# A Rockdale Operations Standard Operating Procedure

Department Name: Engineering, Maintenance & Construction

Document Number: EMC

- SOP

- 2006 Page 1 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 Scr ubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/9/2004 6/9/2004 2/7/2003 2/6/2003 9:09 AM 1:39 PM 8:01 AM 2:31

PM 2:16 PM 2:12 PM Special Hazards: Failure to follow procedures correctly and maintain proper eq u ipment

parametrics may result in equipment damage and/or a MACT parametric

exceedance

Significant

Environmental

Aspect: Following this procedure will ensure that proper ste ps 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 Page 2 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 Scr ubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/9/2004 6/9/2004 2/7/2003 2/6/2003 9:09 AM 1:39 PM 8:01 AM 2:31

PM 2:16 PM 2:12 PM PROCEDURE TO:

Control Fan Amps

Water Flow

Outlet Emissions

Dust Collecting Hoppers NOTE: All Pot room 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 inspe ctions 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

Measureme nt 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 com puter 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 par ametric 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 co mpliance 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 Page 3 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 Scr ubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/9/2004 6/9/2004 2/7/2003 2/6/2003 9:09 AM 1:39 PM 8:01 AM 2:31

PM 2:16 PM 2:12 PM PROCEDURE TO:

Control Fan Amps

Water Flow

Outlet Emissions

Dust Collecting Hoppers

(continued) Measurement Method

. GPM signal is i ndicated 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 comput er 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 leve ls.

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 devi ce 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.

Measure ment 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 th e 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 actio n. 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 Page 4 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 Scr ubber System



### Controlled Document if Viewed On

- Line. If Printed, Valid for 24 Hours from Print Date/Time.

Print Date/Time 5/27/2011 6/9/2004 6/9/2004 2/7/2003 2/6/2003 9:09 AM 1:39 PM 8:01 AM 2:31

PM 2:16 PM 2:12 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

. Vacuu m 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 c leaned. PROCEDURE TO:

Control Fan Amps

Water Flow

Outlet Emissions

Dust Collecting Hoppers

( continued)