K
M OPERATING MANUAL FOR
DEGUMMING
I SECTION
K U M A R M E TA L I N D U S T R I E S
A N I S O 9 0 0 1 - 2 0 0 0 C O M PA N Y
PLOT NO-7, MIRA CO-OP IND
E S TAT E , W. E X P H I G H W AY, M I R A , D I S T -
T H A N E 4 0 1 1 0 4 ( IPage
KUMAR METAL INDUSTRIES N D1I A )
Water Degumming:
The oil is delivered to the system by the Feed Pump via
Economizer or feed heater where it is heated to 65 – 75o C
and this oil is mixed with pre calculated quantity of soft
water in an inline mixer. Oil water mixture is fed to the
hydration tank to give sufficient residence time for
hydratable gums to Condition or agglomerate. This mixture
of water & soya oil is then pumped to separator where the
oil and hydrated gums are separated. The separated gums
are collected to gum tank and transfer to the storage.
Vacuum drying:
Washed oil is fed continuously to the Vacuum dryer and
sprayed through specially designed nozzles. The vacuum
dryer is kept under a vacuum of 60 torr. The dried oil from
the vacuum chamber is continuously pumped out by
pump to send in bleaching section.
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STARTING UP
NOTE
1. Check speed setting of mixture :
A. Set speed according to instruction in special recommendation.
B. Two speed or single speed electric motors, vibrators depending on
design.
2. Ensure that there is hot water in process water tank (T-131)
3. Process water:
A. Start the process water pump P-131.
B. Open the service water valve at the inlets to the separator (S-101) and
open valves for bowl flushing water in the neutralization.
C. Switch on control voltage to the Slop oil pump P-106.
4. Separator: Start the separator according to operating routines.
5. Vacuum system: Start the vacuum in good time so that there is vacuum
when the plant produces oil.
6. Separator: When the separator have attained full speed and are ready for
production open the inlet valves for oil & close the service water valves.
7. Stand by: THE PLANT IS NOW IN STAND BY MODE READY TO
RECEIVE OIL.
UTILITY
1. Check the steam pressure at PRS header (2-3 / cm2)
2. If the pressure is not in desired range of 2-3 kg/ cm2 than adjust the PRV as
per the instruction manuals for PRS.
3. Ensure that there is uninterrupted supply of clean cooling water for seal
flushing of separators.
4. Standby arrangement for supply water should be made for emergency
requirement in case of of power failure.
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DEGUMMING
1. Ensure that adequate in hot water is available in hot water T131.
2. Check that steam at correct pressure (3 bar g) is available.
3. Ensure that there is uninterrupted supply of process (cold) water.
4. Open the valve (TCV-131) in the steam inlet line to T 131 and heat the water
to 85 – 90C.
5. After keeping crude oil in the main thank in recirculation for at least 45
minutes start pumping oil to T 001 or T 002.(Oil feed tank) After taking
full charge of oil in T001 or T002, When the oil level reaches the lowest
blade start the agitator of the T 001 or T 002.
6. Start pump P 101 and start feed crude oil to the plant.
7. Open the valves for routing of oil as per the process route water degumming.
8. Adjust the oil flowrate into the plant by controlling the valve at the outlet of
oil flowmeter FM 101.
9. Open the valve before the control valve TCV 101 in the steam inlet line to
the PHE E101 and heat the oil so that the temperature of the oil at the outlet
of E 101 is 60-65 C. Open the steam trap line valves to ensure discharge of
condensate.
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WATER DEGUMMING
1. Route the oil to the precipitation tank (hydration tank HT 101 ) directly
through the inline mixer IM.
2. Start adding hot water in the inline mixer IM-101 from FT 101 as required.
3. When the oil level reaches the bottom sight glass of the HT 101, start the
agitator.
Caution: Don’t keep the agitator in running condition when the vessel is
empty.
4. Ensure that the separator S 101 has attained full speed and ready for
accepting feed. The valve to T 106 at the outlet header should be kept open.
5. When the oil level is visible at the upper sight glass of the HT 101 star the P
- 102 pump and start feeding the separator by Separation heater (E-102).
6. Open the valve before the control valve TCV 102 in the steam inlet line to
the PHE E102 and heat the oil so that the temperature of the oil at the outlet
of E 102 is 65-70 C. Open the steam trap line valves to ensure discharge of
condensate.
7. Maintain the oil level in the hydration tank by adjusting the valve in the re
circulation line at the discharge of the P 102 pump or VFD.
8. The back pressure at the outlet of the degumming Separator S 101 should be
so maintained that a slightly cloudy to clear oil leaves the separator at the
lowest possible pressure that can be steadily kept.
9. Once the quality of the oil at the outlet of the separator is acceptable divert
the flow of oil from the slop oil tank (T106) to the Vacuum driyer (VD -
101) by degummed oil heater (E-103).
[Link] the valve before the control valve TCV 103 in the steam inlet line to
the PHE E103 and heat the oil so that the temperature of the oil at the outlet
of E 103 is 95-100 C. Open the steam trap line valves to ensure discharge of
condensate.
[Link] the gum transfer pump, P-142, to pump the gums from T-142 to storage
tank after gums have started collecting in T-142.
[Link] the plant is stable monitor the following parameters:
A. Oil flowrate into the plant;
B. Oil temperature at the outlet of E -101;
C. Hotwater flowrate into the Inline mixer (IM);
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D. Level in hydration tank;
E. Consistency of gums;
F. Oil quality at the outlet of the separator S-101;
G. Steam pressure;
H. Water level in the hot water tank T-131;
I. Level in the crude oil tank T-001 or T-002;
J. Oil content in gums;
[Link] the slop oil pump P-106 to pump the oil coming into T-106 to crude oil
tank T-001 or T002.
NOTE: P-106 should be started at the same instance as feeding to the
separator S-101 commences.
DRYING:
1. Start the vacuum pump system well in advance.,
2. Drain the catch pot of any condensed vapours,
3. Start the dried oil pump P-105 by VFD to send the dried oil
4. Open the valve before the control valve TCV 106 in the cold water inlet line
to the PHE E106 and cold the oil so that the temperature of the oil at the
outlet of E 106 is (as per required) Open the outlet line valves to ensure
discharge of E-106.
5. When the vacuum in the dryer is 700-720 mm Hg divert the flow at the
outlet of S-101 separator from T-106 towards VD.
6. When the oil quality at the VD header is approved, divert the flow from T-
106 towards the degummed oil tank by degummed oil cooler by (E-104).
7. Open the valve before the ball valve cold wate inlet line to the PHE E104
and reduce the oil temperature so that the temperature of the oil at the outlet
of E 104 is 35- 40 C. Open the outlet wate line valves to ensure discharge of
hot water to the cooling tower.
8. When the drying section has become stable monitor the following
parameters:
A. Oil quality at the outlet of S-101,
B. Back pressure at the outlet of S-101,
C. Whether oil is going along with gums or not,
D. Hot water tank level,
E. % moisture of dried oil,
F. Phosphorus ppm of dried oil,
G. Level in VD,
H. Vacuum in VD,
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I. Whether foaming is taking place in the VD or not,
J. Drain the catchpot of condensed vapours at regular intervals,
K. Wash water flowrate to FM-102 & FM 103,
L. Speed of M-103,
M. Temperature of hot water,
N. Pressure at hot water header,
O. Process water for seal flushing.
DO AND DONOT
1. TREATMENT SHOULD BE STARTED ONLY AFTER FLOWS AND
TEMPERATURES ARE STABILISED. WHEN OPERATING
CONDITIONS ARE UNSATISFACTORY ALWAYS DIVERT THE
FLOW AFTER THE SEPARATORS (S-101) VACUUM DRYER (VD)
TO SLOP OIL TANK (T-106) AND RE-ESTABLISH STABILITY.
2. WHEN THE DEGUMMED OIL / DRIED OIL IS NOT OF
APPROVED QUALITY DIVERT THE FLOW TO THE SLOP OIL
TANK (T-106)
3. RESPECTIVE ANALYSIS SHOULD BE CARRIED OUT AT
REGULAR INTERVALS TO ASCERTAIN THE PRODUCT AND BY
PRODUCT QUALITY AND FOR MAINTAINING A CHECK ON
THE PROCESS.
4. PRECAUTIONS FOR OPERATING MECHANICAL EQUIPMENTS
SHOULD BE ADHERED TO AS DESCRIBED IN THE RESPECTIVE
INSTRUCTION MANUALS.
5. CRUDE OIL SHOULD BE ANALYSED FOR GUM CONTENT
( HYDRATABLE ), M.I.V., & FREE FATTY ACID BEFORE
FEEDING IT TO THE PLANT SO AS ENSURE ADEQUATE
DOSING OF HOT WATER.
6. CHECK THE AVAILABILITY OF UTILITIES PRIOR TO TAKING
OIL IN THE PLANT.
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7. CHECK THE LEVEL OF LUBE OIL IN THE SEPARATOR GEAR
BOX AND PUMPS.
STOPPING AND EMPTYING
STOP OVER NIGHT WITH CONGEALING FATS
1. Empty Hydration tank – Stop feed to plant. Process oil in H.T.
2. Flushing with water.
Degumming - Adjust the back – pressure in the water-wash stage so that the oil is
clear. When the oil leaving the separator no longer is of approved quantity, turn the
flow towards the slop tank (t-106)
3. Hearing – Close down the steam to heaters.
4.
5. Dryer – Empty the drier, close down the Vacuum pump (VC-101)
barometric water to the condensers and Stop the P-107 .
6. Separators –
A. Stop the separators according to operating routine.
B. Rense and clean before stop.
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TROUBLE SHOOTING
1. Insufficient oil flow into plant:
A. Strainers in suction of P-101/102 may be choked. Clean.
B. At discharge side of P-101 may be choked. Check.
C. There may choking in pipeline.
D. Pump may not be developing sufficient head. Impeller chocked.
E. Motor may not be developing sufficient RPM.
F. PHE E-106 or E-101 may be choked.
DEGUMMING
1. No gum separation:
A. Low back pressure.
B. Insufficient water for hydration.
C. Temperature may be high.
D. Insufficient residence time.
E. Bowl could be chocked.
2. Inconsistent gums:
A. Water may be excess.
B. Temperature may be high.
3. Too much oil with gums:
A. Temperature may be low. As such increased quantity of oil is absorbed
by the gums.
B. Too high back pressure.
4. Back pressure fluctuation – Bowl may be choked fluctuation.
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