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PROJECT: Shuweihat S2 Independent Water and Power Producer REMINERALIZATION PLANT CLIENT: TITLE: Doosan Heavy Industries & Construction Co., Ltd TRAINING MANUALS
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Project
TRAINING MANUALS
2067MANG003010
DOOSAN Document Number
AE1166-DN05-GKA-427802
0
REV Rev
15/10/10
DATA Date
FOR REVIEW
EMISSIONI E REVISIONI Issues and revisions
PAOLINO
DISEGN. Drawn
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PROJECT: Shuweihat S2 Independent Water and Power Producer REMINERALIZATION PLANT CLIENT: TITLE: Doosan Heavy Industries & Construction Co., Ltd TRAINING MANUALS
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PURPOSE OF THE MANUAL ................................................................................. 9 DESCRIPTION ...................................................................................................... 10 REMINERALIZATION PLANT SYSTEM ARRANGEMENT .................................. 12 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 3.1.6 3.2.1 3.2.2 3.2.3 3.2.4 3.2.5 3.2.6 Area 1 Functionality Basic Description ...................................... 12 Area 2 Functionality Basic Description ...................................... 12 Area 3 Functionality Basic Description ...................................... 13 Area 4 Functionality Basic Description ...................................... 13 Area 5 Functionality Basic Description ...................................... 13 Area 6 Functionality Basic Description ...................................... 14 CO2 Vacuum Booster Pumps Area (Area 1).............................. 15 Limestone Dissolution Filters Area (Area 2) .............................. 17 Absorbers / Degasifiers / Chemicals Area (Area 3) ................... 18 Limestone Recharging and Storage Area (Area 4) ................... 22 Sedimentation and Sludge collecting system (Area 5) .............. 24 Neutralization system (Area 6) .................................................. 25
OPERATION ......................................................................................................... 28 4.1 General Safety Requisites for Plant Operation ............................................ 28 4.1.1 4.1.2 4.1.3 4.1.4 4.2.1 4.2.2 4.3.1 4.3.2 4.3.3 4.3.4 4.3.5 Access to Site and Site Conditions............................................ 28 Basic Safety Rules .................................................................... 28 First Aid ..................................................................................... 29 Electric Power............................................................................ 29 Operational Checks ................................................................... 30 Operational Log Sheets ............................................................. 31 Plant Set Points Check .............................................................. 32 Distillate Header Flowrate ......................................................... 32 Analysis Plan and Tables .......................................................... 32 Limestone Chips Storage and Preservation .............................. 33 Plant Load Change Procedure .................................................. 34
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OPERATION: BASED UPON SD AND OM (CONTROL LOOPS, ETC.) .............. 35 5.1 Gas Extraction after Water Distillation - Operation Philosophy (Common to Groups) ....................................................................................................... 35 5.2 Gas Extraction after Water Distillation - Control Philosophy (Common to Groups) ....................................................................................................... 36 5.2.1 5.2.2 Control System Major Variables ................................................ 36 Discharge Pressure and Water Level in Drain Separators ........ 36
5.3 Gas Purification - Operation Philosophy (Common to Groups) .................... 40 5.4 Gas Purification - Control Philosophy (Common to Groups) ........................ 41 5.5 CO2 Gas Absorption - Operation Philosophy (GROUP #1) .......................... 41 5.6 CO2 Gas Absorption - Control Philosophy (GROUP #1) .............................. 43 5.6.1 5.6.2 5.6.3 5.6.4 5.6.5 5.6.6 5.6.7 Absorbers Load Variations ........................................................ 43 Acidified Distillate Level Control in the Absorbers ..................... 44 Inlet CO2 Gas to Absorber Flow Control .................................... 45 Inlet Distillate to Absorber Flow Control ..................................... 46 Proportion of Distillate to the Absorbers and Absorber By-pass 46 Absorber Booster Pumps Control .............................................. 47 Absorbers Pressure Control ...................................................... 47
5.7 Limestone Filters (Chemical Reaction) - Operation Philosophy (GROUP #1)48 5.8 Limestone Filters (Chemical Reaction) - Control Philosophy (GROUP #1). 50 5.9 Limestone Filters (Regeneration and Recharge) - Operation and Control Philosophy (GROUP #1) ............................................................................. 51 5.9.1 5.9.2 5.10 5.11 5.12 5.13 5.14 Limestone Filters Regeneration................................................. 51 Limestone Filters Recharge....................................................... 59
Sedimentation and Slurry Collecting System - Operation Sedimentation and Slurry Collecting System - Control Philosophy Polyelectrolyte Dosing System - Operation Philosophy (Common) 64 Degasifying Process - Operation Philosophy (GROUP #1)............ 66 Degasifying Process - Control Philosophy (GROUP #1) ................ 68 5.14.1 Degasifying System Control .................................................... 68
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5.14.2 5.14.3 5.14.4 5.15 5.16 5.17 #1) 5.18 5.19 #1) 5.20 6
Degasifier Level Control .......................................................... 68 Degasifier Extraction Pumps Control ....................................... 69 Degasifier Fans Control ........................................................... 69
Degasifier Acid Cleaning System ................................................... 70 NaClO Dosing System - Operation Philosophy (Common and NaClO Dosing System - Control Philosophy (Common and GROUP ....................................................................................................... 71 NaOH Dosing System - Operation Philosophy (Common and NaOH Dosing System - Control Philosophy (Common and GROUP ....................................................................................................... 75 Neutralization System (Common)................................................... 77
ALARMS AND ACTIONS ...................................................................................... 78 6.1 Effects of Variations from the Design Operation Conditions ........................ 79 6.1.1 6.1.2 6.1.3 Variations in Acidified Distillate Flowrate to Limestone Filters .. 79 Variations in Fan Air Flowrate to Degasifier .............................. 79 Variations in the Proportion Between Distillate to Absorber and
Absorber Bypass ............................................................................ 80 6.2 Remineralization Group #1 Critical Alarms .................................................. 81 6.3 Subsequent Actions upon Alarm Signals ..................................................... 85 6.3.1 6.3.2 6.3.3 6.3.4 6.3.5 7 Level Alarms .............................................................................. 86 Flow Alarms ............................................................................... 87 Pressure Alarms ........................................................................ 88 Temperature Alarms .................................................................. 90 Analyzers Alarms....................................................................... 90
TROUBLESHOOTING .......................................................................................... 91 7.1 Introduction................................................................................................... 91 7.2 System troubleshooting ................................................................................ 91 7.2.1 7.2.2 7.2.3 CO2 Gas compression system .................................................. 92 Absorber system........................................................................ 94 Limestone Dissolution system ................................................... 95
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7.2.4 7.2.5
EMERGENCY PROCEDURES ........................................................................... 100 8.1 Introduction................................................................................................. 100 8.2 Emergency Cases not Requiring Plant Group Shut-down ......................... 100 8.2.1 8.2.2 8.3.1 8.3.2 8.3.3 8.3.4 Electric Power Supply Failure.................................................. 100 Valve Blocking for Absorber .................................................... 101 Minimum Distillate Flow to Plant Group ................................... 101 Whole Cooling Water Circuit Failure ....................................... 101 Remineralization Plant Power Failure (AC-electrical power) ... 102 Failure in Plant Instrument Air Supply ..................................... 102
GENERAL SAFETY PRECAUTION .................................................................... 103 9.1 Introduction................................................................................................. 103 9.1.1 9.1.2 9.1.3 9.1.4 10.1 10.2 10.3 10.4 11.1 11.2 Access to Site and Site Conditions.......................................... 103 Basic Safety Rules .................................................................. 103 Electric Power.......................................................................... 104 Mechanical Equipment / Instrumentation Maintenance ........... 105
10 BASIC RULE OF FIRST AID ............................................................................... 106 General ......................................................................................... 106 Inhalation ...................................................................................... 106 Eye injuries from liquid splashes or concentrated vapour ............ 106 Skin burns from liquid splashes or concentrated vapour .............. 107 General Descriptions .................................................................... 107 Maintenance Procedures for Vessels and Tanks ......................... 108 11.2.1 11.2.2 11.3 11.4 Regular Maintenance during Operation................................. 108 Maintenance during Plant Group / Equipment Stop .............. 108
General Maintenance Procedures for Valves and Piping System 110 CO2 Gas Compression System .................................................... 111 11.4.1 Maintenance for Drain Separators and Purification Filters .... 111
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11.5 11.6 11.7 11.8 11.9 11.10 11.11 11.12 12.1 12.2 12.3 12.4 12.5 12.6
Absorption System ....................................................................... 112 11.5.1 11.6.1 11.7.1 Maintenance for Absorption Towers ...................................... 112 Maintenance Works for Limestone Filters ............................. 114 Chemical cleaning procedure ................................................ 116 Limestone Dissolution System ..................................................... 114 Maintenance for Chemicals Tanks ............................................... 115 Sedimentation and Sludge Collection System.............................. 117 Instrument / Service Air & Service Water System ........................ 117 Limestone Recharging System..................................................... 117 Neutralization System................................................................... 118 Electrical Equipment ..................................................................... 118 Introduction ................................................................................... 119 Preservation Procedures for Mechanical Equipment and Preservation Procedures for Vessels and Tanks ......................... 119 Preservation Procedures for Piping and Accessories .................. 120 Preservation Procedures for Utilities and Consumables .............. 121 Access to Site ............................................................................... 121
Instrumentation........................................................................................... 119
13 TERMS AND ABBREVIATIONS.......................................................................... 122 14 REFERENCE DOCUMENTS .............................................................................. 126 14.1 Process Engineering .................................................................... 126 14.1.1 14.1.2 14.1.3 14.1.4 14.1.5 14.2 14.2.1 14.2.2 Recarbonation and CO2 Compressor Systems .................... 126 Back-Wash Water Recovery, Sludge Treatment and Degassing System................................................................. 127 Chemical Dosing System ...................................................... 127 Mass Balance documents ..................................................... 128 Recarbonation and CO2 Compressor Systems .................... 128 Back-Wash Water Recovery, Sludge Treatment and
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14.2.3 14.2.4 14.3 14.4 14.5 14.6 15.1 15.2 15.3 15.4 15.5 15.6 15.7 15.8
Civil Engineering........................................................................... 130 Piping Engineering ....................................................................... 130 Instrumentation ............................................................................. 131 Electrical ....................................................................................... 131 Typical Potable Water System Flow Block Diagram .................... 133 Bypass Operational Method ......................................................... 135 Typical Limestone Filter Description & Operation ........................ 136 Typical Operation of Absorbing Towers ....................................... 139 Typical Operation of Degasifying Tower & pH Adjustments ......... 141 Absorption Recarbonation Degasifying Control System......... 143 Corrosion Index - Langelier Saturation Index ............................... 145 Alkalinity and pH Measurement Methods ..................................... 147 15.8.1 15.8.2 Total Alkalinity ....................................................................... 147 Alkalinity and Water Quality................................................... 147
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2 DESCRIPTION
The Remineralization Plant comprises N.2 groups, each one operating at 50% capacity:
Group #1 treats distillate coming from Evaporators #61, #62, #63; Group #2 treats distillate coming from Evaporators #64, #65, #66.
This configuration allows to respect the general design criteria that any failure of a single valve or equipment does not lead to a complete Plant production outage. Each Group is basically composed of N.2 Absorption Towers, followed by N.6 Limestone Dissolution Filters and N.1 Degasifier. In absorption towers, the CO2 contained in the compressed vent gas is absorbed into the distillate, in order to reach the required concentration at the inlet of limestone filters. In the degasifier, residual CO2 concentration is decreased to the value required before final chemical dosing.
Both Remineralization Groups are served by a unique common Vent Gas Recovery System, designed for compression and purification of vent gas coming from all evaporators.
Nos. 2 Sedimentation and Slurry Systems are dedicated to backwashed water of each Group, with total Nos. 3 Drying Beds and N.1 Polyelectrolyte Dosing System common to the whole Plant.
No.1 NaOH Dosing System, for pH adjustment of remineralized water, and N.1 NaClO Dosing System, for disinfection of remineralized water, serve both Remineralization Groups, with dosing pumps specific for each Group.
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Refer to Section 4 Operation, which provides clear and consolidated system description, process description and control system description; that presentation approach is the most suitable for this complex Remineralization System.
Section 4 refers to treatment of distillate coming from Evaporators #61, #62, #63, so that Vent Gas Recovery System, a Remineralization Group, Sedimentation and Slurry System, NaOH Dosing System, NaClO Dosing System, Neutralization System are described, for common parts and for Group #1. The same section is applicable to Group #2.
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The limestone filters require a periodical regeneration treatment, to be properly executed in order to ensure optimal operation on the long run.
It is important to ensure proper storage and preservation of limestone for this area, as well as regular maintenance of the system and its effectiveness.
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basin and pumped to limestone filters inlet header. This operation is periodically required, in order to allow sludge inlet from the next regeneration filter. The sedimentation and sludge collecting area should be regularly inspected / maintained for correct service.
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3.2.1 CO2 Vacuum Booster Pumps Area (Area 1) 3.2.1.1 CO2 Vacuum Booster Pumps
The CO2 booster pumps are characterized by the following key figures (for specific information, please refer to the relevant equipment data sheet): Item ID tag Capacity Discharge pressure and temperature Electric motor power (at 40C) Number of units in operation / standby 61//66GKG01AP001 693,84 kg/hr 5.00 bar(a) 160 kW From 1 to 6 (depending on plant load) Max 59.9 C
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3.2.2 Limestone Dissolution Filters Area (Area 2) 3.2.2.1 Limestone Dissolution Filters
The twelve plant limestone dissolution filters are characterized by the following key figures (for specific information, please refer to the relevant equipment data sheet): Item ID tag Internal diameter and TL TL height Design pressure and temperature Operating pressure and temperature Limestone height / grain size Number of units in operation / standby 06GKK1021BB001 5200 mm 5 bar(g) 2 bar(g) Max 3886 4800 mm 10 + 2 standby or recharging 4500 mm 60 C 43 C MAX 2-4 mm
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3.2.3.2 Degasifiers
The degasifying towers are characterized by the following key figures (for specific information, please refer to the relevant equipment data sheet): Item ID tag Internal diameter and TL TL height Design pressure and temperature Operating pressure and temperature Packing height / density Number of units in operation 06GKM01/11BB001 3700 mm Full of Water ATM 18,8 m3 2 9190 mm 60 C 43 C ATM 60 Kg/m3
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3.2.3.10
The Liquid Chlorine unloading pumps are characterized by the following key figures (for specific information, please refer to the relevant equipment data sheet): Item ID tag Capacity and head Operating temperature Electric motor power Number of units in operation / standby 06GKP11/12AP001 20 m3/hr 25 - 43 C 5,5 kW 1 + 1 (stand-by) 10 m
3.2.3.11
The Liquid Chlorine storage tank are characterized by the following key figures (for specific information, please refer to the relevant equipment data sheet): Item ID tag Internal diameter and TL TL height Design pressure and temperature Operating pressure and temperature NaOCl concentration and density Number of units in operation 06GKP01BB001 3000 mm Full of water Atm 12 % 1 + 1 (stand-by) 6850 mm 60 C 40 C MAX 1200 Kg/m3
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The Liquid Chlorine dosing pumps are characterized by the following key figures (for specific information, please refer to the relevant equipment data sheet): Item ID tag Capacity and head Operating temperature Electric motor power Number of units in operation / standby 06GKP03//06AP001 15 - 155 l/hr 43 C MAX 0,37 kW 2 + 2 (stand-by) 2 bar (G)
3.2.4 Limestone Recharging and Storage Area (Area 4) 3.2.4.1 Limestone Main Loading Hoppers
The main loading hopper for limestone recharging is characterized by the following key figures (for specific information, please refer to the relevant equipment data sheet): Item ID tag Overall Height Overall Width Operating volume 06GKL01/11BB001 3865 mm 4142 mm 10.5 m3
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3.2.5 Sedimentation and Sludge collecting system (Area 5) 3.2.5.1 Recovery Pumps
The recovery pumps are characterized by the following key figures (for specific information, please refer to the relevant equipment data sheet): Item ID tag Capacity and head Operating temperature Electric motor power Number of units in operation / standby 06GKE01//04AP001 42 m3/hr 43 C 11 kW 2 + 2 (stand-by) 40 m
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4.1
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4 OPERATION
General Safety Requisites for Plant Operation
Moreover, those in charge of chemical products handling must always wear protection dresses as follows: Suitable glasses for eyes protection Suitable overdresses Suitable gloves
Operators should never be allowed to start operations within the chemical storage area or chemicals handling activities without the above mentioned protection equipment; these safety requirements apply also for all chemicals related activities such as tanks draining, basement cleaning, etc.
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When performing chemicals handling activities, a minimum of two operators are required to allow immediate help in case of danger; in this case, a breathing apparatus (20 lt. capacity) must be also available for at least one of the operators. A strict work permission procedure must be applied from operators chief for chemicals handling. In case of any damage to persons as result of contact with chemicals, injured persons must be immediately washed with fresh service water and medical assistance immediately requested. In case of exposure, even for short periods, to any fumes, medical assistance is always required to detect possible lung damages. In particular, before operating within a chemical tank, the operator should check that the basic rules previously described are obeyed.
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The operator is recommended to make every effort to maintain functions of safety valves. The operator is recommended to examine the exterior of all equipment daily for symptoms of
k) The operator is recommended to clean the corroded area(s) by using a wire brush or scraper, until sound metal is exposed, and then coated with a protective compound. l) The operator is recommended to examine the rubber lining of all rubber-lined equipment, if possible and where provided. Especially limestone dissolution filters shall be examined during the limestone recharging time. m) The operator is recommended to ensure that all valves and fittings are maintained in good working order. n) The operator is recommended to inspect all fixed and sliding feet and ensure that the holding down bolts are secure and in good conditions. o) The operator is recommended at any time to keep the site clean and free from obstacles.
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Sampling interval Every 15 days Every 15 days Every 15 days Every 15 days Every 30 days
Analysis to perform Distillate characteristics as per design specifications Dissolved CO2 content Conductivity a. Residual CO2 content b. Alkalinity a. NaOH concentration b. Purity of solution (SS, oil, etc.) a. Purity of limestone
Acidified distillate from absorption tower Distillate to limestone filters Carbonated distillate from limestone dissolution filters outlet collector NaOH solution from dosing tank
Every 30 days
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Please refer to document number AE1166-XG02-GKG-427801 for reference (CO2 booster pumps P&ID). Plant load may therefore vary from 20% to 100% of maximum allowable load for each distiller (see mass balance drawings for reference), depending on the number of running booster vacuum pumps. When performing load changes, the operator should take into account the followings: Limestone dissolution filters are designed according to a default distillate flowrate of 494,236 m3/hr for each vessel; small changes from default value e.g. 10% during load changes are however allowable without compromising process effectiveness CO2 absorbers are designed for 100% of plant load each i.e. at full load even a single absorbing tower running is allowed, without compromising process effectiveness Degasifying unit is designed for 100% of plant load and is forecasted to run at all plant loads CO2 purification filters are forecasted to run as per 1 + 1 configuration at all plant loads
During load variations, each equipment will be started according to the same procedure forecasted for plant normal start up i.e. provided checks on valves, alarms, cooling water lines, etc.
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At this stage of the process, mass balance for the gas inlet streams/flows (not considering the drainages from drain separators or pumps) does not substantially change; its main values (in the worst case of vent gas coming from the after-condenser i.e. 100% load summer condition) are reported in Table below: Total gas flow to booster vacuum pumps CO2 flowrate Air flowrate Steam flowrate Suction temperature Suction pressure Max discharge temperature Discharge pressure 4027.74 kg/hr 2197.74 kg/hr 1440.00 kg/hr 390.00 kg/hr 55 C 0.813 bara 50 C 5.000 bara
5.2
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Pressure inside the Drain separator is monitored at DCS through pressure Transmitter PIT 61GKG02CP002 (62/62/64/65/66GKG02CP002 for the other units). In case of high pressure inside the drain separator, a high pressure alarm, item PIA+ Z+ 61GKG02CP002 (PIA+ Z+ 62GKG02CP002, PIA+ Z+ 63GKG02CP002 and PIA+ Z+ 64GKG02CP002, PIA+ Z+ 65GKG02CP002, PIA+ Z+ 66GKG02CP002 for the other units), is generated at DCS, while the trip signal is transmitted to the related booster vacuum pump. An additional dedicated pressure switch item PS A+ Z+ 61GKG01CP081 is also installed directly on CO2 booster pump delivery, before entering Drain separator. Related high pressure alarm is transmitted to the DCS, while the trip signal is transmitted to the related booster vacuum pump A pressure indicator, item PI 61GKG02CP501 (PI 62GKG02CP501, PI 63GKG02CP501, PI 64GKG02CP501, PI 65GKG02CP501 and PI 66GKG02CP501 for the other units), indicates the discharge pressure of the booster vacuum pumps. Valve, item AA304, is provided for the PI isolation. The CO2 gas pressure entering the pumps is indicated by the pressure indicator, item PIT 61GKG01CP001 (PIT 62GKG01CP001, PIT 63GKG01CP001, PIT 64GKG01CP001, PIT 65GKG01CP001and PIT 66GKG 01CP001 for the other pumps). A safety valve, item AA191, is also installed on each drain separator to protect the Drain separator vessels against overpressure.
(LS--/LS-/LS+/LS++ LS--/LS-/LS+/LS++
62GKG02CL081/2/3/4, 64GKG02CL081/2/3/4,
LS--/LS-/LS+/LS++ LS--/LS-/LS+/LS++
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65GKG02CL081/2/3/4 and LS--/LS-/LS+/LS++ 66GKG02CL081/2/3/4 for the other units), are installed in order to provide to the DCS the signals LOW-LOW, LOW, HIGH and HIGH-HIGH water level, for each separator. LOW-LOW and HIGH-HIGH level switches are alarm switches for the operator in the
Level for condensed water in the separator is kept at its set value by using two pneumatic operated ball valves, items 61GKG02AA101 and 61GKG02AA102 (62GKG02AA101 and 62GKG02AA102, 63GKG02AA101 and 63GKG02AA102, 64GKG02AA101 and 64GKG02AA102, 65GKG02AA101 and 65GKG02AA102, 66GKG02AA101 and 66GKG02AA102 for the remaining five vessels). The signal to close or to open the valves is transmitted by the LOW and HIGH level switches items LS61GKG02CL082 and LS+ 61GKG02CL083 (LS- 62GKG02CL082 and LS+ 62GKG02CL083, LS63GKG02CL082 and LS+ 63GKG02CL083, LS- 64GKG02CL082 and LS+ 64GKG02CL083, LS65GKG02CL082 and LS+ 65GKG02CL083, LS- 66GKG02CL082 and LS+ 66GKG02CL083 for the other units). The excess water will be discharged to the drain or the separator will be filled with water branched from the cooling closed circuit, accordingly. During the system start-up the pneumatic valve item AA101 on stream item 61GKG83 BR001 opens as soon as energized, to allow the vessel to reach the proper liquid level. During normal operation, the control is performed by the related level switches. In case of pneumatic valves malfunctioning, HIGH-HIGH or LOW-LOW level will be reached inside the vessel, and the related alarm will be transmitted to the DCS. A signal will be transmitted to the booster vacuum pump, item 61GKG01AP001 (62GKG01AP001, 63GKG01AP001, 64GKG01AP001, 65GKG01AP001 and 66GKG01AP001 for the other units), which will shut down the system. The related pump shutdown status and related information will be transmitted to the operator interface devices.
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5.2.2.3 Sealing Water Flowrate and Temperature 5.2.2.3.1 Sealing Water Flowrate Sealing water flowrate for each booster vacuum pump is monitored by using the low flow switch, item FS- 61GKG03CF081 (FS- 62GKG03CF081, FS- 63GKG03CF081, FS- 64GKG03CF081, FS65GKG03CF081 and FS- 66GKG03CF081 for the other units). In case of low sealing water flowrate, e.g. due to leakages, etc. an alarm, item FA- Z- 61GKG03CF081 (FA- Z- 62GKG03CF081, FA- Z- 63GKG03CF081, FA- Z- 64GKG03CF081, FA- Z- 65GKG03CF081 and FA- Z- 66GKG03CF081 for the remaining units), is generated to the DCS, and related booster vacuum pump is shut down.
5.2.2.3.2 Sealing Water Temperature The temperature of sealing water is monitored by using a temperature switch, item TS+ 61GKG03CT081 (TS+ 62GKG03CT081, TS+ 63GKG03CT081, TS+ 64GKG03CT081, TS+ 65GKG03CT081 and TS+ 66GKG03CT081 for the other units). In case of sealing water high temperature condition e.g. due to a malfunction of the heat exchanging system, an alarm item TZ+ 61GKG03CT081 (TZ+ 62GKG03CT081, TZ+ 63GKG03CT081, TZ+ 64GKG03CT081, TZ+ 65GKG03CT081 and TZ+ 66GKG03CT081 for the other pumps), is transmitted to the DCS and the related booster vacuum pump is shut down.
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The flow indicator and transmitter, item FIT 61GKG04CF001 (FIT 62GKG04CF001, FIT 63GKG04CF001, FIT 64GKG04CF001, FIT 65GKG04CF001 and FIT 66GKG04CF001 for the other units), transmits its value to the control room. A LOW/HIGH flowrate alarm, item FA -/+ 61GKG04CF001 (FA -/+ 62GKG04CF001, FA -/+ 63GKG04CF001, FA -/+ 64GKG04CF001, FA -/+ 65GKG04CF001 and FA -/+ 66GKG04CF001 for the other units), is transmitted to the operator interface, in case of a LOW/HIGH value for gas flowrate, from drain separator. The pressure of CO2 gas, on the discharge collector to the CO2 compression area, is monitored by using the pressure indicator and transmitter item PIT 06GKG01CP001, which is installed through the valve item AA301. The controller keeps a constant pressure inside the collector. In case of high pressure, the controller actuates the pneumatic control valve, item AA151, allowing gas discharge to the atmosphere. If the pressure value is below the set value, a low pressure alarm, item PICA- 06GKG01CP001 is transmitted to the DCS. Valve item AA151 is equipped with a local transmitter, item GT 06GKG01CG151, which transmits a signal of off-set condition to the indicator, item GI 06GKG01CG151, located at the DCS.
5.3
After compression, CO2 gas flows through the valve, item AA001, to a gas purification filter (item 06GKG01BB001 or 06GKG02BB001). Each filter is designed for 100% of unit load. The unit is designed to divert the stream to an operating filter, while the other is in standby mode (for maintenance, substitution of filtering media, etc.). The group is also equipped with a by-pass manual valve, item 06GKG03AA001. Each filter is filled with a suitable activated carbon layer, which has the function of removing volatile organic compounds, odours, etc., and ensures that the CO2 gas enters the absorption stage with the minimum pollutants content.
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The filters have been designed for an expected changeover period of six (6) months operation. After the design time has elapsed, the operating filter needs to be shut down by the operator, and its activated carbon charge replaced. At this time, the gas flow is manually diverted by the operator to the standby filter. Each vessel is provided with a discharge valve, item AA401, installed at the bottom. A safety valve item AA191 precludes overpressure conditions inside the filter. In each filter the activated carbon layer is loaded inside a recharging basket, which is fixed inside the inner part of vessel by means of bolts and a supporting ring. The basket is equipped with a lifting lug for periodical substitutions of the filtering media.
5.4
No automatic controls are provided for the gas purification filters, items 06GKG01BB001 and 06GKG02BB001. Filters are manually switched to the operation or standby mode, by opening the related inlet / outlet valves, that allow the flow to one or the other unit. A safety valve, item AA191, is installed on the top of each purification filter. A differential pressure switch, item 06GKG02CP081, is provided in order to check the pressure loss through the operating filter.
5.5
After compression and purification, CO2 gas is fed to an absorber (item 06GKJ01BB001 or 06GKJ02BB001), and dissolved in the distillate, branched from distillate header and sent in by an absorber booster pump (item 06GKJ06AP001 or 06GKJ07AP001). Each absorber is designed for 100% of unit load. Their operation concept is: N.1 absorbing tower in operation and N.1 absorbing tower in stand-by mode. An amount of distillate from header (the amount which is not by-passed) is sent to stream item 06GKJ05 BR001, where it is branched off into two lines: 1. A portion of it (absorber by-pass) is by-passed to the outlet of absorbers unit;
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2. The rest of it is fed to a CO2 absorber by means of an absorber booster pump. Each absorber booster pump (Doosan scope) is designed for 100% of unit load. Their operation concept is: N.1 pump in operation and N.1 pump in stand-by mode. After booster pumping stage, branched distillate water flows through the pneumatic control valve item 06GKJ01AA151 into the distribution system of a CO2 absorber, located at the top of the vessels. For maintenance purposes, valve item 06GKJ01AA151 is provided with a by-pass system. Compressed CO2 gas from the previous purification stage, enters into an absorber, through the pneumatic control valve item 06GKG08AA151 and the check valve item 06GKG08AA201 (06GKG08AA202 for the other tower). The pressure at the bottom of the vessel (therefore, the available head for pumps) depends on both internal gas pressure and liquid level inside the tower. For maintenance purposes, valve item 06GKG08AA151 is provided with a by-pass system. The CO2 gas absorber is a packed counter flow type absorbing tower, i.e. the CO2 gas flows upwards to the top, while the branched distillate is distributed from the top of the vessel. After gas absorption, distillate enriched with CO2 flows downwards to the bottom of the absorber. Air, which is about 40 times less soluble than the CO2 gas, flows to the top part of the absorber, from where it is removed and discharged, while approximately 94% of inlet CO2 gas is dissolved, forming acidified distillate. Acidified distillate is removed from the bottom of the tower through the check valve item 06GKJ03AA201 (06GKJ04AA201 for other tower), and butterfly valve item 06GKJ03AA001 (06GKJ04AA001 for other tower), and blended with the remaining portion of distillate which has been branched from the main header but has not been fed to the absorber (absorber by-pass), before entering the limestone dissolution filters (chemical reaction stage). The absorbers by-pass is the stream item 06GKJ05 BR002. The distillate flows into it through the manual butterfly valve item 06GKJ05AA001, then the pneumatic control valve item 06GKJ05A151, and check valve item 06GKJ05AA201.
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Both towers are equipped with a manual drain valve item AA402, while valves items AA601 on the outlet lines, allow periodical sampling of the acidified distillate. Each absorber is equipped with a safety valve item AA191. Backwash water for limestone filters is branched off from the main distillate by-pass line, on line item 06GKK50 BR001, through the butterfly valve item AA001. Distillate is also branched for chemical dosing (stream item 06GKJ31 BR001), from the distillate line entering the Remineralization plant, item 06GKJ05 BR001. At the final stage of the remineralization process, by-pass distillate from group header is fed through the pneumatic control valve item 06GDK20AA151, to be mixed with recarbonated distillate flow from the limestone filters system.
5.6
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Based upon the total distillate flow indications transmitted by FIT 06GDK10CF001, the control system proportionally reduces or increases the distillate flow to CO2 gas absorber, within the maximum and minimum design flow (from 100% down to 60% for each evaporator). Above value is assigned by the controller (item FC 06GKJ01CF001) to the flow control valves on the absorber distillate inlet line and by the controller (item FC 06GKG08CF001) to the flow control valves on the absorber CO2 inlet line. The control system will automatically change the set value for the controller, item FC 06GKJ01CF001, and distillate flow rate to the absorber. Changes in the set point will affect the opening of the pneumatic control butterfly valve, item 06GKJ01AA151, installed on stream, item 06GKJ01 BR001. CO2 gas flow rate to the absorbers will be also changed. The control system will change the set value for the inlet gas flow controller item FC 06GKG08CF001, upon changes of inlet distillate flow rate. Changes of the set point will affect the opening of the pneumatic control valve, item 06GKG08AA151, installed on stream, item 06GKG08 BR001. The method of changing the inlet flowrates set points for the absorbing tower depends on the unit outlet alkalinity, mass balance relationship with distillate conditions.
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cases of HIGH or LOW level. The purpose of maintaining the acidified distillate level at its set point is to continuously provide the required static head, necessary to feed the limestone dissolution filters. Off-set conditions for the control valve are monitored in the control room by using the indicator of opening percentage, item GI 20GKJ02CG152 (GI 20GKJ04CG151 for the other unit), upon the signal from the transmitter item GT 06GKJ01CG152 (GT 06GKJ02CG151 for the other unit). Signal of HIGH-HIGH level in the absorber, and the subsequent possibility of flooding conditions, is given by the level switch, item LS++ 06GKJ01CL082 (LS++ 06GKJ02CL082 for the other unit), connected to the vessel through the valves, items AA307 and AA308. In case the HIGH-HIGH level alarm is reached, the operating Absorber booster pump is stopped and alarm, item LA++ 06GKJ01CL082 (LA++ 06GKJ02CL082 for other unit), will be sent to the control room. The level switch, item LS-- 06GKJ01CL081 (LS-- 06GKJ02CL081 for the other unit), provides a signal of LOW-LOW level condition. The operator is informed through the LOW-LOW level alarm, item LA-06GKJ01CL081 (LA-- 06GKJ02CL081 for the other unit). The local level indicator, item LI 06GKJ01CL501 (LI 06GKJ02CL501 for the other unit), is connected to the vessel through the valves, items AA305 and AA306; drainage of the indicator is possible by using the valve item AA401.
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DCS.
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Gas inlet valve item 06GKG08AA151 is equipped with a local transmitter, item GT 06GKG08CG151, which transmits a signal of off-set condition to the indicator, item GI 06GKG08CG151, located at the
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to the DCS.
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pressure conditions, with respect to the set point, the alarm, item PA+- 06GDK10CP001, is transmitted
Malfunction conditions for the pressure control valve are transmitted to the DCS, by the transmitter, item GT 06GDK10CG151. The indications from the indicator, item GI 06GDK10CG151, are transmitted to the DCS. The absorber by-pass stream, item 06GKJ05 BR001, is controlled by the control valve, item 06GKG05AA151; the valve is actuated by the pressure indicator and controller, item PIC 06GKJ09CP001, which receives signals from the indicator and transmitter, item PIT 06GKJ09CP001, installed on the valve, item AA301. The purpose of this control loop is to maintain a constant pressure value at the absorber system outlet, by regulating the absorber by-pass.
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The local pressure indicator and transmitter, item PIT 06GKJ01CP001 (PIT 06GKJ02CP001 for the other unit), transmits pressure values to the DCS. An alarm, item PIA+- 06GKJ01CP001 (PIA+06GKJ02CP001 for the stand-by unit), is generated in case of HIGH or LOW pressure conditions, inside the vessel, with respect to the set point value.
5.7
Acidified distillate, after blending with the distillate portion not fed to the absorbers (absorber by-pass distillate), is sent to limestone dissolution filters items 06GKK10BB001 to 06GKK15BB001, where the following chemical reaction occurs: CaCO3 + CO2 + H2O Ca++ + 2 (HCO3- ) CaCO3 is provided inside the limestone filters as a powder of suitable grain size, while CO2 and H2O are those resulting from the previous absorption process. As result of the chemical reaction, recarbonated distillate at filters outlet will reach the required level of alkalinity. Acidified distillate is distributed to each filter by using a common collector, item 06GKJ08 BR101, flows through the manual valve, item AA001, and the automatic on-off valve item AA101. The flow is measured and distributed from the top of the vessel by using internal distributors. The distillate flows downwards, through the limestone layer, and reaches the bottom of the vessel. It has a lower level of CO2, and an increased quantity of Ca++ and HCO3 ions.
Recarbonated distillate leaves the filter through the pneumatic control valves, items AA151 and pneumatic on-off AA102, towards the treated water common collector. In case of a malfunction or of unavailability of the inlet line / valve, the inflow of acidified water can be discharged to the drain, through the automatic valve, item AA107. When the limestone recharging is required, an amount of the recarbonated distillate is removed from the bottom of the vessel through the automatic valve, item AA108, and used for limestone filters recharging operation. This is periodically needed in order to restore limestone conditions and to ensure
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a correct chemical reaction effectiveness inside the vessel. The distillate to the recharging system is collected in the common stream, item 06GKL04 BR001. Limestone slurry from the ejectors area flows from the common collector, item 06GKL14 BR002, into each filter, through the automatic valve, item AA109, and related internal limestone distributors. Distillate for periodical regeneration enters each filter through the automatic valve item AA103. Each vessel is provided with a manual drain valve item AA401, which is opened for maintenance operations. Backwash flow rate is set at a set point value of 530 m3/hr by the control system, in order to ensure a proper filter backwash without removal of limestone powder through the top distributor. An automatic vent valve, item AA106, is provided at the top of each vessel (for air discharge during air bubbling and refilling operations), while the automatic valve, item AA107, opens for a partial vessel drainage just above the limestone bed level before the air bubbling step of the regeneration procedure takes place. The air scouring step nozzle is located approximately at the middle height of the limestone packing but it is distributed from the lower internal vessel distributor. Air is fed through the automatic valve, item AA105, at a pressure of 1.5 bara and a flowrate of 1300 Nm3/hr. A sampling point is provided for each limestone dissolution filter. A periodic sampling is performed by opening the related valve, items AA601. Three sight glasses, items M1, M2 and M3, are installed on each limestone dissolution filter in order to allow the operator to perform a visual inspection of the limestone packing, distillate height above limestone after drain down, distance of the layer from distributors. Therefore, a lower level of the limestone or damages in the internal distributors, etc. can be identified and corrective action can be taken as required.
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5.8
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The operator can select from the control room which filters (out of the N.6 group limestone filters) to operate. The selection will be in accordance with the group load (number of distillers in operation), environmental conditions, units situation at that time (e.g. maintenance, etc.). If the system is required for maximum group production, N.5 filters will be in operation, while one is in stand-by, loading or regeneration mode. In general, the number of filters is related to the number of distillers in operation (therefore to flow of acidified distillate from absorbers area), and to the CO2 gas flowrate at the different operating conditions. However, the control room operator has, at any time, the possibility to activate or exclude any limestone filter from the process. Accordingly, summation of the flow to each limestone filter will determine the amount of remineralized water produced for the group. Remineralized water flowrate from each limestone dissolution filter is controlled in order to obtain the required product water. This is performed in accordance with the linear velocity and uniform distribution requirements inside each vessel. The control is performed by regulating the flow control pneumatic valve, item AA151, installed on the outlet line of each filter. The flowrate from the absorbers to limestone filters is measured by the sensing elements, items FE 06GKK10//15CF001, and a signal is transmitted to the DCS by the local flow indicators and transmitters, items FIT 06GKK10//15CF001. The indicators and controllers, items FIC 06GKK10//15CF001, set at the value decided by the operator (default value is 495 m3/hr), acts on the pneumatic control valve, items AA151. In case of LOW/HIGH flowrate condition, which may lead to improper system performance, alarms, items FA-/+ 06GKK10//15CF001, are transmitted to the DCS. Flow indicators and transmitters, items FIT 06GKK10//15CF001, transmit the inlet flowrate value, for each filter, to the items FY 06GKK10//15CF001, which summarizes the flows from all vessels and provides an indication of the total load, to the limestone dissolution system in the DCS. Off-set conditions for the outlet valves, AA151, are sent by the transmitters items GT 06GK10//15CG151 to DCS, and displayed by the indicators, items GI 06GK10//15CG151. When, during the operation, excessive quantity of insoluble materials are accumulated in the limestone filter,
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acidified distillate flow decreases, even if the outlet valve item AA102 is completely open. The subsequent off set-of the flow valve controller will inform the control room operator. He will then proceed with the limestone filter regeneration sequence. Usually, when regeneration sequence is activated for a filter, this is changed over with another one, ready for operation; each limestone filter is typically changed over every 10 days by using a stand-by filter. When filters are in operation, under dissolution conditions, the distillate flow control pneumatic valves, items AA151, are in control conditions, and the valves at the inlet and outlet of the vessel, respectively, items AA101 and AA102, are in full open position. All other valves are closed.
5.9
Limestone Filters (Regeneration and Recharge) - Operation and Control Philosophy (GROUP #1)
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The regeneration procedure for limestone dissolution filters consists of the following steps:
Permissive conditions for Drain Down start: 1. All valves of selected filter for regeneration will be in closed position except for vent valve (filter in stand-by mode). 2. No other filter will be in regeneration sequence. 3. The Sedimentation Basin item 06GKE01BB001 will be in LOW LOW level condition (threshold from level indicator controller item LIT 06GKE01CL001). 4. Limestone Recharging selection Yes/No will be done. 5. If any of above events is not satisfied, the message DRAIN DOWN NOT POSSIBLE will be displayed on DCS monitor; once all permissive conditions are available, the sequence will proceed automatically.
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In case of valve malfunction during the step starting or during the step itself, the message DRAIN DOWN FAILED will be displayed on DCS monitor. All valves will be closed. The operator will reset the regeneration sequence. The filter will go to stand-by mode. Once the malfunction is removed, the operator will empty the Sedimentation Basin (down to the LOW LOW level) by means of a Slurry Pump, item 06GKE05AP001 or 06GKE06AP001, then will re-start the regeneration sequence. 20 minutes after the opening of Drain Down valve 06GKK10//15AA107 (time to be adjusted during commissioning), the same valve is closed and on DCS monitor will appear DRAIN DOWN COMPLETED. Vent valve 06GKK10//15AA106 remains open.
Considering that in normal operating conditions (at maximum load) about 28050 kg of limestone are needed to recharge one limestone filter, N. 1 Main Loading Hopper volume is sufficient to charge limestone filter. Before starting the Limestone Recharge step, the operator will have to fill up the main loading hopper item 06GKL01BB001 with limestone, using a Bobcat Loader. Then the operator will check that:
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both the suction valves of the Recharging Pumps are open; both the discharge valves of the Recharging Pumps are closed.
Furthermore the operator will check that the inlet/outlet valves of one ejector are open and moves the gravity diverter direction accordingly. At Field Panel, the operator will then select and start a Limestone Booster Recharging Pump (item 06GKL05AP001 or 06GKL06AP001), After pump start, the operator slowly will open the discharge valve of the same pump until its full opening. The operator then will check that the Main Hopper knife valve for unloading, item 06GKL01AA001, is open (partially to better operate the system). Then at field panel he starts the Limestone Bucket Elevator item 06GKL02AF001 and the Limestone Charging Screw Conveyor item 06GKL01AF001. The Screw Conveyor motor is equipped with a dedicated inverter in order to allow an easy speed variation without using mechanical equipment. The inverter also checks the machine velocity: if the machine is started and is running below the normal speed, an alarm will be displayed locally and to DCS, and the Conveyor and the Bucket Elevator will stop. Inside each Filling Hopper one HIGH level switch is installed (items LS+ 06GKL03CL081 and LS+ 06GKL03CL082). If during operation the HIGH level for a level switch is reached, the Screw Conveyor and the Bucket Elevator will be stopped and an alarm (items LA+ 06GKL03CL081 or LA+ 06GKL03CL082) will be sent to DCS. When the Main Hopper is completely unloaded, the operator first has to stop the Screw Conveyor, and, after approximately 5 minutes, the Bucket Elevator. The Recharging Pump will remain running. At this stage the operator has to close the knife valve, item 06GKL01AA001, charging the Main Loading Hopper up to half capacity, and then start the Bucket Elevator and the Screw Conveyor before opening again the knife valve.
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1. No other limestone filter will be in automatic regeneration sequence. 2. Drain Down step is finished. 3. No LOW pressure alarm (item PA- 06GKL04CP081 from Pressure Switch item PS 06GKL04CP081). If any of permissive conditions is not satisfied, the message RECHARGE NOT POSSIBLE will be displayed on DCS screen and the relevant equipments (pumps, screw conveyor, bucket elevator) will be disabled to start. Once the corrective action is taken (if required) and all permissive conditions are available, the operator will have possibility to start recharging equipment.
Interlock conditions for Limestone Recharge: LOW Screw rotation velocity alarm item SS- Z- 06GKL01AF001; HIGH level for a Filling Hopper item LS+ 06GKL03CL081 and LS+ 06GKL03CL082; valves / recharging equipments malfunction; LOW pressure for Limestone Recharging Booster Pumps unit, item PA- 06GKL04CP081.
In case of occurrence of any of the above conditions, the message RECHARGE FAILED will be displayed on DCS screen. Once the corrective action has been taken (if required) and all permissive conditions are available, the operator will have possibility to start recharge equipment. Permissive for starting condition after equipment malfunction can be given only from DCS operator (in CCR) after receiving field operator confirmation that the corrective action has been taken and the specific problem has been solved. The stop or trip of the Recharging Pumps will cause the stop of the Screw Conveyor and the Bucket Elevator. The stop or trip of the Bucket Elevator will stop the Screw Conveyor, but will not stop the Recharging Booster Pumps. In case of need, the operator can stop the running Recharging Pump from the local field panel, causing the entire sequence to stop.
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At the end of the sequence, once all the required limestone quantity has been recharged into the filter, the operator on field will inform the DCS operator that the sequence has been correctly finished and the DCS operator will select from DCS screen the push button CONTINUE AFTER RECHARGE. No automatic stand-by for motor overload is foreseen for equipment of the Recharging System. IMPORTANT: After Recharge, the discharge valves of the Recharging Pumps, the ejector inlet/outlet valves and the Main Hopper knife valve must be closed by on site operators.
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Permissive conditions for Air Scour start: 1. No other filter will be in automatic regeneration sequence. 2. Drain Down step is finished. 3. CONTINUE AFTER RECHARGE has been selected (in case Limestone Recharge was performed). If any of above events is not satisfied, the message AIR SCOUR NOT POSSIBLE will be displayed on DCS monitor; once all permissive conditions are available, the sequence will proceed automatically.
Interlock conditions for Air Scour: In case of valve malfunction or unavailability of both air blowers (i.e. MCC trip for both blowers), the message AIR SCOUR FAILED will be displayed on DCS screen; the running blower, if any, will stop and all valves will be closed. In case of cooling fan trip, the relevant blower will be stopped. The operator will reset the regeneration sequence by means of reset pushbutton on DCS screen; the filter will go into stand-by mode. Once the malfunction is removed, the operator will empty the Sedimentation Basin (down to the LOW LOW level) by means of a Slurry Pump, item 06GKE05AP001 or 06GKE06AP001, then will re-start the regeneration sequence.
5.9.1.3.1 Air Scour Blowers Control The air scour blowers are activated by the automatic limestone filters regeneration sequence. Their operation concept is the following: N.1 blower in operation mode and N.1 pump in stand-by mode. On each blower discharge line local pressure indicators items, PI 06GKK30CP501 and PI 06GKK31CP501 are installed using the valves, items AA301. Blowers are started up / shut down by the DCS operator, using the hand switches, items HS 06GKK30AN002 and HS 06GKK31AN002. Upon a signal from DCS to start Air Scour step, the automatic valve, item AA101, on stream, item 06GKK32-BR003, is opened and let line venting for 30 seconds, in order to avoid blower start up under load conditions. After the set time has elapsed, the valve is closed.
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06GKK32CG082.
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Off-set condition for the valve are monitored by the limit switches, items GS 06GKK32CG081 and GS
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Permissive conditions for Backwash start: 1. No other filter will be in automatic regeneration sequence. 2. Air Scour step is finished. If any of above conditions is not satisfied, the message BACKWASH NOT POSSIBLE will be displayed on DCS screen; once all permissive conditions are available, the sequence will proceed automatically.
Interlock conditions for Backwash: In case of valve malfunction (any on-off or control valve), the message BACKWASH FAILED will be displayed on DCS screen. The control valve and all the on-off valves will be closed. The operator will reset the regeneration sequence by means of reset pushbutton on DCS screen; the filter will go into stand-by mode. Once the malfunction is removed, the operator will empty the Sedimentation Basin (down to the LOW LOW level) by means of a Slurry Pump, item 06GKE05AP001 or 06GKE06AP001, then will re-start the regeneration sequence.
5.9.2
The Limestone Recharging System comprises the following main equipment: No. 1 Main Loading Hopper (06GKL01BB001); No. 1 Limestone Charging Screw Conveyor (06GKL01AF001); No. 1 Limestone Bucket Elevator (06GKL02AF001); No. 1 Two-Way Gravity Diverter (06GKL02AF002); Nos. 2 Filling Hoppers (06GKL03BB001 and 06GKL03BB002); Nos. 2 Limestone Ejectors (06GKL10BN001 and 06GKL11BN001); Nos. 2 Limestone Booster Recharging Pumps (06GKL05AP001 and 06GKL06AP001).
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The recharged limestone properties are indicated in the following Table: Limestone grain size distribution Limestone loose bulk density Limestone purity, as CaCO3 Recharged Limestone Properties For the remineralization group a limestone chips storage area is provided (by DHICO), with main data indicated in following Table: Overall limestone consumption (at maximum flow and number of operating filters) Design storage area capacity Storage area length Storage area width Storage area height Limestone Storage Area Main Data Limestone chips are discharged, from the trucks, close to the storage area, and moved from the end wall to the entrance. A mobile wheeled shovel is used to pile limestone, up to a maximum level of 1.6 meters. The first entrance bay of the shelter is left free, for the first 1 meter. Main Loading Hopper is partially buried in a concrete basin, in order to make limestone chips recharging from limestone storage area easier. The mobile wheeled shovel, used to pile up limestone into the storage areas, will be used also for Main Loading Hopper recharging activities. A concrete stair is provided by the Main Loading Hopper, to let personnel reach the bottom of the basin and to make maintenance operations, inspections, etc.. easier. The Screw Conveyor, item 06GKL01AF001, is installed under the Main Loading Hopper, with the purpose to transfer limestone chips through the knife valve, item 06GKL01AA001, to the Bucket Elevator item 06GKL02AF001 and to the Two-Way Gravity Diverter item 06GKL02AF002. 19.2 m3/day 580 m3 as minimum (for 30 days) 20 m 18 m 2m 1.5 4 mm 1450 kg/m3 > 90%
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The Conveyor is equipped with an inverter, in order to guarantee correct operation of the recharging system and to allow a limestone flowrate to Diverter variation of +/- 30% from design flowrate. The scope of the Two-Way Gravity Diverter is to let limestone flow, by gravity, using a rotating blade mounted inside, towards a Filling Hopper and related Limestone Ejector installed below, while the other filling hopper and related ejector are in stand-by mode. Before the start of recharging, the operator selects limestone filling hopper and related ejector, positioning accordingly the gravity diverter rotating blade. Each Filling Hopper has a capacity of 0.3 m3. Distillate drained at the bottom of the limestone filter through the valve, item AA108, starting from the level of the exhausted bed, is used as motive water for the ejectors, in a closed circuit. Water is pumped to the selected ejector through the ejector inlet valves, item 06GKL10AA001 or 06GKL11AA001, by using a Recharging Pump, item 06GKL05AP001 or 06GKL06AP001. Both Recharging Pumps are designed for 100% capacity. The pumps operation concept is the following: N.1 pump in operation mode and N.1 pump in stand-by mode. Distillate flows through the suction valve, item AA001, of the operating pump, is pumped up to the required pressure and then fed as motive water to an ejector through the check valve, item AA201, and discharge valve, item AA002. Limestone is sucked by motive water. The limestone-water mix is sent through the valve item AA001 to the limestone filter to be recharged and it flows inside through two recharging nozzles, located below the acidified distillate distributor. The limestone recharging system is provided with a local control panel. After enabling from the DCS, all operations are actually performed locally, by the operator. The main functions of the local control panel are the following:
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1. Start-up of Recharging Pumps, Bucket Elevator, Screw Conveyor; 2. Shut-down of Recharging Pumps, Bucket Elevator, Screw Conveyor; 3. Enabling of signal display for panel.
5.10 Sedimentation and Slurry Collecting System - Operation Philosophy (GROUP #1)
Water resulting from backwash of limestone dissolution filters contains impurities forming a slurry, which is separated from water and removed. Slurry is composed of fine particles, but heavy enough to allow sedimentation process, i.e. particles are removed by means of gravity. Therefore, in accordance with the water clarification principles, backwashed water is fed from the limestone dissolution filters area, into a sedimentation basin, item 06GKE01BB001. In there, the water is kept for a residence time of 12 hours (as maximum) without disturbance, in order to allow proper particles sedimentation and separation process. After the residence time has elapsed, slurry accumulated at the bottom of the basin is removed and disposed into drying beds (N.3 drying beds are in common for both remineralization groups), while the clarified water, containing a slight amount of slurry, is recovered from the top of the basin and pumped to limestone filters inlet header. Those operations are periodically required, in order to allow backwashed water inlet from another filter. Slurry removal from the bottom of sedimentation basin is performed by using a Slurry Pump, item 06GKE05AP001 or 06GKE06AP001. After selection of pump, sludge is pumped out and then sent to drying beds through the check valve, item AA201 and discharge valve, item AA001. The pumps operation concept is the following: N.1 pump in operation mode and N.1 pump in stand-by mode A service water line is provided for the slurry disposal system, in order to ensure periodical cleaning and flushing after maintenance of the slurry discharge lines. Clarified water is pumped to the group limestone filters inlet header, by using a Recovery Pump, item 06GKE01AP001 or 06GKE02AP001. The water suction is from the sedimentation basin and the
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discharge is through the check valve, item AA201, and discharge valve, item AA001. Each Recovery Pump is provided with an independent suction line. The pumps operation concept is the following: N.1 pump in operation mode and N.1 pump in stand-by
5.11 Sedimentation and Slurry Collecting System - Control Philosophy (GROUP #1)
This system is used to separate the backwashed water from suspended solids after backwash of limestone filters. The system comprises the following equipment: No. 1 Sedimentation Basin (06GKE01BB001); Nos. 2 Recovery Pumps (06GKE01AP001 and 06GKE01AP001); Nos. 2 Slurry Pumps (06GKE05AP001 and 06GKE06AP001); No. 1 Polyelectrolyte Dosing tank (06GKO01BB001) Nos. 2 Polyelectrolyte Dosing pumps (06GKO01/03AP001)
During limestone filter backwash the water rich of suspended solids flows to the sedimentation basin. The slurry will be accumulated at the bottom of sedimentation basin. The operator will select from DCS, the Recovery Pump to use as the main one; in case of main pump failure, the stand-by one will start automatically. Once backwash has finished the water will be kept in the sedimentation basin for 12 hours, as maximum; residence time value will be changeable through a timer at DCS. When the residence time is over, main Recovery Pump will start automatically and will send the clarified water to the limestone filter inlet header. When the Sedimentation Basin LOW level will be reached, the running Recovery Pump will be automatically stopped by means of level controller item LIT 06GKE01CL001; also the LOW level alarm item LIA- 06GKE01CL001 will be sent to DCS. Each backwash and related recovery operations, the operator on field will start manually a Slurry Pump to transfer the slurry into drying beds.
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During slurry disposal the operator on field, if needed, can open the fluidification valve 06SCB31AA001 to make sludge transfer easier and to avoid sludge clogging in the line. Once the slurry has been completely removed, the operator will stop the Slurry Pump and will perform manually line flushing for cleaning purpose and in order to avoid particles clogging in the line, that can overload slurry pump motor at next start-up. When the Sedimentation Basin LOW-LOW level will be reached, the running Slurry Pump will be automatically stopped by means of level controller item LIT 06GKE01CL001; also the LOW level alarm item LIA-- 06GKE01CL001 will be sent to DCS. Sedimentation basin level Transmitter item LIT 06GKE01CL001 will also be equipped with a HIGH level threshold LIA+ 06GKE01CL001 in order to send alarm to DCS operator for high level of water reached in the basin. This alarm shall be placed in order to avoid overflow from the basin and confirming the filling of the tank.
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The solution flows through valves items 06GKO02AA001 and valves items 06GKO02AA002 and 06GKO02AA003, which are installed upstream of suction filters, items AT833, in order to allow operator to perform maintenance, etc. Each pump discharge line is provided with a check valve items 06GKO02AA201. The polyelectrolyte solution level in the Dosing Tank can be locally monitored, by using the level gauge, item LI 06GKO01CL501. The level gauge is connected to the tank by valves item 06GKO01AA301 and item AA302. During normal operation, these valves are in open position. A level transmitter, item LT 06GKO01CL001, is installed on the polyelectrolyte dosing tank. In case of LOW level condition for the tank, the LOW level transmitter and alarm, item LA-Z- 06GKO01CL001 (or item LA-Z- 06GKO01CL001), will trip running pump and running agitator and will generate an alarm in the DCS. The polyelectrolyte dosing pumps, items 06GKO02AP001 and 06GKO03AP001, shall be mohnoscrew type and will operate in the main and stand-by modes; it is recommended to operator to perform a periodic switch-over between dosing pumps, in accordance with the time schedule, in order to ensure a uniform, equipment mechanical stress, components wear, etc. In case of trip signal transmitted from main pump to the DCS (e.g. in case of an electrical fault), the stand-by one will start automatically. Each mohnoscrew dosing pump is provided with a manual motovariator in order, specially during commissioning, to adjust the dosing flow. On each dosing pumps discharge lines, items 06GKO03 and 06GKO04, the following equipments are installed: - a local pressure indicator and switch, respectively item PIS+ 06GKO02CP081 and item PIS+ 06GKO03CP081, which allows the operator on field to monitor discharge pressure and protect the running pump from overpressure due to unexpected clogging of delivery pipe or any manual valve closed by mistake; - a flow gauge, respectively item FI 06GKO02CF501 and item FI 06GKO03CP501, which allows the operator on field to monitor polyelectrolyte discharge flow rate.
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Each fan is provided with an outlet check valve, item AA201, and a suction valve, item AA001, connected to a suction filter. Based upon the adjustments made on the fans air flowrate, the degasifier outlet distillate pH value can be slightly controlled and modified (increased/decreased), with the removal factor of CO2 gas. Degasified distillate is extracted from the bottom of degasifier through valve item AA001, by using N.2 Degasifier Extraction Pumps, item 06GKM03AP001 or 06GKM04AP001 (Doosan scope). Both Degasifier Extraction Pumps are designed for 100% capacity. The pumps operation concept is the following: N.1 pump in operation mode and N.1 pump in stand-by mode. The extraction pumps discharge collector to the common chemical dosing system, item 06GKM08 BR001, is provided with a sampling point, through the valve item AA601. The extraction pumps discharge collector, item 06GKM08 BR001, is provided with a recycle line to degasifier, item 06GKM09 BR019. The recycle flow to degasifier is controlled by the pneumatic on-off valve, item 06GKM09AA101, which is opened when the pump discharge flow is too low and can cause NPSH problems for the pump suction. Degasified distillate flow, not recycled, is fed to the common chemical dosing system, through the automatic level control valve, item 06GKM08AA151, installed on the line, item 06GKM08 BR001. Degasifer is provided with a manual drainage valve, item AA402. It is provided also with overflow, effective in case of HIGH level in the unit. A drainage line is connected to the top of the tower for condensed steam. Degasifying System main data are indicated in following Table: Excess CO2 gas removal efficiency Outlet recarbonated distillate pH Outlet recarbonated distillate pressure Degasifying Main Data Approx. between 44% and 70% (according to load and seasonal operating conditions) Approx. 7.1 Approx. 1.2 bara
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Degasifier.
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If the flowrate for the degasifier extraction pump discharge line is below the minimum set point (1200 m3/hr), the local flow indicator and controller, item FIT 06GKM08CF001, will give a signal and flow alarm, FA- 06GKM08CF001, which is transmitted to the DCS. The pneumatic on-off valve (with flow limit device) on the recycle stream, item 06GKM09 BR009, will be, therefore, actuated by deenergising the related solenoid valve. An amount of the degasified distillate is, therefore, recycled to the degasifier inlet to increase the pump suction flow. When the level inside the degasifier decreases below the LOW-LOW level, the LOW-LOW level switch, item LS-- 06GKM01CL081 will trip the running degasifier extraction pump. The degasifier extraction pumps, items 06GKM03AP001 and 06GKM04AP001, will operate in the main and stand-by modes; in case of main pump trip, the stand-by one will start automatically.
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For this reason, the discharge line of degasifier extraction pumps, item 06GKM08 BR001, is provided with a level control valve, item 06GKM08AA151, which is controlled by the indicator and controller, item LIT 06GKM01CL001, which is installed on the degasifier using the valves items AA303 and
Local indication of level conditions inside the degasifier is given by the indicator, item LI 06GKM01CL501, installed on the vessel using the valves items AA301 and AA302; the indicator can be drained by opening the valve, item AA401.
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5.16 NaClO Dosing System - Operation Philosophy (Common and GROUP #1)
In order to disinfect the product water, a NaClO injection is performed (at 12% by weight water solution). The injection point is located on degasified remineralized water line, item 06GKB01 BR001, after injection of main header distillate, before the in-line mixer. The NaClO dosing system comprises pieces of equipment used for both Remineralization groups or dedicated to each Remineralization Group. Common equipment are N.2 NaClO Dosing Tanks, items 06GKP01BB001 and 06GKP02BB001, equipped with Agitators, items 06GKP01AM001 and 06GKP02AM001, and other accessories. Pieces of equipment specific to each Remineralization Group are the dosing pumps and related accessories. Dosing of NaClO solution to be injected into Group #1 line is performed by means of dosing pump, item 06GKP03AP001 or 06GKP04AP001. Each tank is provided with a drain valve, item AA401. The solution flows through valves items AA001 and valves items AA002, which are installed upstream of suction filters, items AT832, in order to allow operator to perform maintenance, etc. The line item 06GKP03 BR001 and related valves, items AA001 and AA002, for system flexibility, interconnect the outlet lines of each NaClO Dosing Tank, so that, in case a Dosing Tank is not
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available (preparation of the chemical, maintenance, etc.), the operator will close related outlet line valve and open other Dosing Tank outlet line valve; in this way, each Dosing Pump can be fed from
Each pump discharge line is provided with a dampener and a check valve item AA201. Dampeners are connected on the outlet lines using the valves, items AA302. Injection of NaClO solution into product water line is performed through the valves, items AA001, on discharge line, item 06GKP07 BR001. Each pump discharge line is provided with a dampener and a check valve item AA201. Dampeners are connected on the outlet lines using the valves, items AA302.
5.17 NaClO Dosing System - Control Philosophy (Common and GROUP #1)
The NaClO solution level in each Dosing Tank can be locally monitored, by using the level gauges, items LI 06GKP01CL501 and LI 06GKP02CL501, for tanks 06GKP01BB001 and 06GKP02BB001 respectively. The level gauges are connected to respective tanks by using the valves, item AA301 and item AA302. During normal operation, these valves are in open position. On each NaClO Dosing Tank, a level transmitter, respectively item LT 06GKP01CL001 and item LT 06GKP02CL001, is installed. In case of LOW level condition for a tank, the LOW level transmitter and alarm, item LA- Z- 06GKP01CL001 (or item LA- Z- 06GKP02CL001), will trip running pump and running agitator and will generate an alarm in the DCS. The dosing pumps, items 06GKP03AP001 and 06GKP04AP001, will operate in the main and standby modes; it is recommended to operator to perform a periodic switch-over between dosing pumps, in accordance with the time schedule, in order to ensure a uniform, equipment mechanical stress, components wear, etc. In case of trip signal transmitted from main pump to the DCS (e.g. in case of an electrical fault), the stand-by one will start automatically.
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AUTO mode can not be used for agitators. If a trip signal is transmitted from an agitator to the DCS (e.g. in case of an electrical fault), the operator will check level status of the other dosing tank, and provided that tank is full up, in order to restore normal process performance, will manually start up the related agitator, if in stand-by mode, will open the manual valve, item 06GKP03AA001 (or 06GKP03AA002), on selected dosing tank outlet line and will close the valve, item 06GKP03AA002 ( or 06GKP03AA001), on other tank outlet line. The disinfection depends on the effectiveness of NaClO dosing. Each dosing pump is provided with an automatic, electronic type stroke adjustment connected to the group main header flow transmitter item FIT 06GDH10CF001. The signal from the local flow meter is transmitted to the DCS, which provides control signals (4-20 mA) to group dosing pumps stroke control actuators. An off-set conditions for the flowrate controller, on which the dosing pumps rely, can be considered as a minor fault condition; therefore, no shutdown or other action will be taken by the control system. On each dosing pumps discharge lines, items 06GKP03 BR002 and 06GKP04 BR002, the following equipments are installed: A local pressure indicator, respectively item PI 06GKP03CP501 and item PI 06GKP04CP501, which allows the operator on field to monitor NaClO discharge pressure; A flow gauge, respectively item FI 06GKP03CF501 and item FI 06GKP0l.l4CP501, which allows the operator on field to monitor NaClO discharge flowrate; A safety valve, items AA191, with discharge back towards the related Dosing Tank.
5.18 NaOH Dosing System - Operation Philosophy (Common and GROUP #1)
After the excess CO2 has been removed in the degasifier, remineralized distillate is finally blended with the main distillate by-pass. The mixing, between the by-pass distillate flow and the recarbonated distillate flow, which flows through the valve, item AA001, of stream item 06GKM08 BR001 occurs in a in-line static mixer, item 06GKB01AM001. The final product water flowrate is increased and the product water reaches the required level of alkalinity of 60 ppm as CaCO3, accordingly.
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Downstream of the in-line mixer, located next to Potable water storage tanks, sampled through the valve item AA601, enters five analysers: No. 1 pH indicator / transmitter / controller analyser (item AIT 06GKB02CQ001); No. 1 conductivity indicator / transmitter / controller analyser (item AIT 06GKB02CQ002); No. 1 alkalinity indicator / transmitter / controller analyser (item AIT 06GKB02CQ003); No. 1 Cl2 concentration indicator / transmitter / controller analyser (item AIT 06GKB02CQ004); No. 1 turbidity indicator / transmitter / controller analyser (item AIT 06GKB02CQ005).
In order to eliminate the remaining CO2 content in the product water, a NaOH injection is performed (at 25% by weight water solution). The CO2 consumption is determined in accordance with the following chemical reaction: NaOH + CO2 Na+ + (HCO3-) The reaction produces Na+ and HCO3- ions. In order to comply with the product water specifications, the injection point is located before the in-line mixer for remineralized distillate and by-pass distillate, on product water line, item 06GKB01 BR001. The NaOH dosing system comprises pieces of equipment common to both Remineralization Groups and others specific for each Group. Pieces of equipment common to both Remineralization Groups are the N.1 (1x100%) NaOH Storage Tank, item 06GKN13BB001, N.2 (2x100%) NaOH Transfer Pumps, items 06GKN14AP001 or 06GKN15AP001 and other accessories and N.2 (2x100%) NaOH Dosing Tanks, items 06GKN01BB001 and 06GKN02BB001, equipped with Agitators, items 06GKN01AM001 and 06GKN02AM001, and other accessories. Pieces of equipment specific to each Remineralization Group are the dosing pumps and related accessories. Dosing of NaOH solution to be injected into Group #1 line is performed by means of a dosing pump, item 06GKN03AP001 or 06GKN04AP001. Each tank is provided with a drain valve, item AA401.
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NaOH 45% solution is stored in the dedicated NaOH Storage Tank, item 06GKN13BB001, which is filled by means of an Unloading Pump, item 06GKN11AP001 or 06GKN11AP001, directly connected
NaOH 45% solution is fed to NaOH Dosing Tanks, and also to Neutralization System Soda Tank item 06GKH02BB001, by means of a NaOH Transfer Pump, item 06GKN14AP001 or 06GKN15AP001. NaOH 45% solution piping is insulated in order to prevent caustic soda crystallization; for the same reason NaOH Storage Tank is electrically heated with NaOH Heater item 06GKN13AH001 that is started/stopped depending on a dedicated temperature switch item TS +/- 06GKN13CT081 . The distillate for chemical dilution (up to the required 25% injection concentration) is supplied directly to NaOH Dosing Tanks from the absorption inlet line, item 06GKJ31 BR001, through the inlet valves, items 06GKJ34AA001 and 06GKJ35AA001. The solution flows through valves items AA001 and valves items AA002, which are installed upstream of suction filters, items AT831, in order to allow operator to perform maintenance, etc. The line item 06GKN03 BR001 and related valves, item AA001 for Tank 06GKN01BB01 and item AA02 for Tank 06GKN02BB001, for system flexibility, interconnect the outlet lines of each NaOH Dosing Tank, so that, in case a Dosing Tank is not available (preparation of the chemical, maintenance, etc.), the operator will close related outlet line valve and open other Dosing Tank outlet line valve; in this way, each Dosing Pump can be fed from any Dosing Tank. Injection of NaOH solution before the in-line mixer is performed through the valve, item AA001, on discharge line, item 06GKN07 BR001. Each pump discharge line is provided with a dampener and a check valve item AA201. Dampeners are connected on the outlet lines using the valves, items AA302.
The final treatment stage main data are indicated in following Table:
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Approx. between 96% and 99% (according to load and seasonal operating conditions) Approx. between 7.9 and 8.4 (according to load and seasonal operating conditions)
Final Treatment Stage Main Data The analyzers allow to monitor and continually record during operation, locally as well as at the DCS, the main product water parameters. Based upon the measured values, the operator will proceed and solve malfunctions, if any.
5.19 NaOH Dosing System - Control Philosophy (Common and GROUP #1)
The NaOH solution level in the NaOH Storage Tank can be locally monitored, by using the level gauge, items LI 06GKN13CL501. The level gauge is connected to the storage tank by using the valves, item AA301 and item AA302. During normal operation, these valves are in open position. On NaOH Storage Tank, a level switch, item LS- 06GKN13CL081, is installed. In case of LOW level condition for a tank, the LOW level alarm, item LA- 06GKN13CL081 will trip running NaOH transfer pump and will generate an alarm in the DCS. The NaOH solution level in each Dosing Tank can be locally monitored, by using the level gauges, items LI 06GKN01CL501 and LI 06GKN02CL501, for tanks 06GKN01BB001 and 06GKN02BB001. The level gauges are connected to respective tanks by using the valves, item AA301 and item AA302. During normal operation, these valves are in open position. On each NaOH Dosing Tank, a level transmitter, respectively item LT 06GKN01CL001 and item LT 06GKN02CL001, is installed. In case of LOW level condition for a tank, the LOW level transmitter and alarm, item LA -Z- 06GKN01CL001 (or item LA -Z- 06GKN02CL001), will trip running dosing pump and running agitator and will generate an alarm in the DCS. The dosing pumps, items 06GKN03AP001 and 06GKN04AP001, will operate in the main and standby modes; it is recommended to operator to perform a periodic switch-over between dosing pumps, in
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accordance with the time schedule, in order to ensure a uniform, equipment mechanical stress, components wear, etc. In case of trip signal transmitted from main pump to the DCS (e.g. in case of an electrical fault), the stand-by one will start automatically. AUTO mode cannot be used for agitators. If a trip signal is transmitted from an agitator to the DCS (e.g. in case of an electrical fault), the operator will check level status of the other dosing tank, and provided that tank is full up, in order to restore normal process performance, will manually start up the related agitator, if in stand-by mode, will open the manual valve, item AA001, on selected dosing tank outlet line and will close the valve, item AA001, on other tank outlet line. The purpose of the NaOH dosing system is to eliminate the residual CO2 in the product water and to adjust the final pH value (at approx. 0.1 higher than the saturated pH value), minimizing the corrosive effect of water. The set point of product water pH analyser, item AIT 06GKB03CQ001, will be around 8. The product water pH depends on the effectiveness of NaOH dosing. Each dosing pump is provided with an automatic, electronic type stroke adjustment connected to the pH analyser. The signal from the local pH meter is transmitted to the DCS, which provides control signals (4-20 mA) to group dosing pumps stroke control actuators. An off-set conditions for the pH controller, on which the dosing pumps rely, can be considered as a minor fault condition; therefore, no shutdown or other action will be taken by the control system.
On each dosing pumps discharge lines, items 06GKN05 BR001 and 06GKN06 BR001, the following equipments are installed:
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A local pressure indicator, respectively item PI 06GKN05CP501 and item PI 06GKN06CP501, which allows the operator on field to monitor NaOH discharge pressure; A flow gauge, respectively item FI 06GKN05CF501 and item FI 06GKN06CF501, which allows the operator on field to monitor NaOH discharge flowrate; A safety valve, items AA191, with discharge back towards a related Dosing Tank.
The neutralization pit will be equipped with a fluidisation system working with compressed air for the liquid streams mixing. The neutralization procedure will be performed manually by the operator, in two steps. Once the pit has been filled, the operator will start a Drain Pump by means of the local pushbutton; the pump water suction is from the neutralization basin and the discharge is through the check valve, item AA201, and discharge valve, item AA001, to disposal. Each drain pump is provided with an independent suction line and relevant priming tank item 06GKH01/02BB001; the feed water for priming tanks is supplied directly from the absorption inlet line, item 06GKJ36 BR001. The pumps will be protected from dry running by means of the:
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Tank.
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LOW level switch, item LS- 06GKH03CL081, installed in the LOW level switch, item LS- 06GKH01CL081 (or LS- 06GKH02CL081), installed in the Priming
The first stage of neutralization procedure is liquid recirculation into the pit: the operator will open the recirculation valve, item 06GKH03AA001, and close the discharge valve, item 06GKH03AA002, in order to achieve proper mixing and to monitor pH value (by means of pH indicator / transmitter / controller analyser item AIT 06GKH03CQ001); according to pH value, acid or soda will be injected into the pit, with the drain pumps continuing in recirculation mode and the operator monitoring pH value. Acid injection will be performed by using Acid Dosing Pump, item 06GKH05AP001, while soda injection will be performed by using Caustic Dosing Pump, item 06GKH06AP001. These pumps will started in local by hand switches HS 06GKH05AP001 and HS 06GKH06AP001 respectively. The second stage of neutralization procedure is liquid transfer to disposal: once the solution has been neutralized, the operator will open the discharge valve, item 06GKH03AA002, and will close the recirculation valve, item 06GKH03AA001. Acid solution is stored in the Acid Tank, which is filled by means of a Portable Unloading Pumps. The Acid Tank is equipped of an Hydraulic Seal, item 06GKH01BB02, draining down to neutralization pit. NaOH 45% solution is stored in the Soda Tank, which is filled by means of NaOH Transfer Pump, item 06GKN14AP001 or 06GKN15AP001, from NaOH Storage Tank, item 06GKN13BB001. NaOH 45% solution piping is insulated in order to prevent caustic soda crystallization. The distillate for chemical dilution is supplied directly to Soda Tank from the absorption inlet line, item 06GKJ31 BR003.
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Sensible variations of plant variables / parameters from design operation conditions may lead to product water quality out of required specifications, shortened life for equipment and machineries and possibly unsafe operating conditions for plant personnel.
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6.1.3 Variations in the Proportion Between Distillate to Absorber and Absorber Bypass
Proportion of distillate fed to the absorber and absorber bypass results from process requirements and calculations, and it is set by the operator by acting on the relevant flow controllers / control valves within the absorption area. If for any reason, at parity of other conditions, this proportion is altered, the resulting distillate entering the limestone dissolution filters area will be characterized of a different dissolved CO2 content, leading thus to different carbonation reaction conditions. If the proportion distillate to absorber bypass / distillate to absorber is increased, resulting acidified distillate will be characterized of a lower CO2 content available for the dissolution reaction. Limestone powder inside the dissolution filters will be consumed in a longer time and resulting outlet water from filters characterized by lower alkalinity content. On the other hand, if the proportion distillate to absorber bypass / distillate to absorber is decreased, resulting acidified distillate will be characterized of a higher CO2 content available for the dissolution reaction. Limestone powder inside the dissolution filters will be consumed in a shorter time and resulting outlet water from filters characterized by an excess of CO2, which will lead to an increase in NaOH solution dosage after the degasifier.
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6.2
No 1 2 3 4 5 6 7 8 9 10 11
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12
LI - A- - Z- - 06GKE11CL001
13
LA+ 06GKL03CL081/082
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Tag
Service Low Flow Level of Sealing Water to CO2 Vacuum Booster Pumps Low/High Flow of Drain Separator Gas Out to Purification Filter
Range -
61/62/63/64/65/66GKG03CP081 2 FA-/+61/62/63/64/65/66GKG04CF001
0-150 m3/h 0-12000 m3/h 0-2900 m3/h 0-700 m3/h 0-250 m3/h 0-700 m3/h 0-3600 m3/h 0-700 m3/h
150 m3/h
Total Distillate Low/High Flow Level Low/High Flow of Distillate to Absorption System Low Flow of Distillate to CO2 Absorber 06GKJ01BB001
1700/10000 m3/h 480 / 2500 m3/h 370 / 580 m3/h 30 / 200 m3/h 270 / 560 m3/h 1200 / 3000 m3/h 480 / 600 m3/h
6 FA-/+06GKG08CF001 7 FA-/+06GKK10//15CF001
Low/High Flow of CO2 to Absorption System Acidified Water to Limestone Dissolution Filter Low/High Flow
8 FA-/+06GKM08CF001
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Tag
Service Booster vacuum pump inlet low pressure Booster vacuum pump outlet high pressure Drain separator high pressure Purification filters inlet low pressure Main Header distillate bypass high high - high- low very low pressure
Set point 0,6 barA 5,2 barg 4,5 barg 2,6 barg 4,5/4,3/2, 6/ 2,4 barg
6 PA + - 06GKJ01CP002
0-6 barg
CO2 Absorber high-low pressure Acidified distillate to Limest. Filters high-low pressure Recarb. Water high-low pressure In-Out Purification Filters High Pressure Drop Recharging from Limestone filters low pressure
3,9 / 2,4 barg 4,2 / 2,4 barg 4 / 2,6 barg 1,1 bar 0,4 barg
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Tag
Range -
1 TZ+61/62/63/64/65/66GKG03CT081
No
Tag
Service Potable Water High/Low pH Potable Water High/Low Conductivity Potable Water Low Alkalinity
Range 0-14 0-600 S/cm 0-100 ppm CaCO3 0-2,5 ppm 0-6 NTU
Set point 9,2 / 6,5 200 / 400 S/cm 50 ppm CaCO3 1 / 0,1 ppm 5 NTU
4 AIT A +/- 06GKB10CQ004 5 AIT A + 06GKB10CQ005 Analyzer Alarm and Set Point List
Same Range and Set point values are valid for Instruments installed on Group#2.
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6.3
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During the plant operation, it may be possible that some abnormal operating conditions occur, leading accordingly to the displaying of alarms in the CCR. In the event of any system / equipment failure, it is mandatory to locate the cause and take the immediate and subsequent actions described, as follows:
The immediate actions are taken to ensure the safety of the personnel and equipment. The subsequent actions are taken when the alarm condition indicates that the immediate actions will not return the system to its normal duty or to its standby function. The potable water plant instrumentation and control equipment is provided with several alarms, whose typology may be classified for the purposes of the plant as follows: Flow alarms Pressure alarms Temperature alarms Level alarms Analyzers alarms Rotating speed alarms
In case of steady / frequent alarm(s) activation on DCS/DCS, the operator is requested to perform investigation on the possible causes, which may affect process efficiency and equipment safety. The operator will proceed as described in the following sub-paragraphs.
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Low Level Alarms
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When low level alarms are activated for a vessel or a tank, the operator will act as follows: 1. Follow and check on CCR level indication (if provided) for the vessel / tank; if alarms switch on frequently or do not switch off within a reasonable time, it is necessary to perform a local check within the vessel / tank 2. Check either locally and from CCR (where indication is provided) that all valves are positioned in accordance to the required configuration, and no valves are blocked or disconnected, etc. 3. Check that all set points for controllers and alarms are set at the required values 4. Check the operating variables for the upward and downward systems connected within the vessel / tank 5. Locally check that no leakages are present for the vessel / tank and the piping systems for the area interested by the alarm; leakages may cause water loss and subsequent low level inside the vessel 6. If none of the above, check the electrical and instrumentation system / connections, and functioning of level switch relevant to the alarm. Upon very low level conditions, pumps connected to the vessel / tank (if provided) should get into trip conditions, in order to protect the pump(s) and very low level alarm activate in CCR. The operator will locally check this condition in order to protect equipment from damages.
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High Level Alarms
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When high level alarms are activated for a vessel or a tank, the operator will act as follows: 1. Follow and check on CCR level indication (if provided) for the vessel / tank; if alarms switch on frequently or do not switch off within a reasonable time, it is necessary to perform a local check within the vessel / tank 2. Check either locally and from CCR (where indication is provided) that all valves are positioned in accordance to the required configuration, and no valves are blocked or disconnected, etc. 3. Check that all set points for controllers and alarms are set at the required values 4. Check the operating variables for the upward and downward systems connected within the vessel / tank 5. If none of the above, check the electrical and instrumentation system / connections, and functioning of level switch relevant to the alarm. Upon very high level conditions, flooding and subsequent overflow from the vessel / tank (if overflow is provided) may occur. In case of need, the operator will act on the drain valves (if provided) in order to avoid such condition.
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High Pressure Alarms 1. If a high pressure alarm is activated for a vessel, check that: a. Gas is correctly fed to the vessel at right flowrate and pressure from the upward stream / equipment. Different feeding conditions may in fact be cause of high pressure b. All valves are in the correct position for operation and are not blocked or leaking c. Set points for controllers and alarm have been properly configured 2. If a high pressure alarm is activated for a piping line or equipment, the operator will check upward and downward the pressure measuring point that: a. Gas / water is flowing inside the line at correct flowrate i.e. the equipment upward the measuring point is correctly running / working. b. All valves are in the correct position and are not blocked or leaking c. Set points for alarms and controllers within the system have been properly configured d. If alarm is activated for only one unit, cause of alarm is likely to be due to a local equipment malfunction, rather than a circuit failure; the operator will investigate accordingly and check for local piping / equipment.
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7 TROUBLESHOOTING
Introduction
The paragraph consists of a general guide for the system troubleshooting. Troubleshooting for standard plant auxiliaries and equipment such as pumps, valves, etc., are included in the relevant maintenance manuals
7.2
System troubleshooting
Unplanned variations in operating conditions observed during the routine compilation of the operational logs, or indicated by the alarm system should be immediately investigated and remedial actions put into practice. As the variations observed in the operating conditions may be caused by the failure or malfunction of the supervisory or monitoring system, it is imperative that the operator should first confirm that the relevant instrumentation correlates. If there are any differences in the indications then the Instrument Maintenance Department must be informed so that they can investigate and correct the fault. The major process faults which are liable to be experienced during the operation of the unit are detailed in the following subsections. The troubleshooting does not include any faults which could arise from the incorrect setting of any of the process valves or from the non-observation of the operating procedures.
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CASE 1 FAULT:
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PROBABLE CAUSE
REMEDIAL ACTION
Manual valve on top of vacuum system in close position. Open manual valve CASE 2 FAULT: Compressed vent gas pressure (PIT 06GKG01CP001) high pressure alarm. PROBABLE CAUSE REMEDIAL ACTION
Manual valves downstream the pressure transmitter Check the line to Absorber and open the closed. Control valve 06GKG01AA151 closed required valves. Check the operation of control valve
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PROBABLE CAUSE
REMEDIAL ACTION
Leakage on the line from Compressors to Check the line to Absorber and eliminate Absorber leakage.
CASE 4 FAULT: CO2 gas compressors TRIP PROBABLE CAUSE REMEDIAL ACTION
High pressure at Compressor discharge (PA+ Refer to CASE 2 61/62/63/64/65/66GKG02CP081) Low flow of sealing water indicated by the alarm Check that valves on sealing water line are open. FA- 61/62/63/64/65/66GKG03CF081. Check the proper function of Flow switch.
High temperature of sealing water indicated by Check that valves on sealing water line are open. the alarm TA+ 61/62/63/64/65/66GKG03CT081 Check the proper function of Temperature switch.
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CASE 1 FAULT:
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06GKJ01/02/11/12AA152 are correctly working. Gas flowrate to Absorber is low Check that gas flow control valves
06GKG08/09AA151 are correctly working. Increase gas flow on DCS Distillate flow to Absorber is lower than the Check automatic value (design value) that the distillate control valve
Distillate flow bypassing Absorbers is higher than Check the automatic value (design value)
that
the
distillate
control
valve
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CASE 1 FAULT:
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Check that acidified water flow to Limestone Filters is according to the Operation Chart. Check that the N of filters in service is compliant to Operation Chart. Check that all service inlet/outlet valves of the Limestone Filters in operation are open.
CASE 2 FAULT: Very high conductivity (alkalinity) downstream limestone filters (manual sampling).
PROBABLE CAUSE
REMEDIAL ACTION
Incoming distillate from desalination units with No action required in limestone system. high conductivity
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instrument maintenance Dosing pump abnormal operation. Check pH set point, stroke controller. Adjust accordingly.
CASE 2 FAULT: pH of recarbonated water too low (AIT 06GKB10/20CQ001) PROBABLE CAUSE pH meter malfunction Check REMEDIAL ACTION manufacturers recommendations for
instrument maintenance Degasifier fan (06GKM20/21/23/24AN001) trip. Dosing pump abnormal operation. Check if degasifier fan in stand-by is available. Check pH set point stroke controller. Adjust accordingly
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REMEDIAL ACTION Inform mechanical maintenance staff for checking the pulsation dampers.
instrument maintenance Control valve (by DOOSAN) not working Hypochlorite dosing pump (by Operate the valve by emergency hand wheel.
DOOSAN) Check pump-operating condition. Stand-by pump may be started while main pump is under checking.
abnormal operation
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instrument maintenance Control valve (by DOOSAN) not working Hypochlorite dosing pump (by Operate the valve by emergency handwheel.
DOOSAN) Check pump operating condition. Stand-by pump may be started while main pump is under checking.
abnormal operation
Hypochlorite
solution
concentration
CASE 3 FAULT: Conductivity of recarbonated water too high (AIT 06GKB10/20CQ002) PROBABLE CAUSE Conductivity meter malfunction Check REMEDIAL ACTION manufacturers recommendations for
instrument maintenance Incoming distillate from desal units with high conductivity Check Desal unit proper operation (by DOOSAN)
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instrument maintenance
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8 EMERGENCY PROCEDURES
Introduction
An emergency procedure is regarded as that unsafe condition(s) for the operator and/or plant equipment, which lead to immediate action, but not necessarily to shut down for the whole plant. In this subsection, emergency procedures for plant equipment and machinery will be discussed; emergency cases leading to whole plant stop are regarded as emergency shutdown (ESD).
8.2
In case of Booster Vacuum Pump trip, consider the load variation condition during pump stop. Re-establish starting conditions for the tripped motor, after the emergency situation has been solved. If electrical power supply is under total failure for the potable water plant, wait until the emergency condition has been solved and removed, then proceed as above described.
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8.3
Since the safety of the plant group is vital, all the conditions / uncontrollable events which may lead to unsafe operation of the plant group have to be identified properly. Such conditions will form the initiating conditions or the causes for ESD; the following causes for ESD have been identified, as follows:
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WARNING: The following are general rules for safe handling of potential hazardous materials used in the potable water plant and are to be intended as minimum requirements to the operators. Any applicable national or local law, code or regulation must be implemented and is prevailing on the following safety precautions.
Moreover, those in charge of chemical products handling must always wear protection dresses as follows: Suitable glasses for eyes protection Suitable overdresses Suitable gloves
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Operators should never be allowed to start operations within the chemical storage area or chemicals handling activities without the above mentioned protection equipment; these safety requirements apply also for all chemicals related activities such as tanks draining, basement cleaning, etc. When performing chemicals handling activities, a minimum of two operators are required to allow immediate help in case of danger; in this case, a breathing apparatus (20 lt. capacity) must be also available for at least one of the operators. A strict work permission procedure must be applied from operators chief for chemicals handling. In case of any damage to persons as result of contact with chemicals, injured persons must be immediately washed with fresh service water and medical assistance immediately requested. In case of exposure, even for short periods, to any fumes, medical assistance is always required to detect possible lung damages. In particular, before operating within a chemical tank, the operator should check that the basic rules previously described are obeyed.
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B. Electrical / Instrumentation Equipment Drivers for rotating machinery Pressure gauges and switches Temperature gauges and switches Flow meters Level gauges and switches Control valves actuators.
It is important that the operator strictly observes the recommendations of suppliers instructions and manuals, in particular concerning: Maintenance time schedule Spare parts and lubricants to be used Dismounting and installation procedures / drawings Maintenance tools / equipment to be used Recommended safety precautions.
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10.1 General
Call a doctor immediately Be prepared: Keep an irrigation bottle readily available, containing 2,5 % each of (natrium tetraborate) and boric acid (H3B03) in distilled water. A service water line should be available near all bulk installations with chemicals. When applying first aid, the persons assisting should be available near all bulk installations with ammonia When applying first aid, the persons assisting should be duly protected to avoid further injury. borax
10.2 Inhalation
Move affected personnel into fresh air immediately, and remove clothing restricting breathing. Call a doctor / ambulance with oxygen equipment immediately Keep the patient still and warmly wrapped with blankets If mouth and throat are burn, let the conscious patient drink water, taking small mouthfuls. If conscious and the mouth is not burnt, give hot, wet tea o coffee (never try to feed an unconscious person). Oxygen may be administered, but only when authorized by doctor. If breathing fails, apply artificial respiration.
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11.2 Maintenance Procedures for Vessels and Tanks 11.2.1 Regular Maintenance during Operation
During plant operation, the followings should be at least obeyed and regarded as required regular maintenance operations: Check and confirm that lubrication and greasing is provided for all valves connected to the vessel / tank; lubrication and greasing should be checked and performed regularly, and valves operated at least every ten days in order to check blockings, etc. Check and confirm absence of leakages within the external shell or piping lines / connections Check and confirm proper conditions and tightness for bolts / nuts; replace / substitute corroded or missing bolts / nuts, if necessary
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Internal Distributors & Packing If the vessel / tank is provided with internal distributors or packing, the operator will perform the following operations: 1. Enter the vessel / tank through the manholes, where allowed 2. Check for all distributors / packing the followings: a. That all bolts / nuts or any other installed part is not corroded. Replace, if necessary b. Tightness for bolts / nuts and distributors; tighten if required and as necessary c. The required orientation of distributors; check absence of deformations or irregular configuration d. Check mechanical supports for the distributors / packing e. Absence of clogging or damage for the distributors (e.g. due to irregular flowrates, foreign matter, etc.). Consider dismounting and flushing with service water / air, or substitution, if needed f. Replace gaskets, where provided
Shell Internal Conditions The operator will enter the vessel / tank through the manholes (where allowed) and carefully perform a surface inspection for the internal conditions for the shell. Action against corrosion phenomena or damaged internal lining (where provided) must be immediately taken.
Cleaning of Internals During maintenance, vessels / tanks should be cleaned inside, and all foreign matter such as sand, dirty particles, etc. removed before subsequent operation. The operator will clean by means of suitable tools in order to not damage linings / or internal shell; service water should be used. After cleaning, carefully check and confirm that all tools, accessories, moving parts etc. have been removed from inside.
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Typical maintenance operations for valves and piping systems involve: Replace all strainers / gaskets (where provided) during line stop / standby Grease if necessary and as required at regular intervals During stop and if required, dismount valves / accessories and repair / substitute as per technical specifications and suppliers instructions Damages for piping external lining must be performed in accordance with the relevant suppliers instructions and recommendations Regularly check all piping supports.
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demister only; however, it is not recommended to stop the tower only to perform such maintenance operation. 3. As soon as drainage is completed, the operator will enter the vessel through the DN 600 manholes, proceeding for tower internals as follows: Check tightness and conditions (absence of corrosion, etc.) of all bolts / nuts for gas and distillate distributors; damaged parts must be removed and substituted, if necessary. All substituted bolts and nuts are strictly required to be of same material as original, in order to avoid further internal corrosion and damages/breakage during subsequent operation. Substitution of gaskets, if any and if required. Check on the absence of breakages, leaks or clogging for the distributors; after dismounting, clean with service water / air, if necessary. Check absence of tensions or deformations of distributors within the internal structure of the vessel; in particular verify that plant operation (flows, pressures, etc.) did not lead to distribution pipes damage. Particular care should be given to the inlet gas distributor, which is supported and connected by the packing bed supporting grid. The operator is suggested to re-install the internal distributors at their original positions, with no exchanges, if dismounted. Particular care must be observed in checking the tower packing, packing supporting grid and bed limiter mesh. The operator will check that all clamps are properly installed and the structure is in good general working conditions. 4. At fully empty absorber conditions, the operator will perform a visual inspection of internal shell. If damaged, check for absence of corrosion on the bare metal and repair 5. For the top demister, the operator will: Verify correct installation of demister, verifying tightness of bolts / nuts. Repair / substitute, if necessary. Check demister pad conditions.
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12 PRESERVATION PROCEDURES
12.1 Introduction
When the plant or a section of it is required to be shut-down / stopped for a certain period, or a long time exists between erection completion and start-up, the following recommendations are provided to the operator, as general preservation rules.
1. Check and confirm that all isolation valves are in the closed position. External matter (sand, dirty matter, rain, etc.) may in fact enter the vessel / piping and further result harmful for connected machinery and piping during time. In general, no openings to the external (e.g. level indicators nozzles, etc.) should be left for the vessels. 2. Check and confirm that lubrication and greasing is provided for all valves connected to the vessel; lubrication and greasing should be regularly checked and performed, and valves weekly operated in order to check blockings, etc. 3. All vessels must be kept clean inside, and all matter such as sand, dirty particles, etc. removed before operating; drain all water inside, if any. All tools / moving parts must be removed from inside. 4. If placed at their position, ensure that manholes are fixed to the vessel by means of the relevant bolts / nuts.
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In order to proceed with preservation and prior to start up, all piping should be checked as follows: 1. Check and confirm that piping installation is completed with no leakages, wrongly performed or uncompleted welding, etc. 2. Check and confirm that all connections for flanges, accessories, valves, etc. are properly executed, and no bolts / nuts are missing. If needed, repair / substitute as per technical specifications. 3. Check and confirm that external lining, where provided, is not damaged; if so, repairing should be considered. The operator will proceed with inspection / repairing of the bare pipe first, and further for lining; please refer to the relevant suppliers instructions and recommendations. 4. Check that, if any terminal part is not connected to any equipment / system, suitable cover is provided by means of plastic caps, etc. Caps should be fixed in a manner to avoid introduction of foreign material such as sand, dirty matter, rain, etc. inside piping. 5. Provide suitable coverage for all accessories such as pressure gauges, flowmeters, level indicators, transmitters, etc. Analyzers and probes should be cleaned as per suppliers instructions. 6. Check and confirm that all piping valves are in the closed position. External matter (sand, dirty matter, rain, etc.) may in fact enter and further result harmful for connected machinery performance and resistance during time. In general, no openings to the external of any kind should be left for the vessel.
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During preservation period, access to all systems of the potable water plant site should be completely allowed, easy and safe. Site should be kept clean and tidy, and all obstacles removed.
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Absorbing tower
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Absorption Assimilation of molecules or other substances into the physical structure of a liquid or solid, without chemical reaction.
Activated Carbon Filtering A process by which certain undesired particles and matter are absorbed from a solution within an organic absorbent, being further removed from the latter by means of suitable regeneration procedure.
Air Scour The removal of surface debris from a filtering media layer particles.
Alkalinity Total alkalinity (also called M alkalinity) is that which will react with acid as the pH of the sample is reduced to the methyl-orange endpoint about pH 4.2. Another significant expression is P alkalinity, which exists above pH 8.2 and is that which reacts with acid as the pH of the sample is reduced to 8.2.
Anion A negatively charged ion resulting from dissociation of salts, acids or alkalies in aqueous solutions.
Cation A positively charged ion resulting from dissociation of salts, acids or alkalies in aqueous solutions.
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Change Over
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Procedure which allows a standby limestone dissolution filter to be put into service, being exchanged with an operating one needing regeneration.
Conductivity The capability of a substance to conduct heat or electricity. Electrical conductivity is usually expressed in micro-Siemens / cm.
Conductivity Analyzer Function of this instrument is to continuously indicate the conductivity of the fluid that is passing through the line where it is installed. This instrument, when a given set point is reached, may in some processes generate alarms or activate other equipment.
Degasifier Unit A cylindrical vessel where air and acidified water are fed and meet in a counterflow manner, in order to allow CO2 removal from water to the atmosphere and less chemical consumption for further pH increasing stage.
Filtration The process of separating solids from a liquid by means of a porous substance trough which only the liquid / gas passes.
Flow Indicator Function of this instrument is to continuously indicate the value of the fluid flow rate that is passing through the line where it is installed.
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Flow Totalizer Hardness
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Function of the instrument is to indicate the total flow rate passed through the line where it is installed.
Hardness is given by the sum of concentrations of magnesium and calcium salts in water. Permanent hardness is the excess of hardness over alkalinity, temporary hardness is hardness equal or less than alkalinity. These are also referred to as non-carbonate hardness and carbonate hardness, respectively. Solubility of these ions is limited for any fluid, because they may deposit and form scale.
Langelier Index A parameter for expressing the degree of saturation of a water as related to calcium carbonate solubility.
Limestone Dissolution Filter A pressure vessel containing crushed limestone of suitable grain size, fed with acidified distillate, where the chemical reaction CaCO3 + CO2 + H2O Ca++ + 2 (HCO3-) takes place.
Packing The fill in a confined space in a stripping vessel, ranging from simply shaped units such as rocks or slats to complex shapes that provide large surface area per unit volume.
Percolating Speed Expressed in m/h, it results from the flowrate / section area ratio. Percolating speed is often used as ruling parameter for design of filtering vessels, etc.
pH A means of expressing hydrogen ion concentration in terms of powers of 10; the negative logarithm of the hydrogen ion concentration.
File name: 2067MANG003010
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pH Analyzer
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Function of this instrument is to indicate the pH value of the fluid in contact with the analyzer probe. In some processes the signal may be sent to a LCP which compares it with a given set point and start / stop remedies in order to correct the pH value (e.g. caustic and acid dosing).
Pressure Indicator Function of this instrument is to continuously indicate the fluid pressure in the point where it is installed.
Recarbonation A process which produces an increase of Ca++ and HCO3- ions in water, according to the chemical reaction CaCO3 + CO2 + H2O Ca++ + 2 (HCO3-).
Regeneration of Limestone Filters A periodical process which allows limestone filters to be recharged with new limestone powder and removal of dirty matter (by means of backwashing and air bubbling), in order to correct the cause of head losses and poor chemical reaction effectiveness.
Saturation Index The relation of calcium carbonate to the pH, alkalinity, and hardness of a water to determine its scaleforming tendency.
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14 REFERENCE DOCUMENTS
14.1 Process Engineering 14.1.1 Recarbonation and CO2 Compressor Systems
AE1166-XG02-GKG-427801 P&ID for Vent gas recovery system AE1166-XG02-GKJ-427801 P&ID for CO2 absorption system (Group #1) AE1166-XG02-GKJ-427802 P&ID for CO2 absorption system (Group #2) AE1166-XG02-GKK-427801 P&ID for limestone dissolution Group #1 (1/2) AE1166-XG02-GKK-427802 P&ID for limestone dissolution Group #1 (2/2) AE1166-XG02-GKK-427803 P&ID for limestone dissolution Group #2 (1/2) AE1166-XG02-GKK-427804 P&ID for limestone dissolution Group #2 (2/2) AE1166-XG02-GKL-427801 P&ID for limestone recharging system Group #1 AE1166-XG02-GKL-427802 P&ID for limestone recharging system Group #12 AE1166-XG02-GKG-427801 P&ID for instrument / service air AE1166-XW03-GKA-497801 System Calculation sheet AE1166-XS00-GKG-497801 System Description AE1166-XW01-GKA-497801 Data sheet for booster vacuum pump skid AE1166-XW01-GKA-497802 Data sheet for CO2 purification filters AE1166-XW01-GKA-497803 Data sheet for CO2 absorbers AE1166-XW01-GKA-497804 Data sheet for limestone filters AE1166-XW01-GKA-497805 Data sheet for air scouring blowers with outline dwg. AE1166-XW01-GKA-497806 Datasheet for limestone recharging system AE1166-XW01-GKA-497807 Data sheet for limestone recharging pumps with outline dwg.
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AE1166-XW01-GKA-497809 Data sheet for sludge pumps with outline dwg. AE1166-XW01-GKA-497810 Data sheet for neutralized water drain pumps with outline dwg. AE1166-XW01-GKA-497811 Data sheet for Acid tank AE1166-XW01-GKA-497812 Data sheet for Soda Tank AE1166-XW01-GKA-497813 Data sheet for Neutralization NaOH dosing pumps with outline dwg. AE1166-XW01-GKA-497814 Data sheet for Nutralization Acid dosing pumps with outline dwg.
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14.5 Instrumentation
AE1166- YB03-GKA-827801 DCS sequence & interlock logic diagrams AE1166- YB03-GKA-827802 DCS loop diagrams AE1166- YL01-GKA-827801 DCS I/O List AE1166- YL01-GKA-827802 Instrument list AE1166-YT01-GKA-827801 Instrument Data Sheets including Analyzers AE1166-YL15-GKA-827801 Cable list (instrument) AE1166-YL15-GKA-827802 Cable list (electric) AE1166-YD04-GKA-827802 Instrument and panel layout dwgs (Area 1/2/3/4) AE1166-YV02-GKA-827801 Instrument interconn. Wiring Diagram (from field to JB) AE1166- YK09-GKA-827802 Local Panel dwgs & terminal strip AE1166- YK09-GKA-827801 Instrument Hook-Up dwg with BOM AE1166-YL01-GKA-827804 Alarms and Set point list AE1166- YL01-GKA-827805 DCS I/O List with J.B. grouping AE1166-YFD-GKA-827801 Mimic Diagram AE1166-XW01-GKA-427831 Data sheet for Control Valves AE1166-XF00-GKA-497836 Outline dwgs for Control Valves Globe & butterfly <10 AE1166-XF00-GKA-497841 Outline dwgs for Control Valves Butterfly >10
14.6 Electrical
AE1166-YL03-GKA-827801 BOM for Electrical materials AE1166- YD04-GKA-827804 Local Panel terminal block diagrams AE1166- YS18-GKA-827804 Control Panel circuit diagram including wiring diagram for electric AE1166-YT01-GKA-827804 Electric tracing Data Sheets AE1166-YB03-GKA-827802 Electrical hook-Up dwg AE1166-YL06-GKA-827801 Electrical load list
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AE1166-YT01-GKA-827803 Electrical motor data sheet with dwg AE1166-YB03-GKA-827803 Electrical motor sectional dwg AE1166-YD16-GKA-497829 Cable Route drawings AE1166-YD16-GKA-497830 Cable Route drawings cable assignment
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15 ATTACHMENTS
The following attachments are included for the purposes of the training manual and should be used and illustrated during the potable water plant training classes.
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As the operator can see from the picture, distillate flows downward through the vessel, and CO2 contained in the distillate reacts with the limestone powder while crossing the filter. At the bottom of the vessel acidified distillate is collected, with a reduced content of CO2 accordingly. During recarbonation, therefore, limestone powder is progressively reduced and must be recharged at regular intervals, or depending on operation requirements and distillate characteristics. The following five items are regarded to be the major parameters affecting the reaction above mentioned: a. LV, linear velocity through the limestone dissolution filter b. CO2 concentration in the influent c. Size of limestone d. Height of limestone layer e. Purity of limestone
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* Typical Absorber *
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SI
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Description
General recommendations
- 5.0 - 4.0 - 3.0 - 2.0 - 1.0 - 0.5 0.0 0.5 1.0 2.0 3.0 4.0 5.0
Severe corrosion Moderate corrosion Moderated corrosion Moderated corrosion Mild corrosion Mild corrosion Balanced Some faint coating Mild scale forming Mild scale forming Moderate scale forming Severe scale forming Severe scale forming
Treatment recommended Treatment recommended Treatment recommended Treatment should be considered Treatment should be considered Treatment probably not needed Treatment typically not needed Treatment typically not needed Some aesthetic problems Some aestheticconsider treatment Treatment should be considered Treatment probably required Treatment required
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