DM Manual Doshion

M/s .Rawest Power Pvt.Ltd. Prepaid By : Mahendra Checked by :

PROJECT: Rawest Power Pvt Ltd POC NO : 1954 Document: Operation and Maintenance Manual

Doshion Veolia WATER SOLUTION

OPERATION & MAINTENANCE MANUAL FOR DM SYATEM PLANT SUPPLIED TO:

M/S RAJWEST POWER PVT LTD BADMER PLANT SUPPLIED BY:

M/S. DOSHION VEOLIA WATER SOLUTION PLOT NO. 24, 25, 26, PHASE - II, G.I.D.C. ESTATE, VATVA, AHMEDABAD - 382445. GUJARAT, INDIA

M/s. Rawest Power Pvt Ltd

POC – 1954

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1



OPERATION MANUAL

Sr.No.

Section

Page

01.

Introduction

3

02.

Cautions

5

03.

Description

8

04

Technical Specification ( Mechanical )

30

05

Technical Specification ( Elect / Inst )

31

06.

Operation & Control Philosophy

32

07.

Chemical & Power consumption.

56 & 58

08

Maintenance & Trouble Shooting

59

09

Water analysis & Test methods

81

10.

Lab. Equipment list & Equipment History

104

Card


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2



INTRODUCTION


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3

M/s .Rawest Power Pvt.Ltd. Prepaid By : Mahendra


Checked by :

INTRODUCTION:

Water treatment, today has become a very integral part of almost every industry. Treatment of water is required for various purposes, right from potable use to industrial applications such as for food & beverages, leather, textile, heavy chemicals, power plants & for hotel industries. Also treatment of waste water especially effluents from toxic disposals attracts attention due to increased global awareness of ecological & environmental protection.

Treatment of water implicitly means changing its physical & mainly, its chemical properties by removing undesirable suspended & dissolved impurities of organic & inorganic as well as biological impurities. The level of chemical dosing involved & methods adopted for treatment are according to the end consumers requirements as well as the nature of composition of raw water sources; which are mainly from surface wells, lakes, rivers, or from underground sources such as deep wells & in some cases from sea.

The

specific

method

adopted

for

conventional

treatment

such

as

flocculation/coagulation , filtration and disinfection, lime soda softening process, electro dialysis, demineralization, reverse osmosis and others are depends upon the product quality requirement .


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CAUTIONS


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5



CAUTIONS READ THIS MANUAL:Prior to operating or servicing this plant, this manual must be read and understood. If any doubt exists, call for assistance before proceeding. This manual and other associated manuals are desirable to keep with operators and service people of the plant. USE PROPER POWER CONNECTION:Use proper wiring and connection methods to satisfy industrial electrical code. SHOCK HAZARD:Connect this device to a properly grounded connection in accordance with the National electrical code. “DO NOT” under any circumstances remove the ground wire or ground prong from any power plug / connection. Do not use extension cords without proper consideration. DO NOT REMOVE COVER OR PANEL:To avoid electrical shock hazard, do not remove covers or panel when power is supplied to the electrical equipments when covers or panel’s are removed. DEVICE LABELING:Under any circumstances, do not remove any caution, warning or other descriptive labels from the plant until the conditions warranting the label are dominated. DO NOT OPERATE UNDER AN INFLAMMABLE ATMOSPHERE:To avoid fire or explosion, do not operate this plant in an explosive environment.


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WARRANTEE / GUARANTEE:DOSHION, Guarantees the proposed product to be free from defects in material or workmanship when operated in accordance with written instructions for a period of three years from commissioning or three & half years from receipt, whichever is shorter. Parts not manufactured by DOSHION are covered by their manufacture’s warranties which are normally one year. It is the obligation of the User to maintain regular operating data record. DOSHION may request these records in the warranty claim evaluation. User must notify DOSHION at the very first sign of change in performance of the DOSHION unit. Such notification should be in writing and should include all data requested on the operating log sheets. AFTER SALES TECHNICAL SERVICES: If you wish to return goods for repair, warranty evaluation and / or credit, please have your original sales order or invoice available. Customer should send their written complain / claim to customer care division at, M/s. DOSHION VEOLIA WATER SOLUTION PVT.LIMITED. Plot no. 24, 25, 26, Phase - II, G.I.D.C. estate, Vatva, Ahmedabad – 382 445, Gujarat, Phone no. : 091 - 079 - 2583 1156, 2589 1916, 2589 3586 Fax no. : 091 - 079 - 2583 3302 Or send electronic mail to, [email protected]. DOSHION customer care representative will provide necessary instructions.


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DESCRIPTION


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8



Sr.No. 1.

NAME OF ITEM FEED WATER PUMP

2.

ACTIVATED CARBON FILTER

3.

STRONG ACID CATION EXCHANGER

4.

DG TOWER

5.

DEGASSED WATER STORAGE TANK

6.

DG BLOWER

7.

DEGASEED WATER TRANSFER PUMP

8.

STRONG BASE ANION EXCHANGER

9.

MIXED BED

10.

MIXED BED BLOWER

11.

BULK ACID STROGE TANK

12.

BULK CAUSTIC STORAGE TANK

13.

ACID UNLOADING PUMP

14.

CAUSTIC UNLOADING PUMP

15.

ACID MEASURING TANK FOR SAC

16.

ACID MEASURING TANK FOR MB

17.

CAUSTIC DILUTION TANK FOR MB

18.

CAUSTIC DILUTION TANK FOR SBA

19.

CAUSTIC FEED PUMP

20.

N-PIT

21.

AMT FOR N-PIT

22.

LIME DOSING TANK FOR N-PIT

23.

NEUTRALIZATION WATER TRANSFER PUMP

24.

REGENRATION WATER PUMP


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25.

PRIMING TANK

26

INTERMEDIATE TANK

27

BASKET SRAINER

28

DOSING TANK

29

NAOCL DOSING PUMP

30

NAOH DOSING PUMP

31

HCL DOSING PUMP

32

ULTRA FILTRATION MODULE

33

UF FEED PUMP

34

UF BACK WASH PUMP


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M/s .Rawest Power Pvt.Ltd. PROJECT: Rawest Power Pvt Ltd POC NO : 1954

Prepaid By : Mahendra

Document: Operation and Maintenance Manual

Checked by :

FEED WATER PUMP: FWP- 1101/ A/B/C The Vertical Turbine Type capacity 100M3/Hr raw water transfer pump (2W + 1S) MOC CI is incorporated in the system to transfer the raw water from raw water storage tank to Activated Carbon Filter. ACTIVATED CARBON FILTER (ACF): Activated carbon filter is provided in order to remove colour, odour free chlorine & organics to some extent. The activated carbon media is a very good adsorbent which adsorbs the free chlorine from filtered water. It is a MSEP(2W+1S) Vertical pressure vessel. This unit is charged with an activated carbon bed, which is supported on a layer of silex and pebbles. Free chlorine, colour & Organics to some extent from filtered water are removed by activated carbon. Chlorine reacts with Activated Carbon as follows C + 2Cl2 + 2H2O

=

4HCl + CO2

STRONG ACID CATION UNIT: -

The Cation Exchange unit (SAC) contains a strongly acidic cation exchanger in a regenerated form. The exchanger takes up the cations in water in exchange for hydrogen ions (H+) which it gives up. The cations i.e. Calcium (Ca), Magnesium (Mg) and sodiums (Na) exist in the form of chloride, sulphate, carbonate and bicarbonate salts which get converted to their equivalent acids. When the cation exchanger is exhausted and has no more hydrogen ions available for exchange with cations, it is regenerated with acid to replenish the hydrogen ions.

It is an MSRL (2W+1S) vessel fitted with top header piping fitted with nozzles/strainers for inlet water uniform distribution, bottom distribution plate with nozzles/strainer for water outlet as well as to prevent slippage of the resin, chemical M/s. Rawest Power Pvt Ltd

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Checked by :

header pipe works fitted with nozzles/strainers for regeneration of the resin bed and vessel frontal pipe work with valves for normal & back wash, regeneration and rinse operation. The vessel is filled with cation resin for a calculated volume as per the water quality and ionic load with sufficient height of free board as a provision for bed expansion. All the piping inside the vessel is rubber lined for adequate thickness to prevent corrosion as well as to safe guard the quality of water.

The chemical reactions given below illustrate the process of demineralization.

CATION EXCHANGER:

NaCl

+

R-H

=

R - Na

+

HCl

Sodium

Hydrogen

Sodium

Hydrochloric

Chloride

Exchanger

Exchanger

Acid.

MgSO4

+

Magnesium

Hydrogen

Magnesium

Sulphuric

Sulphate

Exchanger

Exchanger

Acid.

Ca (HCO3)

2R-H

+ 2R-H

=

=

R2 Mg

+ H2SO4

R2Ca

+ 2CO2

Calcium

Hydrogen

Calcium

Carbon

Bicarbonate

Exchanger

Exchanger

Dioxide


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12

+

2H2O Water



REGENERATION:

R Na

HCl

OR

Hydrochloric Acid

R2Mg

+

OR

OR

R2Ca

H2SO4

Sodium

sulphuric acid

RH +NaCl OR MgCl2 =

OR CaCl2

sodium, magnesium or

Magnesium

calcium chloride

Or calcium

or CaSO4

Exchanger

DEGASIFICATION SYSTEMS:

DEGASSER TOWER

Water from SAC unit outlet feeds in to 1400 dia X 3300 HOS de-gasser tower for removal of free carbon-dioxide in the feed water. De-gasser tower is a forced draft type atmospheric tower fitted internally with a top distributor plate and bottom collector plate. Polypropylene pall rings are filled in the tower to sprinkle water. DEGASSER WATER STORAGE TANK:

It is RCC Horizontal tank fitted in the system to store de-gasser treated water. Size of DGWST 7100 L X 7100 W X 4500 H. & capacity 200m3.


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DEGASSER BLOWER:

Three nos. Centrifugal type of air blowers of CI. Construction are provided for blowing high flow, low pressure air for de-gasification. 1846M3/min @55mWc blower forced air by degasser blower is passed in counter current direction while the decationic water is sprayed from the top, thus removing the free carbon dioxide produced during splitting of alkaline salts.

DEGASSER WATER TRANSFER PUMP:

Three nos. of de-gasser water transfer pumps are provided to transfer water from DGWST to SBA unit. The each pump having a capacity of 100 m3/hr @4 KG / CM2 & the MOC of the pumps is SS-316.

STRONG BASE ANION EXCHANGER:

The strong base anion exchange unit (SBA) contains a strong base anion exchanger in a regenerated form. The exchanger takes up all the anions and Silica, in water from WBA outlet is exchanged for hydroxide ions (OH-) which it gives up. When anion exchanger is exhausted and has no more hydroxide ions available for exchanger with anions, it is regenerated with caustic soda to replenish the hydroxide ions.

It is an MSRL(2W+1S) vessel fitted with inlet bell mouth for uniform water distribution, bottom distributor for water outlet as well as to prevent slippage of the resin, chemical header pipe works fitted with nozzles/strainers for regeneration of the resin bed and vessel frontal pipe work with valves for normal & back wash, M/s. Rawest Power Pvt Ltd

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Checked by :

regeneration and rinse operation. The vessel is filled with SBA resin for a calculated volume as per the water quality and ionic load with sufficient height of free board as a provision for bed expansion. All the pipings inside the vessel are rubber lined for adequate thickness to prevent corrosion as well as to safe guard the quality of water.

The chemical reactions given below illustrate the process of demineralization. H2 (SO4)2

(SO4)2

2HCl

2Cl

2(HSiO3)

+ R - OH =

2(HCO3)

2(HSiO3) R

+ H2O

2(HCO3)

Sulphuric Acid,

Hydroxide

Sulphate

Hydrochloric Acid

Exchanger

Chloride

Sililic Acid

Salilic

carbonic Acid

Carbonic

Water

REGENERATION : (SO4)2

SO4

2(Cl)

Cl2

2(HSiO3)

R

+

2NaOH =

R - OH

+ Na2

2(HCO3) Sulphate, Chloride

(HSiO3)2 (HCO3)2

Sodium Hydroxide

Salilic, Carbonic

Sodium Sulphate Hydroxide

Sodium Chloride

Exchanger

Sodium

Silicate Sodium Bi-carbonate


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06.


MIXED BED UNIT:

Mixed bed demineraliser unit embodies a single column of Doshion CSA-9 (Strong Acid Cation Exchange Resin) and Doshion ASB-108 (Strong Base Anion Exchange Resin) material mixed intimately together. Water passing through the column comes repeatedly in contact with these resins and is thus in effect subjected to an almost infinite number of dematerializing stages. Dematerialized water of extreme purity is produced - purity that cannot be equaled by any other commercial method. Mixed bed demineralizers are regenerated with acid and alkali but the ion exchange resins must be separated before this can be done. Bed separation is accomplished by back-washing-this carries the lighter anion resin sinks to the bottom. Two completely separated and super imposed layers are thus formed, into which the acid and alkali solutions and rinse water are introduced through specially designed spreaders. After regeneration the two resins are remixed with compressed air.

It is an MSRL (2W+1S) vessel fitted with inlet header for uniform water distribution, bottom distribution plate with nozzles/strainer for water outlet as well as to prevent slippage of the resin, header pipe works for acid/caustic fitted with nozzles/strainers for regeneration of the resin bed for cation/anion and vessel frontal pipe works with valves for normal & back wash, regeneration and rinse operation. The vessel is filled with cation/anion resin for a calculated volume as per the water quality and ionic load with sufficient height of free board as a provision for bed expansion. All the pipings inside the vessel are rubber lined for adequate thickness to prevent corrosion as well as to safe guard the quality of water.


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MIXED BED BLOWER: For through mixing of Cation and anion resins after MB regeneration, two nos. twin lobe type positive displacement type air blowers (one working and the other as standby) are provided in the system for supplying the required air at sufficient quantity and pressure for effective mixing of the resin bed.

BULK ACID STORAGE TANK To store the acid from the outside tankers a separate MSRL vessel with all necessary associated pipe works, valves, level indicators, inlet, outlet and overflow nozzles has been incorporated to receive as well as to supply acid to AMT for carrying out the regeneration of the MB & SAC vessel. A suitable centrifugal pump of adequate head and capacity of recommended MOC has been provided for unloading acid from the outside tankers as well as to supply acid to the plant for regeneration purpose. BULK CAUSTIC STORAGE TANK To store the caustic from the outside tankers a separate MSRL vessel with all necessary associated pipe works, valves, level indicators, inlet, outlet and overflow nozzles has been incorporated to receive as well as to supply caustic to CDT for carrying out the regeneration of the MB & SBA units. A suitable centrifugal pump of adequate head and capacity of recommended MOC has been provided of recommended material of construction for unloading caustic acid from the outside tankers as well as to supply acid to the plant for regeneration purpose.


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10.


ACID MEASURING TANK FOR SAC:

This comprises of separate tanks in MSRL for acid incorporating all nozzles for chemical inlet, service water inlet, level gauge, overflow, drain, fume absorber etc. Also included with the associated pipe works and valves in CPVC for connecting the tank and the power water source via ejector for creating the necessary vacuum for injection of chemical at 4 to 6% w/v for the resin bed. The concentration of the chemicals in the solution tank is maintained at 30 to 32 % w/v. For proper regeneration the flow rates recommended at different stages to be maintained properly as well as quantity of chemicals for each cycle of regeneration. 11.

CAUSTIC DILUTION TANK FOR SBA:-

This comprises of separate tanks in MSEP for caustic service incorporating all nozzles for chemical inlet, service water inlet, level gauge, overflow, drain, etc. Also included with the associated pipe works and valves in CPVC for connecting the day tank and the power water source via ejector for creating the necessary vacuum for injection of chemical at 4 to 6% w/v for the resin bed. The concentration of the chemicals in the solution tank is maintained at 30 to 32 % w/v. For proper regeneration the flow rates recommended at different stages to be maintained properly as well as quantity of chemicals for each cycle of regeneration.

12. ACID MEASURING TANK FOR MB:

This comprises of separate tanks in MSRL for acid, incorporating all nozzles for chemical inlet, service water inlet, level gauge, overflow, drain, fume absorber etc. Also included with the associated pipe works and valves in MSRL for connecting the tank and the power water source via ejector for creating the necessary vacuum for M/s. Rawest Power Pvt Ltd

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injection of chemical at 4 to 6% w/v for the resin bed. The concentration of the chemicals in the solution tank is maintained at 30 to 32 % w/v. For proper regeneration the flow rates recommended at different stages to be maintained properly as well as quantity of chemicals for each cycle of regeneration. 13.

CAUSTIC DILUTION TANK FOR MB:

This comprises of separate tanks in MSRL for caustic service, incorporating all nozzles for chemical inlet, service water inlet, level gauge, overflow, drain, fume absorber etc. Also included with the associated pipe works and valves in MSRL for connecting the day tank and the power water source via ejector for creating the necessary vacuum for injection of chemical at 4 to 6% w/v for the resin bed. The concentration of the chemicals in the solution tank is maintained at 30 to 32 % w/v. For proper regeneration the flow rates recommended at different stages to be maintained properly as well as quantity of chemicals for each cycle of regeneration. 14. NEUTRALISATION SYSTEM:

Neutralization pit operation:Auto / Manual selection will be provided for Disposal and recirculation valves. Pre condition for Neutralization pit pump starting:1. Pump ‘Module Ready’ ( MCC not Disturbed ) feedback from MCC should be available. Pump will be operated by the operator through PLC soft button Control Desk push Buttons.


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Interlock:A soft button will be provided for operator selection of Neutralisation Pit compartment. Logic of N-Pit operation:Re-circulation valve will open immediately after starting of effluent transfer pump. A pH transmitter will monitor the pH value of the Effluent. If pH value is within limits for 10 minutes discharge valve will open and then recirculation valve will close automatically. Whenever effluent pH goes outside the desired limits, operator alarms will be generated. In addition pH value will be displayed on the Operator station.

Condition:- 1. If pH value is lower than pre set range for more than 30 seconds then Recirculation valve will open and then discharge valve will close automatically. Operator will manually open Caustic dosing valve and start dosing. After the pH value reaches the preset range operator will manually close dosing valves. If pH value remains within limits for 10 minutes discharge valve will open and then recirculation valve will close automatically.

Condition – 2 If pH value is higher than pre set range for more than 30 seconds then Recirculation valve will open and then discharge valve will close automatically. Operator will manually open Acid dosing valve and start dosing. After the pH value reaches the preset range


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operator will manually close the dosing valves. If pH value remains within limits for 10 minutes discharge valve will open and then recirculation valve will close automatically. INTERMEDIATE STROGE TANK. The final product from MB vessel is stored in tank of adequate capacity to distribute water further for process, for UF system. UF FEED PUMP: UF Feed pumps 2 Nos having a capacity of 50 m3/hr @ 2.5 Kg/cm2 along with necessary suction , discharge piping , pressure gauges for pumping the DM water to the UF system through basket filter BASKET FILTER: For removing the fine suspended particles from the water and particles due to non performance of Sand filter. On line Basket Filter with 100 micron absolute rating is provided to removes the suspended particles down to 100 micron. The basket filter is provided with local pressure gauges for monitoring pressure drop and choking of filter. UF SYSTEM: Cross flow membrane filtration technique is for the separation of suspended or dissolved materials by molecular weight & size. Application of a pressure difference causes the membrane to act like a sieve. Substances smaller than pore size of the membrane passes through with solvent as permeate, while larger solutes or particles are retained as concentrate. This separation technique is easy to handle and requires no phase change no addition of chemicals and little energy. Ultra filtration and Nano filtration membranes are high density micro porous skin cast onto a highly porous substructure. The substructure acts only as support for the extremely thin active layer and generally has no effect on the filtration characteristics of the membrane. Since the actual discriminating barrier is extremely thin, very high flux can be easily achieved. Due to the


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highly asymmetric structure, all rejected material is retained on the membrane surface and internal pore fouling is virtually eliminated. 08. UF BACK WASH PUMP: A Horizontal centrifugal pump of SS 316 has been provided in the system to supply UF treated water from DM water storage tank for supplying the required quantity water for back washing and flushing the UF module at the required head and capacity. The pump is provided with necessary piping connections, pressure gauge, valves and control interlocks. For details, please refer the technical data sheets for all mechanical equipments.

.

DM WATER STRORAGE TANK:

The final product water from the MB vessel is stored in a tank of adequate capacity to distribute water further for process, for regeneration of all DM units upon completion of the OBR or as required.

DM WATER REGENRATION PUMP:

Permissive for starting of pump:1. MODULE READY (MCC not Disturbed) feedback should be available from the MCC. 2. DM Water storage Tank level should not be Low. The Regeneration Pumps will be provided with following selections: • •

AUTO / MANUAL RWP- 3101/3102

In Manual mode of operation the Pumps can be started using soft buttons from Operator


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Workstations. In Auto mode of operation Pump selected MAIN pump will start when any SAC / SBA / MB are put in Regeneration. STANDBY pump will start automatically if the MAIN pumps trips electrically or MAIN pump fails to start. If one SBA / MB is in Service and another SAC / SBA / MB is taken in Regeneration / Backwash then the Standby pump will start automatically. That is if one stream is running and another vessel is taken in Regeneration / Backwash then both the Regeneration Pumps will be in operation. On completion of Regeneration / Backwash cycle the STANDBY pump will switch OFF automatically. The inlet valve of the DM Storage Water Tank selected for filling will be opened Manually from the Operator workstations. Regeneration pumps will TRIP on any of the following conditions: • Electrical TRIP • DM Water Storage tank Level Low Both pumps status (Running/Electrically healthy/stop) will be displayed in PLC Workstation graphics. Operator alarms will be generated for Low and High level of DM tanks. .


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Checked by :

BASIS OF DESIGN:

A) FEED WATER ANALYSIS: Sr.No. 1. 2. 3. 4. 5. 6. 7 8 9 10. 11.

Para meter

Un it

Data

CALCIUM as CaCO3 MAGNESIUM as CaCO3 SODIUM as CaCO3 TOATL HARDNESS as CaCO3 SULPHATE as CaCO3 CHLORIDE as CaCO3 Total Dissolved Solids Silica Alkalinity(Total) Turbidity PH

Mg/l Mg/l Mg/l Mg/l Mg/l Mg/l Mg/l Mg/l Mg/l NTU

90 70 49 160 9.00 20.00 210-370 30.0 180.00 3000 8.5-8.8

Out put water Quality DM WATER QUALITY Na+ K <0.1 ppm Ca < 1 ppm CL + F < 0.1 ppm SILICA ACID

( SIO2Nh2O) <0.05 ppm

PH <8.8


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GUARANTEED WATER QUALITY # CLARIFLOCCULATOR

Turbidity KMnO4 No. O2 absorbed Mg/I, 4 hours at 37 Deg. C

Less than 15 NTU Nil

# GRAVITY FILTERS Turbidity

1 NTU (max)

EFFLUENT QUALITY FOR D.M. PLANT ACF Turbidity Free Chlorine Content

Nil Nil

SAC Sodium (Na)

1 ppm

SBA SiO2


< 0.2 ppm

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MB Total dissolved solids, (max) Total Hardness Chloride Total Silica as SiO2, (max) Iron as Fe, (max) Conductivity at 20 deg. C (max) PH Turbidity


< 0.05 ppm Nil Nil < 0.01 ppm Nil 0.1 μS/cm 7 ± 0.2 at ambient Nil

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26

Deg

C




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PROCESS DESCRIPTION AND DESIGN BASIS


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BRIEF DESCRIPTION OF DM PLANT:

The fundamentals of Demineralization process and the basic water chemistry involved are being explained herewith.

As explained earlier, prior to Demineralization of water, is the removal of all cation & anion of all minerals which mostly constitute as total dissolved substances (TDS). The Pre-treatment is required to remove the components of impurities, meaning as Total suspended solids. Hence the water from the supply is treated first called as Pre -Treatment to remove the TSS, colour, odour & turbidity. The detail of the pretreatment is being explained in the subsequent chapter. But in brief the chemically treated especially with sodium hypochlorite, coagulant & flocculate water allows pass through different vessels such as ACF through different beds of cylix, pebbles, sand, Activated carbon to make the water free from impurities before subjecting the same for Demineralization.

The basic water chemistry of demineralization explained here. When the pre-treated water with absence of TSS is passing through resin of H & OH form, the resin will continuously exchange its H& OH form with water continuously containing cations and anion.

The exhausted resin beds are being reactivated & reserved by regenerating the same with Acid, allocation of HCL, Noah formation & anion resins respectively as explained under plant operation.


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B. TREATED WATER QUALITY:

Sr. No.

PARAMETERS

OUTLET

1

Conductivity @ 25 C

<1 micro S / cm after MB outlet (Before pH correction)

2

Reactive Silica as SiO2

0.02 ppm max

3

PH

6.8 to 7.2 after pH correction dosing

Note: The treated water quality is subjected to following

1

The feed quality is same as specified in your inquiry. In case of any change in the quality of raw water the same may have implications on operating parameters or on end results of the system.

2

The feed limiting conditions mentioned as below are strictly maintained. The operation of demineralization so strictly done as per reports should be sent to us for monitoring of system and to suggest suitable actions for better and smooth operation of the system.

3

Pure chemicals, original spares and consumable specified by us are used in DM plant. Sufficient inventory of spares for at least 1 year is to be maintained.


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Checked by :

TECHNICAL SPECIFICATIONS MECHANICAL AS PER ATTACHED ANNEXURE: 1


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Checked by :

TECHNICAL SPESIFICATION OF ELECTRICAL AND INSTRUMENTATION AS PER ATTACHED ANNEXURE: 2


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Checked by :

OPERATION AND CONTROL PHILOSOPHY


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BRIEF SYSTEM DESCRIPTION: A.

SYSTEM OPERATION The Plant operation for ACF, SAC, DGWST, SBA & MB and UF are manual with all frontal valves manually operated as per the operation guide lines provided for regeneration & Service cycle upon completion of the OBR. For details refer the details furnished below.

A.1

BASIC OPERATION GUIDE LINES

A.1.1 All the system pipe work are to be lined up properly before commissioning operation of any part of the system such as pre treatment, ACF SAC, DGWST,SBA,Mixed Bed & UF . All the valves are tagged for easy identification for closing and opening as per the guidelines provided in our comprehensive Operation & Maintenance Manual A.1.2 Activated carbon filters are to be backwashed for 25 minutes at the rated flow once in a day or if the pressure drop across the vessel exceeds 0.8 kg/cm2 whichever is earlier. A.1.3 All the chemical solution for pretreatment dosing, SAC, SBA & MB such as Acid & Alkali are to be prepared at the right concentration and dosage at the right capacity to achieve desirable water quality. A.1.4 All the equipments are to be started after ensuring the system’s pipe work and vessel is full of water and free of air. A.1.5 Water samples from different stages of the treatment plant are to be taken regularly for checking Hardness, TDS & Conductivity of water from SAC outlet, SBA outlet & MB outlet water to assess the performance level A.1.6 Detailed recording of the plant parameters in standard log sheets, to check and review the performance of the plant as well as to observe for any abnormalities. A.1.7 Mixed bed is to be put on regeneration for Cation and Anion resin bed upon completion of OBR period as per the guidelines provided in our Operation & Maintenance Manual. The rated quantity of Acid & Caustic Soda is to be used with correct concentration in the solution Tank (30%). The final solution inlet to the vessel will be at 5 to 6%. A.1.8 Thorough air mixing of Cation & Anion after regeneration and final rinsing of the bed is required for achieving rated quality of water.


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OPERATION SEQUENCE Pre Treatment Select the filter water pump, after ensuring adequate head of water in the DM Clarified water storage tank. Keep the pump discharge kept throttled. Check the free rotation of the shaft and direction. Start the pump to maintain the flow of 90 M^3/hr at adequate discharge head. Select the Filter water pump & two nos. of ACF for operation of one stream, after ensuring adequate head of water in the clear water storage tank. Keep the pump discharge kept throttled. Check the free rotation of the shaft and direction. Start the pump to maintain the flow of 90 M^3/hr..

Line up ACF after ensuring the vessel is full of water and free of air. Ensure full opening of the Header & Service inlet valves ACF V-1101,V2101 & V-3101 And V-1102,V-2102 & V-3102 and outlet valves V1106,V2106 & V3106 Rest of the valves are to be fully closed and flow across vessel to be maintained at 90M^3/hr.

STATUS

(Now pre treated, filtered water is available for subsequent treatment scheme. Refer the attached Timing scheduled for back washing procedure of the ACF Ensure partial opening of the back wash inlet valve V-1105,2105,3105 and full opening of air release valve V1108,2108,3108 the SAC vessel before taking ACF in to the service cycle to prevent sudden pressurization of the vessel. After taking ACF in to the service, fill up the vessel with water and to remove the air completely from the vessel. Line up the SAC vessel after regeneration of the resin by opening the Header & service inlet and outlet of the vessel V-1109,2109,3109 & V-1110,2110,3110 and outlet valve V-1118,2118,3118 All the other valves of the vessel are to be fully closed. Keep the flow rate across SAC at 90 m^3/hr for each stream (2S+1S) at the inlet of the SAC. Now SAC, treated process water is available at the rate of 90 M^3/hr. SAC to be subjected to regeneration after completion of OBR value after the specified duration of operation at the rated flow. Please refer the regeneration procedure for the SAC attached. Check the outlet parameters of the SAC water at the outlet of the vessel before commencing the regeneration.


POC – 1954


PAGE

34



Ensure partial opening of the Header & service inlet V-1121,2121,3121 & V1122,2122,3122 and air release valve V-1132,2132,3132 of the SBA to fill the water in the vessel and to remove the air completely. Line up the SBA by opening inlet and outlet valves fully opened V-1122, 2122, 3122 & V-1130, 2130, 3130 maintain the flow rate across the system 90 M^3/hr per stream ( 2W+1S). Ensure partial opening of the Header & service inlet V- 1133,2133,3133 & V1134,2134,3134 and air release valve V- 1145,2145,3145 of the MB to fill the water in the vessel and to remove the air completely. Start to fill the MB vessel full of water and free of air Line up the MB by opening inlet and outlet valves fully opened V1134,2134,3134 & V-1143,2143,3143 to maintain the flow rate across the vessel 90M^3/hr for each vessel (2W+1S),. The above operation is to be done after ensuring the following : - Thorough mixing of cation and anion resin after regeneration - Status of the resin . It should be fully in regenerated condition or in completion of OBR after completion of last regeneration.) - Check the conductivity of MB outlet water for within the specified limits. Demineralised water at the rate of 90M3/hr is available please refer the attached sheet for regeneration procedure of the mixed bed. Also refer the field instruments for conductivity and flow at the outlet of mixed bed. Note: All the frontal valves for ACF, SAC, SBA and MB are operated according to the operation as per the sequence mentioned above.


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35



BACKWASHING

BACKWASHING OF THE ACTIVATED CARBON FILTER Backwashing of the ACF is to be carried out in case of observing the pressure drop across the vessel as 0.8kg/cm² or once in 20 hours of operation whichever is earlier. -

Also in case of observing more than the specified limit of slip of colour, odour or presence of organics in the ACF outlet, the backwashing turning should be adjusted accordingly.

BACKWASHING PROCEDURE OF ACF The procedure as under. 1].

Close the service inlet and outlet valve fully closed (V-1102, 2102, 3102&V1106,2106,3106),

2].

Open the air release valve of the ACF (V-1108,2108,3108)

3].

Open the Back Wash inlet valve (partially open) (V-1105,2105,3105)

4].

Ensure the vessel is full of water and free of air

5].

Open the Back wash outlet valve (V-1103,2103,3103)

6].

Close the air release valve (V-1108.2108,3108)

7].

Continue the backwashing at the specified flow rate 55M3/Hr. for a period of 25 minutes till the backwash outlet water is clear of suspended impurities

8].

Take the vessel into normal operation as explained in the previous chapter..


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36



STRONG ACID CATION REGENERATION PROCEDURE & NORMAL OPERATION •

Ensure opening of the service inlet & outlet valve of the Activated Carbon Filter.

•

Open SAC inlet valve (V-1110, 2110, 3110) and air release valve (V-1120, 2120, 3120). When water starts coming through air release pipe. Close (V-1120, 2120, 3120) and open/adjust rinse outlet valve (V-1119, 2119, 3119). Rinse the unit at final rinse flow rate for 5 minutes. Open conductivity isolation valve and switch on the conductivity meter. Check the conductivity, if satisfactory then close rinse outlet valve and open and adjust SAC outlet valve (V-118, 2118, 3118) to the required service flow rate.

NORMAL STOPPING: Switch off the conductivity meter, and close conductivity isolation valve. Close the inlet (V-1110, 2110, 3110) and outlet (V-1119, 2129, 3129) valve. Release pressure by opening air release valve (V-1120, 2120, 3120). SAC REGENERATION DATA TABLE - I FOR TIMINGS: 01. SAC

Backwash Middle collector flush Pre injection Acid injection Acid slow rinse Final rinse

05 mins 05 mins 03 mins 20 mins 28 mins 09 mins

BACK WASH TO BE CARRIED OUT EVERY 7TH REGENERATION AND FOLLOWED BY DOUBLE INJECTION. FLOWRATES AND TIMING CAN BE CHANGED AS PER SITE REQUIREMENT. Note- Please note, during the normal operation & regeneration of the DM Plant vessels as explained below the valves other specified should be kept in closed condition.


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37



REGENERATION: For the first six months of operation, the SAC unit is regenerated at its rated output between regeneration. If the quality of the treated water is satisfactory, the output between two regenerations may be stepped up after the initial six months. If the treated-water quality is still satisfactory then the run should be terminated on Sodium breakthrough. Note in case of longer operation of the plant if the product water quality from SAC unit is not as per the requirement after regeneration; we recommend doing the double quantity regeneration of SAC unit after 8-10 regeneration. PREPARATION OF REGENERANTS: Pour the Hydrochloric Acid for the cation regeneration in the acid measuring tank to prepare 30-32% by w/v HCL solution. The quantity of HCL (30%) per regeneration for one SAC unit:

1390.98 Kg.

BACK WASH: Open slowly backwash inlet valve (V-1116, 2116, 3116) and backwash outlet valve (V-1111, 2111, 3111). Maintain the required flow rate by adjusting the outlet valve (V-1111, 2111, 3111). After ten minutes of backwashing close the valves (V-1116, 2116, 3116 & V-1111, 2111, 3111). Recommended flow rate 44.2 M3/Hr.. This operation is to ensure loosing of the resin bed to remove fines and any other impurities. MIDDLE COLLECTOR FLUSHING This operation is to ensure clearing of the middle collector piping for any traces of resin and other impurities, before commencing the acid injection. To operate the following valves for five minutes. The flow rate is to be maintained as 44.2 m3/hour for 5 minutes. ACID PREINJECTION / DOWN FLOW : This step is carried out to set the flows for injection. The middle collector outlet valve, service inlet valve, acid inlet valve, power water inlet valve are opened for stabilizing the flow rates.


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38



ACID INJECTION ( CCR) Acid injection is being carried out at the rated flow for a period of 25-30 minutes by operating the following valves & all other valves should be kept closed. (Recommended flow rate 35.8 M^3/hr) • • •

Acid solution inlet to vessel Acid ejector suction valve Rinse outlet valve

- V1117, 2117, 3117 - V5076 - V-1119, 2119, 3119

ACID SLOW RINSE After acid inject, acid slow rinse has been carried out by operating the following valves for a period of 28 minutes. The flow rate is 29.80M^3/hr. • •

Acid solution inlet to vessel Rinse outlet valve

- V-1117, 2117, 3117 - V-1119, 2119, 3119

FINAL RINSE: After acid slow rinse, final rinse has been carried out for a period of 15 minutes by operating the following valves • •

Service Inlet Rinse outlet


V-1110, 2110, 3110 V-1119, 2119, 3119

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39



Checked by :

STRONGE BASE ANION REGENERATION PROCEDURE & NORMAL OPERATION • •

Ensure opening of the service inlet & outlet valve of the SBA. Open SBA inlet valve (V-1122, 2122, 3122) and air release valve (V-1132, 2132, 3132). When water starts coming through air release pipe. Close (V-1132, 2132, 3132) and open/adjust rinse outlet valve (V-1131, 2131, 3131). Rinse the unit at final rinse flow rate for 5 minutes. Open conductivity isolation valve and switch on the conductivity meter. Check the conductivity, if satisfactory (conductivity Should be less than<10.00 µs/cm) then close rinse outlet valve and open and adjust SBA Outlet valve (V-1130, 2130, 3130) to the required service flow rate 90 M3/Hr..

NORMAL STOPPING: Switch off the conductivity meter, and close conductivity isolation valve. Close the inlet (V1122, 2122, 3122) and outlet (V-1130, 2130, 3130) valve. Release pressure by opening air release valve (V-1132, 2132, 3132) SBA REGENERATION DATA TABLE - I FOR TIMINGS 01. SBA

Backwash Middle collector in Caustic injection Slow rinse Final rinse

05 mins. 03 mins. 20 mins. 32 mins. 20 mins.

Note- Please note , during the normal operation & regeneration of the DM Plant vessels as explained below the valves other specified should be kept in closed condition. REGENERATION : For the first six months of operation, the SBA unit is regenerated at its rated output between regeneration. If the quality of the treated water is satisfactory, the output between two regenerations may be stepped up after the initial six months. If the treated-water quality is still satisfactory then the run should be terminated on conductivity breakthrough. Note in case of longer operation of the plant if the product water quality from SBA. Unit is not as per the requirement after regeneration; we recommend to do the double quantity regeneration of SAC. unit after 8-10 regeneration.


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40



PREPARATION OF REGENERANTS: Fill the caustic dilution tank with water and gradually add Noah (100%) to make 30-32% solution. The concentration of diluted regenerant may be confirmed either by checking the specific gravity or by titration. The quantity of NaoH (48%) per regeneration per SBA unit:

547.30 kg.

BACK WASH: Open slowly backwash inlet valve (V-1128, 2128, 3128) and backwash outlet valve (V-1123, 2123, 3123). Maintain the required flow rate 19 M3/Hr. by adjusting the outlet valve (V-2123, 1123, 3123). After five minutes of backwashing close the valves (V-1128, 2128, 3128 &V1123, 2123, 3123 ) . Recommended flow rate 19M^3/hr. This operation is to ensure loosing of the resin bed to remove fines and any other impurities. MIDDLE COLLECTOR FLUSHING This operation is to ensure clearing of the middle collector piping for any traces of resin and other impurities, before commencing the acid injection. To operate the following valves for five minites. The flow rate is to be maintained as.19 m3/hour. • •

Middle collector inlet valve Backwash outlet valve

V-1126, 2126, 3126 V-1123, 2123, 3123

CAUSTIC PREINJECTION (CCR) Open service inlet valve, caustic inlet valve, power water inlet valve, and SBA middle collector outlet valve to set the flow rates. CAUSTIC INJECTION (CCR) Caustic injection is being carried out at the rated flow for a period of 25 minutes by operating the following valves & all other valves should be kept closed. (Recommended flow rate 27.3 M^3/hr) • • • • •

Balance water (service inlet) Power water for Caustic ejector Caustic solution inlet to vessel Caustic ejector suction valve Rinse outlet valve


- V-1125, 2125, 3125 - V-5170, 5171 - V-1129, 2129, 3129 - V- 5150, 5155 - V-1131, 2131, 3131

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41



CAUSTIC SLOW RINSE After Caustic injection, acid slow rinse has been carried out by operating the following valves for a period of 64 minutes. • • • •

Balance water (service inlet) Power water for Caustic ejector Caustic solution inlet to vessel Rinse outlet valve

- V-1125, 2125, 3125 - V- 5170, 5171 - V-1129, 2129, 3129 - V-1131, 2131, 3131

FINAL RINSE: After Caustic slow rinse, final rinse has been carried out for a period of 30 minutes by operating the following valves • •

Service Inlet Rinse outlet


V-1122, 2122, 3122 V-1131,2131,3131

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42



MIXED BED REGENERATION PROCEDURE & NORMAL OPERATION Note- Please note, during the normal operation & regeneration of the DM Plant vessels as explained below the valves other than specified should be kept in closed condition. •

Ensure the Opening of service inlet & outlet valve of the SBA.

•

Open M.B. inlet valve (V-1134, 2134, 3134) and air release valve (V-1145, 2145, 3145). When water starts coming through air release pipe. Close (V-1145, 2145, 3145) and open/adjust rinse outlet valve (V-1166, 2166, 3166). Rinse the unit at final rinse flow rate 11.4M3/Hr. for 15 minutes. Open conductivity isolation valve and switch on the conductivity meter. Check the conductivity, if satisfactory (conductivity should be less than<1.0 µs/cm) then close rinse outlet valve and open and adjust M.B. outlet valve (V1143, 2143, 3143) to the required service flow rate.

NORMAL STOPPING: Switch off the conductivity meter, and close conductivity isolation valve. Close the inlet (V1134, 2134, 31346) and outlet (V-1143, 2143, 3143) valve. Release pressure by opening air release valve (V-1145, 2145, 3145). REGENERATION: For the first six months of operation, the mixed-bed unit is regenerated at its rated output between regeneration. If the quality of the treated water is satisfactory, the output between two regenerations may be stepped up after the initial six months. If the treated-water quality is still satisfactory then the run should be terminated either on silica or conductivity breakthrough. Note in case of longer operation of the plant if the product water quality from M.B. unit is not as per the requirement after regeneration, we recommend to do the double quantity regeneration of M.B. unit after 8-10 regeneration. PREPARATION OF REGENERANTS: Fill the caustic dilution tank with water and gradually add NaOH (100%) to make 48% BY W/V solution. The concentration of diluted regenerant may be confirmed either by checking the specific gravity or by titration. Pour the sulfuric acid for the cation regeneration in the acid measuring tank after filling water in tank to prepare 30-32% by w/v HCL solution. The quantity of NaoH (48%) per regeneration -

177.55 Kg.

The quantity of HCL (30%) per regeneration -

284.7 Kg.


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43



BACK WASH: Open slowly backwash inlet valve (V-1141, 2141, 3141) and backwash outlet valve (V-1135, 2135, 3135). Maintain the required flow rate by adjusting the outlet valve (V-1135, 2135, 3135). Continue for the backwashing for the period of five or more till the physical separation of cation & anion bed as well as removal fines and other impurities from the bed. Close the valves (V-1141, 2141, 3141 & V-1135, 2135, 3135). MIDDLE COLLECTOR FLUSHING This operation is to ensure clearing of the middle collector piping for any traces of resin and other impurities, before commencing the acid injection. To operate the following valves for five minites. • •

Middle collector inlet valve Backwash outlet valve

V-1138, 2138, 3138 V-1135, 2135, 3135

CAUSTIC INJECTION (CR) Open the middle collector outlet valve, open balance water valve i.e. back wash inlet valve , Caustic inlet valve to the vessels , Caustic ejector power water valve and caustic ejector suction valve . Adjust the power water valve for proper injection of caustic solution at the recommended flow rate for a period of 15 minutes. The concentration of caustic solution to the MB bed is adjusted 5-6% by w/v after ejector outlet When the level of caustic solution in the caustic dilution tank has dropped to the bottom of the caustic solution suction pipe, immediately close ejector suction valve and power water valve. Care should be taken not to allow any air to be drawn into the unit through the suction pipe. Recommended flow rate during the caustic injection as 13.6 m3/hour. • •

Suction valve for Caustic Ejector MB Vessels caustic inlet valve


-

V-5160, 5165 V-1146, 2146, 3146

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44



CAUSTIC SLOW RINSE: After injection 5-6% W/V NaOH solution. the system should be under caustic slow rinse for a period of 15minutes by operating the following valves. •

MB Vessels caustic inlet valve

-

V-1146, 2146, 3146

ACID INJECTION: Acid injection is being carried out at the rated flow for a period of 15 minutes by operating the following valves. • • • • •

Acid Balance water Suction valve for Acid Ejector MB Vessels Acid inlet valve Balance Water in service inlet valve MB rinse outlet valve

-

V-1140, 2140, 3140 V-5077, 5078 V-1137, 2137, 3137 V-1136, 2136, 3136 V-1166, 2166, 3166

ACID SLOW RINSE After acid inject, acid slow rinse has been carried out by operating the following valves for a period of 15 minutes. • • •

MB Vessels Acid inlet valve Balance Water in service inlet valve MB rinse outlet valve


-

V-1137, 2137, 3137 V- 1136, 2136, 3136 V-1166, 2166, 3166

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45



DRAIN DOWN: •

Open rinse outlet valve (V-1166, 2166, 3166) and air release valve (V-1145, 2145, 3145) when the water is drained to the level of top inspection side glass window, above the anion resin layer. Then close the rinse outlet (V-1166, 2166, 3166).

AIR MIXING: Open air release valve (V-1145, 2145, 3145) and then open air inlet valve (V-1142, 2142, 3142) and start the air blower for air mixing the anion and cation bed. This operation is continued for 10 minutes & then close air inlet valve (V-1142, 2142, 3142) after stopping the air blower and blower discharge valve. REFILLING AND FINAL RINSE: This operation should be done immediately after air mix to avoid any separation of resins inside the unit. Open inlet valve fully (V-1134, 2134, 3134) and air release valve (V-1145, 2145, 3145). When water starts coming through air release pipe close air release valve (V1145, 2145, 3145) and open/adjust rinse outlet (V-1166, 2166, 3166) valve. Rinse the unit for 04 minutes at the service flow rate. Open the conductivity isolation valve to check the MB outlet conductivity, if it is satisfactorily, close the rinse outlet (V-1166, 2166, 3166) valve and open service outlet valve (V-1143, 2143, 3143). The unit is ready for next service run.

ULTRAFILTRATION UNIT UFFP PUMP: UFFP-1001 A/B Permissive of starting of pump: 1. Module Ready (Overload Tripping) feedback should be available from the MCC. 2. UF-2101 A/B system should be selected in service (In AUTO mode of operation). 3. Intermediate DM Water storage tank level should not be Low (In AUTO mode of operation). 1 UF product water storage tank level should not be high ( In Auto Mode of operation) The UFFP Supply selections:


Pumps

will

be

provided

POC – 1954


PAGE

46

with

following



1. AUTO / MANUAL 2. PUMP-A / PUMP-B In Manual mode of operation The Pumps can be started if permissive 1 to 3 are met. In Auto mode of operation Selected Pump will start when any of the UF 2101 A/B is put in Service Mode. Standby pump will start automatically if the selected pump TRIP. An alarm will also generate due to Electrical Tripping. An alarm will be generated if Discharge header pressure reached HIGH set point.

1 2 3 4

UFFP supply pumps will TRIP on any of the following conditions: Electrical TRIP Both UF 2101A/B out of service (In AUTO mode of operation) Intermediate Water Storage Tank level Low (In AUTO mode of operation) UF product water storage tank level High (In AUTO mode of operation) Both pumps status (Running/Electrically displayed in PLC work station graphics.

Tripping)

will

be

UF Operation: Each UF will have the following selections: 1. AUTO / MANUAL 2. SERVICE / BACKWASH / CHEMICAL CLEANING

1. 2. 3. 4.

Service Cycle: In this section following equipments will be used, UF modules UF-2101A/B DM Water Storage Tank DMWST-1001 A/B/C UF backwash Pump UFBP-10011 A/B Chemical Cleaning System

Anyone UF stream A and B working. There will be two mode of operation in UF, which will be selected by operator through soft selection on Display.


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47



1. UF Operation Cycle (Service + Backwash + Fast Flush) 2. UF Chemical Cleaning Cycle Operator has select two pumps for service cycle and then start UF stream through display. 1. UF Operation Cycle: Initial Fast Flush: At every first start of UF system, valve related to Fast flush will be opened and then UFFP-1001 A/B will be started. This cycle will be continued for set time for Initial Fast Flush cycle. Service Cycle: After Fast Flush cycle, PLC will check following conditions before starting Service cycle. 1. Level of UF product water storage tank shall not be high 2. UFFP selected for Service cycle shall be electrically healthy. If these conditions found healthy all valves related to first half of service cycle will be opened, this cycle will be continued for set time for First half of Service Cycle. At completion of first half of service cycle, valve related to second half of service cycle will be opened, this cycle will be continued for set time for Second half of service Cycle. Service cycle will be terminated incase of following interlocks, 1. Level of IDMWST storage tank low. 2. Level of DM product water storage tank High. 3. UF Feed pressure high 4. Diff. Pressure across UF Modules is high Incase of one of UFFP feed pump tripped during service cycle, standby UFFP feed pump will be started by PLC. Respective message will be displayed indicating fault and stream, and hooter will sound. Back-wash Cycle:


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48



After completion of service cycle, PLC will check following conditions, 1. Level of UF product water storage tank shall not be low. 2. UFBP Back wash pumps UFBP-1001 A & B shall be electrically healthy If these conditions found healthy PLC will open valve required for first half of backwash cycle. Then Backwash pumps UFBP-1001 A & B will be started. This cycle will be continued for set time for first half of back-wash. At completion of first half, valves related to second half will be opened and after 3 sec valves for first half will be closed. This will be continued for second half of backwash. UF backwash cycle will be terminated incase of following interlock 1. Level of DM product water storage tank low 2. UF backwash pump UFBP-4101 A or B electrically tripped. 3. UF backwash pressure high. Fast Flush: After completion of backwash cycle, valves related to Fast Flush will be opened. After 3 sec UFFP pumps UFFP-1001 A or B will be started. This cycle will run for set time of Fast Flush. These three cycles (i.e. Service, backwash and fast flush) will be continued one by as per time set automatically. Incase of power failure during Service cycle or Fast Flush, PLC will start fast flush cycle first with power on. Incase of power failure during Backwash, PLC will start backwash cycle first with power on. Timers of UF service cycle, fast flush cycle & backwash cycle shall be retentive. 2. CHEMICAL CLEANING OF UF SECTION:


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49



Chemical Cleaning will be selected and performed manually by Chemical Cleaning pump. Levels of the tank will be monitored by Low level switch provided at CIP tank. Respective Auto valves will be opened as per valve sequence when Chemical Cleaning is started. Then after 3sec message for CIPRP start will come. This cycle will be performed till operate stop it. Interlocks: 1. If any neutralization pit level goes high then backwash will be stopped. 2. A ‘Hold’ soft button will be provided to prolong the current step at operator discretion. 3. At every step control system will check for the required drive / valve feedbacks. In case any of the feedback is not received within the set time, an operator alarm will be raised and the Service / Backwash / Fast Flush cycle will pause. An ‘over ride’ soft button will be provided for the Operator to reset the alarm and continue with the cycle. If backwash cycle stopped due to any reason backwash cycle timer will pause but not reset. Operator has to reset the timer manually. Valve sequence Chart for UF 2101 A/b Valve Sequence is as per attached Annexure. Attachment: 1. PLC Control Interlocks 2. Valve Sequence For Vessels


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50



Acid and Caustic Handling Area:-

Filling operation of Acid Tanks

Acid Tank AMT (SAC) ( 1001A ), AMT (MB) ( 1001B ) filling operation will be done by

operator through PLC work station soft

button. When level of the

respective tank becomes high acid inlet valve will close automatically.

Acid Tank, AMT (SAC), AMT (MB) level status will display in the PLC work station.

Filling operation of Caustic tanks

CDT (SBA) ( 1001A ), CDT (MB) ( 1001B ) filling operation will be done by operator through manual work. When level of the respective tank becomes high caustic inlet valve will close automatically.

Agitators of the CDT tanks will trip on low level of the respective CDT tank. Agitator will be start by operator through PLC/MCC/LPBS.

CDT (SBA), CDT (MB) level and agitator status will be displayed in the PLC work station.

Acid Tanks and Caustic Tanks filling shall be manual. The level high and low shall be alarmed at CRT.


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51



1. Neutralization pit operation:-

Pump shall be started and stopped manually. Pre condition for Neutralization pit pump starting:-

2.

Neutralization Pit level should not be low low.

3.

Neutrally influent disposal pump starter should not be tripped.

Status of the pump will be displayed in the PLC work station graphics. Interlock:-

If N-Pit -level become low Pump will trip automatically and an alarm will Generate.

Logic of N-Pit operation:-

Recirculation valve will open within 30 sec after starting of effluent transfer pump. PH transmitter will monitor the PH value for 10 min if pH value within limit recirculation valve will close and discharge valve will open.

Condition: - 1.

If PH value lower than pre determine range value for more than 10 min:Recirculation valve remain open. Caustic dosing valve will open. When PH value reach to predetermine range dosing will be stopped. When PH value is within the prescribed range continuously for 10 min, discharge valve will open and recirculation valve will close in auto.


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52



Condition – 2

If PH value higher than pre determined range value for more than 10 min. Recirculation valve remains open. Acid dosing valve will open and start dosing. When PH value reach to predetermine range dosing will stop. If PH with in range continuously for 10 min, discharge valve will open and recirculation valve will close.


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53



Checked by :

CHEMICAL & POWER CONSUMPTION


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54



Checked by :

CHEMICAL CONSUMPTION


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55



CHEMICAL CONSUMPTION:

Client

M/s.Rajwest Power Pvt Ltd. CHEMICAL CONSUMPTION DATAS

Sr. No.

1 2 3 4

Consumption / Day

ITEM

Hydrochloric Acid for SAC 30% Hydrochloric Acid for MB 30 % Caustic Soda for SBA 48% Caustic Soda for MB 48 %


No. of Stream

1390.98

2

284.07

2

570.30

2

177.55

2

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56



POWER CONSUMPTION


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57




Checked by :

POWER CONSUMPTION: POWER CONSUMPTION DATA FOR THE DRIVES IN OUR SCOPE OF SUPPLIES Motor load Power connecte absorbed d Load kW / kW DRIVE Qty. Qty (Rated Offere Workin (Actual Operation power) d g Power) Details

Sr. No.

ITEM

1

Clarified Water pump

03

02

15

Continuous

2

DGWTP

03

02

22

Continuous Intermittent Intermittent

3

DGB

03

02

0.75

4

Acid Unloading Pump

02

01

2.2

5

MBB

02

01

0.75

6

RWP Caustic Unloading Pump N-Pit transfer Pump

02

01

7.5

UF Feed Pump UF back wash pump Agitator Agitator

Intermittent Intermittent

7 8 9 10 11 12 Note: 1

Intermittent 02

01

2.2

02

01

15

02

01

7.5

02 03 03

01 03 03

15 1.5 0.75

Intermittent

Continuous Intermittent

Flow 100M3/hr @ 35MWC 1846M3/hr @ 55MWC 100M3/hr @ 35MWC 10M3/hr @ 15MWC 4.54M3/hr @ 4000MWC 30M3/hr @ 30MWC 10M3/hr @ 15MWC 100M3/hr @ 30MWC 55M3/hr @ 2.5 Kg/Cm2 96M3/hr @ 2.5 Kg / Cm2

Continuous Continuous

There may be slight variation in the Power Consumption of +/- 2% over the values provided above depending on the Voltage / Current / Frequency etc supplied to the system


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58




Checked by :

MAINTENANCE & TROUBLE SHOOTING


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59



SYSTEM MAINTENANCE:

This section consists of summary of system maintenance tasks which include scheduled maintenance, trouble shooting and repairs. This section is to be read in conjunction with the detailed maintenance/trouble shooting/repair instructions in the respective manuals supplied by various manufacturers. All maintenance should be documented in a maintenance log, as to maintain a chronological history of all maintenance tasks performed. While attempt has been made to make this section as exhaustive as possible, site specific problems are not included here. Need to evolve and establish detailed maintenance schedule specific to the site may exist and instruction for handling such situations may be added to this section, in consultation with the manufacturer, where necessary. SCHEDULED MAINTENANCE: Regular preventive maintenance tasks are recommended on a periodic basis. The critical aspects are summarized below. INSTRUMENT CALIBRATION: Recommend intervals for calibration tasks as recommended on a periodic basis. The critical aspects are summarized below to serve as guide.


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60



Checked by :

INSTRUMENT RECOMMENDED INTERVAL

Conductivity instruments

90 days

Flow indicator

30 days

Pressure indicators

100 days

Pressure switch

30 days

pH instrument

90 days

ROUTINE MAINTENANCE: Open the valve bodies periodically and check the condition of internal parts and lubricate the seats/spindles.

ALSO REFER VENDOR’S OPERATION MANUALS.

PRESSURE SAND FILTER:-

TROUBLE SHOOTING SR.

SYMPTOM

POSSIBLE CAUSE

ACTION

NO. 01.

Pressure drop across the bed & reduction in outlet flow rate.

(a) Media bed may be

Clean up media bed and

fouled.

carry out backwash.

(b) Media is not backwashed properly.

02.

(a) Fine sand coming out of filter plant.


(a) Fine gravel under

Re- bed the unit.

bed may have

POC – 1954


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61



(b) High turbidity at outlet.

shifted. (b) Channelisation of filter bed.

03.

Drain flow is less than what is listed in the specifications.

a) Clean backwash flow

a) Backwash flow control plugged.

control.

b)Drain line is restricted.

b) Clear any obstructions in drain line. c) Air scouring for 20-30 Minutes.

PRESSURE SAND FILTER

Once a week, backwash the filter for about one hour, in order to

minimize

accumulation of solids in the filter bed.

Once in a six months, open up the filter vessel and remove all the filter media/under bed. Clean the internal surfaces. Then recharge the under bed and filter media sequentially and close the filter vessel.

CHARGING THE MEDIA

[1]

Unpack the under bed materials, comprising four grades of pebbles and one

grade of crushed gravel. Wash each separate grade thoroughly with water to make it free from dust, dirt and other impurities.

[2]

Open the backwash inlet valve to fill up water upto a small level in the vessel.

Charge the first (coarser) layer of pebbles into the vessel with extreme care, so as to M/s. Rawest Power Pvt Ltd

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62



avoid damaging the laterals or nozzles/strainers, and arrange the pebbles properly around the laterals. Level the layer and note its depth. [3]

charge the remaining layers of pebbles and gravels successively in a similar

manner, first increasing the water level stepwise to cover each successive layer(by opening backwash inlet valve), then charging and leveling each layer, and noting the bed depth at each stage. Check and note the total depth of the under bed.

[4]

Unpack the mixed sand media and wash it thoroughly with water, to make it

free from dust, dirt and other impurities.

[5]

Open the service inlet valve and fill up about half the vessel with water.

Charge the mixed sand media and level the top surface uniformly. Check the bed depth.

[6]

Fit the inverted bell mouth distributor by bolting. Using a rubber gasket for

jointing. WASHING THE MEDIA [1]

Open the backwash outlet valve fully, and open the backwash inlet valve

ensuring that sand is not carried over to drain. Continue backwashing until the effluent is completely clear, and then close both the valves. [2]

Open the rinse outlet valve and drain the water level in the vessel to just

below the surface of the filter bed. Scrape the top surface and remove any fines and dust collected on the surface. [3]

Close the vessel by bolting (manhole cover), using a rubber gasket for joining.

[4]

Connect the air release pipe work.

CLEANING OF FILTER BED:M/s. Rawest Power Pvt Ltd

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Once in about six months, open the vessel manhole, remove any lumps or debris from the top surface of the filter bed. Carry out extended backwash as above, drain down the water level just below bed surface and scrape the top surface to remove any fines or dust collected.

If oil-free compressed air is available, it can be used for air scouring of the filter bed after the backwashing as above. For this purpose, connect an M.S. Pipe (1.0 - 1.5 meters long) to a flexible base. Drain the water level in the filter to 70-80 mm above the bed level and insert the M. S. pipe into the filter bed to the extent of about one meter. Connect the flexible hose to the source of compressed air and start the air supply. Continue air scouring of the bed for about 20-30 minutes. Then remove the M. S. pipe from the filter bed and backwash the filter bed until the effluent is clear. Drain the water level and again scrape the top surface to remove any fines or dust collected.

Close the filter vessel manhole cover before returning the filter to service. ACTIVATED CARBON UNIT CHARGING THE MEDIA (ACTIVATED CARBON): [1]

All the activated carbon washed with clean water to removing dust particles

and other impurities upto the effluent is clear.

[2]

Open the backwash inlet valve to fill up water upto a small level in the vessel.

Charge the activated carbon into the vessel with extreme care. Check and note the total depth of the underbid.

[3]

Unpack the activated carbon wash it thoroughly with water, to make it free

from dust, dirt and other impurities. M/s. Rawest Power Pvt Ltd

POC – 1954


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64


[4]


Fit the inverted bell mouth distributor by bolting. Using a rubber gasket for

jointing.

[5]

Close the vessel by bolting (either the manhole cover or the top body flange

joint), using a rubber gasket for joining.

[6]

Connect the air release pipe work.

WASHING THE MEDIA (ACTIVATED CARBON): [1]

Open the backwash outlet valve fully, and open the backwash inlet valve,

ensuring that activated carbon particles are not carried over to drain. Continue backwashing until the effluent is completely clear, and then close both the valves.

[2]

Open the rinse outlet valve and drain the water level in the vessel to just

below the surface of the filter bed. Scrape the top surface and remove any fines and dust collected on the surface.

CLEANING OF FILTER BED :

Once in about one month, open the vessel manhole and remove any lumps or debris from the top surface of the filter bed. Carry out extended backwash drain down the water level just below bed surface and scrape the top surface to remove any fines or dust collected.


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If oil-free compressed air is available, it can be used for air scouring of the filter bed after the backwashing as above. For this purpose, connect an M.S. Pipe ( 1 - 1.5 meters long) to a flexible base. Drain the water level in the filter to 70-80 mm above the bed level and insert the M.S. pipe into the filter bed to the extent of about one meter. Connect the flexible hose to the source of compressed air and start the air supply. Continue air scouring of the bed for about 20-30 minutes. Then remove the M.S. pipe from the filter bed and backwash the filter bed until the effluent is clear. Drain the water level and again scrape the top surface to remove any fines or dust collected.

Close the activated carbon vessel manhole cover before returning the filter to service.

ROUTINE MAINTENANCE :

Open the valve bodies periodically and check the condition of internal parts. Replace diaphragms if cut or frayed, and lubricate the seats / spindles.

Once in year, open up the filter vessel and remove all the filter media/underbid. Clean the internal surfaces. Then recharge the underbid and filter media sequentially and close the filter vessel.


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66



SAC/SBA UNIT :

CAUSE

ACTION

Poor backwashing

Regular check of flow and duration adjust with changes in water temperature and pressure.

Under drain failure Cation resin bed depth

Resin passing to unit which follow.

increase in multi bed.

Low pressure

Reduce flow

P. decreases with flow

Increased temperature

A) lower viscosity

drop

B) check wash rate at higher temperature. Resin loss, reduced bed

Check for loss to sewer during wash

depth

Under drain failure Resin decross-link reduces density : A) resin attrition due to age B) oil contamination. Flotation due to released gases if wash inlet valve used to throttle.

HYDROGEN CATION Loss of capacity

Increased loading and / or

A) increase regenerant

distribution

B) add resin


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67



C) investigate pretreatment Over run capacity, previous A) normal regenerant does not restore. run

Double regenerant qty. For next cycle. B) adjust end of run determination.

Iron, manganese,

A) check water supply quality.

aluminium coating &

B) check regenerant chemicals for

precipitates

contaminants. C) chemically cleaned resins. D) pretreatment for removal

Channeling, poor

A) s.s. Loading

distributions.

B) iron and other metals C) low flow D) poor distribution E) broken

Resin age

or clogged distributors.

Upto 3-5 years loss in capacity consider normal check resin moisture to show decross-link analysis resin to determine remaining useful life.

Resin loss

Excessive wash Under drain failure

Regenerant concentration

A) check pumps, ejectors, drawdown

and quality

etc. B) check dilution flows, time settings, apply correct amount at correct concentration.

Excessive rinsing

A) analysis for end or recycle B) adjust rinse period to suit time cycle.

Resin oxidation

A) pressure of oxidants (chlorine) and oxygen.


POC – 1954


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68



B) in presence of catalyst (iron) decrosslinking which reduce capacity and eventually high pressure drop. C) replace if 60 % moisture or higher


POC – 1954


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69



Calcium Sulphate

Sulphuric acid regenerant unit calcium in

precipitation (barium

treated water.

sulphate precipitation)

Remove with chemical cleaning readjust acid concentration

Calcium Phosphate

Chemically clean pre-treatment for

colloidal silica, zirconium,

removal before exchanger.

titanium oxides, oils grease. Poor quality

Valve leakage

Check bed. Bed sample v/s. Outlet pipe sample (before and after valving special caution on was inlet valve check limit stops on electric valves check air pressure.

CAUSE

ACTION

Excessive flow

Insufficient reaction time reduces flow.

Low flow rates

Poor distribution channeling place one or more units in stand by recycle treated water to inlet.

Improper regeneration


Set regeneration cycle as

POC – 1954


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70



Resin fouled, chemically clean, pretreat

Iron in treated

for removal prior to exchange additives during each regeneration. recommended.

Loss of capacity Chemical precipitation

Hardness in regenerant water and

/ or leakage from cation unit or silica precipitation. Organic fouling

Pretreatment for removal chemically clean resin oxidation of cation resin can foul anion.

Resin age, resin loss,

As in weak base and previous notes

channeling poor distribution

(excessive caustics concentration

regenerant concentration,

reduce capacity)

quantity over exhaustion. Heavy metal fouling

Check cation for fouling check regenerant for iron chemically clean.

Excessive

Chemically clean pretreated to control organisms.

Poor quality

High silica in treated water

Organics fouling, chemical clean, check regenerant concentration and quantity, check regenerant temperature

Low temperature

Slow reaction rates reduce flow rates pre-heat feed.


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71



Checked by :

CAUSE

ACTION

Calcium in treated water (should be

Calcium sulfate, precipitation on

zero)

sulfuric acid regenerates clean. Adjust acid concentration and time of application. Calcium Phosphate or other complexes you feed.

Hardness in treated water (should

Valve leakage high flow channeling

be zero)

poor distribution.

Excessive sodium in treated water.

Over run capacity, check regenerant concentration and quantity investigate up flow or hydrochloric acid regenerant.

High Pressure

Valve Partially closed

Check and adjust all valve

Internal distributor

Backwash

Blockage with resin, iron, debris

Inspect, repair / clean distributor

Increased flow rate

P. Increases with flow

Increased S.S. Loading

Mid cycle backwash

Bed Compaction

Air Or mechanical stir to

Drop

supplement backwash Resin fines

Remove with backwash

Cation resin decross link.

Analyze resin. Replace if 60% or higher moisture.

Lower water temperature

P. Increases with higher viscosity at low temperature

Broken under drain, resin OR sub fill

Inspect internals

in collectors OR outlet pipe.


POC – 1954


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72



Checked by :

Channeling.

Backwash Check Collectors Check valve operating speeds. Check support bed upset.

Poor backwashing

Regular check of flow and duration adjust with changes in water temperature and pressure.

Anion resin bed depth increase in

Under drain failure

multi bed Biological growths

Chemically clean pretreat to control organisms

Low pressure

Reduce flow

P.Decrease with flow

Increased temperature

Lower viscosity check wash rate at

Drop

higher temperature Resin loss, reduced bed depth

Check for loss during wash under drain failure. Resin decors-link reduces density. Resin attrition due to age oil contamination. Flotation due to released gases if wash inlet valve used to throttle.

Loss of capacity


Increase Hcl regenerant, add CSA-

(Strong Acid

distribution

9 resin investigate pre-treatment.

Over run capacity, previous run.

Normal regenerant does not

Cation – MB)

restore double regenerant adjust end of run determination. Excess sodium in treated water.


POC – 1954


Over run capacity

PAGE

73



Checked by :

check regenerant Concentration and quantity investigate up flow or hydrochloric acid regenerant. Iron, Manganese, Aluminum coating

Check water supply

& precipitates

Check wash Check regenerant chemicals for contaminates. Chemically clean resins pretreat for removal.

Channeling, poor distribution

Check wash SS loading Iron and other metals Low Flow Poor distribution Broken or clogged distributors.

Resin age

Up to 5 yrs loss in capacity considered normal check resin moisture to show decors-link analyze resin to determine remaining useful life.

Resin loss

Excessive wash over drain failure.

Regenerant concentration and

Check Pumps, Ejectors, Drawdown

quantity

etc. Check dilution flows, time setting apply correct amount at correct concentration.

Excessive rinsing.

Analyze for end OR rinse determination adjust rinse period to


POC – 1954


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74



Checked by :

suit. Resin oxidation

Pressure of oxidants (chlorine) and oxygen in presence of catalysis (iron) decors-linking which reduce capacity and eventually high pressure drop. Replace if 60% moisture or higher.

Poor Quality

Calcium Phosphate colloidal Silica,


Zirconium, Titanium, Oxides, Oils


Valve Leakage.

Check bed sample v/s outlet pipe sample (before & after valving special caution on was inlet valve. Check limit stops on electric valves check air pressure.

Excessive flow

Insufficient reaction time reduces flow.

Low Flow Rates.

Poor distribution channeling place one or more units in stand by recycle treated water to inlet.

Loss of capacity

Increased loading of exchangeable

Add ASB-108 resin increase

(Strong Base

Ions

regenerant check degassifier for

Anion – MB)

carbon dioxide removal check for change in Organic fouling

% anions.

Pretreat for removal chemically clean resin oxidation of cation resin can foul anion.

Resin age, resin loss, channeling

See in previous section.

poor distribution regenerant concentration, quantity over


POC – 1954


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75



Checked by :

exhaustion. Heavy Metal fouling

Check cation for fouling. Check regenerant for iron chemically clean.

Poor Quality

High silica in treated water.

Organic fouling. Chemical clean. Check regenerant concentration & quantity. Check regenerant temp.

Low temperature


Iron in treated

Resin fouled. Chemically clean Pretreat for removal prior to exchanger additives during each regeneration.


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76



ALKALI BRINE TREATMENT FOR ANION RESIN

Organically fouled anion resins can be treated for removal of organic fouling or resin by using (1.5 to 2 bed volume) of solution containing 10% NaCl + 2% NaoH to be percolated through the bed and keep preferably 24 hrs for soaking and minimum 12 hrs. If dark brown colour appears continuously through the extended rinse procedure repeat the same procedure . Whenever, solution is colorless the organic fouling is considered to be removed.

SODIUM HYDROXIDE SOLUTION AT 22°C

SPECIFIC GRAVITY

GRAMS / 100 ML

PRECENT NAOH

1.0095

1.010

1.010

1.0207

2.041

2.041

1.0318

3.095

3.095

1.0428

4.171

4.171

1.0538

5.269

5.269

1.0648

6.389

6.389

1.0758

7.531

7.531


POC – 1954


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77



Checked by :

MB UNIT : TROUBLE SHOOTING Loss of capacity


Increase Hcl regenerant, add CSA-

(SAC – MB)

distribution

9 resin investigate pre-treatment.

Over run capacity, previous run.

Normal regenerant does not restore double regenerant adjust end of run determination.

Excess sodium in treated water.

Over run capacity check regenerant concentration and quantity investigate up flow or hydrochloric acid regenerant.

Iron, Manganese, Aluminum

Check water supply

coating & precipitates

Check wash Check regenerant chemicals for contaminates. Chemically clean resins pretreat for removal.

Channeling, poor distribution

Check wash SS loading Iron and other metals Low Flow Poor distribution Broken or clogged distributors.

Resin age

Up to 5 yrs loss in capacity considered normal check resin moisture to show decors-link


POC – 1954


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78



Checked by :

analyze resin to determine remaining useful life. Resin loss

Excessive wash over drain failure.

Regenerant concentration and

Check Pumps, Ejectors,

quantity

Drawdown etc. Check dilution flows, time setting apply correct amount at correct concentration.

Excessive rinsing.

Analyze for end OR rinse determination adjust rinse period to suit.

Resin oxidation

Pressure of oxidants (chlorine) and oxygen in presence of catalysis (iron) decors-linking which reduce capacity and eventually high pressure drop. Replace if 60% moisture or higher.

Calcium Phosphate colloidal


Silica, Zirconium, Titanium,


Oxides, Oils Poor Quality

Valve Leakage.

Check bed sample v/s outlet pipe sample (before & after valving special caution on was inlet valve. Check limit stops on electric valves check air pressure.

Excessive flow

Insuf. reaction time reduce flow.

Low Flow Rates.

Poor distribution channeling place


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79



Checked by :

one or more units in stand by recycle treated water to inlet. Loss of capacity

Increased loading of

Add ASB-108 resin increase

(Strong Base

exchangeable Ions

regenerant check degassifier for

Anion – MB)

carbon dioxide removal check for change in Organic fouling

% anions.

Pretreat for removal chemically clean resin oxidation of cation resin can foul anion.

Resin age, resin loss, channeling

See in previous section.

poor distribution regenerant concentration, quantity over exhaustion.

Heavy Metal fouling

Check cation for fouling. Check regenerant for iron chemically clean.

Poor Quality

High silica in treated water.

Organic fouling. Chemical clean. Check regenerant concentration & quantity. Check regenerant temp.

Low temperature



POC – 1954


PAGE

80




Checked by :

ANALYSIS


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81



CHEMICAL CONTROL

Instructions for making chemicals tests on samples of the cation and anion treated water are given on the attached testing instructions.

CATIONS UNITS :

(1)

The water leaving the cation unit will be acid to methyl orange indicator, the

extent of the acidity depending on the total dissolved solids in the raw water. The exchange of calcium, magnesium and sodium ions takes place in strick chemical equivalence and the raw water analysis is given in the description.

(2)

In practice it will be found that the actual acidity of the cation treated water -

known as the free mineral acidity (FMA) - will approach very closely to the EMA, with most waters, the FMA should be within 3 to 5 ppm of the EMA.

(3)

The higher the EMA of the raw water the greater will be the difference

between it and the FMA. This will be reflected in higher conductivity and chloride figures in the dematerialized water.

(4)

The chemical composition of many waters is liable to vary from time to time,

and in consequence there will be an equivalent variation in the amount of good quality water produced by the cation unit.. When this occurs the unit should be rinsed till two successive tests give the same figures for FMA.


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82



ANION UNIT :

(1)

The treated water from the anion unit immediately after regeneration is

virtually free from co2, silica and other dissolved solids apart from a trace of sodium hydroxide. At this stage the PH value will be around 9.0 and the electrical conductivity less than 10-20 micro- ohms. This PH will be maintained, with a steady fall in treated water conductivity unit the point of break through of co2 and silica, when there will be a sharp drop in PH value to a new low level around PH 6.5 to 7.0. After this point has been 5 ppm but the conductivity will still be low, normally between 2 to 5 micro-ohms; the water will also contain co2 and silica.

(2)

If the present of silica and co2 is objectionable the anion unit must then be

regenerated, other wise the unit can remain in service until a rise in conductivity indicates that the anion exchange material is exhausted the amount of Sodium Hydroxide in the dematerialized water, is dependent on the analysis of the raw water and on the cation leakage from the cation unit. The latter is partly a function of the raw water quality, and partly a function of the type and quality of acid used for regeneration.

(3)

The Phenolphthalein alkalinity of the dematerialized water during the silica

free part to the run will normally be about 2 to 5 ppm, but will also increase will increasing dissolved solids in the raw water.

(4)

The conductivity variation is rather indefinite. 1.0 ppm of Nacl results in a

conductivity of 1.8 micromohs. Hence when the conversion to NaoH stops there will be a decrease in conductivity but at the same time there will be on increase due to non-removal of co2.


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The following analytical test methods are included in the attached

E.M.A.

F.M.A.

Chloride

Free CO2 (cation water) Free CO2 (raw water) Silica (0-1 ppm)

Silica (0-1 ppm)

Alkalinity

Hardness


POC – 1954


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84

sheets.



TEST : EQUIVALENT MINERAL ACIDITY (E.M.A.)

REAGENTS : 1.

DOSHION CSA - 9, STRONGLY ACIDIC, CATION EXCHANGE RESIN.

2.

APPROXIMATELY 2N HYDROCHLORIC ACID.

3.

SCREENED METHYL ORANGE INDICATOR.

4.

0.02 N SODIUM HYDROXIDE SOLUTION.

METHOD : Measure under water, 50 ml. Settled of doshion CSA - 9 into a chromatographic tube. The tube should be fitted with an outlet tap or screw clip at the bottom. If an ordinary glass tube is used, above this outlet a plug of glass wool to support the bed of ion exchange resin is required. Pass 50 ml of sample and discard the effluent. Pass two 100 ml. Aliquots through the column at the same rate collecting the respective effluents separately. Titrate each of the effluents in turn with 0.02N Sodium Hydroxide using screened methyl orange as indicator.

MLS OF TITRATION (B) --------------------------------

X 1000 = PPM E.M.A. AS CaCO3

MLS OF SAMPLE (A) REGNERATION OF CATION COLUMN : Backwash the ion exchange resin in an upward direction with distilled or deionised water to loosen the bed, allow the bed, to settle, drain water down to the resin surface and pass 250 ml. Of 2N Hydrochloric acid in a downward direction through the column at a rate of 3-5 ml/min. Rinse the column with distilled or deionised water until the effluent is alkaline to screened Methyl Orange.


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85



NOTE : 1.

The column prepared in the above manner may be used for several

determinations before it is exhausted. It is capable of exchanging the equivalent of 5000 mgm. Of calcium carbonate, when exhausted it need simply be washed, regenerated and rinsed again.

2.

This test actually determines the acidity equivalent to the

dissolved neutral

salts in the water (Sulphate + Chloride + Nitrate).

TEST : FREE MINERAL ACIDITY (F.M.A.)

REAGENTS AND APPARATUS :

Burette for standardized sodium hydroxide conical flask. 100 ml. Graduated cylinder. 0.02N (N/50) sodium hydroxide solution. screened Methyl Orange indicator. preparation of indicator solution Dissolve 0.2 g. Of crystalline methyl orange in a mixture of 25 ml. Methylated spirits and 25 ml. Deionised water. Dissolve 0.28 g. Xylene cyanol ff in a mixture of 25 ml. Methylated spirits and 25 ml. Deionised water mix the two solutions together.


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Checked by :

METHOD :

1.

Measure out 50 ml. Of the sample and pour into the flask.

2.

Add three drops of screened methyl orange indicator. The sample

should

Run in 0.02n sodium hydroxide solution a few drops at a time until

the

turn.

3.

sample turns Smokey-grey. Mix thoroughly while adding the

solution.

CALCULATION :

Free mineral acidity = BURETTE READING X 20 PPM AS caco3. NOTE :

This test is used to check water treated by a cation exchanger

regenerated with

acid TEST

:

CHLORIDES


burette for Silver Nitrate silver nitrate solution 0.02N (N/50) Potassium chromate indicator solution Phenolphthalein indicator solution Nitric acid 0.02 (N/50) 100 ml. Graduate cylinder


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87



10 ml. Graduated pipette (for boiler water or water with a high

chloride

content). 150 ml. Conical flask.

METHOD :

1.

Measure a 100 ml. Sample of the water to be tested in the graduated

cylinder, then pour sample into the conical flask.

2.

Add five drops of Phenolphthalein indicator; if the sample turns

0.02N Nitric acid until the pink colour is just

discharged.

3.

Add five drops of potassium chromate indicator.

4.

Run silver nitrate into the sample, drop by drop, with constant

the yellow colour begins to acquire a faint orange

5.

pink run in

shaking until

tint.

Note the burette reading - 'A' measure out 100 ml. Of distilled (or deionised) water, pour into

repeat the test procedure. Note the burette reading -


POC – 1954


'B'.

PAGE

88

the flask and



CALCULATION :

Chloride content = ('A' - 'B') ml. Of 0.02N silver nitrate used x 10 expressed in parts per million (ppm) as caco3. NOTE : In the case of boiler water or waters with a high chloride content a smaller sample should be taken e.g., 10 ml. The result should then multiplied accordingly e.g. if a 20 ml. Sample is used multiply the burette reading by 50.

CHLORIDES

Mercuric nitrate method for determination of chloride REAGENTS AND APPARATUS :

Burette for Mercuric Nitrate 0.02N Mercuric Nitrate Hg (N03)2 solution. concentrated Nitric acid. distilled water. 0.02N sodium chloride solution. 0.1% w/v solution DiPHenylcarbazone. Nickel Nitrate (buffer solution) 100 ml. Graduated pipettes. 250 ml. Conical flasks.


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89



REAGENTS :

1.

0.02N Mercuric Nitrate Hg (No3)2 :

Dissolve 3.24 gms Hg (No3)2 or 3.42 gms Hg (N3)2 in approximately 500 ml. Of deionised or distilled water which contains 3 ml. Of concentrated nitric acid. When totally dissolved make up to 1 litre standardize as under procedure against standard sodium chloride solution.

2.

Standard sodium chloride solution (0.02N) :-

Dissolve 1.17 gms of predried analar Sodium chloride in 1 ltr. Of distilled or dionised water (i.e. Ml. 0.02n NaCl = 1 MGCl as caco3). 3.

0.1% w/v solution of DiPHenylcarbozone in Iso-Propanol or Ethanol. This solution is unstable and should be renewed monthly.

4.

Nickel Nitrate (buffer solution) :4 molar crystalline Nickel Nitrate solution containing 5 ml. Of concentrated Nitric acid per 100 ml. Of solution.

PROCEDURE :

Measure 100 ml. Of sample into a 250 ml. Flask, add 2 ml. DiPHenylcarbazone solution and mix. And 1 ml. Of nickel nitrate buffer solution and mix again. The resulting solution should be a pale green colour. If the solution has an orange tint, add nitrate drop wise until the green tint is achieved. Titrate the solution with


POC – 1954


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90




Checked by :

mercuric nitrate until a faint but persistent violet colour is observed (i.e. The end point). CALCULATION :

Chloride content =

ml. Of titration solution x 1000 -------------------------------ml. Of sample

Expressed in ppm chloride as caco3. TEST RESIDUAL CO2 IN CATION EXCHANGER TREATED (H.I.) WATER REAGENTS AND APPARATUS : -

Sodium hydroxide 0.02 N (N/50) Phenolphthalein indicator solution. Methyl orange indicator solution. Burette for standard alkali. Co2 flasks 10 ml graduated cylinder

PROCEDURE :-

1.

100 ml. Samples of H.I. Water are measured into two 250 ml. Co2 flask.

2.

The first is carefully titrated with N/50 NaoH to M.O. End point and the

heading (A) noted.


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91



NOTE :

The N/50 NaoH is rendered free from carbonate by passing the solution through a strongly basic anion exchange such as deacidite ASB-108 in the hydroxide form during the titration i.e. The lower half of the burette with de-acudute FF (IP) (OH) form originally washed to an N/50 NaoH in/out balance with N/50 NaoH. TEST : FREE CARBON DIOXIDE3. carbonate free N/50 naoh to P

The second sample is now titrated with

Phenolphthalein end-point and the reading (B)

noted. CALCULATION :

(B) - (A + 0.8) x 8.8 = ppm co2


Burette for sodium carbonate solution. Sodium carbonate solution 0.040 (n/25) Phenolphthalein indicator (solution or tablets) 100ml. Nessler cylinder. Glass stirring rod. PROCEDURE : 1.

Fill the nessler cylinder to the 100 ml. Mark with the water being tested,

avoiding splashing and add 2 tablets or 20 drops of Phenolphthalein indicator.

2.

Run in 0.04 N sodium carbonate, a few drops at a time with gentle stirring

until a pale pink colour is produced which persists for one minute. Take the burette reading. M/s. Rawest Power Pvt Ltd

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INTERPRETATION OF RESULT :

Free carbon dioxide content= burrette reading x 10 (expressed in parts/ million) (ppm) as CaCO3. TEST SILICA (0-1 PPM) - MOLYBDENUM BLUE METHOD.

REAGENTS :

1.

ACID MOLYBDATE SOLUTION :

75 gms. Of ammonium molybdate are dissolved in 500 ml. Of distilled water. 322 ml. Of 10/n sulPHuric acid are added gradually with constant shaking. The solution is then made up to 1 litre with silica free water.

Note : Approx. 10/n sulPHuric acid is prepared by mixing 100 ml. Of conc. Acid with 260 mls. Silica-free water.

2.

10% w/v tartaric acid solution (or 10% oxalic acid solution).

3.

Reducing agent.

A)

90 gms. Sodium metabisulPHite are dissolved in 800 ml. Of silica free water.

B)

7 gms. Anhydrous sodium sulPHite are dissolved in 10 ml. Silica-free water.

Together with 1.5 gms. Of 1 - amino, 2 - naphthol, 4 - sulPHonic acid. Solution (b) is mixed with solution (a) and the total volume made up to 1 litre with silica-free water.


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APPARATUS : Lovibond nessleriser Disc for silica 0.2 - 1.0 ppm Two 50 ml. Graduated tubes for nessleriser. Pipettes Alternatively a spectrophotometer may be used at the wave length corresponding to a maximum absorption (approx. 800 mu. But the exact wave length will have to be checked on each individual instrument.)

METHOD :

50 mls. Of the water under test is treated with 2.0 ml. Acid molybdate solution and allowed to stand for 5 mins. At a temperature of 20 -30°c. If a tinge of yellow appears, 4 ml. Of 10% tartaric (or oxalic) acid is added to the sample followed by 1.0 ml. Of reducing agent and the sample allowed to stand for 20 mins. The blue colour of the sample is compared with that of a blank comprising the same water without reagents, using either A B.D.H. Lovibond nessleriser or a previously calibrated absorption meter.

NOTE :

SILICA FREE WATER : Prepare and store in A polythene bottle a large batch of water containing not more than 0.005 Sio2 determine the silica content of the water by treating it as a sample as under 'method'. This water is used to prepare reagents and standards and to dilute samples when necessary - distilled water from an all metal 'still' or water which has been passed successively through a mixed bed deionization unit and a strongly basic anion exchanger such as a de-acidite asb-108 unit regenerated with naoh at a level of 20 lbs./cu.ft. Has been found to meet this specification. M/s. Rawest Power Pvt Ltd

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TEST SILICA (0-20 PPM) - MOLYBDENUM BLUE METHOD. REAGENTS AND APPARATUS : BDH lovibond nessleriser. Disc with colour standards 0.05 mg. To 1.0 mg Sio2. 10% w/v Aqueous solution of Ammonium Molybdate. 2N Sulphuric Acid solution.

METHOD :

1.

Fill one of the nessler glasses to the 50 ml. Mark with the sample and place in

the left hand compartment of the nessleriser. 2.

Fill the other nessler glass with the sample at 25-30°c. Add 4 ml. Of the 2n

sulphuric acid and 2 ml. Of the ammonium molybdate solution. Mix thoroughly, place in the right hand compartment and allow to stand for 10 minutes. 3.

Fit the glass standard disc in the hinged lid.

4.

Stand the nessleriser facing a uniform source of light, looking north if possible

and compare the colour of the sample with the colours in the disc. Rotate the disc until the colours are matched.

INTERPRETATION OF RESULT :

Silica content in parts/million (ppm)= disc. Reading x 20 as Sio2. Should the colour in the test solution be deeper than the deepest standard, a fresh test should be carried out using a smaller quantity of sample and diluting to 50 ml. With distilled water before adding the reagents.


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NOTE : Most colourless salts, even when present in relatively large quantities are without influence upon the colour produced in the test provided the concentration of free acid is not unduly disturbed. Phosphates, however, must be absent, since they respond to the test and yield a yellow colour similar to that produced by silica. Phosphates maybe removed by treating 100 cc. Of the solution under test with 50 ml. Of Sorensen’s borate buffer solution (PH 10.0) and 2 ml. Of 2N Calcium Chloride solution; after mixing and allowing to stand for 2 hours the mixture is filtered. The test is made on 50 ml. Of the filtrate by the method described above. As Sorensen’s borate buffer invariably contains silica derived from the glass bottle, a blank test should be carried out and the necessary correction made. The result must be multiplied by 1.5.


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TEST


ALKALINITY -(TOTAL METHYL ORANGE AND PHENOLPTHALEIN)


Burette for standard acid Nitric acid 0.02 n (n/50) 100 ml. Graduated measuring cylinder Conical flask (150 ml.) Phenolphthalein indicator solution Screened Methyl Orange indicator solution 10 ml. Graduated pipette Sodium ThiosulPHate 10% w/v solution.

METHOD : If the alkalinity of the water is low, 100 ml. Of sample should be measured using the graduated cylinder. Otherwise a 10 or 20 ml. Portion of sample should be taken with the pipette.

1.

Transfer the appropriate amount of sample to the conical-flask and add 5 drops of Phenolphthalein indicator.

2.

Run in 0.02 N Nitric Acid from the burette until the pink colouration is just discharged.

3.

Note the volume of acid used multiply by the appropriate factor (see table) and record as 'p'.

MLS OF SAMPLE TAKEN

FACTOR

100

x

10

20

x

50

10

x

100


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Checked by :

4.

If the water is chlorinated add 2 drops of sodium thiosulPHate solution. Add 2 drops of screened methyl orange indicator and continue the addition of acid until the solution just turns to Smokey grey.

5.

Read the burette again note the total amount of acid used in both titration

and mutiply by the appropriate factor (see the table above) record result as

'm'.

INTERPRETATION OF RESULTS :

The relative quantities of bicarbonate and carbonate and caustic alkalinity can then be obtained from the following table : BICARBONATE

CARBONATE

CAUSTIC

P=nil

m

nil

P<1/2 m

m-2p

P=1/2 m

nil

2p

nil

P>1/2 m

nil

2(m-p)

2 p-m

P= m

nil

nil

p

2p

nil nil

The above results are expressed in parts/million (ppm) as CaCO3 NOTE : 1.

Screened Methyl Orange Indicator solution. preparatian of indicator solution-dissolve 0.2g of crystalline

Methyl range in

mixture of 25 ml. Methylated spirits and 25 ml. Deionised water. Dissolve 0.28 g Xylene Cyanol ff in a mixture

of 25 ml. Methylated spirits and 25 ml. Deionised

water. Mix the two solutions together. M/s. Rawest Power Pvt Ltd

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2.

For most raw water samples, as also lime softened waters a 100 ml. Sample.

3.

Use Sodium Thio-sulPHate solution before addition of Methyl Orange only if

water has been chlorinated e.g.from bottling precipitators. TEST HARDNESS REAGENTS AND APPARATUS

1.

N/50 E.D.T.A.

4.0 grams of disodium dihydrogen ethylene diamine tetra acetate are dissolved in 800 mis. Of water and standardised and adjusted a standard hardness solution unit 1 ml.=1 m.gm. Caco3

2.

AMMONIA BUFFER

(a)

Dissolve 16.9 g Ammonium Chioride, NH4C in 143 ml. Conc ammonium

hydroxide, NH4OH; add 125 g of Magnesium salt of EDTA (this salt is available commercially) water. (b)

A buffer containing the Magnesium salt of EDTA may also be made as follows

:

Dissolve 16.9 g NH4CL in 143 ml. Conc nh2oh. Weigh out 0.25 g MgSo4. 7H2O. Transfer qnantitativly to a 100 ml. Volumetric flask. And make up to colume with distilled water. Pipet 50.0 ml. Of this solution into a porcelain dish; add a few drops of the NH4cl-NH4oH solution (sufficient to achieve a PH of 10.0-10.1); add 2-3 drops of indicator solution and titrate with edta with continucus stirring until a steel-blue colour with no tinge of red is present. To the 50 ml. Of solution remaining in the volumetric flask add exactly the volume of edta required in the above titration. Add this solution to the NH4cl-NH4oH mixture and make up to 200 ml. With distilled water.


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Keep the solution (A or B) in a plastic or resistant glass container, tightly stoppered to prevent loss of nh3 or pickup of Co2.

3.

INDICATOR

Mix 0.5 g of Erichrome black t with 4.0 g Hydroxylamine Hydrochloride. Dissolve this mixture in 100 ml. Of 95 per cent Ethyl or Isopropyl Alcohol. 4.

BURETTE FOR N/50 EDTA. 250 ml. Beaker. 50 ml. Measuring cylinder Stirring rod For soft water use 750 ml. Evaporating dish and magnetic or

electric

stirrer. 50 ml. Measuring cylinder. METHOD

A.

FOR RAW WATER

A 50 ml. Quantity of the water is measured out in a measuring cylinder. 40 ml. Of this are placed in a 250 ml. Beaker: 1 ml. Of buffer solution and 6-8 drops indicator are added. The titration is then carried out by adding EDTA solution from the burette, until the last ring of red disappears. The last 10 ml. Of water are then added and the titration completed to the same end-point. The liquid in the beaker is stirred and supported on a stand, through which the beaker is illuminated from underneath by a blue lignt.


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CHLORINE TEST PROCEDURE

Measure 5 ml. of the reagent in to a glass cylinder to this add rapidly 50 ml. of the water under test mix throroughly allow to stand for 1 minute and then compose the colour with the colour chart.

COLOUR PRODUCED

CHLORONIDE

WHITE MILKY FLUORESCENT

NONE

FOINTLY PINK & MILKY

0.1 PPM

PINK

0.2 PPM

RED

0.5 PPM

PURPLE

0.6 PPM

VIOLET

0.8 PPM

BLUE

1.0 PPM

CHEMICAL ANALYSIS OF WATER FOR TSS, TDS & TS

TS

TOTAL SOLIDS

TSS

TOTAL SUNSPENDED SOLIDS

TDS

TOTAL DISSOLVED SOLIDS

TS

TDS + TSS

Total solids are considered to be the sum of dissolved and suspended solids. In water sources the dissolved solids which usually pre dominate, consist mainly of in organic salts, small amount of organic matter and dissolved gases. The suspended


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solids contain much of the organic matter. Any increase of these tends to increase the degree of pollution of water if used for public health purposes. Moreover this parameter is very important for analysis especially in Reverse Osmosis plants as a measure of it’s performance. The determination of total solids is made of evaporation and drying of measured sample water in a pyrex beakor (or) China Dish. Since water may contain small amounts of suspended matter it is usual; these to be determined separately as the total solids in filtered and unfiltered of water sample. The difference between the total solids in unfiltered and filtered sample is then taken as a measure of suspended solids present.

Hence, to carry out the following analysis for unfiltered and filtered sample to determine TDS & TSS as ppm for a water sample from a particular source. PROCEDURE :

1]

Weigh accurately a thoroughly cleaned and dried evaporating dish of 250ml -

say ‘m1’ gram on laboratory physical balance.

2].

Take 100 ml of water sample in it

3].

Evaporate the water carefully to dryness

4].

When it is almost dried, keep the dish in a hot air over for 110 - 100°C

5].

When residual water is removed completely, cool it at a desiccators to room

temperature and find the mass of residual along with the dish - say ‘m2’ gram Mass of the residual = (m2 - m1) = X gram M/s. Rawest Power Pvt Ltd

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The Total solids in the sample

= X x 106 --------- = 104 x ppm 102

Note: Repeat the above for filtered and unfiltered of the sample to determine TSS separately.


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LIST OF ABBREVIATION


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104




Checked by :

LIST OF ABBREVIATIONS 1.

BOD

:

Bio-Chemical Oxygen Demand

2.

CDI

:

Continuous Deionization

3.

cfu

:

Colony Forming Unit

4.

cm

:

Centimeter

5.

COD

:

Chemical Oxygen Demand

6.

DM Water

:

Dematerialized Water

7.

ETP

:

Effluent Treatment Plant

8.

IDR

:

Indion Duo Rapide

9.

ms

:

Microsiemens

10.

ml

:

Milliliter

11.

MSRL

:

Mild Steel Rubber Lined

12.

ppm

:

Parts per Million

13.

ppb

:

Parts per Billion


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Checked by :

14.

RO

:

Reverse Osmosis

15.

SDI

:

Silt Density Index

16.

TDS

:

Total Dissolved Solid

17.

TOC

:

Total Organic Carbon

18.

UF

:

Ultra Filtration

19.

SMBS

:

20.

UV

:

Ultra Violet

21.

FRP

:

Fiber Reinforced Plastic

22.

PP

:

Poly Propylene

23.

MS

:

Mild steel

24.

SS

:

Stainless Steel

25.

CI

:

Cast Iron

26.

PVC

:

Poly Vinyl Chloride

27.

OBR

:

Output Between Regeneration

28.

SAC

:

Strong Acid Cation


Sodium Meta bi Sulphate

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Checked by :

29.

SBA

:

Strong Base Anion

30.

SPM

:

Stroke Per Minute

31.

ROSA

:

Reverse Osmosis System Analysis


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Checked by :

M/s RAJWEST POEWR PVT LTD EQUIPMENT HISTORY LIST

EQUIPMENT : MODEL MAKE

Date

: :

Service Carried Out

Spares Replaced

Remarks by Maint. Engineer


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Note: To enter all the detail of services carried out and spares replaced and to periodically review the status of the equipment. BRANCH OFFICES / AGENTS / REPRESENTATIVES AVAILABLE IN ALL MAJOR CITIES; FOR MORE INFORMATION PLEASE CONTACT:

REGD. OFFICE & FACTORY : M/s DOSHION VEOLIA WATER SOLUTION Plot Nos : 24-25-26, G.I.D.C. Estate, Phase - II, Vatva, AHMEDABAD - 382 445 Phone No. : 583 1156 / 589 1916 Fax No.

: 30406229

MUMBAI OFFICE: OFFICE NO.3, II FLOOR “A”WING,GODREJ COLLISEUM, EASTERN EXPRESS HIGHWAY, B/H. EVERAD NAGAR ,SION (E) MUMBAI - 400 022 Phone No : 022 – 24043189 , 24081193 Fax No.


: 022 - 24072611

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Checked by :

DELHI OFFICE: C-147, MADUBAN , NR.UNIVERSAL PUBLIC SCHOOL, NEW DELHI - 110 092.

Phone No. : 011 – 22502064,22022175,32910195 Fax No.

: 011 - 22044979

CHENNAI OFFICE : V-3. 1ST Floor 4TH MAIN ROAD, ANNANAGAR CHENNAI - 600 040 Phone No. : 044 – 26221401,26220591 Fax No.


: 044 - 2622 0591

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Can Do For You .......

EFFICIENT FIELD SERVICE We maintain a highly trained staff of engineers to service your equipment for maintenance, or to assist you, should emergencies ever occur.

COMPLETE REPAIR SERVICE Our engineers will repair your equipment as per specifications, using only genuine spare parts. SPARE PARTS

By stocking genuine Doshion spare parts, we can help you avoid costly delays, or substituting inferior parts. using genuine spare parts on your Doshion equipment will help to keep even older machinery running in good - as - new condition Doshion’s prompt factory shipment to ensure you on time delivery.


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DM Manual Doshion

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