A

Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC-SOP-2006 Page1 of 4

Title: Control Plan for Line 4 East Wet Scrubber System

 ROCKDALE OPERATIONS - SMELTING AND INGOT PAGE 1 OF 3

 Document Number: PMT-SOP-2006

 Title: Control Plan For Line 4 East Wet Scrubber System

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

Print Date/Time 5/27/20116/9/20046/9/20042/7/20032/6/2003 9:09 AM1:39 PM8:01 AM2:31 

PM2:16 PM2:12 PM

Special Hazards: Failure to follow procedures correctly and maintain proper equipment 

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.

Formatted

Formatted

Formatted
A

Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC-SOP-2006 Page2 of 4

Title: Control Plan for Line 4 East Wet Scrubber System

 ROCKDALE OPERATIONS - SMELTING AND INGOT PAGE 1 OF 3

 Document Number: PMT-SOP-2006

 Title: Control Plan For Line 4 East Wet Scrubber System

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

Print Date/Time 5/27/20116/9/20046/9/20042/7/20032/6/2003 9:09 AM1:39 PM8:01 AM2:31 

PM2:16 PM2:12 PM

PROCEDURE TO:

Control Fan Amps

Water Flow

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 

. Minimum 200 Amps, Normal 250 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 

. Minimum 179 GPM, Normal 222 GPM

pH Operating Range

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

 
A

Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC-SOP-2006 Page3 of 4

Title: Control Plan for Line 4 East Wet Scrubber System

 ROCKDALE OPERATIONS - SMELTING AND INGOT PAGE 1 OF 3

 Document Number: PMT-SOP-2006

 Title: Control Plan For Line 4 East Wet Scrubber System

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

Print Date/Time 5/27/20116/9/20046/9/20042/7/20032/6/2003 9:09 AM1:39 PM8:01 AM2:31 

PM2:16 PM2:12 PM

PROCEDURE TO:

Control Fan Amps

Water Flow

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

. Exercise 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.

 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 bag drops 

 to be normal and dirty bag detector to be below 100. 

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.
A

Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC-SOP-2006 Page4 of 4

Title: Control Plan for Line 4 East Wet Scrubber System

 ROCKDALE OPERATIONS - SMELTING AND INGOT PAGE 1 OF 3

 Document Number: PMT-SOP-2006

 Title: Control Plan For Line 4 East Wet Scrubber System

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

Print Date/Time 5/27/20116/9/20046/9/20042/7/20032/6/2003 9:09 AM1:39 PM8:01 AM2:31 

PM2:16 PM2:12 PM

 Dust Collecting Hoppers

Operating Range 

. Empty or near empty.

Measurement Method

. Manual tapping everyday and ensuring proper hopper controls and dust 

 collection.

Control Method

. Vacuum every 48 hours for 13D1.

Consequences of Deviation

. Dust backs up into baghouse filters which leads to filter damage and high outlet 

 emissions. 

Corrective Action

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

PROCEDURE TO:

Control Fan Amps

Water Flow

Outlet Emissions

Dust Collecting Hoppers

(continued)