ROCKDALE OPERATIONS - SMELTING AND INGOT PAGE 1 OF 4

 Document Number: PMT-SOP-2005

 Title: Control Plan For Line 3 Wet Scrubber System

A

Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC-SOP-2005 Page1 of 6

Title: Control Plan for Line 3 Wet Scrubber System

Controlled Document if Viewed On-Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/20116/9/20046/8/20042/6/20032/5/2003 9:08 AM1:35 PM3:41 PM1:57 

PM1:25 PM12:59 PM12:23 PM

Special Hazards: FAILURE TO FOLLOW PROCEDURES CORRECTLY AND MAINTAIN 

 PROPER EQIPMENT PARAMETRICS MAY RESULT IN EQUIPMENT 

 DAMAGE AND/OR A MACT PARAMETRIC EXCEEDANCE.

Significant 

Environmental 

Aspect:

Following this procedure will ensure that proper steps are taken to decrease adverse 

impacts to the environment. 

PREPARATION

TAG & LOCK

TRY

 . ALWAYS FOLLOW THE PROPER TAG, LOCK AND TRY PROCEDURE 

 WHEN PERFORMING MAINTENANCE REPAIRS AND/OR 

 REPLACEMENTS WHERE APPLICABLE.

CONFINED SPACE: . ALWAYS FOLLOW THE PROPER CONFINE SPACE ENTRY PROCEDURE

WHEN PERFORMING MAINTENANCE REPAIRS AND/OR

REPLACEMENTS WHERE APPLICABLE.
 ROCKDALE OPERATIONS - SMELTING AND INGOT PAGE 1 OF 4

 Document Number: PMT-SOP-2005

 Title: Control Plan For Line 3 Wet Scrubber System

A

Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC-SOP-2005 Page2 of 6

Title: Control Plan for Line 3 Wet Scrubber System

Controlled Document if Viewed On-Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/20116/9/20046/8/20042/6/20032/5/2003 9:08 AM1:35 PM3:41 PM1:57 

PM1:25 PM12:59 PM12:23 PM

PROCEDURE TO:

Control Fan Amps

Water Flow

ESP’s

Outlet Emissions

Dust Collecting Hoppers

NOTE: All Potroom Fume Control MACT parametric alarms must be acknowledged 

within one hour of the time the alarm was initiated. All MACT exceedances and 

malfunctions must be reported and documented within one hour of the initial 

identification. If any inspections and/or repairs are to be made, use all required tag, 

lock, try and confine space entry procedures 

where applicable.

 Fan Amps (MACT Parameter)

Operating Range ESP’S 

. Minimum 129 Amps, Normal 161 Amps

Operating Range 13D1 

. Minimum 177 Amps, Normal 222 Amps

Measurement Method

. Amp signal is indicated on computer control screen (Wonderware) and on a field 

 display (Panelview and analog meter)

. MACT compliance data values are indicated on computer screen (Access) and 

 values and trends are indicated on computer control screen (Wonderware).

Control Method

. Ensure fan damper is positioned for proper MACT parametric requirements.

Consequences of Deviation

. Below minimum parametrics can cause low potdraft, high potline roof emissions 

 and MACT parametric exceedances.

Corrective Action

. Exercise or open damper to keep within required MACT parametric values. 

 Report problems to supervision. Refer to MACT Reaction Plan SOP’s for required 

 fan amps. If control device is below MACT compliance start another or an 

 additional fan(s).

 

 Water Flow (MACT Parameter) And pH Level

GPM Operating Range ESP’S 

. Minimum 176 GPM, Normal 220 GPM

GPM Operating Range 13D1 

. Minimum 188 GPM, Normal 235 GPM

pH Operating Range

. 8-10 at basin, 10-12 at clearwell

 
 ROCKDALE OPERATIONS - SMELTING AND INGOT PAGE 1 OF 4

 Document Number: PMT-SOP-2005

 Title: Control Plan For Line 3 Wet Scrubber System

A

Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC-SOP-2005 Page3 of 6

Title: Control Plan for Line 3 Wet Scrubber System

Controlled Document if Viewed On-Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/20116/9/20046/8/20042/6/20032/5/2003 9:08 AM1:35 PM3:41 PM1:57 

PM1:25 PM12:59 PM12:23 PM

PROCEDURE TO:

Control Fan Amps

Water Flow

ESP’s

Outlet Emissions

Dust Collecting Hoppers

(continued)

Measurement Method

. GPM signal is indicated on computer control screen (Wonderware) and on a 

 field display (Panelview and Panametric meter). PH signal is indicated on 

 computer control screen (Wonderware) and field pH meter.

. MACT Compliance data values are indicated on computer screen (Access) and 

 values and trends are indicated on computer control screen (Wonderware). 

Control Method

. Ensure water valves are positioned for proper MACT parametric requirements. 

 Ensure correct amounts of lime for proper pH levels. 

Consequences of Deviation

. Below minimum parametrics can cause high outlet emissions and MACT 

 parametric exceedances. High and low levels of pH can cause inadequate 

 scrubbing and excess solids which leads to build-up.

Corrective Action

. Excersise or open header valves to keep within required MACT parametric 

 values. 

 Always leave the main valve fully open. Report problems to supervision. Refer 

 to MACT Reaction Plan SOP’s for required fan amps. If control device is 

 below MACT compliance start another or an additional scrubber(s). Monitor 

 lime slaker operation and controls.

 ESP Primary Voltage (MACT Parameter)

Operating Range 

. Minimum 140 Volts, No Normal

Measurement Method

. Volt signal is indicated on computer control screen (Wonderware), on a field 

 BHA controller and an analog meter.

. MACT Compliance data values are indicated on computer screen (Access) and 

 values and trends are indicated on computer control screen (Wonderware). 

Control Method

. Ensure precipitator is on and primary voltage is above the required MACT 

 parametric minimum.

Consequences of Deviation

. Below minimum parametrics can cause high outlet emissions and MACT 

 parametric exceedances. 

 
 ROCKDALE OPERATIONS - SMELTING AND INGOT PAGE 1 OF 4

 Document Number: PMT-SOP-2005

 Title: Control Plan For Line 3 Wet Scrubber System

A

Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC-SOP-2005 Page4 of 6

Title: Control Plan for Line 3 Wet Scrubber System

Controlled Document if Viewed On-Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/20116/9/20046/8/20042/6/20032/5/2003 9:08 AM1:35 PM3:41 PM1:57 

PM1:25 PM12:59 PM12:23 PM
 ROCKDALE OPERATIONS - SMELTING AND INGOT PAGE 1 OF 4

 Document Number: PMT-SOP-2005

 Title: Control Plan For Line 3 Wet Scrubber System

A

Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC-SOP-2005 Page5 of 6

Title: Control Plan for Line 3 Wet Scrubber System

Controlled Document if Viewed On-Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/20116/9/20046/8/20042/6/20032/5/2003 9:08 AM1:35 PM3:41 PM1:57 

PM1:25 PM12:59 PM12:23 PM

PROCEDURE TO:

Control Fan Amps

Water Flow

ESP’s

Outlet Emissions

Dust Collecting Hoppers

(continued)

Corrective Action

. Ensure dust collecting hoppers to be empty and call supervision to have 

 cleaned. If below minimum is still present call supervision for an I@E 

 technician. If control device is below MACT compliance start another or an 

 additional precipitator(s).

 

 ESP Primary Voltage (MACT Parameter)

Operating Range 

. 140 Volts, No Normal

 ESP Secondary Current (MACT Parameter)

Operating Range 

. Minimum 10 mAMPS, No9.66 mAmps, No Normal

Measurement Method

. Milliamp signal is indicated on computer control screen (Wonderware), on a 

 field BHA controller and an analog meter.

. MACT Compliance data values are indicated on computer screen (Access) and 

 values and trends are indicated on computer control screen (Wonderware). 

Control Method

. Ensure precipitator is on and secondary current is above the required MACT 

 parametric minimum.

Consequences of Deviation

. Below minimum parametrics can cause high outlet emissions and MACT 

 parametric exceedances.

Corrective Action

. Ensure dust collecting hoppers to be empty and call supervision to have 

 cleaned. If below minimum is still present call supervision for an I@E

 technician. If control device is below MACT compliance start another or an 

 additional precipitator(s).

 Outlet Emissions

Operating Range 

. Dry and white to off-white color.

Measurement Method

. Daily visible inspection per SOP.

Control Method

. Initiate corrective action per SOP. Ensure water GPM to not be above set 

 maximum value. Ensure ESP to be in operation with primary voltage and 

 secondary current above the MACT parametric minimum. Ensure 13D1bag 

 drops to be normal and dirty bag detector to be below 100. 
 ROCKDALE OPERATIONS - SMELTING AND INGOT PAGE 1 OF 4

 Document Number: PMT-SOP-2005

 Title: Control Plan For Line 3 Wet Scrubber System

A

Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC-SOP-2005 Page6 of 6

Title: Control Plan for Line 3 Wet Scrubber System

Controlled Document if Viewed On-Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/20116/9/20046/8/20042/6/20032/5/2003 9:08 AM1:35 PM3:41 PM1:57 

PM1:25 PM12:59 PM12:23 PM

Consequences of Deviation

. Abnormal emissions is an indication high gaseous and/or particulates.

Corrective Action

. Initiate corrective action. Refer to MACT Reaction Plan SOP for visible 

 emissions.

 Dust Collecting Hoppers

Operating Range 

. Empty or near empty.

Measurement Method

. Manual tapping everyday and ensuring proper hopper controls and dust 

 collection.

Control Method

. DPU system operating for ESP’s. 

Consequences of Deviation

. Dust backs up into ESP direct current power wires and plates causing a short 

 which leads to low parametric values causing high outlet emissions and MACT 

 parametric exceedances. 

Corrective Action

. Ensure dust collecting hoppers to be empty and call supervision to have cleaned. 

PROCEDURE TO:

Control Fan Amps

Water Flow

ESP’s

Outlet Emissions

Dust Collecting Hoppers

(continued)