PART 1

D.M.PLANT 1(THERMAX SUPPLIEDPLANT)

CPP - UTILITY

RELIANCE INDUSTRIES LIMITED.

HAZIRA.

I N D E X

PART 1 ( Thermax Supplied DM Plant)

[1] Basic concept engineering and operation philosophy

[2] Specification of input/output and water balance

[3] Detail construction features of main equipment

[4] Sequential start-up and shutdown of plant

[5] Trouble shooting and remedies

[6] Instruments and their setpoints/interlocks

[7] Do and Donot

[8] Preservation of equipments

[9] Safety precaution & MSDS of HCl & NaOH

PART 2 (Ion Exchange Supplied DM Plant)

[1] Introduction with Schematic Diagram of DM Plant 3.

[2] General Description of DM Plant Vessels.

[3] Technical Datas.

[4] Control phylosophy of DM Plant 3.

[5] trouble Shootings

[6] SOP for DM water transfer form DM plant2 to DM plant1, PTA 1/2 and POY plants.

CHAPTER 1

BASIC ENGINEERING CONCEPT & OPERATION PHILOSOPHY

1.01 Introduction

Filtered water available from water treatment plant has no physical impurities but chemical

impurities like dissolved salt, silica and carbondioxide etc are there.

This water cannot be used in process, where high purity products are required and for high

pressure boilers to avoid scaling and corrosion. Chemical impurities are of cation like Ca,

Mg, Na and Anions like Cl, SO4, NO3, Silica etc. These are called Cationic and anionic load

respectively. Total of cations and anions are called Total Dissolved Solids (TDS). All these

are mentioned equivalent of CaCO3 ppm. Removal of total dissolved solids can be done by

distillation, reverse osmosis and demineralisation process. Out of these, demineralisation by

ion exchange is cheaper and easier. Different type of resins are used to remove cations and

anions.To remove cations, Hydrogen resin RH is used and to remove anions Hydroxide resin

ROH is used.

Following are the general reactions :

i. Cation exchange reactions

NaCl + HR -------- NaR + HCl

MgSO4 + 2HR -------- R2Mg + H2SO4

Regeneration reaction with HCl

NaR + HCl -------- HR + NaCl

MgR2 + 2HCl -------- 2HR + MgCl2

Produced HCl and H2SO4 go in anion exchanger units.

iii. Anion exchange reactions

RaOH + HCl -------- RCl + H2O

2RaOH + H2SO4 -------- R2SO4 + 2H2O

iv. Regeneration reaction with NaOH

RaCl + NaOH -------- RaOH + NaCl

R2SO4 + 2NaOH -------- 2ROH + Na2SO4

Three streams of DM water, in the plant are installed, each has capacity of 150 m3/hr for 20

hrs/day. This plant is supplied, erected and commissioned by M/s Thermax Ltd. Each

stream contains pressure sandfilter (PPS), activated carbon filter (FAC), strong cation

exchanger (SAC), Degasser tower (DGT) with degasser blowers (BDG) and degassed water

pump (PDG). Weak base anion exchanger (WBA) , Strong Base Anion (SBA) And Mixed

Bed (MB). To polish the condensate, condensate polishing plant is there. It contains

activated carbon filter (FAC-CP) and mixed bed exchanger (MBCP). To avoid damages of

resins due to high temperature, heat exchangers are fixed to cool condensate before

condensate polishing unit.

Materials of construction of piping and equipments upto inlet of SAC are MS and from SAC

outlet are MSRL or SS. D.M. Water tanks , treated condensate tank, and effluent neutralising

tanks are of MS/RCC with epoxy lining.

To measure quantity of filter water at PPS inlet and at MB outlet, flow integration, flow

indicator are fixed. To measure quality of DM water pH meter, conductivity meter, silica

analyser are fixed at outlet line of WBA, SBA and MB & MBCP.

1.02 b Design basis of condensate polishing unit.

Normal condensate recovery 74.0 m3/hr i.e. 1800 m3/day

Peak condensate recovery 97.00 m3/hr i.e. 2200 m3/day

Plant size is selected to polish 2400 m3/day condensate

1.02 c DM water and condensate storage tank

DM tanks 1600 m3 x 2 nos = 3200 m3. Assuring 12 hrs storage in normal condition of plant

cap. for storage.

Row condensate tank of 2000 m3 capacity assuring 20 hrs. storage.

1. Plant is designed considering 10% excess ionic load & silica 20 ppm as SiO2 in R.W.

2. Plant is designed considering outdoor installation.

3. Plant is semiautomatic.

4. Velocity in resin bed is considered max. 0.75 M/Sec.

5. Fluid velocity is max. 2M/sec. When three streams are running on peak load.

6. 33 - 18% HCI and 20% NaOH is used for regeneration and neutralising of effluent.

1.03 BRIEF DESCRIPTION

1.03.1 DM Water Plant

Filtered water from water treatment plant is coming to PPS to give good quality water to ion

exchanger to avoid the fouling/scale on resin. Scale of mud on resin reduces the ion

exchange capacity of resin. Different size of Pebbles and sand are used as filter media.

Outlet water from PPS goes into FAC. It contains activated carbon which removes COD ,

FRC , oil, grease and Fe if any. For measuring performance of PPS and FAC no instruments

are fixed but pressure gauges are fixed to know differential pressure between inlet and outlet

of each unit. From FAC, water goes to storage acid cation bed. It is MSRL, vertical counter

current pressure vessel, it contains 18150 litres of Tulsian resin of M/s Thermax. Counter

current means service water flow and regeneration flow are in opposite direction. Counter

current is preferred to ensure perfect regeneration of resin. Pressure gauges are fixed to

know pressure drop.

Backwash of SAC is optional and is not done in every regeneration cycle. Conductivity

meters show the exhaustion of resin started , which indicates the regeneration of unit is

required. Hydrogen from resin T-42 takes cation from water and gives out Hydrogen to from

acid.

Sodium is less reactive Ion. So leakage of Na+ (on starting exhaust of resin) occur first. To

know Na+ leakage from SAC, on line Na+ analyser or differential conductivity meter is fixed

in outlet of SAC.

One ppm of Na+ gives conductivity of 1.8 micro moh/cm. Bicarbonates are decompose in

CO2 and H2O. This produced CO2 is removed by degasser. So SAC outlet water is pumped

to degasser unit. SAC outlet has pH 3.5 to 5.0. Degasser contains two nos. of towers, one

degasser storage tank, three air blowers and four degassed water pumps (Three run and one

standby). Degasser towers are filled with 35-38 mm diameter * 35-38 mm length of

polypropylene reaching rings.

Water enters at the top of the towers and pumping of air by blowers from bottom of the

towers, free CO2 is removed by air and only dissolved CO2, 5 ppm equivalent of CaCO3

remain in water. Degassed water is stored in degassed storage tank, which is provided with

high and low level switches to maintain certain level in tank. Degassed water pumps are

pumping water to WBA. WBA is a cocurrent MSRL vertical pressure vessel. It contains

6000 lits of A-2X resin in each unit. Resin is only reactive with low pH i.e. strong acid like

H2SO4 and HCl. But not with weak acids like carbonic and silica. Conductivity meter with

high alarm is provided in outlet of WBA. Regeneration of the unit is done by through fare,

i.e. regeneration of WBA and SBA is done at a time and regenerant and slow rinse of SBA is

used in WBA. Outlet water from WBA goes to SBA, it is a counter current MSRL vertical

pressure vessel, it contains 3800 litrs. Of A-27 resin.

Strong anions are removed in WBA. Weak anions like silica and carbonic acids are removed

in SBA. Conductivity meter, silica analyser and pH meter with high alarm are fixed in outlet

of SBA. Till silica and carbonic acids are removed pH, remains high and rise in conductivity

due to CO2 but silica has no effect on pH and conductivity. Outlet water from SBA goes to

MB.

MB is MSRL vertical co-current pressure vessel, it contains cation T-42 and anion A-27

resin each of 1900 litrs.

Generally most of the ions are removed in SAC, WBA and SBA units. Extremely pure water

is produced by mixed bed, using relatively lower quantities of regenerant and almost

independent of feed water ionic load.

Characteristic of MB unit is that exhaustion point is very sharp when either of the resin

exhausted the conductivity rise sharply. At this stage MB should be cut out from service &

resins must be separated for regeneration.

Separation is achieved by back washing and distributing water flow evenly. Anion exchange

resin has got lower sp. Gravity than that of cation resin. So, two clearly define layers are

formed. Then allow the resin to settle. On completion of back washing MB has both types

of resin so it takes care even any ions are slipped from preceding ion exchanger and gives

good quality of water. In MB outlet , pH meter , silica analyser, conductivity meter with

high alarm are fixed to observe performance of MB working.

DM water outlet from MB has :

pH ------ 6.2 to 7.4

Conductivity ------ 0.2 microohms/cm

Silica ------ < 0.02 ppm as SiO2.

1.03.2 Condensate Polishing Unit

Condensate from boiler and process plants is being recovered to save DM water and to utilise

heat of condensate for generation of steam. Return condensate from plants contains Fe and

other chemical impurities due to small leakage in equipment / pipe exact analysis of raw

condensate is not available but plant is designed considering TDS-4 ppm and Silica - 1 ppm

as a SiO2. Condensate polishing unit contains 1 no. of activated carbon filter (FAC-CP) and 1

no. of mixed bed unit (MB-CP). Purpose and material of construction are same as of FAC

and MB units of DM plant.

Condensate from different plant is coming in condensate return header. Before going to raw

water condensate tank, return condensate is cooled from 90 deg C to 55 deg C in two nos. of

plate type heat exchangers with the help of treated condensate going to CPP, Condensate is

further cooled with the help of C.W. before going to Raw Condensate Tank.

Condensate from CPP comes directly to raw condensate tank . From raw condensate tank it

goes to Condensate Polishing Unit after cooling it from 70 deg C to 42 deg C in one no. of

plate type exchanger with the help of cooling water which is available at 34 deg C from

cooling tower. Plate type heat exchangers are supplied by Larsen & Toubro Ltd. Mixed bed

(MB) unit contains 1200 ltrs of T-42 cation and A-27 anion resin of each. These resin can

withstand upto maximum temperature for (continuous operation) of 55 deg C so, high

temperature alarm and tripping of condensate feed pump at high temp. Interlock is provided

as resin is highly sensitive of high operating temperature.

Pump of D.M. water and condensate plant are supplied by M/s Becon Wair Ltd, material of

construction of pumps for raw/treated condensate and DM water is SS 304.Cooled raw

condensate at 42 deg C is fed to FAC-CP where COD, oil, grease and Fe are removed.

Backwash of FAC-CP is done once/day. Pressure gauges at inlet and outlet are fixed . Outlet

condensate from FAC-CP is fed to MB-CP where cation, anions and silica are removed. pH

meter, conductivity meter and silica analyser with

high alarm are fixed in the outlet of MB-CP to see the performance of unit.

CHAPTER 2

2.1 RAW WATER INPUT & DM WATER OUTPUT SPECIFICATION

Sr. No,.

Parameters Units Raw WaterIn put

DM water Outputt

1. Turbidity NTU 2.0 NIL2. Total suspended solid MG/L NIL NIL3. Total dissolved solid MG/L -- 0.54. pH -- 7 - 8 6.5 - 7.05. Electrical conductivity Micromhos/c

m--- 0.2

6. Dissolved oxygen Mg/L --- ---7. Free carbon dioxide Mg/L --- ---8. Oxygen consumed by org.

mattersMg/L 4.5 ---

9. Total hardness Ppm as CaCO3 134 NIL10. M.O. Alkalinity -do- 187 NIL11. Phenolphth alein -do- NIL ---12. Bicarbonate -do- --- ---13. Hydroxide -do- --- ---14. Sulphate as SO4 --- 36.5 ---15. Chloride as NaCl Ppm 45.1 ---16. Nitrates Ppm as CaCO3 --- ---17. PO4 (Phosphate) -do- --- ---18. Calcium -do- 72 NIL19. Magnesium -do- 62 NIL20. Sodium -do- 135 ---21. Sodium Ppm as CaCO3 0.9 0.00922. Manganese -do- --- ---23. Aluminium -do- --- ---24. Copper -do- --- ---25. Free Ammonia As NH3 ppm --- ---26. Silica as SiO2 Ppm 20 0.02

* Oxygen consumed in organic matter is less than 0.1 PPM in drinking water.

2.2 SPECIFICATION OF RAW CONDENSATE&TREATED CONDENSATE

Sr No Parameters Unit Rawcond. Treated cond.1. Total dissolved solid PPM 4.0 0.052. Silica as SiO2 PPM 1.0 0.023. Total Fe as Fe PPM --- 0.0054. Total Cu as Cu PPM --- 0.0035. Total Al as Al PPM --- 0.0036. Conductivity Micromho/cm --- 0.27. Temperature deg C 45 45

2.3 SPECIFICATION & CONSUMPTION OF UTILITIES (DESIGNCONDITION)

(A) HCl : IS262-1962.18-33$ concentration consumption on 100% basis.

Normal : 816 x 2 + 76x2 + 75 = 1729 kgs/day7

Peak : 816 x 2 + 76 + 75 = 1783 kgs/day

(B) NaOH : Rayon grade 16 - 20% concentration 100% basis

Normal : 322 x 2 + 114 x 2 + 75 + (108.5 x 6 + 61.7 x 1) x 2 == 955 kgs/day7 7

Peak : 322 x 2 + 114 + 75 + 61.70 + 108.5 = 1003 kgs/day

(C) Instrument Air : 450 NM3/Hr.

(D) Water Consumption for Regeneration

Equipment M3/Regen. Nos / d M3/d Normal M3/d PeakPPS 45 2 90 90FAC 20 2 40 40SAC 187 2 374 374WBA/SBA 74 2 148 148MB 42 (for 7 days) 2 12 42FAC-CP 20 1 10 20MB-CP 41 1 41 41Total 715 755

2.4 VOLUME OF INTERNALS

(A) PPS : 2 nos

Pebble : 40-25 mm 3.8 m3

25-15 mm 3.8 m3

12-8 mm 3.8 m3

8-6 mm 3.8 m3

Crushed gravel: 6 - 25 mm 2.8 m3

Banded sand : 6/16 inches 2.8 m3

Filling sand : 16/32 inches 17.0 m3

(B) FAC - 1 nos FAC-CP 1 no

FAC FAC-CP

Pebble ¾ - ½ inches 1.7 m3 0.85 m3

½ - ¼ inches 1.7 m3 0.85 m3

Coarse silex 1.7 m3 0.85 m3

Fine silex 1.7 m3 0.85 m3

(C) DGT - 2 nos

Rashing ring of polypropylene of 35. 38 mm diameter and 35-38 mm length.

(D) Resins

Name of Nos Liters of resin Volume and type of resinEquipment for equipment T-42 A-27 A-2XSAC 2 18150-1360* 363300+2720* --- ---RBA 2 6000 --- --- 12000SBA 2 3800 + 600* --- 9600+1200* ---MB 2 1900+1900 3800 3800 ---MB+DP 1 1250+1250 1250 1250 ---

Total 41350+2720* 12650+1200* 12000*Inert Resin

CHAPTER 3

DETAILED CONSTRUCTION FEATURES OF EQUIPMENTS

SAC, SBA, WBA and MB are the main equipments of DM water plant. These have major

roll for designing. DM water has different pH at each stages. Ion Exchange is taking place

when the resin bed is compact so resin bed is under pressure during service. Minimum bed

height is maintained more than 1 meter considering water velocity and pressure drop across

the resin bed. Resin bed is expanding during back wash operation so 100% extra space is

maintained equal to resin bed volume to avoid loss of resin during back wash.

Due to Acid/Alkaline pH of water, these equipments are protected against corrosion by

rubber lining. Lining of 4.5 mm of natural rubber with store hardness of 60 deg + 5 deg is

provided. Before rubber line inside surface is sand blasted and brushed with wire brush. All

these equipment have maximum operating pressure of 5-5 kg/cm2g. Equipments are

designed at 6.5 kg/cm2 and tested at 9.75 kg/cm2 pressure. Material of construction is MS of

grade SA 515/516 grade - 70.

To avoid the resin losses during regeneration, nozzles are provided in inlet and outlet

distribution header. These nozzles also help to avoid channelling in resin bed, uniform flow

of acid/alkyl during regeneration, and uniform ionic load on resin.

SAC and SBA are counter current pressure vessel i.e. normal service water flow and

regeneration flow are in opposite direction. Opposite direction flow are required to get

better/high concentration acid/alkyl at the layer of resin from where last product in leaving.

This will give better quality of product. Due to this counter-current flow equipment to avoid

the thrust in bottom, bottom is filled with concrete. WBA and MB are co-current pressure

vessel and don’t require any concrete filling in bottom portion.

Where very low silica contain in DM water is required and only SBA is there SBA is

regenerated with higher concentration of alkyl and WBA is there SBA s regretted with

consumption of alkyl this will increase consumption of alkyl. To reduce the consumption of

alkyl thorough fare system is being used. In this system outlet alkyl and alkyl rinse of SBA

will be used for WBA. This will save the consumption of alkyl per regeneration.

CHAPTER 4

PROCEDURE FOR START UP/SHUTDOWN BACKWASHING &

REGENERATION

4.1 Start-up of plant

Check : All valves of all units are in closed condition.

4.1.1 Filter Water Pump

a. First of all suction valve should remain open.

b. Start filter water pump and slowly open discharge valve.

c. Ensure whether motor direction is correct or not.

d. The discharge pressure should be of 4 kg/cm2

e. Note ampere of the pump.

4.1.2 Pressure Sand Filter (PPS)

a. Filter water pump should be running on.

b. While starting of pressure filter (PPS) first of all open main inlet valve VM1 and then

open air release valve VM12, when air is completely removed and when water start coming

out from VM12, close it and open fast rinse valve VM31 for 10 minutes. After that open VM2

and note inlet cut let pressure.

4.1.3 Activated Carbon Filter (FAC)

a. Sand pressure filter (PPS) should be remain on service.

b. While starting of FAC first of all open main service inlet valve VM1 and then open air

release valve VM12. When air is completely removed and water start coming out from VM12

close it. Open rinse outlet valve VM31 for 10 minutes. Open outlet valve VM2 and adjust it

to get the required flow rate.

4.1.4 Strong Acid Cation (SAC)

a. FAC should be remain on service.

b. Before starting of SAC first of all put it on select regeneration ‘Filling & Fast Rinse”

at the time of filling open main inlet valve VA1 fully & air release valve VA12; when air is

completely removed and when water start coming out from VA12 close it , and take it on

service by opening valve VM2. Don’t take in service unless water quality of fast rinse is as

below:

F.M.A - Same betn two successive samples at 5 minutes interval or 89.7 +/-

0.1.

T/H - Nil

Na+ - Nil

pH - 2.5 - 3.5

4.1.5 Degasser

a. SAC should remain on service.

b. First of all start Degasser Air Blower (BDG) water is entering at the top of tower and

pumping of air blower (BDG) from bottom of tower. Free CO2 is removed by air and only

dissolved CO2 - 6 ppm equivalent of CaCO3 remain in water. Degassed water is stored in

Degassed Storage Tank (SDG) when level come high start degasser water pumps (PDG)

suction valve VM25 should remain open and then slowly open and control by discharge valve

VM26. Keep pressure between 3.2 to 3.8 kg/ cm2 and note ampere of the pump. CO2 after

DGT is 5 ppm.

4.1.6 Weak Base Anion (WBA)

a. PDG should be running on.

Before starting of WBA first of all put it on select regeneration “filling and fast rinse”. At

the time of filling open main inlet valve VA1 (full) and air release valve VA12. When air is

completely removed and when water start coming out from VA12 close it. And give fast rinse

at the time of fast rinse valve VA6 remain open. When quality become normal-i.e.

pH - 5.0 - 5.4

CL - Less than 1 ppm.

Then close fast rinse valve (VA6) and open service out let valve (VA2).

4.1.7 Strong Base Anion SBA

a. WBA should remain on service.

Before starting of SBA first of all put it on service. Select regeneration ‘filling & fast rinse’

at the time of filling open main inlet valve VA1 (full) and air release valve VA12. When air

is completely removed and water start coming out from VA12 close it. And give fast rinse,

at the time of fast rinse valve (VA6) remain open. When water quality becomes normal.i.e.

pH - 7.5 - 9.0

Cl - Nil

Silica - < 0.2 PPM as SiO2 and conductivity - 15 micro /cm then close fast rinse valve

(VA6) and open service out let valve (VA2) for service. And note outlet pressure and control

flow by outlet valve VA2.

4.1.8 Mixed Bed (MB)

a. SBA should remain on service.

Before starting of MB first of all put it on select regeneration ‘filling and fast rinse’ at the

time of filling open main inlet valve Va4 (full) and air release valve VA12. When air is

completely removed and when water start coming out from VA12. Close it, and give fast

rinse, at the time of fast rinse valve (VA6) remain open. When water quality becomes

normal. i.e.

pH - 6.2 - 7.4 CL - Nil (as CaCO3) Silica < 0.02 ppm as SiO2 and

conductivity < 0.2 micro mhos/cm, than close fast rinse valve (VA6) and open service outlet

valve (VA2) for service then note flow and inlet outlet pressure of exchange. Control flow

by VA2.

4.1.9 D.M. Water Tanks & D.M. Water Pumps

1) Open the inlet valve of D.M. Water Tank which is to be taken for service.

2) Ensure that inlet valve of idle tank is closed.

3) Ensure that drain valve of running tank is closed.

4) Start D.M. Water pump as per starting procedure of centrifugal pump.

5) If flow required in less than minimum flow of pump open recirculation valve.

6) Note pressure and ampere of running pumps.

7) Open D.M. water line valve for distribution header.

4.1.10 Starting of Condensate Polishing Plant

1) Check the drain valve of raw condensate tank is closed.

2) Open the inlet and outlet valves of row condensate tank.

3) Open the inlet and outlet valves of heat exchanger no. 1502 (2 nos) for raw

condensate line. Collect the condensate in raw water condensate tank.

4) Start the cooling water flow to heater EA-1503.

5) Close the valve in delivery line GA1502 going treated condensate tank.

6) Keep the condensate drain valve open and start raw condensate pump GA 1502 (as

per procedure). After some time close drain valve and open valve of EA 1503.

7) Adjust the cooling water flow to get outlet condensate temperature around 42 deg C.

8) Start FAC-CP as given procedure of FAC.

9) Start MB-CP as given procedure of MB.

4.1.11 Starting of treated condensate tanks and pumps

1) Ensure that drain valves of treated condensate tank FB 1502 is closed.

2) Open treated condensate valve and DM water coming to treated condensate tank.

3) Start treated condensate pump GA 1503 after getting sufficient level in tank as per

starting instruction of centrifugal pump.

4.2 Back Washing - Regeneration of Vessel

4.2.1 F.P.S.

4.2.1.a Air Scouring - (400 m3 for 10 minutes)

1) Close main inlet valve VM1 and outlet valve VA2.

2) Open valve 12

3) Open valve VA4 and allow water to drain down upto the inlet distribution header

level.

4) Open air blower drain valve VA31.

5) Open air blower discharge valve VA41 and start the blower.

6) Open valve VM11 and close VM31 keep the operation for 10 minutes.

7) Open valve VM31 and stop air blower.

4.2.1.b Backwash (120 m3/hr for 10 minutes)

1) Open wash outlet valve VM4 full.

2) Open wash inlet valve VM3 slowly and adjust the flow such that level in drain sump

is upto wash marker.

3) After 10 minutes till effluent is clear, then close wash and valve VM3 wash outlet

valve VM4.

4.2.1.c Refill

1) Open inlet valve VM land air release valve VM12 when water start coming from

VM12 close it.

4.2.1.d Rinse (150 m3/hr for 10 minutes)

1) Inlet valve VM- open since previous step.

2) Open and adjust rinse outlet valve VM31 such that the level of water in drain sump is

upto rinse market in V notch.

3) After 10 minutes, close rinse outlet valve VM31.

4) Open outlet valve VM2 to take the unit in SERVICE.

4.2.2 FAC

4.2.2.a Back washing (100 m3/hr for 10 minutes)

1) Close main inlet valve VM1 and outlet valve VM2.

2) Open wash outlet valve VA4.

3) Open slowly wash inlet valve AM3 and adjust it such that level of water in the drain

sump is upto wash marker.

4) After 10 minutes or till effluent is clear, then close wash inlet valve VM3 and wash

outlet valve VA4.

4.2.2.b Refill

1) Open inlet valve VM1 and air release valve VM12.

2) When water start coming out full bore from air vent line close VM12.

4.2.2.c Rinse (150 m3/hr for 10 minutes)

1) Inlet valve VM1 is open since previous step.

2) Open and adjust outlet valve VM31 such that the level of the water in drain sump is

upto rinse marker on V notch board.

3) After 10 minutes close rinse outlet valve VM31. Open outlet valve VM2 to take the

unit in SERVICE.

4.2.3 SAC

Main inlet valve VA1 and main outlet valve VA2 remain open. Comparator conductivity

meter will show the ratio of conductivity at the outlet line and resin bed. This ratio will help

to determine and the point of service and to start regeneration.

BACKWASHING WASHING : SAC is regenerated in counter current type of regeneration ,

so backwashing of vessel during every cycle of regeneration is not essential. Generally

backwashing is given after every 7 cycle, but it also depends on site condition. Backwashing

is to be carried out only when it is absolutely necessary. Following are the cut of points of

carrying out backwashing. It is noted that double regeneration is required after backwashing.

1. Excessive pressure drop on exchanger.

2. Inconsistency in quality during service.

3. Excessive fines/foreign particals accumulation during the number of cycle of service.

If required, backwash to be carried out on extended time not by increasing flow rate.

BACKWASHING (OPTIONAL - 3 mts - flow 72 m3/hr)

Select regeneration switch from PLC for SAC A or B service water inlet valve VA1, and

outlet valve VA2 remain close. Backwash inlet valve VA3, acid inlet valve VA7 (full open

full open near MHL1) and backwash outlet valve VA4 remain open. Water can be controlled

by inlet flow indicator. Back wash is continues till outlet backwash water is clear. During

backwashing water will inlet through resin bed from bottom to top and carry mud with it.

- Once in 6 months open - extended backwash to be given for removal of fines.

BEFORE PUTTING THE SAC INTO REGENERATION Following are the pre-condition

to be carrying out -

A. One SAC is to be put into regeneration mode.

B. Acid in MHL/A/B is to be taken by opening VM7 upto high level if it is 18%.

Otherwise at low level for 33% and by adding SBA outlet water by opening VM14 upto high

level.

C. One FPS has to be put in service mode to come into service as and when required.

D. PDG & BDG is to be put in auto mode.

STEP-1 : MIDDLE COLLECTOR WASH (5 mts flow 60 m3/hr)

Middle collector inlet valve VA13 (part and back wash outlet valve VA4 (full) remain open.

This is carriedout to clear the Buttons which are filled on the middle collector. Adjust the

flow by VA13.

STEP-2 : SETTLE BED (2 minutes)

All valves remain closed in this step. The bed is allow to settle after middle collector wash.

STEP-3 : POWER WATER INJECTION (3 mts - flow 51 m3/hr)

Following valves will open :-

1. Acid injector valve VA7.

2. Middle collector outlet valve VA-14.

3. Down flow VA - 15 (part).

4. MHL1 A/B and power water valve VA32 PDG pump and BDG blower put on auto

will come into service immediately.

Down flow is must as it is counter current of regeneration and acid will be injected from

bottom so to keep the resin bed compact, control the power water flow through injector as in

next step acid is to be sucked.

STEP-4 : ACID INJECTION (30 mts flow 150 m3/hr)

Apart from those valve mentioned in step no. 3 one more valve acid outlet valve VA2 of

MHL1 A/B will open. The strength of acid entering the vessel would be between 4 to 5%

this can be checked by specific gravity indicator. The strength of 4% acid solution is 1.018

and that of 5% acid solution is 1.023.

If all acid is consumed in 20-25 mts (i.e. set time) and measured by low level switch, then the

acid outlet valve will close automatically but the step will continue. However, if the level of

acid does not fall to the low level even at the end of set time, the step will change

automatically to the next step, without bothering to wait for the acid measuring to fall to low

level. However, the operator can put the step to hold mode by pressing the hold mode button

on the sequential controller thereby freezing the timer, and release the hold button after as

certaining that all acid has been consumed.

STEP-5: SLOW RINSE (30 mts flow 51m3/hr and down flow 50m3/hr)

Following valves remain open -

1. Acid injection valve VA7.

2. Middle collector outlet valve VA14.

3. Down flow VA15.

4. Power inlet valve VA32 of MHL1 A/B valve VA32 of MHL1 A/B remain closed.

This required to displace the acid from the vessel.

STEP-6: FINAL RINSE (30 mts flow - 150 m3/hr)

Water inlet valve VA1 (full) and rinse outlet valve VA6 (part) will open this step is required

to wash off traces of acid from the vessel. The quality of water coming out from the vessel

can be checked by checking free mineral acidity (FMA). The value of FMA must be same

between two successive reading. If not, rinse must be continued.

STEP-7: OFF

This is the last step and all valve remain closed. At the end of this step, end of SAC

regeneration displace will be given. Then SAC will be taken for service.

BACK WASH & REGENERATION TABLE

Sr Step Flow Rate(m3)

Time(hrs)

Water consumed(m3)

Type of water (m3)

1 Middle collector wash 60.0 5 12.0 Degassed2 Back wash (optional) 72.0 3 3.6 Degassed3 Settle bed - 2 - -4 Power water 51 2 - Degassed5 Acid injection 51.0 25.5 Degassed

Down flow 50.0 50.0 Filter water6 Acid rinse 51.5 24.0 Degassed

Down flow 50.0 25.0 Filter water7 Final rinse 150.0 30 75.0 Filter water

4.2.4 WBA/SBA

THROUGH FARE REGENERATION

The rinse and service operation instruction are same as given in the individual vessel section.

Here both the SBA and WBA will be regenerated at the same time.

Here the regenerant sodium hydroxide will enter SBA and from SBA it will be taken to

WBA. It is worth to noting that SBA is regenerated in counter current type and WBA is co-

current type. SBA need not be back washed during every time of regeneration but WBA has

to be back wash without fail.

Since dilution of alkali is required , water has to be added to alkali and to ensure proper

mixing of alkali. A mixer is provided on each of the measuring tank (Presently not in service

as we get 20% Caustic from T/F directly, so no need of any dilution). The feeding of water

and alkali is manually by VM1 and VM9 respectively without alkali measuring the operator

can not start the through fare regeneration.

BACK WASH OF SBA (optional 10 mts - flow 15 m3/hr)

Following valve remain open -

1. Back wash inlet valve VA3 (part).

2. Back wash outlet valve VA4 (full).

The degassed water will be supply by PDG pumps.

25

30

REGENERATION OF WBA/SBA VESSEL

STEP-1 : WBA - BACK WASH & SBA - Middle Collector Wash (10 mts/5mts)

Following valves will open -

1. Back wash inlet valve VA3 of WBA (open partly flow 22 m3/hr)

2. Back wash outlet valve VA4 of WBA (full).

3. SBA middle collector inlet valve VA13 (part open flow 15 m3/hr) SBA wash outlet

VA4 of SBA is full open. Selected PDG pump will run and ensure sufficient level in SDG

and alkali measuring tank MAK1 A/B.

STEP-2 WBA & SBA SETTLE BED (2 MTS)

All the valve of WBA and SBA remain close in this step with the pump being off.

STEP-3 WBA - Idle SBA - Power Water (3 mts)

Middle collector outlet valve VA14 (full open), down flow valve VA15 (part open flow 8

m3/hr), Alkali inlet valve VA9 (full open), and power water inlet valve VA32 of SBA (part

open flow 14 m3/hr) remain open. All valves of remain closed. This step is same as power

water that of SAC.

STEP-4 SBA-Idle SBA Alkali Injection (5 mts)

WBA -- All valve remain close.

SBA -- Middle collector outlet valve VA14 (full open), down flow valve VA15 (part

flow 8m3/hr). Alkali inlet valve VA9 (full) power water inlet valve VA32 (part 14m3/hr)

and VA2 alkali outlet valve of MAK1 A/B are open. Sp. Gravity of 4% NaOH - 1.040 and

5% NaOH 1.054 will be measured by sp. Gravity indicator.

STEP-5 WBA - Alkali Injection (25 mts)

SBA - Alkali Injection Continuous (20 mts)

WBA Power water outlet valve VA32 on WBA (part open flow 30 m3/hr). Alkali inlet

valve VA9 (full) and rinse outlet valve VA6 (full open) remain open.

SBA Middle collector outlet valve VA14 remain closed and alkali outlet valve VA10

remain open and other valve remain open as per step no. 4.

STEP-6 Rinse - WBA Alkali Transfer - SBA (30 mts)

The valve states for WBA remain the same the valve status for SBA remain the same.

Expect that the alkali outlet valve VA2 of MAK1 A/B remain closed.

STEP-7 WBA and SBA Settle Bed (2 mts)

All the valve and pumps remain the same.

STEP-8 WBA - Fast Rinse, SBA - Idle (10 mts)

WBA inlet valve VA1 (full) and rinse outlet valve VA6 (part) remain open. This will wash

traces of alkali from WBA. SBA all the valves remain close.

STEP-9 WBA Service SBA - Fast Rinse (10 mts flow 150 m3/hr)

WBA Main inlet valve VA1 (full) and outlet valve VA2 (part) remain open.

SBA Service water valve VA1 full and rinse outlet valve VA6 (part open).

The regenerated WBA comes into service, supply water to rinse the traces of alkali in SBA

continue the rinse till quality become acceptable.

STEP-10 OFF SBA-WBA

In this step all the valves remain closed.

Description of

operation

WBA SBA

Flow m3/hr Time minutes Flow m3/hr Time inutesBackwash 22 10 15

(optional)10 or till water is clear.

Middle collector wash NA NA 15 5Alkali injection Down flow

IdleIdle

IdleIdle

148

55

Alkali inje(contd) 30NA

25NA

148

2020

Alk transfer/Alk rinsedown flow.

47NA

25NA

148

3030

Final rinse 150 10 Idle IdleFinal rinse Service - 150 10

4.2.5 MB MIXED BED

MB has both cation and anion resin in mixed condition. So it is essential to back wash the

unit before regeneration to separate both cation and anion resin. Before starting the

regeneration operator has to do the following things :-

1. Acid has to be measured in MHL2 A/B by operating VM7 upto low marked level and

water to high level by VM14.

2. Alkali has to be measured in MAK 2 A/B by operating VM7 low level and water upto

high level. Before putting MB for regeneration following points to be ensured by operator.

I. Ensure acid and alkali have been measured correctly in volume in specific gravity.

II. One PDG pump to be put in the auto mode.

III. One BDG blower is to be started.

IV. One PPS, SAC, WBA, SBA should be in the service mode.

STEP-1 MIDDLE COLLECTOR WASH (5 mts 25 m3/hr)

Middle collector inlet valve VA13, back wash outlet valve VA4 remain open.

STEP-2 BACK WASH (15 mts 30 m3/hr)

Back wash inlet valve VA3 (part) and back was outlet valve VA4 remain open. This is an

import step as the resin have to be separated before regeneration. This is achieved by proper

back washing only. If back washing is proper the anion will settle above middle collector

and cell cation before it.

STEP-3 SETTLE BED (3 mts)

All the valves remain closed in this condition.

STEP-4 ALKALI POWER WATER (3 mts - 3.5 m3/hr & up flow 9.0 M3/hr)

All volume remains close in this step. Following valves remain open -

1. Middle collector outlet valve VA14 (full open)

2. Alkali up flow valve VA16 (part) open.

3. MAK2 A/B power water inlet VA32.

4. Alkali inlet valve VA9.

Upflow is to be maintained. Alkali will be injected from top and collected through middle

collector. Up flow is generated from ballon of vessel and collected to middle collector.

STEP-5 ALKALI INJECTION (15 mts - Flow 4.5 m3/hr)

All valves of stop no. 4 remain same and also new valve MAK-2 A/B alkali outlet valve

VA2 open.

STEP-6 ALKALI RINSE (20 mts - 4.5 m3/hr, up flow 9.0 m3/hr)

Middle collector outlet valve - 14 alkali upflow VA16 MAK 2 A/B power water inlet valve

VA32 and alkali inlet valve VA9 remain open. This step is to ensure proper displacement of

alkali.

STEP-7 SETTLE BED (2 mts)

All valves remain closed.

STEP-8 ACID POWER WATER (3 mts flow 3.5 m3/hr)

The following valves remain open -

1. Rinse outlet valve VA-6 (full open)

2. Acid inlet valve VA-7

3. Acid down flow valve VA-15 (part) and power inlet water VA-32 one of PDG pumps

selected will remain on.

STEP-9 ACID INJECTION (15 mts. injection flow 4.5 m3/hr, & down flow

3.6 m3/hr)

Rinse outlet valve VA6 acid downflow VA15 acid inlet VA7, acid outlet valve of MHL-2

A/B VA2 and VA32 will remain open.

STEP-10 ACID RINSE (15 mts rinse flow 15.0 m3/hr, down flow 3.6 m3/hr)

All valve status is same as step no. 9, but except MHL2 A/B acid outlet valve VA2 remain

closed.

STEP-11 DRAIN DOWN (6 mts)

Wash out valve VA-4, air release valve VA-12 and drain valve VA-17 remain open.

STEP-12 AIR MIXING (20 mts, flow 280 m3/hr)

Wash outlet valve VA4, air inlet valve VA11 from MB and air release valve VA12 remain

open the air from the blower will mix the separated anion and cation resin.

STEP-13 REFILL (2 mts)

Main inlet valve VA1, rinse outlet valve VA-6 and air release valve VA-12 remain open i.e.

water is tilled after air mixing.

STEP-14 FINAL RINSE (15 mts, flow 150 m3/hr)

Main inlet valve VA1 and rinse outlet valve VA6 remain open.

STEP-15 OFF

All the valve remain closed.

BACK WASH & REGENERATION OF FAC-CP AND MB-CP

Condensate polishing unit has FAC-CP and MB-CP regeneration procedure and steps are

same as that of DM water plant FAC and MB respectively. Only MHL-3 and MAK-3 will

be used instead of MHL-2 A/B and MAK-2 A/B respectively.

Stepwise water flow, time and water consumption figure are as follows :-

REGENERATION OF MB/MB-CP UNIT

Step Steps Flow ratem 3/hr

Time minutes

1 Middle collector wash 25/20 5/52 Back wash 30/22 15/153 Settle bed -/- 2/24 Alkali power water 3.5/14 3/25 Alkali injection up flow 4.5/15 & 9.0/20 15/126 Alkali rinse up flow 4.5/15 & 9.0/20 20/207 Settle bed -/- 2/28 Acid power water 3.5/7.5 3/29 Acid injection down flow 4.5/9 & 3.6/9 15/1210 Acid rinse down flow 4.5/7.5 & 3.6/9 15/1511 Drain down -/- 6/612 Air injection 280/280 20/2013 Refill 150/120 2/214 Final rinse 150/140 15/1515 Off -/- 1/1

4.2.6 SHUT DOWN

When total plant is to be stopped for annual shut down stop the plant as below :-

1. Close delivery valve of running treated condensate pump.

2. Lose delivery valve of running raw condensate pump, DM water pump, and the

pumps thereafter.

3. Close outlet valve VA-2 of SAC and MB to make the plant idle.

4. Close individual manual isolation valve to make the respective equipment idle.

5. To make idle any instrument, pump, blower and rotameter close their respective

isolation valves.

BACKWASH : F.P.S.

Steps Flow Rate Time Minute FPS-1 FPS-2M3/Hr. From To From To

Air scouring 400 10Backwash 120 10Rinse 150 10Off/Service …. 01

BACKWASH : FAC

Step Flow Time Minutes FAC-1 FAC-2M3/hr From To From To

Back wash 100 10Rinse 150 10Off/service … 01

BACKWASH : SAC

Step Flow Time Minutes FAC-1 FAC-2M3/hr From To From To

Middle collector

60 10

Back wash 72 3Settle bed - 2Power water 51 3Acid injection

Down flow

15

50

20

20Acid rinse

Down flow

51

30

30

-Final rinse 150 30Off - 1

WBA/SBA - Regeneration

Step SBA WBA SBA-1 WBA-1 SBA-2 WBA-2FlowRate

TimeMts

Flow

TimeMts

Back wash 22 10 15 10Middle collectorwash

- - 15 5

Alkali injector Idle - 14 8

Down flow Idle - 14 8Alkali injector 30 25 14 20Down flow - - 8 20Alkali transfer 47 30 4 30Down flow - - 8 30Final rinse 150 10 Idle IdleFinal rinse Service 150 10

MB/MB-CP REGERATION

Step Flow RateM3/Hr

Time Mts. MB-1 MB-2 MB-CP

From

To From

To From

To

25/20 5/530/22 15/15

2/23.5/14 3/24.5/4.59/20

15/12

4.5/159/20

20/20

-/- 2/23.5/7.5 3/24.5/4.53.6/9

15/12

4.5/7.5 15/15-/- 6/6280/280 20/20150/120 2/2150/140 15/15-/- 1/1

CHAPTER 5

TROUBLE SHOOTING

Sr. No.

Defects Causes Remedies

1. Decreasein capacity between twosuccessive

a. Increase in ionic load. a. Check by analysing everymonth.

regeneration. b. Flow recorder defective.c. Insufficient chemical used.d. Resin dirty. e. Plant being used intermittently. f. Channelling in bed.

b. Check it

c. Check it.

d. Give prolonged backwash.

e. Avoid this. f. Check and ensure uniform. Distribution/ collection.

g. Resin fouled. g) If cation given HCL wash if anion resin give alkaline brine treatment.

h. Resin deteriorated. h. Check and replace charge.

i. Resin quantity insufficient in unit.

i. Check and put up.

2. Treated quality put upto the standard.

a. Cation exhausted.b. Anion exhausted.c. M.B. exhausted.d. M.B. resin not in unform state.e. Some valve like back wash leaking.f. Na slip from anion is high. g. Unit idleh. Unit not sufficiently rinsed.i. Excessive low flow rate.j. Channelling k. Resin fouled.

a. Checkb. Checkc. Checkd. Check and repeat air mix and rinse.e. Check f. Check raw water analysis change in Na/To & S/02/TA ratio use more chemicals.g. Checkh. Rinse to satisfactory quality.i. Adjust to between min/max flow rate.j. Check and ensure uniforms collection/ distribution.k. Check resin and give

I. Resin deteriorated. alkaline brine/ HCl treatment.l. Check resin and replace.

Sr. No.

Defects Causes Remedies

3. Mixed red quality not good.

a. Resin not separated during back wash property.b. Air mix not proper.c. Final rinse not proper.d. Some valve may be leaking and contaminating the treated water.

a. Give extended back wash after exhausting the bed.b. Repeatc. Repeat

d. Check and examine.

4. High residual CO2 from degasser.

a. It can be due to choked suction filter of degasser air blower.b. Improper air flow to the degasser.

c. Degasser blower not in operation.d. Air seal not fitted/ broken resulting in short circulating of air.

a. Check of clean filter. b. Check damper speed of blower and discharge pressure.c. Check and operate blower.d. Check or replace fitting.

5. Unit rinse take long time. a. Flow rate b. Unit exhausted.c. Backwash valve passing.d. Anion resin organically fouled.e. Mixed bed not satisfactory.f. Acid/alkali in unit.

a. Increase flow rate.b. Regenerate unit.c. Check and rectify.

d. Give alkaline brine treatment.e. Carry out air mix once again.f. Faulty design check and rectify. Back wash (followed by ) and rinse again.

6. Flow Rate a. Checked valve and suction strainer of pump.b. in the pump.c. Low inlet pressure.d. Distribution or collecting system chokede. Resin trap at

a. Check.

b. Check.c. Check pump.d. Check.

e. Check and clean.

f. Increase off take.

outlet choked.f. Control valve due to low off take.

Sr. No.

Defects Causes Remedies

7. Pressure drop across the bed increasing day by day.

a. Defective valvesb. Packed resin bed and fines present. c. Collecting system choked.d. Pressure gauge defective.

a. Checkb. Give extended back wash with open manhole and scrap off fines from top surface of the resin.c. Check, repeat back wash.

d. Check and rectify or replace.

8. Flooding in degasser a. Very high air flow.

b. Packed tower choked due to dirt or broken packing materials.

a. Reduce air flow rate by adjusting damper.b. Open and check.

9. Resin being lost. a. Excessive backwash pressure/flow.b. Faulty collecting system.c. Inlet strainer damaged.d. Excessive fine.

a. Check inlet pressure and reduce it.b. Examine same for breakages.c. Choke of replace.

d. Run the plant at design flow rate.

10. Ejector not working e. Low power water damaged.f. Air lock in the unit.

g. Checked and defective valves.h. Ejector nozzle may be checked.i. Topmost back pressure from unit.j. Bulge in pipe lining.

e. Check this. f. Back wash and open air release.g. Examine & rectify.

h. Check

i. Check for choke of collecting system outlet valve.j. Check & rectify.

11. Incorrect reading from rotameters.

a. Checked orifice sub-orifice or inpulse line.b. Dirty glass and float.

a. Check and clean. b. Check and clean.

13. Level electrodes system for measuring and dilution tank not function properly.

a. Improper contact between electrodes and control cabling.b. Shorting of the

a. Check contact and rectify.

two electrodes due to moisture or any foreign material.Improper working at the level controllers.

b. Clean and dry the contacts of moisture & dist.

a. Check.

Sr. No.

Defects Causes Remedies

14. Leakage from acid injection unloading transfer pump.

a. Improper adjustment of the mechanical seal.b. Low strength of sulphuric acid of presence of ferrous sulphate.

a. Check and adjust.

b. Check concentration and take appropriate action.

15. Corrosion in concentrated acid tanks and lines.

a) Low concentration of sulphuric acid.

b) Lining of HCL tank/ pipe line damaged.

a. Check silica gel. reather in acid storage tank and replace silica gel charge if exhausted.

b. Rectify.

16. Improper operation and closing of pneumatically operated valves.

a. Defective solenoid valves.b. Leakage in air line from solenoid valve to the respective control valve.c. Improper contact of micro switch giving false indication to the panel.

a. Check b. Check

a. Check

CHAPTER 6

INSTRUMENTATION AND CONTROL

D.M. Plant is controlled by programmable logic controller (PLC) mounted in control room.

There is no back up control panel for D.M. Water Plant PLC has got redundant control

process units which will achieve simultaneously. It has also got graphic page with all alarm

pages. Operator can operate the plant from control room by PLC. Power for PLC will from

UPS system.

Plant is semi automatic i.e. backwashing of FPS and FAC will be done manually but all

regeneration steps will be done by PLC. Interlocks arrangements are provided for starting,

stopping or closing/opening of valves pumps blower or units when any parameter like

quality, pressure level goes out of specified limits. List of ANNUNCIATIONS AND

INTERLOCKS is as attached.

When compressed Air/PLC will fail, regeneration can be done by operating wheels of

Pneumatic Control Valves. Filling of acid and alkali in measuring tanks will be done

manually as nod auto valves are provided.

6.1 LIST OF ANNUNCIATORS

Sr No[1]

Discription[2] [3] [4] [5]

1. Inlet raw water PSL-051 Pressure Low2. Degassed water pump, discharge

header.

PSL-052 Pressure Low

3. Inlet totalized water at FPS-1 FOW-051A Qty Exceeded4. Inlet totalised water at FPS-2 FQH-051A Qty Exceeded5. Cond. ratio at SAC-1 CCAH-051A Qty High6. Cond. Ratio at SAC-2 CCAH-051B Qty High7. Degassed water storage tank LSL-051 Level High8. Degassed water storage tank LSL-052 Level Low9. Conductivity at WEA-10 outlet CCIH-052A Level High10. Conductivity at WBA-2 outlet CCIH-052B Level High11. Cond. At SEA-1 outlet CCIH-053A Level High12. Cond. At SEA-2 outlet CCIH-053B Level High13. Cond. At MB-1 outlet CCIH-054A Level High14. Cond. At MB-2 outlet CCIH-054B Level High15. Cond. At MB-CP outlet CCIH-055 Level High

Sr No[1]

Discription[2] [3] [4] [5]

16. pH Valve at SBA-1 outlet FPIH-051A Level High17. pH value at SBA-2 outlet PHIH-051B Level High18. pH value at MB-1 outlet PHIH-052A Level High19. pH value at MB-2 outlet PHIH-052B Level High20. pH value at MN-2 outlet PHIH-053 Level High21. pH value at neut. Fit outlet PHIH-054 Level High22. pH value at neut. Fit outlet PHIL-054 Level Low23. Totalised flow at MB-1 outlet FQH-052A Qty Exceeded24. Totalized flow at MB-2 outlet FQH-052B Qty Exceeded25. Silica at SBA-2 outlet AIH-001 Qty Exceeded26. Silica at SBA-2 outlet AIH-002 Qty High27. Silica at MB-1 outlet AIH-004 Qty High28. Silica at MN-2 outlet AIH-005 Qty High29. Silica at MN or outlet AIH-007 Qty High30. Acid measuring tank MHL-1A LSH-059A Level High31. Acid measuring tank MHL-1A LSL-089A Level Low32. Acid measuring tank MHL-1B LSL-089B Level Low33. Acid measuring tank MHL-1B LSL-089B Level Low

Sr No[1]

Discription[2] [3] [4] [5]

34. Alkali measuring tank LSL-053A Level High35. Alkali measuring tank LSL-053A Level Low36. Alkali measuring tank LSL-053B Level High37. Alkali measuring tank LSL-054B Level High38. Acid measuring tank MHL-2A LSH-060A Level High39. Acid measuring tank MHL-2B LSL-060A Level Low40. Acid measuring tank MHL-2B LHS-060B Level High41. Acid measuring tank MHL-2B LSL-060B Level Low42. Alkali measuring tank MAK-2A LSH-055A Level High43. Alkali measuring tank MAK-2A LSL-056A Level Low44. Alkali measuring tank MAK-2B LSH-055B Level High45. Alkali measuring tank MAK-2B LSL-056B Level Low46. Alkali measuring tank MAK-3 LSH-057 Level High47. Alkali measuring tank MAK-3 LSL-058 Level Low48. Acid measuring tank MHL-3 LSH-061 Level High49. Acid measuring tank MHL-3 LSL-061 Level Low50. Degassed water pump PDG-1 … Tripped51. Degassed water pump PDG-2 …. Tripped52. Degassed water pump PDG-3 …. Tripped53. MB air blower BMB-1 …. Tripped

Sr No[1]

Discription[2] [3] [4] [5]

54. MB air blower BMB-2 …. Tripped55. Effluent tank pump PEP-1 …. Tripped56. Effluent trans. Pump PEP-2 …. Tripped57. Degasser air blower BDG-1 …. Tripped58. Degassed air blower BDG-2 …. Tripped59. Degasser air blower BDG-3 …. Tripped60. Regeneration sequence (common

for all the vessels)…. …. Failed

6.2 LIST OF INTERLOCKS (REF. P AND I DIAGRAM DRG.NO. 6F)

INTER Discription (00296/B) AC NO.1. If pressure drops below, then the regeneration should

not start.PSL-051

2. If con. ratio increase, then service cycle of that SAC vessel to trip.

OOAH-051A, 051B

3. If SDG level drops low the PDG pumps to trips. LSL-0524. If PDG header pressure drops below set points, then

the PDG pump selected in AUTO should start.PSL-052

5. If the outlet conductivity increased, then the set point, then the service cycle should stop.

OOIH-052A,052BOOIH-053A,053BOOIH-054A,054BOOIH-055

6. If the totalized flow increases, then the set point, then the service cycle of MB to trip.

FQH-052A, 052B

7. If liquid level in the tank is high, then along with alarm it should give mimic indication.

LSH-059A, 059BLSH-060A, 060BLSH-061LSH-053A,053BLSH-055A,055BLSH-057

8. If liquid level in the tank drops below low set point with injection, then its outlet valve VA-2 should be closed, and the step should get changed.

LSL-089A, 089BLSL-060A, 060BLSL-061LSL-054A, 054BLSL-056A, 056BLSL-058

11. Acid/Alkali Measuring tank should be selected before the start of regeneration, so that particular vessel outlet valve and power water inlet valve will get operated.

MHL-1A-1BMHL-2A-2BMHK-1A-1BMAK-2A-2B

12. Each pressure vessel has an outlet valve VA-2. The limit switch is installed on that valve at close side, it the valve VA-2 does not closed fully then the regeneration should not start.

KA-2 if SAC-1 & 2 WBA-1 & 2MBA-1 & 2MBC P

13. While doing MS regeneration standby WBA and SEA vessel should be selected in Auto service, otherwise MB regeneration shall not start.

WBA/SBA of the other streams.

CHAPTER 7DO AND DONOT

SN. Particulars DO DO NOT

1. Any centrifugal pump trips

1. Stop delivery valve of pump.2. Check level in tanks if LSL is provided and get sufficient level.3. Check over load relay if trip due to overload and check pump.4. Check load in all three phase for same current.5. Temp. of condensate to be lowered if GA/502 trip due to over temp.

Do not start pump.Immediately without rectifying the defect.

Do not start polishing unit before lowering down temp. below 4500.

2. Of counter current exchanger unit.

After back washing of counter current exchanger (SAC & SBA) regenerate the exchanger double volume of regeneration.

Do not back wash counter current exchanger (WBA&MB) at every regeneration.

3. Current Exchanger Unit Backwash the current exchange (WAB & MB) every regeneration.

Do not give double …..of regeneration.

4. Running of Ion Exchange Unit.

Run the units upto design production through the resin is not exhausted.

Do not mean the unit more than design production.

5. Regenerant concentration and time.

Maintain concentrate of Acid/Alkali measuring tank between 45%.

Do not prepare Acid/Alkali solution between specified.

6. SAC injection Maintain minimum injection time.

Injection time should be not less than 15 mints. Do not take SAC on service if BMA variation is three in two same of 5 mts. Interval.

8. Backwash Increase the basic washing time if necessary.

Do not increase the flow rate during back wash for better back washing.

SN. Particulars DO DO NOT

9. Condensate Polishing Run the polishing till the temp. condensate below 45 deg C.

Do not run the condensate polishing unit if temp of condensate is more than -5 deg C.

10. DM Water Parameter Run the plant upto design production through parameters in the range.

Do not run the plant if any parameter is out of range before the design production.

CHAPTER-8

PRESERVATION OF EQUIPMENTS/ MATERIAL

1. RESIN:

Resin should be stored in wet condition only. Put polyethylene bag in drum and fill the resin and water and close the lid.

2. If any exchanger is made idle for short time and resin is inside, hold some water inside the vessel by a closing outlet and fast rinse valve.

3. If PPS and FAC are idle, keep them wet to avoid hard mass on upper layer bed by closing of outlet valve or stop them after backwashing of PPS and FAC.

4. If neutralising pit is idle for long time, keep HDPE lines cleaned to avoid blocking of aeration holes, electrical rotor is removed from its position electrical connection for space heater should be provided.

5. If electrical motor is removed from its position electrical connection for space heater should be provided.

6. All rotating equipments lubricating material (oil/grease) should be replaced with good one if they will be not in use for a long time.

7. If plant is idle for long time, keep measuring tanks empty.

8. If blower (MB Blower) is idle for long time, clean and grease the tubes to avoid further rusting.

CHAPTER-15

SAFETY PRECAUTIONS

1. Unauthorised entry should be stopped in plant.

2. Do not move in plant without wearing safety helmet and safety shoes.

3. Always wear protective face shield and clothing while working on or near chemicals injection pumps.

4. Wear face shield/rubber gloves while handling any chemical.

5. Do not wear loose cloths.

6. Maintain good housekeeping.

7. Check pumps coupling guards are properly fixed.

8. Use hand gloves while operating valves.

PART 2

D.M.PLANT 2 & 3.(ION EXCHANGE SUPPLIED PLANT)

CPP - UTILITY

RELIANCE INDUSTRIES LIMITED.

HAZIRA.

GENERAL DESCRIPTION OP THE EQUIPMENTS :

.1 ACTIVATED CARBON FILTER (Tag No.FA-1158 A/B/C) :

This is a mild steel pressure vessel internally painted. It is externally fitted with MS pipe work, diaphragm and butterfly valves, pressure gauges at inlet and outlet. A differential pressure indicating switch provided across the carbon bed. Activated carbon filter is provided to remove free residual chlorine and non-polar organic matters.Internally the ACF units fitted with header lateral type bottom collecting system which consists of a mild steel epoxy painted (externally and internally) header to which PVC laterals are screwed. Small holes are drilled throughout PVC laterals towards bottom for collecting filtered water.For inlet water distribution, inverted bellmouth type distributor is provided. This distributor is mild steel construction, painted by epoxy paint externally and internally. This distributor acts as an effluent collector during backwash operation of regeneration. Different layers of underbed materials like pebbles, silex etc. are charged as supporting media. Dechlorination grade activated carbon is charged on top of underbed media. The ACF needs to be backwashes when pressure drop across the bed exceeds 0.7 bar

Step-1 : Backwash :

During this operation water is passed through filter bed from bottom to top. Entrapped suspended particles, dirt etc. are remove while passing water from bottom to top and then to drain. Backwash to be continued till the effluent coming out is clear. Flow maintained during this operation is 91.6 m3/hr.

Step-2 : Rinse :

Daring this step water is passed from top to bottom and drained. this oparatlon to be continued till effluent is clear.

2. STRONG ACID CATION UNIT : Tag No.FA-1159 - A/B/C

This is a mild steel vessel lined internally with rubber. It is externally fitted with rubber lined pipe work, diaphragm aalve, pressure gauges at inlet and sampling valves at inlet and outlet.A calibrated orifice board in the drain sump is also provided for controlling various regeneration flows. The water is distributed from the top. The middle collector is of header lateral type. The header is of mild steel rubber lined and rubber covered to which PVC laterals are fitted. Strainers which prevent resin from escaping are screwed to the bottom of the laterals. Bottom collecting system is of strainer on plate type. Double decker (button type) strainers have been used for bottom collecting system whereas mark 871 (disc type) strainers have been used for middle collecting system. The vessel is charged with strongly cationic resin (Indian 225). When the desirea output is obtained or when the quality of outlet water from SAC with respect to sodium ions is deteriorated. Then the unit should be regenerated.

QUALITY OF CATION TREATED WATER :

pH : 2.0 - 3.0Total Hardness : NilSodium + Pottasium : Lesa than 2 mg/l

A resin trap is provided at unit outlet to trap Ion exchange resins in unlikely event of bottom collecting system failure.

The regeneration is carried out as follows :

a) Sub-surface wash / backwash :

Backwash operation is carried out to loosen the bed and to remove the suspended impurities from the resin. Backwash operation is carried out once after 7 regenerations or when pressure drop across the unit increases beyond acceptable limits of 1 bar whichever occurs earlier. When backwash is given to SAC, 120 kg/m3 regeneration level is to be employed to ensure bottom layer of resin is highly regenerated. Sub-surface wash is carried out for each regeneration.backwash is given at 102 m3/hr for 10 minutes and subsurface wash is given at 102 m3/hr for 5 minutes.

b) Acid Pre-injectionbuffer down flow :

The operation is carried out to set the power water flow rate to the required flow before injecting acid.

c) Acid Injectionbuffer down flow :

HCl of 5% concentration is injected at 95.43 m3/hr into SAC, by means of an acid injection ejector. The acid is injected through SAC bottom collecting system and effluent is taken out through middle collector to drain sump. During injection to prevent fluidisatior of SAC bed, a down flow of water is maintained at 95. 43 m3/hr. This injection is carried out for 20 minutes.

d) Slow Rinse :

The excess acid in SAC unit after acid injection is displaced with degassed water at a flow rate of 95.43 m3/hr. Down flow of water is maintained during this stage also. Duration of this step would be 37 mins.

e) Final Rinse :

This operation is carried out to remove excess acid and liberated cations from SAC unit. The operation is carried out for 5 minutes at a flow rate of 200 m3/hr.

3. WEAK BASE ANION (WBA) : Tag No. FA-1161 - A/8/C.

This is a mild steel vessel lined internally with rubber. It is externally fitted with rubber lined pipe work, diaphragm valves, pressure gauge at the inlet and outlet , conductivity indicator at the outlet and sampling valves both at inlet and outlet.A calibrated orifice board in the drain sump is also provided for controlling various regeneration flows. The water is distributed from the top and each arm is provided with PVC bell mouth which will also act as backwash collector. Alkali distributor is also of three arms (inverted bends with PVC spacers and blank flange) made out of mild steel and lined internally as well as externally with rubbers. Bottom collecting system is of strainer on plate type. Mark 79 strainers are directly fitted on the bottom plate. The vessel is charged with weak base anion resin (Indian 850). The regeneration of the unit is done in thoroughfare with SBA. A resin trap is provided to trap ion exchange resins in the unlikely event of the bottom collecting system failure. Flow indicate- is provided at the inlet.

4. STRONG BASE ANION UNIT : Tag No.FA-1162 - /B/C.

It is a mild steel vessel lined internally with rubber. It is externally fitted with rubber lined pipe work, diaphragm valves, pressure gauge at the inlet and sampling valves at inlet and outlet A calibrated orifice board in the drain sump is also provided for controlling various regeneration flows.Backwash outlet and service inlet provided internally, essentially consists of rubber lined rubber covered bell mouth. .The bottom collecting system is of strainer on plate type. Mark 79 strainers are used for bottom collecting system. Thus bottom collecting system is acting as distributor for caustic solution. Middle collecting system is provided with header lateral assembly. The header is mild steel rubber lined rubber coated to which PVC laterals with Mark 871 strainers are fitted. This middle collecting system is acting as a collecting system for regenerant, during regeneration. The vessel is charged with strongly basic anion resin FFIP when the desired output from the pair of units (SBA & WBA) is obtained or when the quality of treated water from SBA outlet with respect to silica is deteriorated then the unit should be regenerated in thoroughfare with WBA using NaOH as regenerant. A resin trap is provided to trap ion exchange resins in the unlikely event of failure of bottom collecting system. A conductivity indicator is provided at the outlet of the unit to give alarm in case the conductivity increased beyond the acceptable limit.Flow Indicator is provided at the inlet. Regeneration of SBA and WBA is carried out simultaneously.The regeneration is carried out in 6 stages.

SBA Treated Water Quality :

pH: : 7.5 to 9.5Conductivity: : less than 10 us/cmSiO2 : less than 0.2 Pam

a) Backwash/Sub-surface wash :

The operation ia carried out to loosen the resin bed and to remove the suspended impurities from the resin. Backwash operation is carried out at 24.12 m3/hr for 5 minutes in WBA unit. SBA backwash shall be done only once in 7 regenerations at 15.93 m3/hr flow for 10 minutes. The sub-surface wash is carried out for each regeneration of SBA unit at 15.93 m3/hr for 5 minutes.

b) Caustic Pre-injection :

This operation is carried out to set the power water flow rate before injecting alkali. The pre-injection flow is 77. 5 m3/hr in WBA and 35.23 m3/hr in SBA unit for 2 minutes. Down flow is given at 42.28 m3/hr flow to prevent fluidisation of resin in SBA.

c) Caustic Injection :

Specified quantity of caustic is injected by means of ventury ejector to regenerate the exhausted resins. 3. 33% caustic solution at flow of 42.28 m3/hr is injected in SBA unit for 30 minutes.

d) Slow Rinse :

This operation is carried out to ensure optimum utilization of alkali injected. The unused alkali in SBA unit after caustic injection, is transferred to WBA with the help of power water . Caustic transfer from SBA unit is carried out at 35.23 m3/hr for 23 minutes into WBA unit. Down flow at 42.28 m3/hr is maintained during this stage also.

e) Rinse :

This operation is carried out to remove excess caustic and liberated anions from both SBA and WBA units. The operation is carried out separately. WBA unit is rinsed at 200 m3/hr for 18 minutes and SBA at 200 m3/hr for 8 min.

1.5 MIXED BED UNIT : Tag No.FA-1163 - A/B/C.

This is a mild steel vessel internally lined with rubber. It is externally fitted with rubber lined pipe work, diaphragm and butterfly valves, pressure gauaes and sampling valves at inlet and outlet. Also a conductivity inidcator , pH indicator and silica analyser are provided at each unit outlet. At common outlet header of mixed bed a flow indicator integrator is provided.A calibrated orifice board in the drain sump is also provided for monitoring various regeneration flows.The middle collector and bottom collecting system are of header lateral type. The header is of mild steel, rubber lined and rubber covered to which PVC laterals are fitted. Strainers which prevent escape of resin are screwed to the bottom of the laterals. Mark ‘V’ strainers have been used.Inlet water distributor is of three arms with strainers to avoid escape of resins during back washing. Bottom dished end portion of the vessel is fitted with concrete which acts as dead weight and prevents the division plate from buckling due to weight of water and resin.The vessel.is charged with a mixture of both strongly acidic cation (Indian 525) and strongly basic anion (Indian FFIP). When desired output from the unit is obtained or when the quality of outlet water with respect to either silica or conductivity is deteriorated, then the unit should be regenerated. Cation resin is regenerated with HCl and anion resin with NaOH.A resin trap is provided to trap ion exchange resins in the unlikely event of failure of bottom collectlnc system.

Regeneration of MB is carried out as follows :

a) Backwash :

This operation is carried out to separate the resins prior to injection of chemicals. Due to difference in densitities, the resins get separated in two layers during the back washing, with cation forming lower layer and anion forming upper layer. Backwash is carried out for 10 min. at a flow rate 40.68 m3/hr.

b) Sub-surface Wash :

This operation is basically carried out to clean the middle collector strainers to ensure proaer distribution / collection during injection of chemicals. Duration of this step is 5 min and flow rate maintained shall be 40.68 m3/hr.

c) Acid Pre-injectiondown Flow :

Water flow for acid injection is established through acid ejector at a flow rate of 8.14 m3/hr. A down flow is maintained at a flow rate of 6.78 m3/hr to prevent diffusion of acid into

anion resin region Effluent is collected by the bottom collecting system and drained to the drained valve Duration of this stea is 2 mins.

d) Acid Injection/Downflow :

Once the pre-injection flows are established , 5% HCl is fed to the unit through middle collecting assembly. Ejector section valve of AMT-2 is adjusted to have the required concentration . Concentration of aad ejector delivery is monitored. Duration of this step is 10 mins

e) Acid Rinse/Downflow :

After completion of the acid injection water is continued to pass at a flow rate of 18 08 m3fhr to displace / fully utilize the regenerant Downflow is continued to maintain during this step. Duration of this step is 15 minutes.

f) Alkali pre-injection/upflow :

Water flow for alkali injection is established through alkali ejector at a flow rate of 25.47 m3/hr. An up flow is maintained at a flow rate of 20.34 m3/hr to prevent diffusion of alkali into cation resin region. Eafluent is collected by the middle collector system. Duration of this step is 2 minutes.

g) Alkali anjectioo/Upflow :

Once the pre-injection flows are established, 3.33% Nash is fed to tae unit through alkali inlet located at the top of resin bed. Ejector section valve of CDT-2 is adjusted to have the required concentration. Concentration of alkali at ejector delivery is monitored. Duration of this step is 15 minutes.

h) Acid Rinse/Upflow :

After completion of alkali injection water is continued to pass at a flaw rate of 50.43 m3/hr to displace / fully utilize the regenerant. Up flow is continued to maintain during this step. Duration of this step is 20 minutes.

i) Drain Down :

Water from the vessel is drained upto about 300 mm above the top surface of resin bed (aparox. half of top inspection winaow). Duration of this step would be approx. 10 minutes.

j) Air Mix :

Air is passed from the bottom of the unit to mix both the resins thoroughly. The mixing and movement of the resin bed can observed through inspection windows. Duration of this step is 10 minutes.

k) Forced Settle :

Resin bed is forced to settle with down flow of inlet water. Faster settling will prevent re-separation of resin bed. Duration of this step is 2 minutes.

l) Refill :

The unit is filled with feed water before rinsing the unit. Duration of this step is 4 minutes.

m) Final Rinse :

Service water is taken from inlet and drained from the rinse outlet for 10 minutes to remove traces of regenerantes and liberated ion from the bed.

n) Rinse Recycle :

At the end of final rinse, rinse water is not allowed to drain and taken back to Degasser Water Tank. This operation is continued till desire quality of treated water is obtained.

2.0 TECHNICAL DATA :

1. DESIGN WATRR ANALYSIS (FOR DM3)

PARAMETERS Raw Water D.M. Water

pH 7 to 9 7 +/- 0.2Conductivity Us/cm at Amb.Temp. - 0.2Turbidity as NTU 2 NilTDS (ppm) 386 0.05Dissolved Oxygen (ppm) 7.6 NegligibleTotal Hardness ppm as CaC03 160 NilM. Alkalinity - do -- 200 NilSulphates - do -- 42 NilChlorides - do -- 106 NilPhosphate - do -- Nil NilCalcium - do -- 60 NilMagnesium - do -- 100 NilSodium - do -- 187 NilIron as Fe 0.5 0.005Silica PPM as SiO2 25.2 < 0.02Free Chlorine PPM < 0.8 NilOrganic Matter PPM < 0.1 NegligibleColloidal Silica as SiO2 0.2 -- Do --

2.2 ACTIVATBD CARBON FILTER (ACF) : Tag No.FA-1158 A/B/C :

Number Off : ThreeDiameter : 3600 mmHeight on straight : 2300 mmMaterial of construction : M.S. Epoxy painted.Type of collecting system : Strainer on plate.Nett Treatment Flowunit : 200 m3/Hr.Time of service cycle : 24 Hrs.Time of Regeneration Cycle : 15 min.Capacity between regeneration : 4000 m3.

Regeneration Flows :Backwash : 91.6 m3/hr Time : 5 - 10 min.

Rinse :122 m3/hr Time : 5 min.

2.3 STRONG ACID CATION EXCHANGER (SAC) : Tag No. FA-1159 A/B/C

Number off : ThreeDiameter : 3800 mmHeight on straight : 4900 mmMaterial of construction : MSR/LCapacity between regenerationunit : 4000 m3Period between regenerationunit : 20 hoursTime for regeneration / unit : 74 minsResin Type : Indion 225 HResin quantity / unit : 30.61 m3Regenerant quantity / unit : 1590.20kgs Hal as 100%Type of bottom collecting : Strainer on PlateType of valve operation : Semi-automatic (PLC Based)

Regeneration Flows :

Operation Flow (m3/hr) Time (Min.)

Backwash (optional) 102.06 5Middle collecter wash 102.06 5Acid pre-injection 47.71 2Down flow 95.43 2Acid Injection at 5% 95.43 20Down flow 95.43 20Acid Rinse 95.43 37Down flow 95.43 37Final Rinse 200 5

2.4 DEGASSER TOWER (DOT) : (Tag No.GB-1153 A/B/C) :

Number Off : ThreeDiameter : 2000 mmHeight on straight : 3750 mmMaterial of construction : MSR/LPacked Bed : Pall RingsPall Rings Quantity per unit : 9 m3

2.5 DEGASSED WATER TANK (DGWT) : (Tag No.PB-1161)Number off : OneDiameter : 12000 anHeight on Straight : 4400Material of construction : MSR/L

2.6 WEAR BASE ANION EXCHANGBR (WBA) : (Tag No.PA-1161 - A/B/C)

Number off : ThreeDiameter : 3200 mmHeight on straight : 3300 mmMaterial of construction : MSR/LCapacity between regenerationunit : 4000 m3

Period between regenerationunit : 20 hoursTime for regenerationunit : 73 mins (Thoroughfare)Resin Type : Indion 850Resin quantityunit : 13.15 m3Regenerant quantity/unia : Throughfare with SBAType of bottom collecting : Strainer on PlateType of valve operation : Semi-automatic (PLC Based)

Regeneration Flows :

Operation Flow (we/hr) Time (Min.)

Backwash 24.12 5Caustic pre-injection 77.84 2Caustic Injection (1.2%) 84.56 30Caustic Rinse 77.55 23Rinse 200 8

2.7 STRONG BASE ANION EXCHANGER (SBA) : (Tag No FA-1162 A/B/C)

Number off : ThreeDiameter : 2600 mmHeight on straight : 2300 mmMaterial of construction : MSR/LCapacity between regenerationunit : 4000 m3Period between regenerationunit : 20 hoursTime for regenerationunit : 73 minutesResin Type : FFIFResin quantityunit : 6.11 m3Regenerant quantityunit : 704.7 as loOa NashType of bottom collecting : Strainer on plateType of valve operation : Semi-automatic (PLC Based)

Regeneration Flows:

Operation Flow (m3/hr) Time (Min.)

Backwash aoptaonal) 15.93 5Sub-surface wash 15.93 5Caustic pre-inaection 35.23 2Down flow 42.28 2Caustic Injection (3.3%) 42.28 30Down flow 42.28 30Caustic Rinse 35.23 23Down flow 42.28 23Final Rinse 200.0 8

2.8 MIXED BED EXCHANGER (MB) : (Tag No.FA-1163 A/B/C)Numher off : ThreeDiameter : 2400 mmHeight on straight : 2900 mm

Material of construction : MSR/LNett Treatment Flow rate / unit : 200 m3/hrPeriod between regeneration / unit : 280 hoursCapacity between regeneration / unit : 56000 m3Resin Type / quantity : 2.26 m3 of Indion 225H

4.203 m3 of Indion FFIPChemicals per Regeneration : 135.6 kg as 100% HCl

252.2 kg as 100% NaOHTime for regeneration : 106 min.Type of valve operation : Semi Automatic

Regeneration Flows :Operation Flow (m3/hr) Time (Min.)

Backwash 40.68 5Middle collector flush 40.68 5Acid pre-injection 8.14 2Downflow 6.78 2Acid Injection 5% 16.27 10Downflow 6.78 10Acid Rinse 18.08 15Downflow 6.78 15Alkali Prelnjection 25.47 2Upflow 20.34 2Alkali injection 30.56 15Upflow 20.34 15Alkali Rinse 50.43 20Upflow 20.34 20Draindown/Air Mix - -Forced settle 200 3Refill 200 3Final Rinse (recycle) 200 3

2.9 DEGASSBR AIR BLOWER (DGB) : (Tag No.GB-1153 A/B/C/S)

Number off : FourCapacity : 94 m3/min.Discharge Head : 50 mmwgMaterial : MSType : Datta Air SystemMake : Ion ExchangeModel : 411A/25Medium : AirRPM : By cliantMotor : By Client

2.10 DEGASSED WATER PUMP : (GA-1160 A/B/C/S)

Number off : 4Capacity : 215 m3/Hr.Discharge Head : 70 mmwcMaterial : SS 316

Type : Horizontal - Centrifugal.Make : SAM Turbo Industry ltd.Model : CPH 100/260.Medium : Degassed waterRPM : 2900 RPMMotor : By cliant.

2.11 MB AIR BLOWER : (GB-1154 - A/S)

Number Off : TwoCapacity : 9 m3/Min. at o.4 kg/cm2 (g)Material of Construction : Cast IronType : Possitive Displacement Twin LobeMotor Speed : 1460 RPMBlower Speed : 1060 RPMMake : Everest.Model No. : 610Medium : AirMotor : By cliants.

2.12 ACID MEASURING TANK FOR SAC : (FB-1155) A/B)

Number Off : TwoDiameter : 2800 mmDepth : 3000 amMaterial of construction : PP/FRPConcentration o' acid in tank 10% Hcl

2.13 ACID MEASURING TANK FOR MB (TAG No.FB-1157A,8

Nuber Of f : TwoDiameter : 1200 mmDepth : 1500 mmMaterial of construction : PP/FRP

Concentration of acid in tank : 10% HCl Acid

2.14 CAUSTIC DILUTION TANK FOR SBA (Tag No.FB-1154 A,B)

Number of f : OneDiameter : 1800 mmDepth : 1600 mmMaterial of Constructtion : MSR/LFluid Stored : Caustic Soda 20 %.

2.16 CAUSTIC DILUTION TANK FOR MB (Tag No.FB-1158A,B)

Number off : TwoDiameter : 1200 mmDepth : 1400 mmMaterial of Constructtion : MSR/L

Capacity / Fluid Stored : Caustic Soda 20a

2.17 Neutralizing pit

Number Off : TwoSize : 14500x9000x4800 DeepMaterial of Construction : RCC Acidalkali Proof Lined

2.18 WASTE WATER DISPOSAL PUMP (Tag No.Ga-1159 A/B)

Number Off : 2 Nos.Capacity : 150 m3/hrMaterial of construction : CI R/LType : Horizontal CentrifugalModel No. : CPP 150 *100- 315RALMake : SU Motors Pvt. Ltd.MOTOR (By Clients) :

2.19 ACID MEASURING TANK FOR N-PIT (AMT3) FB1159

Numbers off :OneHeight :1400 mmMoc :PP/FRP

2.20 CAUSTIC MEASURING TANK FOR N-PIT (CDT3) FB1160Numbers of f : OneDiameter : 1400 mm Height : 1400 mmMoc : MSRL

LIST OF INSTRUMENTS WITH TECHNICAL DATA

2.21 FLOW INDICATING TRANSMITTER (FIT)

Number offered : 2 Nos.Make- model Rosemount : 1151DP4J22BIMIType :Variable Capacitance ( 2 Wire )Power Supply : 24Y DC,600 OHMSOutput Signal : 4-20 MA DC (Linear)Accuracy : -/+ 0.25% of spanRange : 0 - 2500 mm WG

Material of construction : SS 316

Tag No Location Qty.

11-FT-580 Filter Water Inlet Header 1 No11-FT-522 MB Outlet Header 1 No

2.22 pH INDCATING TRANSMITTER :

pH MONITOR ;QuantityMake : Rousement

Range :0 to 14 pHMounting :FieldInput Power supply :24 V DCOutput :4 - 20 mA LinerAccuracy :+/- 0.02 pHTemp. Compensation :AutomaticModel ;1181PH-01-07-11Tag ao. Location11 PHIT-580 A/B/C SBA7a8/9 Outlet11 PHIT-581 A/B/C MB7/8/9 Outlet11 PHIT-582 Waste Disposal Pump Disch

2.23 pH SENSOR ASSBMBLY :

Quantity :7 No Type :Flow through

Model : 399PH- 0&-11 (Tag no -11PHE 580A/B/C)

Make :Rosemount

2.24 PRESSURE INDICATOR (PI)

Type : Bourdon tubeElement Material : SS 316Accuracy :+/- 1 % of full scale range (for PG-

29,30,31, 32-1.5% of FSR)Make : H. GuruConnection : 1/2” NPT(M) BottoomDial Size : 150 mmOver range Protection : 125%

Tag No Location Range Qy.

11 PI-1580 A/B/C ACF7,8,9inlet 311 PI-581 A/B/C ACF 7,8,9 outlet 311 PI-582 A/B/C SAC 7,8,9 inlet 0-10 Kg/cm2 311 PI-583 A/B/C SAC 7,8,9 outlet 0-10 Kg/cm2 311 PI-584 A/B/C SAC 7,8,9utlet 311PI-587 A/B/C WBA 7,8,9 inlet 0-10 Kg/cm2 311 PI-588 A/B/C WBA7,8,9outlet 0-10 kg/cm2 311PI-589A/B/C WBA7,8,9outlet 0-10Kg/cm2 311 PI590A/B/C/ SBA7,8,9 inlet 0-10Kg/cm2 311 PI-591 A/B/C SBA7,8,9 outlet 0-10 Kg/cm2 311 PI-592 A/B/C SBA7,8,9 outlet 0-l0 Kg/cm2 311 PI-593 A/B/C MB 7,8,9 inlet 0-10 Kg/cm2 311 PI-594 A/B/C MB 7,8,9 outlet 0-10 Kg/cm2 311 PI -595 A/B/C MB 7,8,9 outlet 0-10 Kg/cm2 311 PI- 586 A/B/C/S Deggassed water 0-10 Kg/cm2 4

pump discharge11PI-596 A/B Waste water 0-4 Kg/cm2 2

pump discharge11 PI-597 A/S MB Blower A,S 0-0.6Kg/cm2 211-PI-598A/B Regeneration 0-4 Kg/cm2 2

water pump discharge11-PI-599 Instrument air 0-10 Kg/cm2 1

header

Type : Discharge typeQuantity : 4 nosMake : WITRIVRange : 0-250mmwcTag no Location11 PI 85 ABCS Degasser Blower

2.24 Differential Pressure gauge (DPI):

Type : Differential pressure gaugeQty : 2 Nos.Make : SwitzerRange : O-3000 mmwcModel : 106-UE-06-FC

Tag no Location

13DP 1750Across AVGF sand bed13DP 1751 Across AVGF sand bed

2.25 SILICA ANALYSER (SIA-1,2) :

Quantity : 2 Nos.Type : On line calorimetricMake/model Hach / series : 5000,60000Power Supply : 110V AC,50HZOutput : 4 -20 MA DCEnclosure : IP 65/NEMA 4XRange : 0-5000 PPBas SIO2Display : Digital;Accuracy/resolution : 2 PPB /1 PPB RespectivelyMounting : Bench Top

Tag No. Location11 SIA-581 SBA Outlet - common header11 SIA-580 MB Outlet - common header

2.26 SODIUM ANALYSER : Qty Make Model

Qty : 1 no.Make : PolymetronModel : 9073 with'k’ kit

Tag no. Location11 Na A580 SAC Outlet

2 .27 CONDUCTIVITY INDICATING TRANSMITTER :

Numbers Off : 9 Nos.Make : RosemountModel : 150-03-19-54Power Supply : 24V DCType : 2 aire indicating typeSensitivity : < 0.07% spanStability : < 0.05%Mounting : FieldOutput from monitor: 4 -20 MA DC

Tag No. Location11 CIT-580 A/B/C WBA 7, 8, 9 outlet11 CIT-581 A/B/C SBA 7, 8, 9 outlet11 CIT-582 A/B/C MB 7, 8 , 9 outlet

2. 28 a LEVEL INDICATOR : Type : Float & Cord Type Make : Revathi Electronics Material of Construction : Float SS 316Wire Rope : Nylon Location : Degassed Water TankTag no. : 11 LIFB 580

2. 28 Magenetically coupled level indicator:

b) Make : Revathi ElectronicsType : Roller magnet typeScale : Linear marking

Location c-c dist Qty Moc Tag no

AMT1-A,B 2750 2 Polypropylene 11 LI 580 A,BAMT2-A,B 1300 2 Polypropylene 11 LI 581 A,BAMT3 1200 1 Polypropylene 11 LI 584CDT1-A,B 1400 2 SS 304 11 LI 582 A,BCDT2-A,B 1200 2 SS 304 11 LI 583 A,BCD3 1200 1 SS 304 11 LI 585

2 .29 LEVEL SWITCH :

a) Type : Externally side mounted magnetic type float operatedMake : Revathi ElectronicsModelContacts : 5 Amps - 110V ACMaterial of Construction : SS 316Range : 0 - 4400 mmTag No. Location11 LS-580 Degassed Water Tank (HL)11 LS-581 Degasaed Water Tank (LL)

2 .29 LEVEL SWITCH : b) Quantity : : 8 Nos. Type : Top Mbunted Magnetic float operated

Make : Revathi ElectronicsMaterial of Construction : SS 316 for CTD, PP for AMTContacts : 5 Amps, 110 V ACTag No. Location No. of floats11 LS-584A/B CTD-1 A/B 211 LS-585A/B CTD-2 A/B 211 LS-582A/B AMT-1 211 LS-583 A/B AMT-2 2

2.30 TOP MOUNTED LEVEL SWITCH INDICATOR :

Qty : 2 noMake : RevathiRange : 5300 am stem len

Tag no Location11 LIS 586 A NPA11 LIS 586 B NPB

2. 31 DIFFERENTIA PRESSURE INDICATING SWITCH : Qty : 3 nos Make : Switzer

Range : 0-0.75 kg/cm2 Model : LL-C-A-1-HA2-2

Tag no Locationll DPIS 580 Across ACF

2.32 RATE OF FLOW INDICATOR :Make : TracRange : 0-250 m3/hrTag no Location Model11 FI 580 A,B,C ACF 7,8,9 Inlet TG-250-111-CCS11 FI 581A,B,C SAC 7,8,9 Inlet11 FI 582 A,B,C WBA 7,8,9 Inlet TG 250BP-111TG-250BP 111XXSN11 FI 583 A,B,C SBA 7,8,9 Inlet ,,11 FI 584 A,-B,C MB 7,8,9 Inlet ,,

b) Range:0-100 m3/hr AMT 1A,B Ejector ”11 FI 585 A,B power water inlet

(c) Range:0-25m3/hr CDT 1A,B Ejector ,,11 FI 587 A,B power water inlet

(d) Range:0-50 m3/hr CDT 1A,B Ejector ,, 11 FI 587 A,B power water inlet(e) Range : 0-60 m3/hr CDT2A,B Ejector ,,

11 FI 588 A,B power water inlet(f) Range: 0-180 m3/hr ` Inlet to AVGF PA 1363 16-250BP-111CCSN

13 FI 750(g) Range: 0-200 m3/hr Inlet to AVGF PA 1365 16-250BP-111CCSNInlet to AVGF PA 1365 16-250BP-111CCSN

13 FI 751

2.32 PRESSURE SWITCHES :

Quantity : 5 nos. Type : Bellow Sensing Type

Make : SwitzerMaterial of construction : SS 316 bellows, other parts SS 316

Tag No. Model Location

11 PS-580 GM201-02 A7K-22 Filter Water Inlet Header11PS-581 GM201-02C3R-22 DM water Inlet Header11 PS-582 GM201-02C3K-22 DM water Outlet Header11 PS-583 GM201-02A7K-22 Instrument air header 11 PS-584 GM201-02A7K-22 Degassed water

pump discharge header

3. CONTROL PHILOSOPHY-DM WATER PLANT IIIData Sheet No.A4-A70096-12-25

Following are the salient features of control philosophy for operation of Demineralisation Plant III

1. BASIC CONTROLS AND SYSTEM

The instrumentation and control system are provided formonitoring and controlling various process variables related to each equipment and sub-system. .

Operation of the Demineralisation Plant is done semiautomatically through a Programmable Logic Controller (PL), which is used for the purpose of regeneration and service operation of various equipments like SAC, WBA/SBA, MB, Chemical Measuring Tanks and inaection systems. Signals for various alarm condition like high totallsed flow, high conductivity, high Sodium, high Silica, high or low pH,

high or low levels of various process tanks and low pressure will go to the PLC. PLC shall accept all digital and analog signals from the field. A few signals shall be repeated for remote monitoring on DCS as described later in this write-up.

The Demineralisation Plant comprises of three streams. Each stream consists of Activated Carbon Filter, Strong Acid Cation exchanger, Degasser unit, Week Base Anion exchanger, Strong Base Anion exchanger and Mixed Bed. Acid Measuring Tanks, Alkali Measurina aanks, Regenerant Iniection Systems and Effluent Disposal SaJstem is common for all streams.

At a time, only one stream can be regenerated. At least one of the other two streams shall be in operation during regeneration of one stream. Any one of SAC (A/B/C) and any one of WBA/SBA (A/B/C) can be regenerated one by one or simultaneously. Normally, WBA/SBA of a particular chain is operated as a pair. However, provision is made in PLC software sothat any combination of

SAC,WBA, SBA can be selected for regeneration. Selection of required combination is done through keyboard. For regeneration of Mixed Bed (A/B/C) , any one of WBA/SBA

unit should be in service. Regeneration is carried out for individual units as selected.

The starting of the regeneration operation is initiated through PC key board for individual units. Operator intervention is provided at appropriate stages to hold, reset, advance , skip or dwell in stages.Refer to Valve Sequence Chart No.A3-A70096-08-01/0a/03 for details about sequence of valve operations and durations.

2. CONTROL LOGIC

The Control Logic is described for each unit or sub-system starting with Activated Carbon Filter. The procedure follows the process stream flow path ; it is not necessarily reflects of the sequence of control operations.

a) ACTIVATED CARBON FILTER

Service and backwash operations of this unit is totally manual. This unit will be backwashed once in 24 hours or pressure drop across the carbon bed exceeds beyond 0.5 kg/cm2.

Computer display:- Common Inlet Header flow rate m3/hr (11-FIT-580).

Alarm- High pressure drop across ACF (A/B/C) - ll-DIPS-580.- Low Inlet Header pressure - 11-PS-580

(b) STRONG ACID CATION EXCHANGER (SAC-A/B/C)

SAC A or B or C units are taken out of service automatically when any one of the conditions occur :1) 11-PS-580 is in healthy condition(no low pressure alarm)2) 11-LS 582 A/B give high level alarm in AMT lA/B3) The Unit completes 20 hours in service or 11-NaA-580 gives high Sodium alarm

Computer display :- Valve openclose status - Sodium Analyser reading - ll-NaA-580 aA/B/C)

Alarm:- High Sodium at SAC outlet-- (11-NaA-580 (A/BtC))- Regeneration completed

(C) DEGASSER SYSTEM (DG-A/B/C)

Required Degasser to be selected through keyboard. Selected Degasser will automatically come in service when service operation of SAC starts. Corresponding Blower will also be started automatically. In case standby blower is to be operated the same is to be taken in service through remote keyboard or through local push button . DG Pump trips at low level of Degassed Water Tank.V106 will open at high pressure in degasser pump discharge ll-PS-584.

Computer display:

- Open/close status of inlet valve (V-lll)- On-off status of Degasser Pumps is GA 1160 A/B/C/S- On-off status of Degasser Blowers is GB 1153 A/B/C/S- High/low level of Degassed tank FB 1161- On-off status of recirculation valve V106

Alarm- High and low level of Degassed Water Tank

d) Weak Base Anion Exchanger (WBA - A/B/C)

WBA A or B or C Units are taken out of service automatically when any one of the following conditions occurs :

1)11-CIT-580A or ll-CIT-580B or 11-CIT-580C gives high conductivity alarm for WBA-A or WBA-B or WBA-C respectively or SBA- A or SBA-B or SBA-C is taken out of service, OR2) WBA-A or WBA-B or WBA-C completes 20 hours in service (Check timer shall be based on degassed water pump running time.)

The unit will be isolated automatically when whichever of the above conditions occurs first. Units WBA-SBA are taken into and out of service together.

Following permisive for regeneration shall be provided.(for SBA)

-Following switches in healthy condition .11 -LS-584A OR 11-LS-584 B(High level).-pumps P1 A/B/C/S on status.-pumps P2-a/s on status.

Computer display :

- Open / close status of valves- Conductivity at WBA outlet ll-CIT-580 A/B/C

Alarm :

- High conductivity at WBA outlet ll-CIT-580 A/B/C- Regeneration completed

e) Strong Base Anion Exchanger (SBA-A/B/C)

SBA A or B or C Units are taken out of service automatically when any one of the following conditions occurs :

1) 11-CIT-581A or ll-CIT-581B or 11-CIT-581C gives high conductivity alarm for SBA-A or SBA-B or SBA C respectively or

2) SBA-A or SBA-B or SBA-C completes 20 hours in service (check: timer shall be based on degassed water pump running time)3) 11-SiA-580 A/B/C gives high silica alarm at SBA4) 11PHE-580 A/B/C gives high /low PH alarm.

The unit will be isolated automatically when whichever of the above conditions occurs first. Units WBA-SBA are taken into and out of service together.

- Openclose status of valves- Conductivity at SBA outlet 11-CIT-581 A/B/CSilica at SBA outlet 11-SiA-580 A/B/CpH at SBA outlet 11-PHa-580 A/B/C

Alanm :

- High conductivity at SBA outlet 11-CIT-581 A/B/C- High silica at SBA outlet 11-SiA-580 A/B/C- High or low pH at SBA outlet 11-PHE-580 A/B/C

- Regeneration completed

f) Mix Bed - MB A/BIC

MB-A or MB-B or MB-C Units are taken out of service automatically when any one of the following conditions occurs :

1) 11-CIT-582A or 11-CIT-582B or 11-CIT-582C gives high conductivity alarm for MB-A or MB-B or MB-C respectively or2) 11-SiA-581 gives high silica alarm for MB-A or MBB or MB-C respectively or3) MB-A or MB-B or MB-C completes 280 hours in service 4)11PHE-581A/B/C gives high /low PH alarm.

The unit will be isolated automaticall when whichever of the above conditions occurs first.Foaloaing regeneration permissive shall be provided.LS 583

A7B-high,LS585A/Bhigh,PS582- healthy.Regeneration water pu p GA 1161 A/S trips at low pressure at MB outlet common header.

Computer display :

- Openclose status of valve- Conductivity at MB outlet ll-CIT-582 A/B/C- Silica at MB outlet ll-SiA-581 A/B/C- pH at MB outlet ll-PHF-581 A/B/C- Flow rate at MB outlet common header 11-FI-581- Cumulative of flow at MB outlet header ll-FIQ-581

Alarm :

- High conductivity at MB outlet 11-CIT-582 A/B/C- High silica at MB outlet 11-SiA-581 A/B/C- High and low pH at MB outlet ll-PHE-581 A/B/C- Low pressure at MB outlet common header 11-PS-581

g) Acid Measuana Tank AMT - 1/A & B and AMT - 2A & B

Acid Measuring Tanks are provided with pneumatically operated diaphragm valves. These valvea are operated through PLC system to fill required quantity of Acid and dilution water prior to start of regeneration. Bulk Acid for injection is available in 15% concentration. Level switches 11LS-583 in AMT1,2 has 3 points (that is high, intermediate, and low) level awitcaes. In AMTl and AMT2 level switches 11-LS-582 and 11-LS-583 are mounted respectively. Upon reaching high level in AMT1 / 2, tank Full indication will be displayed in CRT. Regeneration cannot be initiated unless this indication is achieved.

AMT 1 & 2 filling ia an independent operation and it can be carried out at any time except during regeneration of SAC, if that particular tank ia selected for regeneration. Filled AMT needs to be further selected for regeneration. Acid injection stage of SAC or MB will be over only after getting feedback signal of

AMT 1 or 2 low level.

Computer Display :

- Tank fulla indication of AMT 1/2- Open / close status of vale,- Low level indication of AMT 1/2

Alarm:

- High level of AMT lea/B & AMT 2-A/B- Low level of AMT 1-A/B & AMT 2-A/B

h) Alkali Measuring Tank - CDT 1-A/B & CDT 2-A/B

Alkali Measuring Tanks are provided with pneumaticall operated diaphragm valvea. these valves are operated through PLC system to fill required quantity of Alkali

prior to start of regeneration. Bulk Alkali for injection is available in 20 % concentration.

In tanks CDT1 and CDT2, 11-LS-584 and 11-LS-585 (each two point, viz., high and low) are mounted respectively. Upon reaching high level in CDTl / 2, 'Tank Full'

indication will be displayed on CRT. Regeneration cannot be initiated unless tank full indication is achieved.

The filling operation can take place independently. Yet it should happen before the related unit is selected ay operator for 'Regeneration mode'.

CDT 1 & 2 filling is an independent operation and it can be carried out at any time except during regeneration of WBA/SBA if that particular tank is selected for regeneration. Filled CDT needs to be further selected for regeneration. Alkali injection stage of SBA or MB will be over only after getting feedback signal of

CDT 1 or 2 low level.

Computer Display :

- 'Tank fulla indication of CDT 1/2 Low level indication of CDT 1/2Open / close status of valve

Alarm :

- High level of CDT l- A/B & CDT 2-A/B- Low level of CDT l-A/B & CDT 2-A/B

I) Pumps & Blowers :

Pumps and blowers can be operated through keyboard or through local push button. For keyboard operation, local / remote selector switch provided in local push button station shall be turned in 'remote' position. For operation through local push button, the selector switch must be turned in 'local' position. For auto operation through PLC, all drives must be kept in 'remote’ position. Degassed blower will start automatically when respective SAC comes in service. If standby blower is to be

operated, the operator needs to initiate operation through keyboard or static blower through local push button station.

Besides those pumps that are in service, filtered water, degassed water and DM water is required for regeneration of related units, required pumps shall be selected through key board before regeneration. Availability of sufficient pressure of water is checked by 11-PS-580 at filtered water inlet header, 11-PS-581 at MB outlet common header.

At the end of completion of regeneration sequence, ahe unit will automatically go in Off mode. In case conductivity of effluent from SBA or MB is above the preset value, final rinse will be continued .ill it falls below the preset value. Alarm annunciator will indicate regeneration completed status. The operator will take decision to put back the stream in service or to keep it as standby.

Individual unit needs to be selected and initiated through keyboard for regeneration. For service operation also, individual unit has to be selected through keyboard.

j) Neutralisation Pit AD 1152 A/B

Operation of Neutralisation Pit is totally manual . The recirculation and disposal of effluent to be knee by opening required valves manually. Effluent disposal pump

trips at low level of neutraliaatlon pit.

Computer display :

- On-off status of effluent disposal pumps GA 1159 A/B and blower GB 1154 A/S.- pH of recirculatingdisposing effluent Low level of N. Pit.

Alarm :

Low level of N Pit ll-LIS-586 A/BHigh/low pH of effluent at disposal pump discharge 11PHIT-582

Pre service rinse :

When a unit is selected for service' mode of operation it undergoes a 'Preservice Rinse'. This happens automatically through the PLC system, before the unit actually comes in Service'. The pre-service rinse will continue till the conductivity at SBA or MB outlet is below the preset value.

Operator interface

Operator interface is envisaged for the following purposes.

1) Selection of exchanger units /pumps/blowers for particular operation.2)Mode selection like Service/Off , regeneration chemical filling, etc.3) Hold, reset, advance, skip, dwell (for regeneration stages)

The operation will be menu based through keyboard. Related page can be called on the terminal and operation can be monitored accordingly.

For regeneration, function of sub-commands viz., hold etc. are as given below.

Dwell :

'Dwell' command will abandon the on going regeneration operation at the point it is interfered with. The vessel will go in ‘off ’ mode. Unless the vessel is 'Reset' by

giving a specific sub-command, the vessel shall undergo regeneration from that point onwards from where it was abandoned, when it is put in regeneration again. 'Resets’.bring the vessel regeneration stage to its starting point.

Advanceskip :'Advanceskip' will advance or aU skip the particaiar stage of regeneration where the command is invoked.

Hold :

'Hold' will keep the vessel in that particular stage for the specified time as desired by the operator.

Alarm display :

Whenever an alarm is generated in the plant it will appear on the bottom of the screen. Thus, a small band of the page already called for will be overlapped by the alarm. When more than one alarm occurs, the latest will be flashed and another small band

will appear showing the number of unacknowledged alarms.Check :It shall be first -out type annunciation.

Following signals are repeated for remote monitoring on the DCS.

1. Unit status (that is, Service/Off / regeneration)2. Instrument reading of ll-CIT-580 A/B/C, 11-CIT-581A/B/C and 11-CIT-582 A/B/C.3. Low pressure alarm of ll-PS-580, 11-PS-581 and 11-PS-5824. Instrument reading of ll-SiA-580 and 11-SiA-581

with stream identification5. Instrument reading of 11-NaA-580 with stream identification.6. Instrument reading of 11-PHIT-580, 11-PHIT-581 and 11PHIT-5827. Instrument reading of ll-FIT-580 and 11-FIT-581

Dynamic status of following will appear on computer screen :

1. Open / close position of pneumatically operated valves with the help of two limit switches provided on the valve,2. starting / stopping of pumps and blowers,3. graphic display of tanks units and their status (that is, Service/Off / regeneration),4. various alarms (as per the list enclosed)5. regeneration stage of units with elapsed time and set time,6. readings of conductivity instruments, pH instruments, flow instruments, Sodium analyser and silica analyzers.

TROUBLE SHOOTING

Sr.No.

Deffects Causes Remedies

1. Decrease in capacity between two successive regeneration.

a. Increase in ionic load.b. flow recorder deffective.c. Insufficient chemicals used.d. Resins dirty.e. Plant being used intermittently.f. Channeling in bed.

g. Resin fouled.

h. Resin detoriorated.I. Resin quantity insufficient in unit

Check by analysis.Check.Check.Give prolonged backwash.Avoid this.Check & ensure uniform distribution / collection.If cation-give HCl wash , if anion - give alkaline brine treatment.Check & replace charge.Check & top up.

2. treated quality is not upto the standard.

a. Cation exhausted.b.Anion exhausted.c. M.B. Exhausted.d. M.B. resins are not in uniform mixed state.e. Some valves like backwash leaking.f. Sodium slipage from cation high.)g. Silica slipage from anion high. h. Unit idle.i. Unit not sufficiently rinsed.

j. Excessive low flow rate.k. Channeling.l. Resin fouled.

m. Resins detorioreted.

Check.CheckCheck.Repeat air mixing & rinse.

Check.Check filter water analysis; change in Na/TA & SiO2/TA ratio; use more chemicals.Check.Rinse to satisfactory qulity.Adjust to between unit min/max. flow rate.Check & ensure uniform collection/ distribution.Check resine & give alkaline brine / HCl treatment.Check resine & replace it.

3. Mixed bed quality not good.

a. Resine not seperated properly during backwash.b. Air mixing not proper.c. Final rinse not proper.d. Some valves maybe leaking & contaminating the treated water.

Give extended backwash after exhausting the bed.Repeat.Repeat.Check & examine.

4. High Residuals a. Chocked suction air filter of degassed air blower.b. Improper air flow to the degasser.

c. Degasser blower not in operation.d. Air seal not fitted / broken resulting in short circuiting of air.

Check & clean filter.

Check damper , speed of blower , discharge pressure.Check & operate blower.Check & replace fitting.

5. Unit rinse takes long time.

a. Flow rate too low.b. Unit exhausted.c. Backwash valve passing.d. Anion resins organically fouled.e. MB air mix not satisfactory.

Increase flow rate.Regenerate unit.Check & rectify.Give alkaline brine treatment.Carry out air mix once again.

f. Acid alkali pockets formed in unit.

Faulty design-check & rectify. Temperarily backwash (followed by air score of MB) and rinse again.

6. Flow rate too low.

a. Checked valve & suction strainer of pump.b. Cavitation in the pump.c. Low inlet pressure.d. Distribution / collecting system chocked.e. Resin trap at outlet choched.f. Control valve shut due to low off take.

Check

CheckCheck pump.Check.Check & clean.Increase off take.

7. Pressure drop across the bed is increasing.

a. Deffective valve.b. Packed resin bed & resin fines.

c. Collecting system chocked.d. Pressure gauge deffective.

CheckGive extended backwash with open manhole & scrap off fines from top surface of the resin.Check, repeat backwash.Check & rectify / replace.

8. Flooding in Degasser

a. Very high flow rate.b. Packed tower chocked due to dirt OR broken packing material.

Reduce air flow rate by adjusting damper.Open & checjk.

9. Resin being lost a. Excessive backwash pressure.b. Faulty collecting system.c. Inlet strainer damaged.

Check inlet pressure & reduce if necessary.Examine same for breakage.Check & replace.

10. Ejector not working.

a. Low power water pressure.b. Air lock in the unit.c. Chocked OR deffective valves.d. Ejector nozzel may be chocked.e. Too much back pressure from unit.

f. Bulge in pipe.

Check this.Backwash & open air release.Examin & rectify.Check.Check for chokage of collecting system , passage of inlet / outlet valves.Check and rectify.

11. Incorrect reading from rotameters.

a. Chocked orifice, sub orrifice or impulse lines.b. Dirty glass and float.

Check and clean.

Check and clean.12. Improper reading

from flow recorded integrator.

a. Chocked impulse line / orrifice.b. DP transmeter require calibration.c. Leakage in signal tube betn.transmeter & recorder.d. Low air pressure for DP transmeter or recorder.

Check & clean.Recalibrate.Check,contact & rectify.

Check.

13. Level electrodes system for measuring & dilution tank not functioning properly.

a. Improper contact between electrodes and control cabling.b. Shorting of the two electrodes due to moisture or any foreign material.c. Improper working of the level controller.

Check,contact and rectify.

Che.ck & dry the contacts of moisture and dirt.Check

14. Leakage from a. Improper adjustment of the Check & adjust,

acid injection / unloading /transfer pumps.

mech.seal.b. Low strength of sulphuric & presence of Ferrus sulphate.

Check concentration and take apropriate action.

15. Corrosion in concentrated acid tanks and lines.

a. Low concentration sulphuric acid .

b. Lining of HCl tank / pipe line damaged.

Check Silicagel breather in acid storage tank & replace silicagel charge if exhausted.Rectify.

16. Improper opening and closing of pneumatically operated valves.

a. Deffective solenoid valve.b. Leakage in air line from solenoid valve to the respective control valve.c. Improper contact of micro switch giving false indication to panel.d. Fused mimic lamp giving false indication to the panel.

Check.Check.

Check.

Check.

17. Improper operation of certain valves during running.

a. Deffective relay in the control circuit.

Check and replace relay.

18. Solid state programme not functioning properl\y.

a. The controller can be kept in hold due to the reason explained under operation.b. Improper operation of the controls for the controller.c. Deffect inside the controller.

Remove the condition which causes hold of controller.Pressure test switch and check the complete cycle.Check the instrument thoroughly from inside.Meanwhile operation may be continued by using bypass toggle switches.

(A) DM WATER TRANSFER FROM DM TANK-2A/2B (FB-1151A/B) TO DM TANK-1A/lB (FB-llOlA/B) THROUGH GA-1152 A/B/S.( Refer attached sketch)

1) Open outlet valve V1A of FB-1151A and/or VlB of FB 1151 B.2) Open common header recirculation valve V2A of FB-115 lA and/or V5B of FB-l l5lB.3) Open the suction valve V2A of GA-l 152 A/B/S and prime the pump by opening its

vent valve.4) Close the valve V8C and V8D near DMTank-lA/lB, if DM Water transferring from

MB-7/8/9 outlet to DM Tank-lA/lB is not going on.5) Close the valve V9, if DM Water transfer from GA1 1 52A/B/S to TC Tank is not

going on.

6) Close V12, if DM Water inter transfer from DM Tank-lA/lB to DM Tank-lB/1A & vice versa is not required.

7) Close V7A and V7B, if inter transfer of DM Water from DMTank-2A/2B to DM Tank-2B/2A & vice versa is not to be done.

8) Open valve V8A to transfer DM Water to FB-llOl A & open valve V8B to transfer DM Water to FB-l 101B.

9) Start the GA-1152 A/B/S from field and crack open its recirculation valve V3A.10) Gradually open its discharge valve V4A fully.11) Open valve V6 gradually till pump GA-1152 A/B/S is not getting over loaded. Current should not crosses 64 Amps. and pressure remain between 3.0 to 5.0 kg/cm2.

(B) DM WATER TRANSFER FROM DM TANK-2A/2B (FB-1151A/B) TO TC TANK (FB-1502) THROUGH GA-1152 AIBIS.( Refer attached sketch)

1) Open outlet valve VIA of FB-1151A and/or V1B of FB1151B.2) Open common header recirculation valve V5Aof FB115 lA and/or V5B of FB-1151 B.3) Open the suction valve V2A of GA-1152A/B/S and prime the pump by opening its

vent valve.4) Close the valve V6, if DM Water transfer from GA- 1152 A/B/S to DMTank-lA/lB is

not required.S) Close Vl l , if DM Water transfer from DMTank-lA/lB to TC Tank is not going on.6) Close V7A and V7B, if inter transfer of DM Water from DM Tank-2A/2B to DM

Tank-2B/2A & vice versa is not to be done.7) Open valve V9 behind the GA-l IS lA/S pump for DM water transfer in TC Tank.8) Start the GA-1152 A/B/S from field and crack open its recirculation valve V3A.9) Gradually full open its discharge valve V4A.10) Open control valve V10 through DM Plant-l operator by giving control command

through computer, till pump GA1152 A/B/S is not getting over loaded. Current should not crosses 64 Amps. and pressure remain between 3.0 to 5.0 kg/cm2.11) Put flow transmeter 11 FT506 in service by opening its respective isolation valve.12) Maintain the TC Tank level by controlling valve V10.

(NOTE: DMplant-I operator has to operate control valve for maintaining TC Tank level)

(C) DM WATER TRANSFER FROM DM TANK-lA/lB (FB-1101A/B) TO TC TANK (FB-1502) THROUGH GA-1151 A/S.( Refer attached sketch )

1) Open outlet valve VlC of FB-1101A and/or V1D of FB1101B.2) Open common header recirculation valve V5C of FB1101A and/or V5D of FB110 1B.3) Open the suction valve V2B of GA- 115 l A/S and prime the pump by opening its vent valve.4) Close V12, if DM Water inter transfer from DMTank-lA/lB to DM Tank-lB / 1A &

vice versa through GA-1151A/ S is not going on.5) Close V9, if DM Water transfer from GA-1152A/B/S to TC Tank is not going on.6) Open valve V11 behind the GA-1151A/S pump for DM water transfer in TC Tank.

7) Start the GA-1151 A/S from field and crack open its recirculation valve V3B.8) Gradually full open its discharge valve V4B.9) Open control valve V10 through DMPlant-l operator by giving control command

through computer, till pump GA1151 A/S is not getting over loaded. Current should not crosses 52 Amps. and pressure remain between 1.5 to 5.0 kg/cm2.

10) Put flow transmeter 11 FT506 in service by opening its respective isolation valve.11) Maintain the TC Tank level by controlling valve V10.

(NOTE: DMplant-I operator has to operate control valve for maintaining TC Tank level)

(D) DM WATER TRANSFER FROM DM TANK-2A/2B (FB-1151A/B) TO PTA-I & II THROUGH GA-1153 A/B/S AND GA-1153 C/D.( Refer attached sketch )

1) Open outlet valve VIA of FB-1151A and / or VlB of FB1151B. for suction of GA-1153 A/B/S.

2) Open outlet valve VIE of FB-1151A and/or V1F of FB1151B for suction of GA-1153 C/D.

3) Open common header recirculation valve V5A of FB-115 l A and/or V5B of FB-1151B.

4) Open valve V3F on DM Water circulation header for circulation of DM Water for GA-1153 C/D and GA-1158 A/S pumps.

5) Open valve V4DD on discharge header of GA-1153 C/D pumps.6) Open the suction valve V2C of GA-1153 A/B/S and prime the pump by opening its

vent valve.7) Open the suction valve V2D of GA-1153 C/D and prime the pump by opening its vent valve.8) Start the GA-1153 A/B/S from field and crack open its recirculation valve V3C.9) Open discharge valve V4C gradually till pump GA-1153 A/B/S is not getting over

loaded. Current should not crosses 51 Amps. and pressure remain between 3.5 to 6.0 kg/cm2.

10) Put flow transmeter 11 FT507 in service by opening its respective isolation valve.11) Start the GA-1153 C/D from field and crack open its recirculation valve V3D.12) Open discharge valve V4D gradually till pump GA-1153 C/D is not getting over

loaded. Current should not cross 62 Amps.and pressure remain between 3.5 to 6.0 kg/cm2.

13) Put flow transmeter 11 FT521 in service by opening its respective isolation valve.

(E) DM WATER TRANSFER FROM DM TANK-2A/2B (FB-115l A/B) TO POY THROUGH GA-1158 A/S.

( Refer attached sketch)

1) Open outlet valve V1E of FB-1151A and/or V1F of FB1151 B for suction of GA-1158 A/S.

2) Open common header recirculation valve V5A of FB -115 lA and/or V5B of FB-1151B.

3) Open valve V3F on DM Water circulation header for circulation of DM Water for GA-1153 C/D and GA-1158 A/S pumps.

4) Open the suction valve V2E of GA-1158 A/S and prime the pump by opening its vent valve.

5) Start the GA-1158 A/S from field and crack open its recirculation valve V3E.

6) Open discharge valve V4E gradually till pump GA-1158 A/S is not getting over loaded. Current should not cross Amps. and pressure remain between to kg/cm2.

7) Put flow transmeter 11 FT511 in service by opening its respective isolation valve.