.
Forced Circulation Effect – II (H-1506) non condensable manual valves -
OPEN.
Forced Circulation Effect – II (H-1506) process condensate line out to
Process Condensate Tank-2 (T-1503).

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
G. H-1507 & V-1507

Shell & Tube side of Forced Circulation Standby Effect (H-1507) under
vacuum condition.
Vapour Liquid Separator for FC Standby Effect (V-1507) under vacuum
condition.
Recirculation Pump for FC Standby Effect (P-1507) running and circulation
rate adjusted.
Recirculation Pump for FC Standby Effect (P-1507) suction line out to
Concentrated Syrup Transfer Pump (P-1512).
Forced Circulation Standby Effect (H-1507) non condensable manual valves
– OPEN.
Forced Circulation Standby Effect (H-1507) evaporation process
condensable line out to Process Condensate Tank–2 (T-1503) with LIC-
150801 in AUTO mode.
8. Ensure Steam Flow Control Valve (FCV-150901) closed. Open upstream side
manual valve of Steam Flow Control Valve (FCV-150901).
9. Ensure steady pressure of low pressure steam header. Inform boiler house
regarding the use of steam.
10. Gradually open manual valve on low pressure steam line to Falling Film Effect – I
(H-1501)
11. Open steam flow control valve (FCV-150901) 5% (Variable) in MAN mode.
Condensation of steam will start on shell side of Falling Film Effect – I (H-1501) by
giving its thermal energy to the circulating fluid on tube side. Adjust venting

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
through non-condensable valves on shell side of Falling Film Effect – I (H-1501)

after ensuring the complete removal of non-condensable.
12. Observe the steam condensation on flow glass provided on Falling Film Effect – I
(H-1501). Condensation can be ensured from flow glass on steam condensate line
of Falling Film Effect – I (H-1501).
13. Gradually open Steam Flow Control Valve (FCV-150901) to 10% (Variable) in
MAN mode. Ensure steam flow through FIT-150901.
14. Similarly ensure Steam Flow Control Valve (FCV-150501) closed. Open upstream
side manual valve of Steam Flow Control Valve (FCV-150501).
15. Ensure steady pressure of low pressure steam header. Inform boiler house
regarding the use of steam.
16. Gradually open manual valve on low pressure steam line to Forced Circulation
Effect – I (H-1505).
17. Open Steam Flow Control Valve (FCV-150501) 5% (Variable) in MAN mode.
Condensation of steam will start on shell side of Forced Circulation Effect – I (H-
1505) by giving its thermal energy to the circulating fluid on tube side. Adjust
venting through non-condensable valves on shell side of Forced Circulation Effect
– I (H-1505) after ensuring the complete removal of non-condensable.
18. Observe the steam condensation on flow glass provided on Forced Circulation
Effect – I (H-1505) Condensation can be ensured from flow glass on steam
condensate line of Forced Circulation Effect – I (H-1505).
19. Gradually open Steam Flow Control Valve (FCV-150501) to 10% (Variable) in
MAN mode. Ensure steam flow through FIT-150501.
20. Steam condensate will start flowing to Steam Condensate Tank (T-1504). Open
Steam Condensate Pump (P-1511) suction drain valve. Close the drain valve after

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
observing clear water from the drain. Level in Steam Condensate Tank (T-1504)
will start rising. When Steam Condensate Tank (T-1504) level reaches 75%
(Variable), open Steam Condensate Pump (P-1511) suction valve and start the
pump. Open Steam Condensate Pump (P-1511) discharge valve. Open manual
valves on discharge line. Open Steam Condensate Tank (T-1504) Level Control
Valve (LCV-150901) in MAN mode. Ensure the flow of steam condensate to steam
condensate return header (B/L) through Thin Stillage Preheater (H-1509A/B).
Take Steam Condensate Tank (T-1504) Level Control Valve (LCV-150901) in AUTO
mode with 50% (Variable) set point.
21. Increase in TI-150101 & TI-150201 is the indication of evaporation from Vapour
Liquid Separator for FF Effect – I (V-1501) or Vapor Liquid Separator for FF Effect
– II (V-1502). Take FQIC-150901 in AUTO mode with the flow at 10% (Variable)
valve opening. Gradually go on increasing the steam flow set point up to required
capacity go on increasing the steam flow set point up to required capacity.
22. Increase in TI-150502 & TI-150602 is the indication of evaporation from Vapor
Liquid Separator for FC Effect – I (V-1505) & Vapor Liquid Separator for FC Effect
– II (V-1506). Take FQIC-150501 in AUTO mode with the flow at 10% (Variable)
valve opening. Gradually, go on increasing the steam flow set point up to required
capacity.
23. Gradually start reducing the opening of Pressure Control Valve (PCV-150801) in
MAN mode. Because of evaporation pressure will start building in Vapour Liquid
Separator for FC Effect - I (V-1505), Vapour Liquid Separator for FC Effect - II (V-
1506) & Vapour Liquid Separator for FC Standby Effect (V-1507). Take PIC-150801
in AUTO mode with 0.2 kg/cm2 (a) set point.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
24. Based on evaporation rate in Vapour Liquid Separator for FF Effect – I (V-1501),
Vapour Liquid Separator for FF Effect - II (V-1502), Vapour Liquid Separator for FF
Effect - III (V-1503), Vapour Liquid Separator for FF Standby Effect (V-1504),
Vapour Liquid Separator for FC Effect – I (V-1505), Vapor Liquid Separator for FC
Effect – II (V-1506) and Vapour Liquid Separator for FC Standby Effect (V-1507)
respective level control valves will open in order to maintain the level.
25. In Sorghum case, Vapours from Vapour Liquid Separator for FF Effect - I (V-1501),
Effect – III (V-1503) and Vapour Liquid Separator for FF Standby Effect (V-1504)
will start condensing on shell side of Falling Film Effect – II (H-1502), Falling Film
Effect – III (H-1503), Falling Film Standby Effect (H-1504) and Process Condenser
(H-1511) respectively by giving its thermal energy to the circulating fluid on tube
side. And Vapors from Vapor Liquid Separator for FC Effect – I (V-1505), Vapor
Liquid Separator for FC Effect – II (V-1506) and Vapor Liquid Separator for FC
Standby Effect will start condensing on shell side of Forced Circulation Effect – II
(H-1506), Forced Circulation Standby Effect (H-1507) and Surface Condenser (H-
1508) respectively by giving its thermal energy to the circulating fluid on tube side.
26. In Corn case, Vapours from Vapour Liquid Separator for FF Effect - I (V-1501),
Effect – III (V-1503) and Vapour Liquid Separator for FF Standby Effect (V-1504)
will start condensing on shell side of Falling Film Effect – II (H-1502), Falling Film
Effect – III (H-1503), Falling Film Standby Effect (H-1504) and Surface Condenser
(H-1508) respectively by giving its thermal energy to the circulating fluid on tube
side.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
27. Process condensate from Falling Film Effect – II (H-1502), Falling Film Effect – III
(H-1503) and Falling Film Standby Effect (H-1504) will start flowing to Process
Condensate Tank – 1 (T-1502) through condensate pot. When Process Condensate
Tank - 1 (T-1502) level reaches 50% (Variable), open Process Condensate Pump - 1
(P-1509) suction valve and start the pump. Open Process Condensate Pump - 1 (P-
1509) discharge valve. Open Process Condensate Tank - 1 (T-1502) Level Control
Valve (LCV-151001) in MAN mode. Ensure the flow of condensate to Process
Condensate Treatment Plant. Take LIC-151001 in AUTO mode with 50% (Variable)
set point.
28. Process condensate from Forced Circulation Effect – II (H-1506), Forced Circulation
Standby Effect (H-1507), Process Condenser (H-1511) and Surface Condenser (H-
1508) will start flowing to Process Condensate Tank – 2 (T-1503). When Process
Condensate Tank - 2 (T-1503) level reaches 50% (Variable), open Process
Condensate Pump - 2 (P-1510) suction valve and start the pump. Open Process
Condensate Pump - 2 (P-1510) discharge valve. Open Process Condensate Tank - 2
(T-1503) Level Control Valve (LCV-150801) in MAN mode. Ensure the flow of
condensate to Process Condensate Tank – 1 (T-1502) through FIT-150801. Take
LIC-150801 in AUTO mode with 50% (Variable) set point.
29. Observe the vapour condensation on flow glass provided on H-1501, H-1502, H-
1503, H-1504, H-1505, H-1506 and H-1507. Condensation can be ensured from flow
glass on condensate line of H-1501, H-1502, H-1503, H-1504, H-1505, H-1506 and
H-1507.
30. Based on evaporation rate in H-1501, H-1502, H-1503, H-1504, H-1505, H-1506 and
H-1507 respective level control valves will open in order to maintain the level.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
31. Ensure tuning of all controllers. Continue the water boiling in Evaporation section
for at least 24 hrs.
32. After ensuring the steady state process parameters during water boiling check the
performance of all equipment. Switchover the respective users to standby pumps,
standby PHE etc. Also check the changeover of evaporation effect one by one.
(Refer: Control & Interlock Descriptive Logic N-10012-4-ILD 1501, section “N-
Changeover Modes for falling film evaporators and forced circulation
evaporators’)

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Steady state Parameters for Water Boiling –
SR.
PARAMTERS TAG NO. UNIT VALUE
NO.
1 V-1501 level LIC-150101 % 50
2 V-1502 level LIC-150201 % 50
3 V-1503 level LIC-150301 % 50
4 V-1504 level LIC-150401 % 50
5 V-1505 level LIC-150501 % 50
6 V-1506 level LIC-150601 % 50
7 V-1507 level LIC-150701 % 50
8 P-1501 to H-1501 Temperature TI-150101 oC 103.5
9 LP steam to H-1501/H-1502 TI-150102 oC 112
10 V-1501 Temp. TI-150103 oC 103.1
12 V-1502 Temp. TI-150202 oC 103.1
14 V-1503 Temp. TI-150302 oC 95.5
16 V-1504 Temp. TI-150402 oC 84.5
18 H-1505 to V-1505 TI-150502 oC 92.3
19 V-1505 Temp. TI-150503 oC 90.6
20 P-1506 to H-1506 Temperature TI-150601 oC 67
21 H-1506 to V-1506 Temperature TI-150602 oC 67
22 V-1506 Temp. TI-150603 oC 65

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
SR.
NO.
23 P-1507 to H-1507 Temperature TI-150701 oC 67
24 H-1507 to V-1507 Temperature TI-150702 oC 67
25 V-1507 Temp. TI-150703 oC 65
26 Cooling water supply Temp. TI-150801 oC 31
27 Cooling water return Temp. TI-150802 oC 41
Thin Stillage Vapor to P-1513A/B oC
28 TI-150803 62
Temp.
29 Thin Stillage to H-1509A/B Temp. TI-150901 oC 80
30 P-1511 to H-1509A/B Temp. TI-150902 oC 112
31 Steam condensate from H-1509A/B TI-150903 oC 84

Temp.
32 H-1509A/B to V-1501/V-1502 Temp. TI-150904 oC 90.91
33 P-1509 to H-1510 Temp. TI-151001 oC 95.5
34 Process condensate from H-1510 Temp. TI-151002 oC 66.52
35 UF permeate from H-1510 Temp. TI-151003 oC 63
36 Thin Stillage Vapor to C-1401 FQIC-150401 Kg/hr 8620
37 LP steam to H-1505/H-1506 FQIC-150501 Kg/hr 685.14
38 Concentrated Syrup to T-1505 FQIC-150601 Kg/hr 8723.26
39 P-1510 out to T-1502 FQI-150801 Kg/hr 4141.25
40 LP steam to H-1501/H-1502 FQIC-150901 Kg/hr 12679.88
41 P-1508A/B out to H-1509A/B FQI-151101 Kg/hr 43458
42 Conc. Nitric Acid to T-1506 FQI-151201 Kg/hr 15000
43 T-1503 level LIC-150801 % 50
44 T-1504 level LIC-150901 % 50

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
SR.
NO.
45 T-1502 level LIC-151001 % 50
46 T-1505 level LIC-151101 % 50
47 T-1501 level LI-151102 % 50
48 T-1506 level LI-151201 % 50
NOTE –
Above parameters are only guidelines. Actual operating parameters shall be fine-
tuned at site during Commissioning.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
PART – III
PROCESS START-UP
AND
PROCESS PARAMETERS

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
3.0. 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. These instructions do 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-up it is necessary to make detailed schedule so as to understand

sequence of start-up of individual sections and their synchronization.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
3.0.1 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-Tagout (LOTO)
procedure
3. Good housekeeping is required to keep the area clean and free of debris.
4. Be cautious from rotary / moving equipment like conveyors.
5. No Smoking Zone.
6. Use safety goggle, gloves and follow safe practices while handling chemicals
like nitric acid and caustic solution.
7. For High temperature steam / other materials, use PPE.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
3.0.2 NORMAL START-UP

1. For water boiling follow procedure given for Evaporation section steam trial.
2. Evaporation to be started in continuation with water boiling. At the end of water &
steam trials plant will be running on water with all stabilized conditions.
3. Initially during plant Start-up stabilise the plant on 70 –80 % plant capacity with
respective steam consumption and slowly increase the feed in order to achieve 100
% capacity.
4. Reconfirm that all pressure controllers and level controllers are in AUTO mode.
Ensure the operation of level controllers by visually observing levels through sight
glasses.
5. Check current drawn by each re-circulation pump. Adjust the current values for
each re-circulation pump for evaporation section by manually opening / closing
discharge valves of respective re-circulation pump.
6. Monitor pressure and temperature of each effect. Fine-tune the shell side vent
valves of Falling Film Effects to avoid building up of non-condensable vapour.
Check and record cooling water inlet and outlet temperatures allow the system to
stabilize. Check concentration in each effect with reference to steady state
parameters given in the table.
7. Ensure other parameters are being maintained as per Steady state Parameters for
Water Boiling.
8. Water from Thin Stillage Feed Tank (T-1501) will start replacing with Thin Stillage.
Heat from steam condensate will be used for preheating the Thin Stillage in Thin
Stillage Preheater (H-1509 A/B).
9. Isolate the standby effects and line out the three falling films and two force
circulation evaporators for operation.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
10. During initial start-up the solid concentration in concentrated syrup will be less
because on less total solids in Thin Stillage mash itself. So do not allow the Thin
Stillage with low total solids to Concentrated Syrup Tank (T-1505). Start P-
1514A/B and divert thin stillage to Feed Tank. After establishment of total solids
from evaporation, divert Concentrated Syrup to storage area.
11. Based on evaporation rate in Falling Film Effect – I (H-1501), Falling Film Effect – II
(H-1502), Falling Film Effect – III (H-1503), Forced Circulation Effect – I (H-1505),
Forced Circulation Effect – II (H-1506) water from evaporators will be replaced by
Thin Stillage. Based on evaporation rate the solid concentration in evaporators will
increase gradually.
12. Keep close watch on –
Current of motors for Recirculation Pump for FF Effect – I (P-1501)
Current of motors for Recirculation Pump for FF Effect – II (P-1502)
Current of motors for Recirculation Pump for FF Effect – III (P-1503)
Current of motors for Recirculation Pump for FC Effect - I (P-1505)
Current of motors for Recirculation Pump for FC Effect - II (P-1506)
Current of motors for Thin Stillage Feed Pump (P-1508A/B)
Current of motors for Process Condensate Pump – 1 (P-1509)
Current of motors for Process Condensate Pump – 2 (P-1510)
Current of motors for Steam Condensate Pump (P-1511)
Current of motors for Concentrated Syrup Transfer Pump (P-1512)
Current of motors for Concentrated Syrup Pump (P-1514 A/B)
V-1505/V-1506 Density indication on DIC-150601
Total solids analysis report from laboratory for Vapor Liquid Separator
for FF Effect - I (V-1501)

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
for FF Effect - II (V-1502)
for FF Effect - III (V-1503)
for FC Effect - I (V-1505)
for FC Effect - II (V-1506)
13. After achieving the solid concentration in evaporation section, divert concentrated
syrup to storage. Take DIC-150601 in AUTO mode with FQIC-150601 in
CASCADE mode. If density at DIC-150601 increases, it will decrease the set point
of FQIC-150601 and vice versa.
14. Check FQI-150801 on process condensate to T-1502 flow rate.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
3.0.3 PROCESS PARAMETERS
FLOW (SORGHUM WITH TANIN CASE):
SR.NO. PARAMETER TAG NO. UNIT VALUE
FQIC-
1 Thin Stillage Vapor to C-1401 Kg/hr 8620
150401
FQIC-
2 LP steam to H-1505/H-1506 Kg/hr 685.14
150501
FQIC-
3 Concentrated Syrup to T-1505 Kg/hr 8723.26
150601
4 Process Condensate to T-1502 FQI-150801 Kg/hr 21736.30
FQIC-
150901
6 Thin Stillage Feed Flow FQI-151101 Kg/hr 43458
FLOW (SORGHUM WITHOUT TANIN CASE):
FQIC-
150401
FQIC-
150501
FQIC-
150601
FQIC-
150901

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
FLOW (CORN CASE):
FQIC-
150401
FQIC-
150601
FQIC-
150901
PRESSURE (SORGHUM CASE)
1. Vapor Liquid Separator V-1501 PI-150102 Kg/cm2 1.15

PIC-
6. Evaporator Vacuum Kg/cm2 0.25
150801

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
PRESSURE (CORN CASE)

PIC-
4. Evaporator Vacuum Kg/cm2 0.31
150801
DENSITY (SORGHUM CASE)
1 Vapor Liquid Separator V-1506 DIC-150601 Kg/m3 1146.9
DENSITY (CORN CASE)
1 Vapor Liquid Separator V-1503 DIC-150601 Kg/m3 1143.9
TEMPERATURE (SORGHUM CASE)
1. P-1501 to H-1501 Temperature TI-150101 oC 103.5
2. LP steam to H-1501/H-1502 TI-150102 oC 112
3. V-1501 Temp. TI-150103 oC 103.1

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
5. V-1502 Temp. TI-150202 oC 95.5
7. V-1503 Temp. TI-150302 oC 84.5
9. H-1505 to V-1505 TI-150502 oC 92.3
10. V-1505 Temp. TI-150503 oC 90.6
11. P-1506 to H-1506 Temperature TI-150601 oC 67
12. H-1506 to V-1506 Temperature TI-150602 oC 67
13. V-1506 Temp TI-150603 oC 65
14. Cooling water supply Temp. TI-150801 oC 31
15. Cooling water return Temp. TI-150802 oC 41

16. TI-150803 62
Temp.
17. Thin Stillage to H-1509A/B Temp. TI-150901 oC 80.01
18. P-1511 to H-1509A/B Temp. TI-150902 oC 112

Steam condensate from H-1509A/B oC
19. TI-150903 84
Temp.
20. H-1509A/B to V-1501 Temp. TI-150904 oC 90.91
21. P-1509 to H-1510 Temp. TI-151001 oC 95.5

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.

Process condensate from H-1510 oC
22. TI-151002 66.52
Temp.
23. UF permeate from H-1510 Temp. TI-151003 oC 63
TEMPERATURE (CORN CASE)
2. LP steam to H-1501 TI-150102 oC 112
3. V-1501 Temp. TI-150103 oC 97.2
5. V-1502 Temp. TI-150202 oC 84.5
6. P-1503 to H-1503 Temperature TI-150301 oC 72
7. V-1503 Temp. TI-150302 oC 70
8. Cooling water supply Temp. TI-150801 oC 31
9. Cooling water return Temp. TI-150802 oC 41

10. TI-150803 67
Temp.
11. Thin Stillage to H-1509A/B Temp. TI-150901 oC 78.17
12. P-1511 to H-1509A/B Temp. TI-150902 oC 112

Steam condensate from H-1509A/B oC
13. TI-150903 82.17
Temp.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
14. H-1509A/B to V-1501 Temp. TI-150904 oC 94.12
15. P-1509 to H-1510 Temp. TI-151001 oC 84.5

Process condensate from H-1510 oC
16. TI-151002 41.08
Temp.
17. UF permeate from H-1510 Temp. TI-151003 oC 80.5
LEVEL

Vapor Liquid Separators V-1501
1 LIC-150101 % 50
level
Vapor Liquid Separators V-1502 50
2 LIC-150201 %
level
3 LIC-150301 %
level
5 LIC-150501 %
level
6 LIC-150601 %
level
Process Condensate Tank - 1 (T-
8 LIC-151001 % 50
1502) level
Process Condensate Tank - 2 (T-
9 LIC-150801 % 50
1503) level
Steam Condensate Tank (T-
10 LIC-150901 % 50
1504)level
Concentrated Syrup Tank (T-1505)
11 LIC-151101 % 50
level
Thin Stillage Feed tank (T-1501)
12 LI-151102 % 50
level

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
TOTAL SOLIDS
1 Concentrated Syrup total solids - % w/w 35
NOTE –
1. Above parameters are only guidelines. Actual operating parameters shall be
fine-tuned at site during Commissioning.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
3.0.4 CLEANING IN PLACE (CIP)

C.I.P. Scheme
The evaporation plant is designed such that CIP of any one Falling Film Effect out of
four Falling Film Effect and CIP of any one Forced Circulation Effect out of three Forced
Circulation Effect can be carried out at a time, while the other evaporators will be in
operation.
3.0.4 a SOP for Preparation of 3-5 % w/w Nitric acid solution in CIP Tank T-1506
1. Ensure Nitric Acid CIP Tank (T-1506) vent line is clear.
2. Ensure CIP Tank (T-1506) is empty.
3. Ensure CIP Tank (T-1506) drain valve is closed.
4. Open valve on fresh water supply line and fill the required quantity of water in the
tank (Check against level of the tank). During normal operation of the plant
instead of fresh water, evaporation condensate can also be taken by opening
respective manual valve.
5. Close valve on water supply line and confirm level in the tank.
6. Open manual valve on CIP Transfer Pump (P-1515) suction and start CIP Transfer
Pump (P-1515) with re-circulation in the tank by opening manual circulation valve.
Keep the liquid in circulation.
7. Ensure Nitric Acid stock in Nitric Acid Storage Tank.
8. Open solenoid valve XV-151201 on Nitric Acid supply line to T-1506. Take
measured quantity Nitric Acid in T-1506 through FIT-151201. Close XV-151201.
Keep Nitric Acid CIP solution under circulation for half hour.
9. Ensure and confirm the Nitric Acid concentration of the tank.
10. Nitric Acid CIP solution is ready for CIP.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
3.0.4 b SOP for Preparation of 3-5 % w/w caustic solution in CIP Tank T-1351
1. Ensure CIP Tank T-1351 vent line is clear.
2. Ensure the CIP Tank (T-1351) is empty.
3. Ensure CIP Tank (T-1351) drain valve is closed.
4. Fresh water has to be used for CIP solution preparation by opening respective
manual valve.
5. Open manual valve on Fresh Water supply line to CIP Tank (T-1351) and fill the
required quantity of water in the CIP Tank (T-1351) (Check against level of the
tank).
6. Close valve on water supply line and confirm level in the tank.
7. Open valve on CIP Pump (P-1351A/B) suction and Start CIP Pump (P-1351A/B)
with re-circulation in the tank by opening re-circulation manual valve. Keep the
liquid in re-circulation.
8. Ensure Caustic stock in Storage Tank.
9. Take measured quantity caustic lye in CIP Tank T-1351.
10. Keep caustic CIP solution under circulation for half hour.
11. Ensure and confirm the caustic concentration of the tank through sample points.
12. Caustic CIP solution is ready for CIP.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
3.0.4.c SOP for CIP of Falling Film Effect – I (H-1501)

1. Ensure CIP tanks are filled with CIP solution.
2. Stop Thin Stillage feed to Vapor Liquid Separator for FF Effect – I (V-1501) by
Closing Solenoid valve XV-150102. Close manual valve on Thin Stillage transfer
line.
3. Stop steam to Falling Film Effect – I (H-1501) by closing manual valve. (Reduce set
point of FQIC-150901 as per requirement). After 2-3 minutes close manual valve on
Vapor line from Vapor Liquid Separator for FF Effect – I (V-1501) and on steam
condensate line.
4. Ensure that Falling Film Effect – I (H-1501) whose CIP is to be performed is
completely isolated from rest of the system.
5. Stop Recirculation Pump for FF Effect – I (P-1501), Open manual Air bleed valve
and release the vacuum in the effect. Let this valve remain open till the entire CIP
operation.
6. Open manual valve on CIP drain line of Vapor Liquid Separator for FF Effect – I
(V-1501) and start CIP Drain Pump (P-1516) (Check CIP Drain Pump suction
before starting). Transfer the Thin Stillage hold up to Thin Stillage Feed Tank (T-
1501) by opening respective manual valve. Drain the effect completely. Open
manual valve on line across Recirculation Pump for FF Effect – I (P-1501) to drain
Discharge line.
7. After draining, stop CIP Drain Pump (P-1516) and close drain valve.
8. Fill the Vapor Liquid Separator (V-1501) with process condensate by opening
manual valve and XV-150101 up to just above normal operating level. Recirculate
this condensate for 30 minutes to 1 hour. And drain it.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
9. Ensure Nitric Acid solution is prepared and ready for transfer. Open XV-151201
Solenoid valve and start CIP Transfer Pump (P-1515). Open manual valve allow
CIP solution to be filled in Falling Film Effect – I (H-1501).
10. When level reaches 50-60% in Vapor Liquid Separator for FF Effect – I (V-1501),
stop CIP Transfer Pump (P-1515), Close manual valve on CIP solution inlet, and
start Recirculation Pump for FF Effect – I (P-1501). .
11. Re-circulate the solution through Falling Film Effect – I (H-1501) for 4 Hr. Stop
Recirculation Pump for FF Effect – I (P-1501). Open CIP drain manual valve and
start the CIP drain pump (P-1516) & transfer CIP solution to Effluent treatment.
12. Ensure Caustic solution is prepared and ready for transfer. Open suction valve and
start CIP Pump (P-1351). Open respective manual valve at CIP Pump (P-1351)
discharge and allow CIP solution to be filled in Falling Film Effect – I (H-1501).
13. When level reaches 50-60% in Vapor Liquid Separator for FF Effect - I start
Recirculation Pump for FF Effect – I (P-1501).
14. Re-circulate the solution through Falling Film Effect –I for 4 Hr. Stop Recirculation
Pump for FF Effect – I (P-1501). Drain Exhaust CIP by opening CIP drain manual
valves. Start CIP drain pump (P-1516) & transfer CIP solution to Effluent
treatment.
15. After this take water in any of the CIP tank T-1506 / T-1351, and transfer it to
Falling Film Effect – I (H-1501) same way like transfer of CIP solution.
16. Recirculate water through Falling Film Effect –I (H-1501) for 1 hrs. Stop
Recirculation Pump for FF Effect – I (P-1501). Drain Exhaust CIP by opening CIP
drain manual valves. Start CIP drain pump (P-1516) & transfer CIP solution to
Effluent treatment.
17. Falling Film Effect – I (H-1501) is now ready and can be taken online.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
18. Close Air bleed valve and open valve on vacuum line to take initial vacuum. When
sufficient vacuum is available close vacuum valve and open XV-150102.
19. When level reaches 50-60% in Vapor Liquid Separator for FF Effect - I start
Recirculation Pump for FF Effect – I (P-1501). Open manual valves on transfer line
from Recirculation Pump for FF Effect – I (P-1501).
20. Open manual valve on steam condensate line and start steam by opening manual
valve. (Adjust set point of FQIC-150901 as per requirement).
3.0.4 d SOP for CIP of Falling Film Effect – II (H-1502)

2. Stop Thin Stillage feed to Vapor Liquid Separator for FF Effect – II (V-1502) by
Closing Solenoid valve XV-150202, XV-150203. Close manual valve on Thin
Stillage transfer line.
3. If Falling Film Effect – II (H-1502) is running on Steam, Stop steam to Falling
Film Effect – II (H-1502) by closing manual valve. (Reduce set point of FQIC-
150901 as per requirement). After 2-3 minutes close manual valve on Vapor line
from Vapor Liquid Separator for FF Effect – II (V-1502) and on steam condensate
line.
4. If Falling Film Effect – II (H-1502) is running on Thin Stillage Vapour, Stop Thin
Stillage Vapor to Falling Film Effect – II (H-1502) by closing respective manual
valve. After 2-3 minutes close manual valve on Vapor line from Vapor Liquid
Separator for FF Effect - II (V-1502) and on process condensate line.
5. Ensure that Falling Film Effect – II (H-1502) whose CIP is to be performed is

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
6. Stop Recirculation Pump for FF Effect – II (P-1502), Open manual Air bleed valve
and release the vacuum in the effect. Let this valve remain open till the entire
CIP.
7. Open manual valve on CIP drain line of Vapor Liquid Separator for FF Effect – II
(V-1502) and start CIP drain Pump (P-1516). (Check CIP drain Pump suction
before starting) Transfer the Thin Stillage hold up to tank Thin Stillage Feed Tank
(T-1501) by opening respective manual valve. Drain the effect completely. Open
manual valve on line across Pump for FF Effect – II (P-1502) to drain Discharge
line.
8. After draining stop CIP drain Pump (P-1516) and close drain valve.
Solenoid valve and start pump CIP Transfer Pump (P-1515). Open manual valve
allow CIP solution to be filled in Falling Film Effect – II (H-1502).
11. When level reaches 50-60% in Vapor Liquid Separator for FF Effect – II (V-1502)
start Recirculation Pump for FF Effect – II (P-1502). Close manual valve on CIP
solution line.
12. Re-circulate the solution through Falling Film Effect – II (H-1502) for 4 Hr. Stop
Recirculation Pump for FF Effect – II (P-1502). Drain Exhaust CIP by opening CIP
drain manual valve. Start CIP drain pump (P-1516) & transfer CIP solution to
Effluent treatment.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
13. Ensure Caustic solution is prepared and ready for transfer. Open suction valve
and start CIP Pump (P-1351). Open respective manual valve at CIP Pump (P-
1351) discharge and allow CIP solution to be filled in Falling Film Effect – II (H-
1502).
14. When level reaches 50-60% in Vapor Liquid Separator for FF Effect – II (V-1502)
start Recirculation Pump for FF Effect – II (P-1502).
15. Re-circulate the solution through Falling Film Effect –II for 4 Hr. Stop
drain manual valves as described above. Start CIP drain pump (P-1516) &
transfer CIP solution to Effluent treatment.
Falling Film Effect – II (H-1502) same way like transfer of CIP solution.
17. Recirculate water through Falling Film Effect –II (H-1502) for 1 hrs. Stop
Effluent treatment.
18. Falling Film Effect – II (H-1502) is now ready and can be taken online.
19. Close Air bleed valve and open valve on vacuum line to take initial vacuum.
When sufficient vacuum is available close vacuum valve and open XV-150202 &
XV-150203. Start Recirculation Pump for FF Effect – II (P-1502) and open manual
valves on transfer line from Recirculation Pump for FF Effect – II (P-1502).
20. Open manual valve on steam condensate line and start steam by opening manual
valve. (Adjust set point of FQIC-150901 as per requirement).

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
3.0.4 e SOP for CIP of Falling Film Effect – III (H-1503)

2. Stop Thin Stillage feed to Vapor Liquid Separator for FF Effect – III (V-1503) by
closing XV-150302 & XV-150303. Close manual valve on Thin Stillage transfer line.
Open manual valve on CIP drain line to divert the excess Thin Stillage to Thin
Stillage Feed Tank (T-1501)/ Concentrated Syrup Tank (T-1505).
3. Stop Thin Stillage Vapor to Falling Film Effect – III (H-1503) by closing respective
manual valve. After 2-3 minutes close manual valve on Vapor line from Vapor
Liquid Separator for FF Effect - III (V-1503) and on process condensate line.
4. Ensure that Falling Film Effect – III (H-1503) whose CIP is to be performed is
5. Stop Recirculation Pump for FF Effect – III (P-1503), Open manual Air bleed valve
and release the vacuum in the effect. Let this valve remain open till the entire CIP.
6. Open manual valve on CIP drain line of Vapor Liquid Separator for FF Effect – III
(V-1503) and start pump CIP drain Pump (P-1516). (Check CIP drains pump
suction before starting). Transfer the Thin Stillage hold up to Thin Stillage Feed
Tank (T-1501)/ Concentrated Syrup Tank (T-1505) by opening respective manual
valve. Drain the effect completely. Open manual valve on line across Pump for FF
Effect – III (P-1503) to drain discharge line.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
allow CIP solution to be filled in Falling Film Effect – III (H-1503).
10. When level reaches 50-60% in Vapor Liquid Separator for FF Effect – III (V-1503)
start Recirculation Pump for FF effect – III (P-1503). Close manual valve on CIP
solution line.
11. Recirculate the solution through Falling Film Effect - III (H-1503) for 4 Hr. Stop
drain manual valve. Start CIP drain pump (P-1516) & transfer CIP solution to
Effluent treatment.
discharge and allow CIP solution to be filled in Falling Film Effect – III (H-1503).
13. When level reaches 50-60% in Vapor Liquid Separator for FF Effect – III (V-1503)
start Recirculation Pump for FF Effect – III (P-1503).
14. Recirculate the solution through Falling Film Effect – III for 4 hr. Stop
Recirculation Pump for FF Effect – III (P-1503). Drain Exhaust CIP by opening CIP
drain manual valves as described above. Start CIP drain pump (P-1516) & transfer
CIP solution to Effluent treatment.
15. After this take water in of the CIP tank T-1506 / T-1351, and transfer it to Falling
Film Effect – III (H-1503) same way like transfer of CIP solutions.
16. Recirculate water through Falling Film Effect –III (H-1503) for 1 hrs. Stop
Recirculation Pump for FF Effect – III (P-1503). Drain Exhaust CIP by opening CIP

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Effluent treatment.
17. Falling Film Effect – III (H-1503) is now ready and can be taken online.
sufficient vacuum is available close vacuum valve and open XV-150302 & XV-
150303. Start Recirculation Pump for FF Effect – III (P-1503) and open manual
valves on transfer line from Recirculation Pump for FF Effect – III (P-1503).
19. Open manual valve on process condensate line and start Thin Stillage vapor by
opening manual valve.
3.0.4 f SOP for CIP of Falling Film Standby Effect (H-1504)

2. Stop Thin Stillage feed to Vapor Liquid Separator for FF Standby Effect (V-1504) by
closing XV-150402 & XV-150403. Open manual valve on CIP drain line to divert
the excess Thin Stillage to tank Thin Stillage Feed Tank (T-1501) / Concentrated
Syrup Tank (T-1505).
3. Stop Thin Stillage Vapor to Falling Film Standby Effect (H-1504) by closing
respective manual valve. After 2-3 minutes close manual valve on Vapor line from
Vapor Liquid Separator for FF Standby Effect (V-1504) and on process condensate
line.
4. Ensure that Falling Film Standby Effect (H-1504) whose CIP is to be performed is
5. Stop Recirculation Pump for FF standby Effect (P-1504), Open manual Air bleed
valve and release the vacuum in the effect. Let this valve remain open till the entire
CIP.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
6. Open manual valve on CIP drain line of Vapor Liquid Separator for FF Standby
Effect (V-1504) and start pump CIP drain Pump (P-1516) (check CIP drain pump
suction before starting). Thin Stillage Feed Tank (T-1501)/ Concentrated Syrup
Tank (T-1505) by opening respective manual valve. Drain the effect completely.
Open manual valve on line across Pump for FF Standby Effect (P-1504) to drain
discharge line.
allow CIP solution to be filled in Falling Film Standby Effect (H-1504).
10. When level reaches 50-60% in Vapor Liquid Separator for FF Standby Effect (V-
1504), stop CIP Transfer Pump (P-1515), Close manual valve on CIP solution inlet,
and start Recirculation Pump for FF Standby Effect (P-1504). Close manual valve
on CIP solution line.
11. Recirculate the solution through Falling Film standby Effect (H-1504) for 4 Hr.
Stop Recirculation Pump for FF Standby Effect – II (P-1504). Drain Exhaust CIP by
opening CIP drain manual valve as described above. Start CIP drain pump (P-
1516) & transfer CIP solution to Effluent treatment.
discharge and allow CIP solution to be filled in Falling Film Standby Effect (H-
1504).

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
13. When level reaches 50-60% in Vapor Liquid Separator for FF Standby Effect (V-
1504), start Recirculation Pump for FF Standby Effect (P-1504).
14. Recirculate the solution through Falling Film Standby Effect for 4 hr. Stop
Recirculation Pump for FF Standby Effect (P-1504). Drain Exhaust CIP by opening
CIP drain manual valves as described above. Start CIP drain pump (P-1516) &
Falling Film Standby Effect (H-1504) same way like transfer of CIP solutions,
16. Recirculate water through Falling Film Standby Effect (H-1504) for 1 hrs. Stop
recirculation Pump for FF Standby Effect (P-1504). Drain Exhaust CIP by opening
CIP drain manual valves. Start CIP drain pump (P-1516) & transfer CIP solution to
Effluent treatment.
17. Falling Film Standby Effect (H-1504) is now ready and can be taken online
sufficient vacuum is available close vacuum valve and open XV-150402 & XV-
150403. Start Recirculation Pump for FF Standby Effect (P-1504) and open manual
valves on transfer line from Recirculation Pump for FF Standby Effect (P-1504).
19. Open manual valve on process condensate line and start Thin Stillage vapor by
opening manual valve.
3.0.4 g SOP for CIP of Forced Circulation Effect – I (H-1505)

2. Stop Thin Stillage feed to Vapor Liquid Separator for FC Effect – I (V-1505) by
closing XV-150502 & LCV-150501.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
3. Close manual valves on steam line to Forced Circulation Effect – I (H-1505), Thin
Stillage Vapor line from Vapor Liquid Separator for FC Effect - I (V-1505), Steam
condensate line and vent line.
4. Ensure that Forced Circulation Effect – I (H-1505) whose CIP is to be performed is
5. Stop Recirculation Pump for FC Effect – I (P-1505) Open manual Air bleed valve
and release the vacuum in the effect. Let this valve remain open till the entire CIP.
6. Start draining the hold up by opening manual valve and by using CIP Drain Pump
(P-1516) to Thin Stillage Feed Tank (T-1501)/ Concentrated Syrup Tank (T-1505).
After removal of hold up close manual valve on CIP drain line and stop CIP Drain
Pump (P-1516).
manual valve up to just above normal operating level. Recirculate this condensate
for 30 minutes to 1 hour. And drain it.
8. Open manual valve on Nitric CIP solution line and Start filling Vapor Liquid
Separator for FC Effect - I (V-1505) by Nitric CIP solution by using CIP Transfer
Pump (P-1515). When level in Vapor Liquid Separator for FC Effect - I (V-1505)
reaches 30-40% stop filling Nitric CIP solution by closing respective manual valve.
Start Recirculation Pump for FC Effect – I (P-1505) and Recirculate the liquid for 3-
4 hrs.
9. Drain Exhaust CIP by opening CIP drain manual. Start CIP drain pump (P-1516) &
10. Procedure in Step 5 and 6 explained above should be repeated with caustic CIP
solution also.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Forced Circulation Effect – I (H-1505) same way like transfer of CIP solution.
12. Recirculate water through Forced Circulation Effect – I (H-1505) for 1 hrs. Stop
Recirculation Pump for FC Effect – I (P-1505). Drain Exhaust CIP by opening CIP
Effluent treatment.
13. Forced Circulation Effect – I (H-1505) is now ready and can be taken online.
3.0.4 h SOP for CIP of Forced Circulation Effect – II (H-1506)

1. Ensure CIP tanks are filled with CIP solution
2. Stop Thin Stillage feed to Vapor Liquid Separator for FC Effect – II (V-1506) by
closing XV-150601, XV-150602, XV-150604 and LCV-150601.
3. If Forced Circulation Effect – II (H-1506) is running on Steam, Stop steam to
Forced Circulation Effect – II (H-1506) by closing respective manual valve
(Reduce set point of FQIC-150501 as per requirement). After 2-3 minutes close
manual valve on Vapor line from Vapor Liquid Separator for FC Effect-II (V-
1506) and on steam condensate line.
4. If Forced Circulation Effect – II (H-1506) is running on Thin Stillage Vapour,
Stop Thin Stillage Vapour to Forced Circulation Effect – II (H-1506) by closing
respective manual valve. After 2-3 minutes close manual valve on Vapor line
from Vapor Liquid Separator for FC Effect-II (V-1506) and on process
condensate line.
5. Ensure that Forced Circulation Effect – II (H-1506) whose CIP is to be
performed is completely isolated from rest of the system

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
6. Stop Recirculation Pump for FC Effect – II (P-1506). Open manual Air bleed
valve and release the vacuum in the effect. Let this valve remain open till the
entire CIP.
7. Start draining the hold up by opening manual valve and by using CIP Drain
Pump (P-1516) to tank Thin Stillage Feed Tank (T-1501)/ Concentrated Syrup
Tank (T-1505). After removal of hold up close manual valve on CIP drain line
and stop CIP Drain Pump (P-1516).
manual valve up to just above normal operating level. Recirculate this
condensate for 30 minutes to 1 hour. And drain it.
9. Open manual valve on Nitric CIP solution line and Start filling the Vapor
Liquid Separator for FC Effect - II (V-1506) by Nitric CIP solution by using CIP
Transfer Pump (P-1515). When level in Vapor Liquid Separator for FC Effect - II
(V-1506) reaches 30-40% stop filling Nitric CIP solution by closing respective
manual valve. Start Recirculation Pump for FC Effect – II (P-1506) and
Recirculate the liquid for 3-4 hrs.
10. Drain Exhaust CIP by opening CIP drain manual. Start CIP drain pump (P-
solution also.
Forced Circulation Effect – II (H-1506) same way like transfer of CIP solution.
13. Recirculate water through Forced Circulation Effect – II (H-1506) for 1 hrs. Stop
Recirculation Pump for FC Effect – II (P-1506). Drain Exhaust CIP by opening

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
CIP drain manual valves. Start CIP drain pump (P-1516) & transfer CIP
solution to Effluent treatment.
14. Forced Circulation Effect – II (H-1506) is now ready and can be taken online.
3.0.4 i SOP for CIP of Forced Circulation Standby Effect (H-1507)

1. Ensure CIP tanks are filled with CIP solution
2. Stop Thin Stillage feed to Vapor Liquid Separator for FC Standby Effect (V-
1507) by closing XV-150701, XV-150702, XV-150603 and LCV-150701.
3. Stop Thin Stillage Vapour to Forced Circulation standby Effect (H-1507) by
closing respective manual valve after 2-3 minutes close manual valve on Vapor
line from Vapor Liquid Separator for FC Standby Effect (V-1507) and on
process condensate line.
4. Ensure that Forced Circulation Standby Effect (H-1507) whose CIP is to be
performed is completely isolated from rest of the system.
5. Stop Recirculation Pump for FC Standby Effect (P-1507). Open manual Air
bleed valve and release the vacuum in the effect. Let this valve remain open till
the entire CIP.
6. Start draining the hold up by opening manual valve and by using CIP Drain
Pump (P-1516) to tank Thin Stillage Feed Tank (T-1501)/ Concentrated Syrup
Tank (T-1505). After removal of hold up close manual valve on CIP drain line
and stop CIP Drain Pump (P-1516).
manual valve up to just above normal operating level. Recirculate this
condensate for 30 minutes to 1 hour. And drain it.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
8. Open manual valve on Nitric CIP solution line and Start filling the Vapor
Liquid Separator for FC Standby Effect (V-1507) by Nitric CIP solution by using
CIP Transfer Pump (P-1515). When level in Vapor Liquid Separator for FC
Standby Effect (V-1507) reaches 30-40%, stop filling Nitric CIP solution by
closing respective manual valve. Start Recirculation Pump for FC Standby
Effect (P-1507) and Recirculate the liquid for 3-4 hrs.
9. Drain Exhaust CIP by opening CIP drain manual. Start CIP drain pump (P-
solution also.
Forced Circulation Standby Effect (H-1507) same way like transfer of CIP
solution.
12. Recirculate water through Forced Circulation Standby Effect (H-1507) for 1 hrs.
Stop Recirculation Pump for FC Standby Effect (P-1507). Drain Exhaust CIP by
opening CIP drain manual valves. Start CIP drain pump (P-1516) & transfer
CIP solution to Effluent treatment.
13. Forced Circulation Standby Effect (H-1507) is now ready and can be taken
online.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
3.0.5 PROCESS MONITORING

Process and Plant design 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 distillation & evaporation 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.
Evaporator profile control

Evaporator temperature profile will set based on set pressure, net heat input and the
solid concentration in the particular effect.
Continuous venting from shell side of heat exchangers is necessary for removal of non
–condensable gases which offer resistance to heat transfer. Excess venting will result
in venting of condensable vapors along with non-condensable vapors, which
ultimately results in loss of heat input to the system.
As an integrated evaporation system with distillation section, it is necessary to
provide required heat to evaporation section, which in turns provides Thin Stillage
vapors to distillation section as heating media.
It is necessary to analyze the concentrated syrup samples in laboratory at regular
intervals for total solids, which will be indication for the operator to adjust the density
set point control of concentrated syrup from final effect.
Excess solid concentration will reflects in handling problems, scaling problems and
ultimately net evaporation reduction.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
3.0.6 FREQUENCY OF ROUTINE ANALYSIS
Sr. Frequency of
Parameters
No. analysis
1 Vapor Liquid Separator For FF Effect – I (V-1501), total solids Once a day
2 Vapor Liquid Separator For FF Effect – II (V-1502), total solids Once a day
3 Vapor Liquid Separator For FF Effect – III (V-1503), total solids Once a day
Vapor Liquid Separator For FF Standby Effect (V-1504), total

4 Once a day
solids
5 Vapor Liquid Separator For FC Effect – I (V-1505), Total solids Once a day
6 Vapor Liquid Separator For FC Effect – Ii (V-1506), Total solids Once a day
Vapor Liquid Separator For FC Standby Effect (V-1507), total

7 Once a day
solids
Vapor Liquid Separator For FF Effect – I (V-1501), Specific
8 Every 2 hours
Gravity & Brix
Vapor Liquid Separator For FF Effect – II (V-1502), Specific
9 Every 2 hours
Gravity & Brix
Vapor Liquid Separator For FF Effect – III (V-1503), Specific
10 Every 2 hours
Gravity & Brix
Vapor Liquid Separator For FF standby Effect (V-1504), Specific
11 Every 2 hours
Gravity & Brix

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Sr. Frequency of
Parameters
No. analysis
Vapor Liquid Separator For FC Effect – I (V-1505), Specific
12 Every 2 hours
Gravity & Brix
Vapor Liquid Separator For FC Effect – II (V-1506), Specific
13 Every 2 hours
Gravity & Brix
Vapor Liquid Separator For FC Standby Effect (V-1507),
14 Every 2 hours
Specific Gravity & Brix
15 Viscosity of concentrated Syrup Once a day
16 Concentrated Syrup Tank (T-1505), Total solids Once a day

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
3.0.7. TROUBLESHOOTING
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.
Operators should check the heat exchanger condensate levels during their normal,
routine rounds of the evaporator. Operators should also become familiar with the
normal evaporator temperature and pressure profile. Many times variations in the
pressure/temperature profile will be the first indication of an ensuing upset.
Important sources of information are the temperature differences between the heating
elements as these can be an indication of abnormal operation. Adequate performance
of the entire evaporator depends most heavily on maintaining a proper
temperature/pressure distribution profile.
Sr.No. Trouble Cause Corrective Action

1 Low Low condensation / Check condenser operation.
evaporation Vacuum Check Cooling water inlet and
rate outlet temperature of condenser
Check Vacuum Pump operation
and sealing /cooling water
temperature.
Low feed temperature Check the feed temperature
through TI-150904 and
performance of Thin Stillage
Preheater (H-1509 A/B). If
necessary take changeover of
Preheater.
Insufficient steam flow and Check and adjust steam
pressure pressure.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Check Steam saturation or scale

Poor heat transfer across
formation by ensuring
heat exchangers -
evaporator temperature profile.
If required Perform CIP.
Inadequate venting. Check that vent lines are open
and clear. The line should feel
warm, if operating satisfactorily.
Inadequate condensate Check that condensate lines are
removal from heat clear and that valves are set
exchangers satisfactorily. Condensate sight
glasses should run single phase.
Air leakage, particularly into Check for leakage.
steam /vapour side of
Evaporation Effect.
2 High solid Higher solid concentration Check for concentration of inlet
conc. of in feed Thin Stillage.
syrup From Lower feed rate Check the operation of density
heat controller DIC-150601.
exchangers High evaporation rate Reduce steam flow rate.
3 Low solids Low solid concentration in Check for concentration of inlet
conc. Of feed Thin Stillage.
syrup Higher feed rate Check the operation of density
controller DIC-150601.
Low evaporation rate Refer point no.1
4 Scaling or Lack of re-circulation Check restrictions / blockage of
Deposition re-circulation line by checking
on tubes performance of recirculation
Pump.
Higher suspended solids in Remove suspended solids from
feed. feed before feeding to
evaporation. Perform chemical
CIP / Hydro-blasting for
removing scaling on tubes as per
requirement.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Variation in vacuum due to Ensure Temperature/Pressure

steam or condenser water of Cooling water supply.
fluctuations. Check and ensure continuous
steam flow.
Variations in feed supply. Ensure and check the
performance of Feed Pump,
Preheater and Control valve.
5 VLS Transfer pumps throughput Check for air leaks in the suction
flooding capacity line to avoid cavitations.
Check the operation of level
controller.
Check and adjust opening of
vents of evaporators.
Check mechanical seal condition
of the pump.
Check steadiness of system
pressure.
6 Entrainment Overloading of separation Reduce evaporation to specified
due to increased vapour figure by controlling steam flow
rate. rate through steam control
valves.
Check and adjust pressure and
temperature of VLS to specified
value.
Overloading of separation Ensure the Performance of air
caused by too high Bleed Control valve (PCV-
operating vacuum. 150801).
Ensure the vent valves of
Evaporators are sufficiently
open.
Boil over of product due to Ensure steady vacuum
variation in vacuum. conditions during operation of
the plant.
Air leakage Check the evaporator Joints.
Fluctuation in Steam Ensure steady steam pressure.
pressure.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
7 Variation in Fluctuations in steam or Check steam and condenser

vacuum condensing water. water supply conditions. Open
Pressure drop across Mist Spray nozzle valve and clean the
Eliminator increased more Mist eliminator with condensate
than 75 mm WC. till Pressure drop reduced less
than 70 mm WC.
Air leakage Locate leakage as described in
this manual.
Improper operation of Ensure healthiness of vacuum
vacuum pump pump and vacuum control
system

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
PART – IV
PROCESS SHUTDOWN
AND
PROCESS START-UP

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
4.0 GENERAL INSTRUCTIONS

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 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’.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
4.0.1 POWER FAILURE
1. Inform boiler house regarding the stoppage of steam in all sections of the
plant.
2. Close steam flow control valve FCV-150901 LP steam to H-1501/H-1502 in MAN

mode depending on operation status.
3. Close steam flow control valve FCV-150501 LP steam to H-1505/H-1506 in MAN
mode depending on operation status.
4. Evaporation condensate line solenoid valves XV-150101, XV-150201, XV-150301,
XV-150401 will open after circulation pumps gets stopped for spray condensate
over falling films for 2-5 minutes.
5. Close Manual valves on steam line. After stopping Recirculation Pump for FF
Effect - I (P-1501), Falling Film Effect – II (H-1502), Falling Film Effect – III (H-
1503), Falling Film Standby Effect (H-1504), Forced Circulation Effect – I (H-1505),
Forced Circulation Effect – II (H-1506) and Forced Circulation Standby Effect (H-
1507), Steam vent valve (XV-150901, XV-150501) will get opened. Open Manual
Vent Valves on Steam vent line of respective Falling Film Effect and FC Effect.
6. Close Manual valves on Thin Stillage vapour line and non-condensable line after
stopping of Recirculation Pump for FF Effect - I (P-1501), Falling Film Effect – II
(H-1502), Falling Film Effect – III (H-1503), Falling Film Standby Effect (H-1504),
Forced Circulation Effect – I (H-1505), Forced Circulation Effect – II (H-1506) and
Forced Circulation Standby Effect (H-1507).
7. Monitor all tank and vapor liquid separator levels.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
START-UP AFTER RESUMPTION OF POWER
1. Ensure electrical power is available.

2. Ensure DCS is ready.
3. Ensure Distillation section is ready for start-up and accepting the Stillage vapors
from evaporation section.
4. Ensure Air Compressor and the auxiliaries and utilities sections are in ready
condition.
5. Ensure process water and cooling water circuit established.
6. Ensure fresh water to vacuum pump is available, start any evaporation vacuum
pump (P-1513 A/B).
7. Ensure pressure indicator and controller PIC-150801 in AUTO mode.
8. Ensure vacuum system is established in evaporation section.
9. Take and ensure sufficient level of Thin Stillage in respective Vapor liquid
separator for FF Effect – I (V-1501), Vapor Liquid Separator for FF Effect – II (V-
1502), Vapor Liquid Separators for FF Effect - III (V-1503), Vapor Liquid Separators
for FF Standby Effect (V-1504), Vapor Liquid Separators for FC Effect – I (V-1505),
Vapor Liquid Separator for FC Effect – II (V-1506) & Vapor Liquid Separators for
FC Standby Effect (V-1507) through flow totalizer and indicator FQI-151101 under
operating mode.
10. Ensure sufficient level in respective Vapor Liquid Separators for FF Effect - I (V-
1501), Vapor Liquid Separators for FF Effect - II (V-1502), Vapor Liquid Separators
for FF Effect - III (V-1503), Vapor Liquid Separators for FF Standby Effect (V-1504),
Vapor Liquid Separators for FC Effect – I (V-1505), Vapor Liquid Separator for FC
Effect – II (V-1506) & Vapor Liquid Separators for FC Standby Effect (V-1507)
under operating mode. Start respective circulation pumps Recirculation Pump for

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
FF Effect – I (P-1501), Recirculation Pump for FF Effect - II (P-1502), Recirculation

Pump for FF Effect - III (P-1503), Recirculation Pump for FF Standby Effect (P-
1504), Recirculation Pump for FC Effect - I (P-1505), Recirculation pump for FC
Effect – II (P-1506) and Recirculation Pump for FC Standby Effect (P-1507) under
operating mode and establish the circulation.
11. Gradually open steam flow control valve FCV-150901 to respective Falling Film
Effect H-1501/H-1502 in MAN mode as per falling film evaporators operating
Mode.
12. Gradually open steam flow control valve FCV-150501 to respective Forced
Circulation Effect H-1505/H-1506 in MAN mode as per forced circulation
evaporators operating Mode.
13. Ensure flow of steam condensate from respective Falling Film Effect H-1501/H-
1502 and Forced Circulation Effect H-1505/H-1506.
14. Thin Stillage Vapor will start condensing on shell side of Falling Film Effect – II
(H-1502), Falling Film Effect – III (H-1503), Falling Film standby Effect (H-1504),
Forced Circulation Effect – II (H-1506) and Forced Circulation standby Effect (H-
1507) depending upon operating Mode of evaporators.
15. Ensure flow of evaporation condensate from Falling Film Effect – II (H-1502),
Falling Film Effect – III (H-1503), Falling Film standby Effect (H-1504), Forced
Circulation Effect – II (H-1506) and Forced Circulation standby Effect (H-1507)
depending upon operating Mode of evaporators.
16. Ensure level in Process Condensate Tank – 1 (T-1502).
17. Start Process Condensate Pump - 1 (P-1509); ensure level indicator and controller

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
19. Start Process Condensate Pump – 2 (P-1510); ensure level indicator and controller
LIC-150801 in AUTO mode. Take Flow Totaliser and Indicator FQI-150801 in
AUTO mode.
20. Ensure level in Steam Condensate Tank (T-1504).
21. Start Steam Condensate Pump (P-1511). Ensure level indicator and controller LIC-
22. Thin Stillage Vapor will start flowing to Mash Column (C-1401).
23. Gradually increase steam to respective Falling Film Effect H-1501/H-1502. Take
Flow Totaliser Indicator and Controller FQIC-150901 in AUTO mode.
24. Gradually increase steam to respective Forced Circulation Effect H-1505/H-1506.
Take Flow Totaliser Indicator and Controller FQIC-150501 in AUTO mode.
25. Start Concentrated Syrup Transfer Pump (P-1512) based on the syrup flow path
status. And line out Concentrated Syrup to Concentrated Syrup Tank (T-1505).
26. Ensure Density Indicator and Controller DIC-15601 is in AUTO mode with Flow
Totaliser Indicator and Controller FQIC-150601 in CAS mode.
27. Monitor Vacuum and level in evaporators.
28. Establish Thin Stillage Feed Tank (T-1501), Concentrated Syrup Tank (T-1505) and
CIP Tank (T-1506) tank circulation.
29. Start Concentrated Syrup Pump (P-1514A/B). Ensure Level Indicator and
Controller LIC-151101 in AUTO mode.
30. Maintain all parameters are as per standard operating parameters mentioned in
section “3.0.3 PROCESS PARAMETERS” of this manual.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
4.0.2 COOLING WATER FAILURE

1. The cooling water is the most important utility of the plant. Plant to be safely
shutdown during the cooling water failure.
2. Inform boiler house regarding the stoppage of steam in all sections of the plant.
3. Take steam flow control valve FCV-150901 in MAN mode and close to zero
position.
position.
5. Stop thin Stillage feed to respective Vapor Liquid separator for FF Effect – I (V-
1501), Vapor Liquid separator for FF Effect – II (V-1502), Vapor Liquid separator
for FF Effect – III (V-1503), Vapor Liquid separator for FF Standby Effect (V-1504),
Vapor Liquid separator for FC Effect – I (V-1505), Vapor Liquid separator for FC
Effect – II (V-1506) and Vapor Liquid Separator for FC Standby Effect (V-1507)
under operating mode through flow Totalizer and indicator FQI-151101.
6. Ensure respective Recirculation pump for FF Effect – I (P-1501), Recirculation
pump for FF Effect – II (P-1502), Recirculation pump for FF Effect – III (P-1503),
Recirculation pump for FF Standby Effect (P-1504), Recirculation pump for FC
Effect – I (P-1505), Recirculation pump for FC Effect – II (P-1506) and Recirculation
pump for FC Standby Effect (P-1507) are in operation as per operating mode.
7. Ensure Evaporation Vacuum pump (P-1513A/B) is in running and Pressure
Indicator and controller PIC-150801 in AUTO mode.
8. Monitor all tank and vapor liquid separator levels.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
START UP AFTER RESUMPTION OF COOLING WATER

3. Ensure distillation section is ready.
condition.
5. Ensure process water and cooling water circuit is established.
6. Ensure respective evaporation vacuum pump (P-1513 A/B) is under operation and
vacuum system is established in evaporation section.
8. Take sufficient level of Thin Stillage in respective Vapor liquid separator for FF
Effect – I (V-1501), Vapor Liquid Separator for FF Effect – II (V-1502), Vapor Liquid
Separators for FF Effect - III (V-1503), Vapor Liquid Separators for FF Standby
Effect (V-1504), Vapor Liquid Separators for FC Effect – I (V-1505), Vapor Liquid
Separator for FC Effect – II (V-1506) & Vapor Liquid Separators for FC Standby
Effect (V-1507) through flow totalizer and indicator FQI-151101 under operating
mode.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.

Mode.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
AUTO mode.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
4.0.3 STEAM SUPPLY FAILURE

position.
position.
3. Monitor all the evaporation effect and tank levels.
4. Stop respective thin Stillage feed to Vapor Liquid separator for FF Effect – I (V-
1501), Vapor Liquid separator for FF Effect – II (V-1502), Vapor Liquid separator
for FF Effect – III (V-1503), Vapor Liquid separator for FF Standby Effect (V-1504),
Vapor Liquid separator for FC Effect – I (V-1505), Vapor Liquid separator for FC
under operating mode through flow totalizer and indicator FQI-151101.
9. Ensure Evaporation Vacuum pump (P-1513A/B)is in running and Pressure
Indicator and controller PIC-150801 in AUTO mode.
10. Monitor all tank and vapor liquid separator levels

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
START UP AFTER RESUMPTION OF STEAM

3. Ensure distillation section is ready.
condition.
5. Ensure process water and cooling water circuit is established.
6. Ensure respective evaporation vacuum pump (P-1513 A/B) is under operation and
vacuum system is established in evaporation section.
mode.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.

Mode.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
AUTO mode.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
4.0.4 INSTRUMENT AIR FAILURE

During instrument air failure condition of 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 exchanges to be adjusted if required.
Due to failure of control valves steam to all 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. Inform boiler house regarding the stoppage of steam in all sections of the plant.
2. Take steam flow control valve FCV-150901 in MAN mode and change set point to
zero.
3. Take steam flow control valve FCV-150501 in MAN mode and change set point to
zero.
4. Monitor all the evaporation effect and tank levels.
5. Ensure and stop thin Stillage feed to respective Vapor Liquid separator for FF
Effect – I (V-1501), Vapor Liquid separator for FF Effect – II (V-1502), Vapor Liquid
separator for FF Effect – III (V-1503), Vapor Liquid separator for FF Standby Effect
(V-1504), Vapor Liquid separator for FC Effect – I (V-1505), Vapor Liquid separator
for FC Effect – II (V-1506) and Vapor Liquid Separator for FC Standby Effect (V-
1507) under operating mode through flow totalizer and indicator FQI-151101.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.

7. Ensure Evaporation Vacuum pump (P-1513A/B) is in running. Monitor vacuum in
evaporation section.
START UP AFTER RESUMPTION OF INSTRUMENT AIR

1. Ensure electrical power is available
3. Ensure distillation section is ready
condition
5. Ensure instrument air header is charged.
6. Ensure steam header is charged.
7. Ensure process water and cooling water circuit is established
8. Ensure required solenoid valves in evaporation section are opened.
9. Establish vacuum circuit for evaporation section and take pressure indicator and
controller PIC-150801 is in AUTO mode.
10. Ensure Thin Stillage Preheater (H-1509A/B) is set up to accept steam condensate
and thin Stillage.
11. Ensure Treated Process Condensate Preheater (H-1510) is set up to accept process
condensate and UF permeate.
12. Take sufficient level of Thin Stillage in respective in Vapor liquid separator for FF

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
mode.
Mode.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
level indicator and controller LIC-150801 in AUTO mode. Take Flow Totaliser and
Indicator FQI-150801 in AUTO mode.
27. Gradually increase steam to H-1505/H-1506. Take Flow Totaliser Indicator and
Controller FQIC-150501 in AUTO mode.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.


PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
4.1 PLANT SHORT SHUTDOWN & START UP AFTER 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.
In this SOP 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 where it is necessary to empty out the
tanks.
Based on the leading factor for plant shut down, operator has to take appropriate and
safe actions accordingly.
4.1.1 PLANT SHORT SHUTDOWN

This mode is to be activated if plant has to close down for small period. It is not
desired that plant activity should be completely stopped in this mode. By selecting
this mode following steps should take place:
1. Inform boiler house regarding the stoppage of steam to the plant.
2. Inform distillation section operator.
3. Start reducing steam to respective Falling Film Effect H-1501/H-1502 gradually by
taking Flow Totaliser Indicator and Controller FQIC-150901 in MAN mode.
4. Start reducing steam to respective Forced Circulation Effect H-1505/H-1506
gradually by taking Flow Totaliser Indicator and Controller FQIC-150501 in MAN
mode.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
5. Stop Thin Stillage feed to respective Vapor Liquid Separator for FF Effect – I (V-
1501), Vapor Liquid Separator for FF Effect – II (V-1502), Vapor Liquid Separator
for FF Effect – III (V-1503), Vapor Liquid Separator for FF Standby Effect (V-1504),
Vapor Liquid Separator for FC Effect – I (V-1505), Vapor Liquid Separator for FC
6. Keep running all respective evaporation recirculation pumps ( Falling Film Effect –
I (H-1501), Falling Film Effect – II (H-1502), Falling Film Effect – III (H-1503),
Falling Film Standby Effect (H-1504), Forced Circulation Effect – I (H-1505), Forced
Circulation Effect – II (H-1506) and Forced Circulation Standby Effect (H-1507)) as
per operating mode.
7. Keep Evaporation vacuum pump (P-1513A/B) running, if it is necessary to stop
vacuum pump, stop vacuum pump after 1 hrs of stopping steam to evaporation
section.
8. Keep cooling water system running, as it is required.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
4.1.2 PLANT START UP AFTER SHORT SHUTDOWN

1. Ensure plant inventory suitable for start up of evaporation section.
2. Ensure power is available.
3. Ensure instrument air is ready.
4. Ensure cooling water circuit established.
5. Ensure steam headers are charged.
6. Ensure all other required utilities are ready to start evaporation section.
7. Inform boiler house regarding plant start up.
8. Inform distillation section for plant start-up.
9. Ensure evaporator circulation pumps are running and all level controllers are in
AUTO mode.
10. Establish vacuum circuit for evaporation section and take pressure indicator and
controller PIC – 150801 is in AUTO mode.
mode.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Mode.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.

LIC-150801 in AUTO mode. Take FQI-150801 in AUTO mode.
24. Thin Stillage Vapor will start flowing to Mash Column (C-1401) through FQIC -
150401.
31. Start Concentrated Syrup Pump (P-1514A/B). Ensure level indicator and controller

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

DURATION SHUTDOWN
Long duration shut down is generally planned shutdown for any reason there are
some planned maintenance jobs, which are to be carried out during shut down;
jobs like hot jobs, vessel entries, and cold jobs too.
4.2.1 PLANT LONG DURATION SHUTDOWN
Following are the steps involved while taking long duration shutdown
1. First of all make shutdown planning with respect to Fermentation, Distillation,

Evaporation, decantation and Dehydration sections. This is important because
after shutdown there should be no fermented mash lying in the Fermentation
section. Fermented mash should be consumed completely.
2. Inform boiler house regarding stoppage of steam to the plant.
3. As per the clearance from boiler house stop steam to respective Falling Film Effect
H-1501/H-1502 by closing flow control valve FCV-150901 in MAN mode.
4. Stop respective Thin Stillage feed to Vapor Liquid Separator for FF Effect – I (V-
1501), Vapor Liquid Separator for FF Effect – II (V-1502), Vapor Liquid Separator
for FF Effect – III (V-1503), Vapor Liquid Separator for FF Standby Effect (V-1504),
Vapor Liquid Separator for FC Effect – I (V-1505), Vapor Liquid Separator for FC
5. Keep running all respective Recirculation pump for FF Effect – I (P-1501),
Recirculation pump for FF Effect – II (P-1502), Recirculation pump for FF Effect –

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
III (P-1503), Recirculation pump for FF Standby Effect (P-1504), Recirculation

pump for FC Effect – I (P-1505), Recirculation pump for FC Effect – II (P-1506) and
Recirculation pump for FC Standby Effect (P-1507)
6. After ensuring evaporation system is cool enough to stop circulation pumps, close
discharge valve of all recirculation pumps and stop Recirculation pump for FF
Effect – I (P-1501), Recirculation pump for FF Effect – II (P-1502), Recirculation
pump for FF Effect – III (P-1503), Recirculation pump for FF Standby Effect (P-
1504), Recirculation pump for FC Effect – I (P-1505), Recirculation pump for FC
Effect – II (P-1506) and Recirculation pump for FC Standby Effect (P-1507)).
7. Empty out Vapor Liquid Separator for FF Effect – I (V-1501), Vapor Liquid
Separator for FF Effect – II (V-1502), Vapor Liquid Separator for FF Effect – III (V-
1503), Vapor Liquid Separator for FF Standby Effect (V-1504), Vapor Liquid
Separator for FC Effect – I (V-1505), Vapor Liquid Separator for FC Effect – II (V-
1506) and Vapor Liquid Separator for FC Standby Effect (V-1507) through CIP
Drain Pump (P-1516) and transferred to CIP Tank (T-1506) or Thin Stillage Feed
Tank (T-1501) or Concentrated Syrup Tank (T-1505) based on its density or based
on duration of shutdown.
9. Stop Process Condensate Pump - 1 (P-1509); Take LIC-151001 in MAN mode.
11. Stop Process Condensate Pump – 2 (P-1510); Take LIC-150801 & FQI-150801 in
MAN mode.
13. Stop Steam Condensate Pump (P-1511). Take level indicator and controller LIC-
150901 in MAN mode.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
14. Close all manual valves on steam header to all users. Stop steam to the plant. Drain
all steam headers by opening respective bypass valves on steam traps.
15. Stop Evaporation Vacuum Pump (P-1513A/B) after 2 hrs after stopping steam to
evaporation plant.
16. Stop cooling water to individual users and stop cooling water pumps after 1 hrs
after stopping vacuum pumps.
17. Open air bleed valves on pressure control valve PCV-150801 and break the
vacuum completely. Close air bleed valve after ensuring the system equalization
with atmosphere.
18. Close manual valves on sealing water to respective pumps.
19. Stop instrument air compressor.
20. Drain the whole system. Drain the cooling water holdup.
Note:-
If it is necessary to have completed shut down of the plant and all tanks needs
to be emptied out.
If the plant shutdown is planned more than 1 month it is advisable to drain
cooling waterside of heat exchangers by opening dummy flanges.
Break the vacuum completely and equalizing with atmosphere Pressure.
Empty out all tanks in evaporation section.
Perform CIP for Plate type heat exchanger and evaporator.
Flush all lines with water and drain completely and open the all pumps and
evaporator drain valve.
Ensure all tanks / PHEs / lines emptied out completely.
Isolate all equipment by manual valves.
All safety norms to be follow before starting any hot / cold job after plant 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 evaporation section.

2. Ensure power is available.
3. Ensure instrument air is ready.
4. Ensure Distillation section is ready for start-up.
5. Ensure sufficient process water is available for start-up.
6. Ensure cooling water circuit established.
7. Ensure water flushing is completed as per pre-start up activities.
8. Ensure vacuum trial is completed as per pre-start up activities.
9. Ensure steam headers charged.
10. Ensure all other required utilities are ready to start evaporation section.
11. Inform boiler house regarding plant start up.
12. Ensure evaporator circulation pumps are running and all level controllers are
in AUTO mode.
13. Establish vacuum circuit for evaporation section and take pressure indicator
and controller PIC – 150801 is in AUTO mode.
14. Take and ensure sufficient level of Thin Stillage/water in respective Vapor
liquid separator for FF Effect – I (V-1501), Vapor Liquid Separator for FF Effect
– II (V-1502), Vapor Liquid Separators for FF Effect - III (V-1503), Vapor Liquid
Separators for FF Standby Effect (V-1504), Vapor Liquid Separators for FC
Effect – I (V-1505), Vapor Liquid Separator for FC Effect – II (V-1506) & Vapor
Liquid Separators for FC Standby Effect (V-1507) through flow totalizer and
indicator FQI-151101 under operating mode.
15. Ensure sufficient level in respective Vapor Liquid Separators for FF Effect - I
(V-1501), Vapor Liquid Separators for FF Effect - II (V-1502), Vapor Liquid

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
Effect (V-1504), Vapor Liquid Separators for FC Effect – I (V-1505), Vapor
Liquid Separator for FC Effect – II (V-1506) & Vapor Liquid Separators for FC
Standby Effect (V-1507) under operating mode. Start respective circulation
pumps Recirculation Pump for FF Effect – I (P-1501), Recirculation Pump for FF
Effect - II (P-1502), Recirculation Pump for FF Effect - III (P-1503), Recirculation
Pump for FF Standby Effect (P-1504), Recirculation Pump for FC Effect - I (P-
1505), Recirculation pump for FC Effect – II (P-1506) and Recirculation Pump
for FC Standby Effect (P-1507) under operating mode and establish the
circulation.
Mode.
18. Ensure flow of steam condensate from respective Falling Film Effect H-
1501/H-1502 and Forced Circulation Effect H-1505/H-1506.
19. Thin Stillage Vapor will start condensing on shell side of Falling Film Effect –
II (H-1502), Falling Film Effect – III (H-1503), Falling Film standby Effect (H-
1504), Forced Circulation Effect – II (H-1506) and Forced Circulation standby
Effect (H-1507) depending upon operating Mode of evaporators.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.

22. Start Process Condensate Pump - 1 (P-1509); ensure level indicator and
controller LIC-151001 in AUTO mode.
24. Start Process Condensate Pump – 2 (P-1510); ensure level indicator and
controller LIC-150801 in AUTO mode. Take FQI-150801 in AUTO mode.
26. Start Steam Condensate Pump (P-1511). Ensure level indicator and controller
27. Thin Stillage Vapor will start flowing to Mash Column (C-1401) through FQIC -
150401.
28. Gradually increase steam to respective Falling Film Effect H-1501/H-1502.
29. Gradually increase steam to respective Forced Circulation Effect H-1505/H-
1506. Take Flow Totaliser Indicator and Controller FQIC-150501 in AUTO
mode.
31. Ensure Density Indicator and Controller DIC-15601 is in AUTO mode with
Flow Totaliser Indicator and Controller FQIC-150601 in CAS mode.
33. Establish Thin Stillage Feed Tank (T-1501), Concentrated Syrup Tank (T-1505)
and CIP Tank (T-1506) tank circulation.

PROJECT REV. ISSUE
NO. NO. DATE
VICENTIN
S.A.I.C.
34. Start Concentrated Syrup Pump (P-1514A/B). Ensure level indicator and
controller LIC-151101 in AUTO mode.
section “3.0.3 PROCESS PARAMETERS” of this manual..
-------------------XXXX------------------

N-10012-4-OPM-1501-0 Operation and Maintenance Manual Evaporation Section PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

N-10012-4-OPM-1501-0 Operation and Maintenance Manual Evaporation Section PDF

Uploaded by

Copyright:

Available Formats

OPERATION AND MAINTENANCE 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-OPM1501

0 05.11..2012 SSK/SAJ PKR/SBG VBJ FOR EXCECUTION

OPERATION AND MAINTENANCE MANUAL EVAPORATION SECTION.

a) the specifications and data provided by the recipient,

OPERATION AND MAINTENANCE MANUAL EVAPORATION SECTION.

SR.NO. CONTENTS PAGE NO.

PART – I THEORETICAL ASPECTS

1.0.1 Theory of Evaporation 09

1.0.2 Process Description 16

1.0.3 Control Logic & Interlock Description 34

1.0.4 Equipment Description 35

1.0.5 List of Pressure Safety Valves 41

PART–II PRE-START-UP ACTIVITIES

2.0 GENERAL INSTRUCTIONS 43

2.0.1 SOP for establishment of cooling water circuit 47

2.0.2 SOP for charging low-pressure steam 48

2.0.3 Water Flushing/Cold Water Trial 49

2.0.4 Vacuum Trial 60

2.0.5 Steam Trial 67

PART – III PROCESS START-UP AND PROCESS PARAMETERS

3.0 GENERAL INSTRUCTIONS 83

3.0.1 Safety Notes 84

3.0.2 Normal Start-up 85

OPERATION AND MAINTENANCE MANUAL EVAPORATION SECTION.

SR.NO. CONTENTS PAGE NO.

3.0.3 Process Parameters 88

3.0.4 Cleaning in Place (CIP) 95

3.0.4.c SOP for CIP of Falling Film Effect – I (H-1501) 97

3.0.4 d SOP for CIP of Falling Film Effect – II (H-1502) 99

3.0.4 g SOP for CIP of Forced Circulation Effect – I (H-1505) 106

3.0.4 h SOP for CIP of Forced Circulation Effect – II (H-1506) 108

3.0.5 Process Monitoring 112

3.0.6 Frequency of Routine Analysis 113

3.0.7 Troubleshooting 115

PART – IV PROCESS SHUTDOWN & PROCESS START-UP

4.0 GENERAL INSTRUCTIONS 120

OPERATION AND MAINTENANCE MANUAL EVAPORATION SECTION.

SR.NO. CONTENTS PAGE NO.

4.0.1 Power Failure 121

4.0.2 Cooling Water Failure 125

4.0.3 Steam Supply Failure 129

4.0.4 Instrument Air Failure 133

4.1.1 Plant Short Shutdown 138

4.1.2 Plant Start-up after Short Shutdown 140

4.2.1 Plant Long Duration Shutdown 143

4.2.2 Plant Start-up after Long Duration Shutdown 146

OPERATION AND MAINTENANCE MANUAL EVAPORATION SECTION.

OPERATION AND MAINTENANCE MANUAL EVAPORATION 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

OPERATION AND MAINTENANCE MANUAL EVAPORATION SECTION.

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

OPERATION AND MAINTENANCE MANUAL EVAPORATION SECTION.

1.0.1 THEORY OF EVAPORATION

LIQUID BOXES - serve as channels to distribute feed to all of the tubes.