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D.M.PLANT 1
(THERMAX SUPPLIEDPLANT)
CPP - UTILITY
RELIANCE INDUSTRIES
LIMITED.
HAZIRA.
INDEX
PART 1 ( Thermax Supplied DM Plant)
[6] SOP for DM water transfer form DM plant2 to DM plant1, PTA 1/2 and POY plants.
CHAPTER 1
1.01 Introduction
Filtered water available from water treatment plant has no physical impurities but chemical
impurities like dissolved salt, silica and carbondioxide etc are there.
This water cannot be used in process, where high purity products are required and for high
pressure boilers to avoid scaling and corrosion. Chemical impurities are of cation like Ca,
Mg, Na and Anions like Cl, SO4, NO3, Silica etc. These are called Cationic and anionic load
respectively. Total of cations and anions are called Total Dissolved Solids (TDS). All these
are mentioned equivalent of CaCO3 ppm. Removal of total dissolved solids can be done by
distillation, reverse osmosis and demineralisation process. Out of these, demineralisation by
ion exchange is cheaper and easier. Different type of resins are used to remove cations and
anions.To remove cations, Hydrogen resin RH is used and to remove anions Hydroxide resin
ROH is used.
Following are the general reactions :
i. Cation exchange reactions
NaCl + HR -------- NaR + HCl
MgSO4 + 2HR -------- R2Mg + H2SO4
Regeneration reaction with HCl
NaR + HCl -------- HR + NaCl
MgR2 + 2HCl -------- 2HR + MgCl2
Produced HCl and H2SO4 go in anion exchanger units.
iii. Anion exchange reactions
RaOH + HCl -------- RCl + H2O
2RaOH + H2SO4 -------- R2SO4 + 2H2O
iv. Regeneration reaction with NaOH
RaCl + NaOH -------- RaOH + NaCl
R2SO4 + 2NaOH -------- 2ROH + Na2SO4
Three streams of DM water, in the plant are installed, each has capacity of 150 m3/hr for 20
hrs/day. This plant is supplied, erected and commissioned by M/s Thermax Ltd. Each
stream contains pressure sandfilter (PPS), activated carbon filter (FAC), strong cation
exchanger (SAC), Degasser tower (DGT) with degasser blowers (BDG) and degassed water
pump (PDG). Weak base anion exchanger (WBA) , Strong Base Anion (SBA) And Mixed
Bed (MB). To polish the condensate, condensate polishing plant is there. It contains
activated carbon filter (FAC-CP) and mixed bed exchanger (MBCP). To avoid damages of
resins due to high temperature, heat exchangers are fixed to cool condensate before
condensate polishing unit.
Materials of construction of piping and equipments upto inlet of SAC are MS and from SAC
outlet are MSRL or SS. D.M. Water tanks , treated condensate tank, and effluent neutralising
tanks are of MS/RCC with epoxy lining.
To measure quantity of filter water at PPS inlet and at MB outlet, flow integration, flow
indicator are fixed. To measure quality of DM water pH meter, conductivity meter, silica
analyser are fixed at outlet line of WBA, SBA and MB & MBCP.
1.02 b Design basis of condensate polishing unit.
Normal condensate recovery 74.0 m3/hr i.e. 1800 m3/day
Peak condensate recovery 97.00 m3/hr i.e. 2200 m3/day
Plant size is selected to polish 2400 m3/day condensate
1.02 c DM water and condensate storage tank
DM tanks 1600 m3 x 2 nos = 3200 m3. Assuring 12 hrs storage in normal condition of plant
cap. for storage.
Row condensate tank of 2000 m3 capacity assuring 20 hrs. storage.
1. Plant is designed considering 10% excess ionic load & silica 20 ppm as SiO2 in R.W.
2. Plant is designed considering outdoor installation.
3. Plant is semiautomatic.
4. Velocity in resin bed is considered max. 0.75 M/Sec.
5. Fluid velocity is max. 2M/sec. When three streams are running on peak load.
6. 33 - 18% HCI and 20% NaOH is used for regeneration and neutralising of effluent.
* Oxygen consumed in organic matter is less than 0.1 PPM in drinking water.
4.2.4 WBA/SBA
THROUGH FARE REGENERATION
The rinse and service operation instruction are same as given in the individual vessel section.
Here both the SBA and WBA will be regenerated at the same time.
Here the regenerant sodium hydroxide will enter SBA and from SBA it will be taken to
WBA. It is worth to noting that SBA is regenerated in counter current type and WBA is co-
current type. SBA need not be back washed during every time of regeneration but WBA has
to be back wash without fail.
Since dilution of alkali is required , water has to be added to alkali and to ensure proper
mixing of alkali. A mixer is provided on each of the measuring tank (Presently not in service
as we get 20% Caustic from T/F directly, so no need of any dilution). The feeding of water
and alkali is manually by VM1 and VM9 respectively without alkali measuring the operator
can not start the through fare regeneration.
BACK WASH OF SBA (optional 10 mts - flow 15 m3/hr)
Following valve remain open -
1. Back wash inlet valve VA3 (part).
2. Back wash outlet valve VA4 (full).
The degassed water will be supply by PDG pumps.
REGENERATION OF WBA/SBA VESSEL
STEP-1 : WBA - BACK WASH & SBA - Middle Collector Wash (10 mts/5mts)
Following valves will open -
1. Back wash inlet valve VA3 of WBA (open partly flow 22 m3/hr)
2. Back wash outlet valve VA4 of WBA (full).
3. SBA middle collector inlet valve VA13 (part open flow 15 m3/hr) SBA wash outlet
VA4 of SBA is full open. Selected PDG pump will run and ensure sufficient level in SDG
and alkali measuring tank MAK1 A/B.
STEP-2 WBA & SBA SETTLE BED (2 MTS)
All the valve of WBA and SBA remain close in this step with the pump being off.
STEP-3 WBA - Idle SBA - Power Water (3 mts)
Middle collector outlet valve VA14 (full open), down flow valve VA15 (part open flow 8
m3/hr), Alkali inlet valve VA9 (full open), and power water inlet valve VA32 of SBA (part
open flow 14 m3/hr) remain open. All valves of remain closed. This step is same as power
water that of SAC.
STEP-4 SBA-Idle SBA Alkali Injection (5 mts)
WBA -- All valve remain close.
SBA -- Middle collector outlet valve VA14 (full open), down flow valve VA15 (part
flow 8m3/hr). Alkali inlet valve VA9 (full) power water inlet valve VA32 (part 14m3/hr)
and VA2 alkali outlet valve of MAK1 A/B are open. Sp. Gravity of 4% NaOH - 1.040 and
5% NaOH 1.054 will be measured by sp. Gravity indicator.
STEP-5 WBA - Alkali Injection (25 mts)
SBA - Alkali Injection Continuous (20 mts)
WBA Power water outlet valve VA32 on WBA (part open flow 30 m3/hr). Alkali inlet
valve VA9 (full) and rinse outlet valve VA6 (full open) remain open.
SBA Middle collector outlet valve VA14 remain closed and alkali outlet valve VA10
remain open and other valve remain open as per step no. 4.
STEP-6 Rinse - WBA Alkali Transfer - SBA (30 mts)
The valve states for WBA remain the same the valve status for SBA remain the same.
Expect that the alkali outlet valve VA2 of MAK1 A/B remain closed.
STEP-7 WBA and SBA Settle Bed (2 mts)
All the valve and pumps remain the same.
STEP-8 WBA - Fast Rinse, SBA - Idle (10 mts)
WBA inlet valve VA1 (full) and rinse outlet valve VA6 (part) remain open. This will wash
traces of alkali from WBA. SBA all the valves remain close.
STEP-9 WBA Service SBA - Fast Rinse (10 mts flow 150 m3/hr)
WBA Main inlet valve VA1 (full) and outlet valve VA2 (part) remain open.
SBA Service water valve VA1 full and rinse outlet valve VA6 (part open).
The regenerated WBA comes into service, supply water to rinse the traces of alkali in SBA
continue the rinse till quality become acceptable.
STEP-10 OFF SBA-WBA
In this step all the valves remain closed.
Description of WBA SBA
operation
Flow m3/hr Time minutes Flow m3/hr Time inutes
Backwash 22 10 15 10 or till
(optional) water is
clear.
Middle collector wash NA NA 15 5
Alkali injection Idle Idle 14 5
Down flow Idle Idle 8 5
Alkali inje(contd) 30 25 14 20
NA NA 8 20
Alk transfer/Alk rinse 47 25 14 30
down flow. NA NA 8 30
Final rinse 150 10 Idle Idle
Final rinse Service - 150 10
BACKWASH : FAC
Step Flow Time Minutes FAC-1 FAC-2
M3/hr From To From To
Back wash 100 10
Rinse 150 10
Off/service … 01
BACKWASH : SAC
Step Flow Time Minutes FAC-1 FAC-2
M3/hr From To From To
Middle 60 10
collector
Back wash 72 3
Settle bed - 2
Power water 51 3
Acid injection 15 20
Down flow 50 20
Acid rinse 51 30
Down flow 30 -
Final rinse 150 30
Off - 1
WBA/SBA - Regeneration
Step SBA WBA SBA-1 WBA-1 SBA-2 WBA-2
Flow Time Flo Time
Rate Mts w Mts
Back wash 22 10 15 10
Middle - - 15 5
collector
wash
Alkali injector Idle - 14 8
Down flow Idle - 14 8
Alkali injector 30 25 14 20
Down flow - - 8 20
Alkali transfer 47 30 4 30
Down flow - - 8 30
Final rinse 150 10 Idle Idle
Final rinse Service 150 10
MB/MB-CP REGERATION
5. Unit rinse take long time. a. Flow rate a. Increase flow rate.
b. Unit exhausted. b. Regenerate unit.
c. Backwash valve c. Check and rectify.
passing.
d. Anion resin d. Give alkaline brine
organically fouled. treatment.
e. Mixed bed not e. Carry out air mix once
satisfactory. again.
f. Acid/alkali in f. Faulty design check
unit. and rectify. Back wash
(followed by ) and rinse
again.
b. Rectify.
b) Lining of HCL
tank/ pipe line damaged.
D.M. Plant is controlled by programmable logic controller (PLC) mounted in control room.
There is no back up control panel for D.M. Water Plant PLC has got redundant control
process units which will achieve simultaneously. It has also got graphic page with all alarm
pages. Operator can operate the plant from control room by PLC. Power for PLC will from
UPS system.
Plant is semi automatic i.e. backwashing of FPS and FAC will be done manually but all
regeneration steps will be done by PLC. Interlocks arrangements are provided for starting,
stopping or closing/opening of valves pumps blower or units when any parameter like
quality, pressure level goes out of specified limits. List of ANNUNCIATIONS AND
INTERLOCKS is as attached.
When compressed Air/PLC will fail, regeneration can be done by operating wheels of
Pneumatic Control Valves. Filling of acid and alkali in measuring tanks will be done
manually as nod auto valves are provided.
6.1 LIST OF ANNUNCIATORS
Sr No Discription
[1] [2] [3] [4] [5]
3. Current Exchanger Unit Backwash the current Do not give double …..of
exchange (WAB & MB) regeneration.
every regeneration.
4. Running of Ion Exchange Run the units upto design Do not mean the unit
Unit. production through the more than design
resin is not exhausted. production.
9. Condensate Polishing Run the polishing till the Do not run the
temp. condensate below condensate polishing unit
45 deg C. if temp of condensate is
more than -5 deg C.
10. DM Water Parameter Run the plant upto design Do not run the plant if
production through any parameter is out of
parameters in the range. range before the design
production.
CHAPTER-8
1. RESIN:
Resin should be stored in wet condition only. Put polyethylene bag in drum and fill
the resin and water and close the lid.
2. If any exchanger is made idle for short time and resin is inside, hold some water
inside the vessel by a closing outlet and fast rinse valve.
3. If PPS and FAC are idle, keep them wet to avoid hard mass on upper layer bed by
closing of outlet valve or stop them after backwashing of PPS and FAC.
4. If neutralising pit is idle for long time, keep HDPE lines cleaned to avoid blocking of
aeration holes, electrical rotor is removed from its position electrical connection for space
heater should be provided.
5. If electrical motor is removed from its position electrical connection for space heater
should be provided.
6. All rotating equipments lubricating material (oil/grease) should be replaced with good
one if they will be not in use for a long time.
8. If blower (MB Blower) is idle for long time, clean and grease the tubes to avoid
further rusting.
CHAPTER-15
SAFETY PRECAUTIONS
2. Do not move in plant without wearing safety helmet and safety shoes.
3. Always wear protective face shield and clothing while working on or near chemicals
injection pumps.
D.M.PLANT 2 & 3.
(ION EXCHANGE SUPPLIED PLANT)
CPP - UTILITY
RELIANCE INDUSTRIES
LIMITED.
HAZIRA.
GENERAL DESCRIPTION OP THE EQUIPMENTS :
Step-1 : Backwash :
During this operation water is passed through filter bed from bottom to top. Entrapped
suspended particles, dirt etc. are remove while passing water from bottom to top and then to
drain. Backwash to be continued till the effluent coming out is clear. Flow maintained during
this operation is 91.6 m3/hr.
Step-2 : Rinse :
Daring this step water is passed from top to bottom and drained. this oparatlon to be
continued till effluent is clear.
This is a mild steel vessel lined internally with rubber. It is externally fitted with rubber lined
pipe work, diaphragm aalve, pressure gauges at inlet and sampling valves at inlet and outlet.
A calibrated orifice board in the drain sump is also provided for controlling various
regeneration flows. The water is distributed from the top. The middle collector is of header
lateral type. The header is of mild steel rubber lined and rubber covered to which PVC
laterals are fitted. Strainers which prevent resin from escaping are screwed to the bottom of
the laterals. Bottom collecting system is of strainer on plate type. Double decker (button
type) strainers have been used for bottom collecting system whereas mark 871 (disc type)
strainers have been used for middle collecting system. The vessel is charged with strongly
cationic resin (Indian 225). When the desirea output is obtained or when the quality of outlet
water from SAC with respect to sodium ions is deteriorated. Then the unit should be
regenerated.
pH : 2.0 - 3.0
Total Hardness : Nil
Sodium + Pottasium : Lesa than 2 mg/l
A resin trap is provided at unit outlet to trap Ion exchange resins in unlikely event of bottom
collecting system failure.
Backwash operation is carried out to loosen the bed and to remove the suspended impurities
from the resin. Backwash operation is carried out once after 7 regenerations or when
pressure drop across the unit increases beyond acceptable limits of 1 bar whichever occurs
earlier. When backwash is given to SAC, 120 kg/m3 regeneration level is to be employed to
ensure bottom layer of resin is highly regenerated. Sub-surface wash is carried out for each
regeneration.
backwash is given at 102 m3/hr for 10 minutes and subsurface wash is given at 102 m3/hr for
5 minutes.
The operation is carried out to set the power water flow rate to the required flow before
injecting acid.
HCl of 5% concentration is injected at 95.43 m3/hr into SAC, by means of an acid injection
ejector. The acid is injected through SAC bottom collecting system and effluent is taken out
through middle collector to drain sump. During injection to prevent fluidisatior of SAC bed,
a down flow of water is maintained at 95. 43 m3/hr. This injection is carried out for 20
minutes.
d) Slow Rinse :
The excess acid in SAC unit after acid injection is displaced with degassed water at a flow
rate of 95.43 m3/hr. Down flow of water is maintained during this stage also. Duration of this
step would be 37 mins.
e) Final Rinse :
This operation is carried out to remove excess acid and liberated cations from SAC unit. The
operation is carried out for 5 minutes at a flow rate of 200 m3/hr.
This is a mild steel vessel lined internally with rubber. It is externally fitted with rubber lined
pipe work, diaphragm valves, pressure gauge at the inlet and outlet , conductivity indicator at
the outlet and sampling valves both at inlet and outlet.
A calibrated orifice board in the drain sump is also provided for controlling various
regeneration flows. The water is distributed from the top and each arm is provided with PVC
bell mouth which will also act as backwash collector. Alkali distributor is also of three arms
(inverted bends with PVC spacers and blank flange) made out of mild steel and lined
internally as well as externally with rubbers. Bottom collecting system is of strainer on plate
type. Mark 79 strainers are directly fitted on the bottom plate. The vessel is charged with
weak base anion resin (Indian 850). The regeneration of the unit is done in thoroughfare with
SBA. A resin trap is provided to trap ion exchange resins in the unlikely event of the bottom
collecting system failure. Flow indicate- is provided at the inlet.
a) Backwash/Sub-surface wash :
The operation ia carried out to loosen the resin bed and to remove the suspended impurities
from the resin. Backwash operation is carried out at 24.12 m3/hr for 5 minutes in WBA unit.
SBA backwash shall be done only once in 7 regenerations at 15.93 m3/hr flow for 10
minutes. The sub-surface wash is carried out for each regeneration of SBA unit at 15.93
m3/hr for 5 minutes.
b) Caustic Pre-injection :
This operation is carried out to set the power water flow rate before injecting alkali. The
pre-injection flow is 77. 5 m3/hr in WBA and 35.23 m3/hr in SBA unit for 2 minutes. Down
flow is given at 42.28 m3/hr flow to prevent fluidisation of resin in SBA.
c) Caustic Injection :
d) Slow Rinse :
This operation is carried out to ensure optimum utilization of alkali injected. The unused
alkali in SBA unit after caustic injection, is transferred to WBA with the help of power water
. Caustic transfer from SBA unit is carried out at 35.23 m3/hr for 23 minutes into WBA unit.
Down flow at 42.28 m3/hr is maintained during this stage also.
e) Rinse :
This operation is carried out to remove excess caustic and liberated anions from both SBA
and WBA units. The operation is carried out separately. WBA unit is rinsed at 200 m3/hr for
18 minutes and SBA at 200 m3/hr for 8 min.
This is a mild steel vessel internally lined with rubber. It is externally fitted with rubber lined
pipe work, diaphragm and butterfly valves, pressure gauaes and sampling valves at inlet and
outlet. Also a conductivity inidcator , pH indicator and silica analyser are provided at each
unit outlet. At common outlet header of mixed bed a flow indicator integrator is provided.
A calibrated orifice board in the drain sump is also provided for monitoring various
regeneration flows.The middle collector and bottom collecting system are of header lateral
type. The header is of mild steel, rubber lined and rubber covered to which PVC laterals are
fitted. Strainers which prevent escape of resin are screwed to the bottom of the laterals. Mark
‘V’ strainers have been used.
Inlet water distributor is of three arms with strainers to avoid escape of resins during back
washing. Bottom dished end portion of the vessel is fitted with concrete which acts as dead
weight and prevents the division plate from buckling due to weight of water and resin.
The vessel.is charged with a mixture of both strongly acidic cation (Indian 525) and strongly
basic anion (Indian FFIP). When desired output from the unit is obtained or when the quality
of outlet water with respect to either silica or conductivity is deteriorated, then the unit
should be regenerated. Cation resin is regenerated with HCl and anion resin with NaOH.
A resin trap is provided to trap ion exchange resins in the unlikely event of failure of bottom
collectlnc system.
a) Backwash :
This operation is carried out to separate the resins prior to injection of chemicals. Due to
difference in densitities, the resins get separated in two layers during the back washing, with
cation forming lower layer and anion forming upper layer. Backwash is carried out for 10
min. at a flow rate 40.68 m3/hr.
b) Sub-surface Wash :
This operation is basically carried out to clean the middle collector strainers to ensure proaer
distribution / collection during injection of chemicals. Duration of this step is 5 min and flow
rate maintained shall be 40.68 m3/hr.
Water flow for acid injection is established through acid ejector at a flow rate of 8.14 m3/hr.
A down flow is maintained at a flow rate of 6.78 m3/hr to prevent diffusion of acid into
anion resin region Effluent is collected by the bottom collecting system and drained to the
drained valve Duration of this stea is 2 mins.
d) Acid Injection/Downflow :
Once the pre-injection flows are established , 5% HCl is fed to the unit through middle
collecting assembly. Ejector section valve of AMT-2 is adjusted to have the required
concentration . Concentration of aad ejector delivery is monitored. Duration of this step is 10
mins
e) Acid Rinse/Downflow :
After completion of the acid injection water is continued to pass at a flow rate of 18 08 m3fhr
to displace / fully utilize the regenerant Downflow is continued to maintain during this step.
Duration of this step is 15 minutes.
f) Alkali pre-injection/upflow :
Water flow for alkali injection is established through alkali ejector at a flow rate of 25.47
m3/hr. An up flow is maintained at a flow rate of 20.34 m3/hr to prevent diffusion of alkali
into cation resin region. Eafluent is collected by the middle collector system. Duration of this
step is 2 minutes.
g) Alkali anjectioo/Upflow :
Once the pre-injection flows are established, 3.33% Nash is fed to tae unit through alkali
inlet located at the top of resin bed. Ejector section valve of CDT-2 is adjusted to have the
required concentration. Concentration of alkali at ejector delivery is monitored. Duration of
this step is 15 minutes.
h) Acid Rinse/Upflow :
After completion of alkali injection water is continued to pass at a flaw rate of 50.43 m3/hr to
displace / fully utilize the regenerant. Up flow is continued to maintain during this step.
Duration of this step is 20 minutes.
i) Drain Down :
Water from the vessel is drained upto about 300 mm above the top surface of resin bed
(aparox. half of top inspection winaow). Duration of this step would be approx. 10 minutes.
j) Air Mix :
Air is passed from the bottom of the unit to mix both the resins thoroughly. The mixing and
movement of the resin bed can observed through inspection windows. Duration of this step is
10 minutes.
k) Forced Settle :
Resin bed is forced to settle with down flow of inlet water. Faster settling will prevent
re-separation of resin bed. Duration of this step is 2 minutes.
l) Refill :
The unit is filled with feed water before rinsing the unit. Duration of this step is 4 minutes.
m) Final Rinse :
Service water is taken from inlet and drained from the rinse outlet for 10 minutes to remove
traces of regenerantes and liberated ion from the bed.
n) Rinse Recycle :
At the end of final rinse, rinse water is not allowed to drain and taken back to Degasser
Water Tank. This operation is continued till desire quality of treated water is obtained.
pH 7 to 9 7 +/- 0.2
Conductivity Us/cm at Amb.Temp. - 0.2
Turbidity as NTU 2 Nil
TDS (ppm) 386 0.05
Dissolved Oxygen (ppm) 7.6 Negligible
Total Hardness ppm as CaC03 160 Nil
M. Alkalinity - do -- 200 Nil
Sulphates - do -- 42 Nil
Chlorides - do -- 106 Nil
Phosphate - do -- Nil Nil
Calcium - do -- 60 Nil
Magnesium - do -- 100 Nil
Sodium - do -- 187 Nil
Iron as Fe 0.5 0.005
Silica PPM as SiO2 25.2 < 0.02
Free Chlorine PPM < 0.8 Nil
Organic Matter PPM < 0.1 Negligible
Colloidal Silica as SiO2 0.2 -- Do --
Regeneration Flows :
Backwash : 91.6 m3/hr Time : 5 - 10 min.
Rinse :122 m3/hr Time : 5 min.
2.3 STRONG ACID CATION EXCHANGER (SAC) : Tag No. FA-1159 A/B/C
Regeneration Flows :
Regeneration Flows :
Backwash 24.12 5
Caustic pre-injection 77.84 2
Caustic Injection (1.2%) 84.56 30
Caustic Rinse 77.55 23
Rinse 200 8
Regeneration Flows:
Regeneration Flows :
Operation Flow (m3/hr) Time (Min.)
Backwash 40.68 5
Middle collector flush 40.68 5
Acid pre-injection 8.14 2
Downflow 6.78 2
Acid Injection 5% 16.27 10
Downflow 6.78 10
Acid Rinse 18.08 15
Downflow 6.78 15
Alkali Prelnjection 25.47 2
Upflow 20.34 2
Alkali injection 30.56 15
Upflow 20.34 15
Alkali Rinse 50.43 20
Upflow 20.34 20
Draindown/Air Mix - -
Forced settle 200 3
Refill 200 3
Final Rinse (recycle) 200 3
Number off :4
Capacity : 215 m3/Hr.
Discharge Head : 70 mmwc
Material : SS 316
Type : Horizontal - Centrifugal.
Make : SAM Turbo Industry ltd.
Model : CPH 100/260.
Medium : Degassed water
RPM : 2900 RPM
Motor : By cliant.
Nuber Of f : Two
Diameter : 1200 mm
Depth : 1500 mm
Material of construction : PP/FRP
Concentration of acid in tank : 10% HCl Acid
Number of f : One
Diameter : 1800 mm
Depth : 1600 mm
Material of Constructtion : MSR/L
Fluid Stored : Caustic Soda 20 %.
pH MONITOR ;
Quantity
Make : Rousement
Range :0 to 14 pH
Mounting :Field
Input Power supply :24 V DC
Output :4 - 20 mA Liner
Accuracy :+/- 0.02 pH
Temp. Compensation :Automatic
Model ;1181PH-01-07-11
Tag ao. Location
11 PHIT-580 A/B/C SBA7a8/9 Outlet
11 PHIT-581 A/B/C MB7/8/9 Outlet
11 PHIT-582 Waste Disposal Pump Disch
Quantity :7 No
Type :Flow through
Model : 399PH- 0&-11
(Tag no -11PHE 580A/B/C)
Make :Rosemount
Tag no Location
Quantity : 2 Nos.
Type : On line calorimetric
Make/model Hach / series : 5000,60000
Power Supply : 110V AC,50HZ
Output : 4 -20 MA DC
Enclosure : IP 65/NEMA 4X
Range : 0-5000 PPBas SIO2
Display : Digital;
Accuracy/resolution : 2 PPB /1 PPB Respectively
Mounting : Bench Top
Qty : 1 no.
Make : Polymetron
Model : 9073 with'k’ kit
2. 28 a LEVEL INDICATOR :
Type : Float & Cord Type
Make : Revathi Electronics
Material of Construction : Float SS 316
Wire Rope : Nylon
Location : Degassed Water Tank
Tag no. : 11 LIFB 580
2. 28 Magenetically coupled level indicator:
Qty : 2 no
Make : Revathi
Range : 5300 am stem len
Tag no Location
11 LIS 586 A NPA
11 LIS 586 B NPB
Quantity : 5 nos.
Type : Bellow Sensing Type
Make : Switzer
Material of construction : SS 316 bellows,
other parts SS 316
The instrumentation and control system are provided formonitoring and controlling
various process variables related to each equipment and sub-system. .
At a time, only one stream can be regenerated. At least one of the other two streams
shall be in operation during regeneration of one stream. Any one of SAC (A/B/C)
and any one of WBA/SBA (A/B/C) can be regenerated one by one or
simultaneously. Normally, WBA/SBA of a particular chain is operated as a pair.
However, provision is made in PLC software sothat any combination of
SAC,WBA, SBA can be selected for regeneration. Selection of required combination is
done through keyboard. For regeneration of Mixed Bed (A/B/C) , any one of WBA/SBA
unit should be in service. Regeneration is carried out for individual units as
selected.
The starting of the regeneration operation is initiated through PC key board for
individual units. Operator intervention is provided at appropriate stages to hold,
reset, advance , skip or dwell in stages.Refer to Valve Sequence Chart
No.A3-A70096-08-01/0a/03 for details about sequence of valve operations and
durations.
2. CONTROL LOGIC
The Control Logic is described for each unit or sub-system starting with Activated
Carbon Filter. The procedure follows the process stream flow path ; it is not
necessarily reflects of the sequence of control operations.
Computer display:
- Common Inlet Header flow rate m3/hr (11-FIT-580).
Alarm
- High pressure drop across ACF (A/B/C) - ll-DIPS-580.
- Low Inlet Header pressure - 11-PS-580
SAC A or B or C units are taken out of service automatically when any one of the
conditions occur :
1) 11-PS-580 is in healthy condition(no low pressure alarm)
2) 11-LS 582 A/B give high level alarm in AMT lA/B
3) The Unit completes 20 hours in service or 11-NaA-580 gives high Sodium alarm
Computer display :
- Valve openclose status
- Sodium Analyser reading - ll-NaA-580 aA/B/C)
Alarm:
- High Sodium at SAC outlet-- (11-NaA-580 (A/BtC))
- Regeneration completed
Computer display:
Alarm
- High and low level of Degassed Water Tank
WBA A or B or C Units are taken out of service automatically when any one of the
following conditions occurs :
1)11-CIT-580A or ll-CIT-580B or 11-CIT-580C gives high conductivity alarm for
WBA-A or WBA-B or WBA-C respectively or SBA- A or SBA-B or SBA-C is
taken out of service, OR
2) WBA-A or WBA-B or WBA-C completes 20 hours in service (Check timer shall
be based on degassed water pump running time.)
The unit will be isolated automatically when whichever of the above conditions
occurs first. Units WBA-SBA are taken into and out of service together.
Computer display :
Alarm :
SBA A or B or C Units are taken out of service automatically when any one of the
following conditions occurs :
The unit will be isolated automatically when whichever of the above conditions
occurs first. Units WBA-SBA are taken into and out of service together.
Alanm :
MB-A or MB-B or MB-C Units are taken out of service automatically when any one
of the following conditions occurs :
The unit will be isolated automaticall when whichever of the above conditions
occurs first.Foaloaing regeneration permissive shall be provided.LS 583
A7B-high,LS585A/Bhigh,PS582- healthy.
Regeneration water pu p GA 1161 A/S trips at low pressure at MB outlet common
header.
Computer display :
Alarm :
Acid Measuring Tanks are provided with pneumatically operated diaphragm valves.
These valvea are operated through PLC system to fill required quantity of Acid and
dilution water prior to start of regeneration. Bulk Acid for injection is available in
15% concentration. Level switches 11LS-583 in AMT1,2 has 3 points (that is high,
intermediate, and low) level awitcaes. In AMTl and AMT2 level switches
11-LS-582 and 11-LS-583 are mounted respectively. Upon reaching high level in
AMT1 / 2, tank Full indication will be displayed in CRT. Regeneration cannot be
initiated unless this indication is achieved.
AMT 1 & 2 filling ia an independent operation and it can be carried out at any time
except during regeneration of SAC, if that particular tank ia selected for
regeneration. Filled AMT needs to be further selected for regeneration. Acid
injection stage of SAC or MB will be over only after getting feedback signal of
AMT 1 or 2 low level.
Computer Display :
- Tank fulla indication of AMT 1/2
- Open / close status of vale,
- Low level indication of AMT 1/2
Alarm:
Alkali Measuring Tanks are provided with pneumaticall operated diaphragm valvea.
these valves are operated through PLC system to fill required quantity of Alkali
prior to start of regeneration. Bulk Alkali for injection is available in 20 % concentration.
In tanks CDT1 and CDT2, 11-LS-584 and 11-LS-585 (each two point, viz., high
and low) are mounted respectively. Upon reaching high level in CDTl / 2, 'Tank Full'
indication will be displayed on CRT. Regeneration cannot be initiated unless tank
full indication is achieved.
The filling operation can take place independently. Yet it should happen before the
related unit is selected ay operator for 'Regeneration mode'.
CDT 1 & 2 filling is an independent operation and it can be carried out at any time
except during regeneration of WBA/SBA if that particular tank is selected for
regeneration. Filled CDT needs to be further selected for regeneration. Alkali
injection stage of SBA or MB will be over only after getting feedback signal of
CDT 1 or 2 low level.
Computer Display :
Alarm :
Pumps and blowers can be operated through keyboard or through local push button.
For keyboard operation, local / remote selector switch provided in local push button
station shall be turned in 'remote' position. For operation through local push button,
the selector switch must be turned in 'local' position. For auto operation through
PLC, all drives must be kept in 'remote’ position. Degassed blower will start
automatically when respective SAC comes in service. If standby blower is to be
operated, the operator needs to initiate operation through keyboard or static blower
through local push button station.
Besides those pumps that are in service, filtered water, degassed water and DM
water is required for regeneration of related units, required pumps shall be selected
through key board before regeneration. Availability of sufficient pressure of water is
checked by 11-PS-580 at filtered water inlet header, 11-PS-581 at MB outlet
common header.
Individual unit needs to be selected and initiated through keyboard for regeneration.
For service operation also, individual unit has to be selected through keyboard.
Computer display :
- On-off status of effluent disposal pumps GA 1159 A/B and blower GB 1154 A/S.
- pH of recirculatingdisposing effluent Low level of N. Pit.
Alarm :
Operator interface
The operation will be menu based through keyboard. Related page can be called on
the terminal and operation can be monitored accordingly.
For regeneration, function of sub-commands viz., hold etc. are as given below.
Dwell :
'Dwell' command will abandon the on going regeneration operation at the point it is
interfered with. The vessel will go in ‘off ’ mode. Unless the vessel is 'Reset' by
giving a specific sub-command, the vessel shall undergo regeneration from that point
onwards from where it was abandoned, when it is put in regeneration again.
'Resets’.bring the vessel regeneration stage to its starting point.
Advanceskip :
'Advanceskip' will advance or aU skip the particaiar stage of regeneration where the
command is invoked.
Hold :
'Hold' will keep the vessel in that particular stage for the specified time as desired by
the operator.
Alarm display :
Whenever an alarm is generated in the plant it will appear on the bottom of the
screen. Thus, a small band of the page already called for will be overlapped by the
alarm. When more than one alarm occurs, the latest will be flashed and another small band
will appear showing the number of unacknowledged alarms.
Check :It shall be first -out type annunciation.
1. Open / close position of pneumatically operated valves with the help of two limit
switches provided on the valve,
2. starting / stopping of pumps and blowers,
3. graphic display of tanks units and their status (that is, Service/Off / regeneration),
4. various alarms (as per the list enclosed)
5. regeneration stage of units with elapsed time and set time,
6. readings of conductivity instruments, pH instruments, flow instruments, Sodium
analyser and silica analyzers.
TROUBLE SHOOTING
Sr. Deffects Causes Remedies
No.
1. Decrease in a. Increase in ionic load. Check by analysis.
capacity between b. flow recorder deffective. Check.
two successive c. Insufficient chemicals used. Check.
regeneration. d. Resins dirty. Give prolonged backwash.
e. Plant being used intermittently. Avoid this.
f. Channeling in bed. Check & ensure uniform
distribution / collection.
g. Resin fouled. If cation-give HCl wash , if anion
- give alkaline brine treatment.
h. Resin detoriorated. Check & replace charge.
I. Resin quantity insufficient in Check & top up.
unit
2. treated quality is a. Cation exhausted. Check.
not upto the b.Anion exhausted. Check
standard. c. M.B. Exhausted. Check.
d. M.B. resins are not in uniform Repeat air mixing & rinse.
mixed state.
e. Some valves like backwash Check.
leaking. Check filter water analysis;
f. Sodium slipage from cation change in Na/TA & SiO2/TA
high.) ratio; use more chemicals.
g. Silica slipage from anion high. Check.
h. Unit idle. Rinse to satisfactory qulity.
i. Unit not sufficiently rinsed. Adjust to between unit min/max.
flow rate.
j. Excessive low flow rate. Check & ensure uniform
k. Channeling. collection/ distribution.
l. Resin fouled. Check resine & give alkaline brine
/ HCl treatment.
m. Resins detorioreted. Check resine & replace it.
3. Mixed bed a. Resine not seperated properly Give extended backwash after
quality not good. during backwash. exhausting the bed.
b. Air mixing not proper. Repeat.
c. Final rinse not proper. Repeat.
d. Some valves maybe leaking & Check & examine.
contaminating the treated water.
4. High Residuals a. Chocked suction air filter of Check & clean filter.
degassed air blower.
b. Improper air flow to the Check damper , speed of blower ,
degasser. discharge pressure.
Check & operate blower.
c. Degasser blower not in Check & replace fitting.
operation.
d. Air seal not fitted / broken
resulting in short circuiting of air.
5. Unit rinse takes a. Flow rate too low. Increase flow rate.
long time. b. Unit exhausted. Regenerate unit.
c. Backwash valve passing. Check & rectify.
d. Anion resins organically fouled. Give alkaline brine treatment.
e. MB air mix not satisfactory. Carry out air mix once again.
f. Acid alkali pockets formed in Faulty design-check & rectify.
unit. Temperarily backwash (followed
by air score of MB) and rinse
again.
6. Flow rate too a. Checked valve & suction Check
low. strainer of pump.
b. Cavitation in the pump. Check
c. Low inlet pressure. Check pump.
d. Distribution / collecting system Check.
chocked. Check & clean.
e. Resin trap at outlet choched. Increase off take.
f. Control valve shut due to low
off take.
7. Pressure drop a. Deffective valve. Check
across the bed is b. Packed resin bed & resin fines. Give extended backwash with
increasing. open manhole & scrap off fines
from top surface of the resin.
c. Collecting system chocked. Check, repeat backwash.
d. Pressure gauge deffective. Check & rectify / replace.
8. Flooding in a. Very high flow rate. Reduce air flow rate by adjusting
Degasser b. Packed tower chocked due to damper.
dirt OR broken packing material. Open & checjk.
9. Resin being lost a. Excessive backwash pressure. Check inlet pressure & reduce if
b. Faulty collecting system. necessary.
c. Inlet strainer damaged. Examine same for breakage.
Check & replace.
10. Ejector not a. Low power water pressure. Check this.
working. b. Air lock in the unit. Backwash & open air release.
c. Chocked OR deffective valves. Examin & rectify.
d. Ejector nozzel may be chocked. Check.
e. Too much back pressure from Check for chokage of collecting
unit. system , passage of inlet / outlet
valves.
f. Bulge in pipe. Check and rectify.
11. Incorrect reading a. Chocked orifice, sub orrifice or Check and clean.
from rotameters. impulse lines.
b. Dirty glass and float. Check and clean.
12. Improper reading a. Chocked impulse line / orrifice. Check & clean.
from flow b. DP transmeter require Recalibrate.
recorded calibration. Check,contact & rectify.
integrator. c. Leakage in signal tube
betn.transmeter & recorder. Check.
d. Low air pressure for DP
transmeter or recorder.
13. Level electrodes a. Improper contact between Check,contact and rectify.
system for electrodes and control cabling.
measuring & b. Shorting of the two electrodes Che.ck & dry the contacts of
dilution tank not due to moisture or any foreign moisture and dirt.
functioning material. Check
properly. c. Improper working of the level
controller.
14. Leakage from a. Improper adjustment of the Check & adjust,
acid injection / mech.seal. Check concentration and take
unloading b. Low strength of sulphuric & apropriate action.
/transfer pumps. presence of Ferrus sulphate.
1) Open outlet valve VIA of FB-1151A and / or VlB of FB1151B. for suction of
GA-1153 A/B/S.
2) Open outlet valve VIE of FB-1151A and/or V1F of FB1151B for suction of GA-1153
C/D.
3) Open common header recirculation valve V5A of FB-115 l A and/or V5B of
FB-1151B.
4) Open valve V3F on DM Water circulation header for circulation of DM Water for
GA-1153 C/D and GA-1158 A/S pumps.
5) Open valve V4DD on discharge header of GA-1153 C/D pumps.
6) Open the suction valve V2C of GA-1153 A/B/S and prime the pump by opening its
vent valve.
7) Open the suction valve V2D of GA-1153 C/D and prime the pump by opening its
vent valve.
8) Start the GA-1153 A/B/S from field and crack open its recirculation valve V3C.
9) Open discharge valve V4C gradually till pump GA-1153 A/B/S is not getting over
loaded. Current should not crosses 51 Amps. and pressure remain between 3.5 to 6.0
kg/cm2.
10) Put flow transmeter 11 FT507 in service by opening its respective isolation valve.
11) Start the GA-1153 C/D from field and crack open its recirculation valve V3D.
12) Open discharge valve V4D gradually till pump GA-1153 C/D is not getting over
loaded. Current should not cross 62 Amps.and pressure remain between 3.5 to 6.0
kg/cm2.
13) Put flow transmeter 11 FT521 in service by opening its respective isolation valve.
1) Open outlet valve V1E of FB-1151A and/or V1F of FB1151 B for suction of
GA-1158 A/S.
2) Open common header recirculation valve V5A of FB -115 lA and/or V5B of
FB-1151B.
3) Open valve V3F on DM Water circulation header for circulation of DM Water for
GA-1153 C/D and GA-1158 A/S pumps.
4) Open the suction valve V2E of GA-1158 A/S and prime the pump by opening its vent
valve.
5) Start the GA-1158 A/S from field and crack open its recirculation valve V3E.
6) Open discharge valve V4E gradually till pump GA-1158 A/S is not getting over
loaded. Current should not cross Amps. and pressure remain between to
kg/cm2.
7) Put flow transmeter 11 FT511 in service by opening its respective isolation valve.