Mtpcl - Wtp o&m Manual

OPERATION

AND

MAINTENANCE MANUAL

FOR

WATER TREATMENT PLANT

CLIENT

M/s. MAADURGA THERMAL POWER COMPANY LIMITED

2 x 30 MW INDEPENDENT POWER PLANT

EPC CONTRACTOR

M/s. CETHAR LIMITED

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INDEX

S. NO DESCRIPTION PAGE NO.

1 INTRODUCTION 3

2 DESIGNED RAW WATER PARAMETERS 5

3 SYSTEM CAPACITY 6

4 SYSTEM DESCRIPTION – BOILER MAKEUP 7

5 SYSTEM OPERATION – BOILER MAKEUP 22

6 SYSTEM DESCRIPTION – COOLING TOWER MAKEUP 42

7 SYSTEM OPERATION – COOLING TOWER MAKEUP 44

8 PERFORMANCE GUARANTEED WATER PARAMETERS 50

9 TOPUP RESIN REQUIREMENT FOR SAC, SBA & MDB 50

10 CHEMICAL ANALYSIS PROCEDURE 51

11 P&ID DIAGRAM FOR WATER TREATMENT PLANT 60

12 POWER CONSUMPTION DETAILS 60

13 TENTATIVE CHEMICAL REQUIREMENTS 60

14 VENDOR'S MANUALS 60

15 TECHNICAL SUPPORT 61

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1) INTRODUCTIONThis document delineates the Operation & Maintenance of the Water Treatment Plant for M/s. Maa

durga Thermal Power Company Limited – 2 x 30 MW Independent power plant located at Bainchua, Tangi,

cuttack, in the state of Orissa.

Water treatment, today has become a very integral part of almost every industry. Treatment of

water is required for various purposes, right from potable use to industrial applications such as for food &

beverages, leather, textile, heavy chemicals, power plants & for hotel industries. Also treatment of

wastewater especially effluents from toxic disposals attracts attention due to increased global awareness

of ecological & environmental protection.

Treatment of water implicitly means changing its physical & mainly, its chemical properties by

removing undesirable suspended & dissolved impurities of organic & inorganic as well as biological

impurities. The level of chemical dosing involved & methods adopted for treatment are according to the

end consumers requirements as well as the nature of composition of raw water sources; which are mainly

from surface wells, lakes, rivers, or from underground sources such as deep wells & in some cases from

sea.

The specific method adopted for conventional treatment such as flocculation/coagulation, filtration

and disinfect ion, lime soda softening process, electro dialysis, demineralization, reverse osmosis and

others are depends upon the product quality requirements.

Stages of Treatment :In general water treatment practice three steps are involved for purification of water.

a) Pretreatments:This treatment is involved to remove the presence of the impurities of Suspended and colloidal

matters, BOD, COD, oil grease any heavy metals.

Equipments Involved in Pretreatments:In pretreatment the following equipments are used depending upon the requirement of treatment

method based on the impurities presence in the raw water.

a) Aeration system

b) Solid Contact Reactive clarifier

c) Various types of filters

d) Ultra filtration

e) Micro filtration

f) Membrane Bio Reactor

g) Micron cartridge filter

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b) Desalination (or) Demineralization:This method is employed to remove the total dissolved salts present in the raw water. Almost more

than 95% dissolved minerals will be removed from this method.

Equipments / Process involved in Desalination

a) Nano Filtration

b) Reverse osmosis system

c) Ion Exchange Process

d) Electro De ionization

c) Post Treatment:This treatment is involved to add or remove some minerals from the desalinated water to meet the

end quality requirement.

Equipments/Process involved in Post Treatment:a) pH doing system

b) Ultra filtration System

c) De mineralization Process

d) Ozonator

e) Ultraviolet Rays

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2. DESIGNED RAW WATER PARAMETER S The raw water analysis considered for the Water treatment plant system design is as follows:-

S. No DESCRIPTION UNIT DESIGN VALUE

1 Source - Bore well

2 pH @ 25 Deg. C - 7.1

3 Turbidity NTU 0.8

4 Total Dissolved Solids ppm 535.5

5 Suspended Solids ppm 26.6

6 M – Alkalinity as CaCo3 ppm 240

7 Total Silica ppm 5.5

8 Sulphate ppm 11.3

9 Calcium Hardness as CaCo3 ppm 242.2

10 Chloride as Cl- ppm 140.5

11 Fluoride as Fl- ppm BDL

12 Total Hardness as CaCo3 ppm 304

13 Nitrate ppm 1

14 Sodium as Na+ ppm 8.4

15 Potassium as K+ ppm 2

16 Magnesium Hardness as CaCo3 ppm 61.8

Note :All other parameters not mentioned above should be “Nil” to achieve the designed outlet quality.

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3. SYSTEM CAPACITY Boiler Make-Up Water Stream :

Total Boiler capacity 2 x 135 TPH

Actual Conditions Design conditions

Boiler Losses (Blow down, Vent etc.) 3.00% 5.00%

Boiler Losses Water Quantity 8.1m3/Hr 13.5 m3/Hr

Operating Hours of Boiler Make-up Stream 20 Hrs / day

13.5 x 24 / 20 = 16.2 m3/hr

Designed Boiler make-up Capacity 20.0 m3/hr

Designed OBR of each SAC 400 m3

Designed OBR of each SBA 400 m3

Designed OBR of each MB 6000 m3

Aux. Cooling Tower Make-Up Water Stream :

Aux. Cooling Tower capacity 2 x 350 m3/hr

Cooling range 10°c

Cycle of concentration 5

Actual Conditions Design conditions

Evaporation loss 10.63 m3/hr 11.45 m3/hr

Blow down loss 2.33 m3/hr 2.51 m3/hr

Drift loss 0.33 m3/hr 0.35 m3/hr

Actual Cooling tower make up water

requirement13.29 m3/hr 14.31 m3/hr

Operating Hours of Aux. CT Make-up

Stream20 Hrs / day

14.31 x 24 / 20 = 17.17 m3/hr

Considering Margin,Designed Aux. CT make-up capacity

20.2 m3/hr

Designed OBR of Softner 404 m3

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4. SYSTEM DESCRIPTION – BOILER MAKEUP FILTER FEED PUMP FOR BOILER MAKEUP : WPP-13001A/B

To feed the raw water from Raw Water Storage Tank to filtration system, Two numbers (1W+1S) of

Filter feed pumps are provided. The capacity of pumps are 40.5 m3/hr @ 3.5 kg/Cm2. The same

pumps shall be used for multi grade filter backwash. Suitable valves are provided for suction and

Delivery line for flow controlling.

CHLORINE DOSING SYSTEM : DOT-53001Chlorine kills bacteria present in water. It also oxidizes the organic substances and for that reason,

it is a good reagent for preventing reproduction of micro organism in the water. Bacteria and other

living organisms, which result in algae formation on the surface of pipes, tanks and bio organic

fouling in membrane, can be destroyed by the addition of an oxidizing agent such as sodium hypo

chlorite into the water as a source of chlorine. Chlorination is required to make water suitable for

portable purposes and as a sterilizing agent to prevent algae growth

NaOCl + H2O HOCl + Na OH

HOCl H+ + Ocl-

Optimization of chlorine dosing :

The chlorine dosing has to be optimized for proper utilization and to avoid excess dosing or

insufficient dosing. Break point chlorination is the best method to optimize the chlorine dosing.

Break Point Chlorination :

Gradual increase of chlorine dosing will increase the residual chlorine but not in proportion to the

excess added and then decreased or there will be no increase in residual chlorine. On further

increases of chlorine dosage, a point is reached beyond which residual chlorine again increase,

such increases then being practically in proportion to the excess added.

This point is known as break point chlorination.

Facilities provided for C hlorine Dosing System : The system consists of 100 liters MSEL tank (DOT53001) with over flow drain arrangement,

magnetic level switch is provided for low-level alarm, and level indicator also provided for visible

level observation.

2 Nos of electronic operated Diaphragm pump (DOP53001A/B) of capacity 4 LPH @ 4kg/cm2 is

provided for chemical dosing in to the pipeline.

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MULTI GRADE FILTER : MGF-13001After the dosing Multi Grade Filter is installed for primary filtration of raw water. It is Dead end

Filtration and there is no rejection. Some residual iron, manganese, clay, inert solids, bacteria, and

other constituents are still present in the water.

Filtration is the process of passing properly treated water through a bed of some type of media for

the purpose of reducing the particle concentration present in the water.

Multi Grade filter of size 1600mm dia and 2300 mm vertical height with both top and bottom dished

end construction provided for primary filtration of raw water. Raw water is passed through a Multi

Grade Filter (MGF) unit in order to remove suspended matters & turbidity present in raw water. It is

an MSRL vertical pressure vessel. Internally it is fitted with inlet top distributor and bottom

collecting system. Externally this unit is fitted MSRL frontal piping with butterfly valve for operation.

Inlet outlet pressure gauges and sampling valves also provided for performance observation of

filter.

This unit is charged with various sizes of pebbles, quartz sands of various sizes as per standard

bed height. Size of the media will be arranged such that the bottom contains larges size of pebbles

and top layer will be fine sand. Suspended matters & turbidity gets removed when raw water is

passed in downward direction through this filter bed under pressure. The Multi Grade Filter is

capable to filter up to particles size of 10 micron to 1 mm.

ULTRA FILTRATION FAST FLUSH TANK : UFT-130015 m3 MSRL tank (Ø1500 x 3300 Ht) has been provided to store the Filtered water. This tank size

has been arrived based on the continuous supply of water to UF Fast flush system, One level

switch is provided to control the level and avoid dry run of Fast flush pump. Float and Board level

indicator is provided for visible level monitoring.

ULTRA FILTRATION FAST FLUSH PUMP : WPP-13003A/BTwo (1W+1S) of UF Fast Flush Pump is provided to Fast Flush the UF Module once in 60 minutes

for one-minute duration. Suitable flow of 52 m3/hr.

BASKET FILTER : BKF-1300152 m3/Hr capacity Basket Filter is provided in the pretreatment section as a polishing filtration step

for removal of fine particulate matters up to 100-micron size. This will help to reduce fouling

potential of ultra filtration. The construction of housing is SS304 and filter mesh is made up of

SS316.

ULTRA FILTRATION MODULE : UFM-13001Membrane technology is advancing more rapidly than any other separation methods and the latest

developments and its versatile nature offers the greatest potential in separation problems since

conventional methods are becoming more & more expensive in all respects. The physical

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membrane separation technique called, as ULTRA FILTRATION (UF) SYSTEM is the most reliable

and economical solution for removal of impurities such as pyrogen, virus, bacteria, colloidal silica

and suspended solids. UF completely replaces the pre-treatment stages such as clarifier, sand

filter and Micron Cartridge filters in certain cases. Hence UF system is a viable solution for the

replacement of conventional pre-treatment. UF system is considered as a clean operation

technique because of its continuous years long operation without any replacement of modules.

The maintenance of conventional pretreatment system is very laborious and also results in

frequent system shutdowns. The porosity of UF modules is uniform which enables uniform

rejection of the impurities. This membrane is also back washable, sterilized and chemically cleaned

thus ensure consistent product water quality throughout the operation time.

The membrane surface in UF system will be constantly under flushing due to reject flow, thereby

reducing the membrane choke-up due to deposition of any impurities if present and delivers

sparkling crystal clear treated water under hygienic conditions. UF system also increases the life of

Reverse Osmosis system because of better-feed water quality and also best for high recovery in

RO system.

ULTRA FILTRATION PRODUCT WATER STORAGE TANK : UST-1300130 m3 RCC Tank (3.5mx3.5mx2.5mHt) has been provided to store the Ultra filtration permeate

water. This tank size has been arrived based on the continuous supply of water to RO system and

UF backwash system. One level switch is provided to control low level, High level and avoid dry

run of RO feed pump and back wash pump. Level Gauges are provided for Visible level

observation.

ULTRA FILTRATION BACK WASH PUMP : WPP-13004A/BTwo (1W+1S) of UF Back Wash Pump is provided to Back Wash the UF Module once in 60

minutes for one-minute duration. Suitable flow of 52 m3/hr.

RO FEED PUMP : (WPP-13005 A/B)

To feed the water from UF Product Water Storage Tank to RO system, Two Nos (1W+1S) of RO

Feed Pumps are provided. Capacity of the RO feed pump is 32.5 m3/hr @ 2.5 kg/Cm2.Suitable

valves are provided for suction and Delivery line for flow controlling.

HCL DOSING SYSTEM : DOT-53002Most of natural surface and ground waters are almost saturated with CaCO3. The solubility of

CaCO3 depends on the pH, as can be seen from the following equation:

Ca2+ + HCO3– ↔ H+ + CaCO3

By adding H+ as acid, the equilibrium can be shifted to the left side to keep calcium carbonate

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dissolved. Use food-grade quality acid.

CaCO3 tends to dissolve in the concentrate stream rather than precipitate. The Langelier

Saturation Index (LSI) for brackish waters and the Stiff & Davis Stability Index (S&DSI) for

seawaters can express this tendency. At the pH of saturation (pHs), the water is in equilibrium with

CaCO3.

The definitions of LSI and S&DSI are:

LSI = pH – pHs (TDS < 10,000 mg/L)

S&DSI = pH – pHs (TDS > 10,000 mg/L)

Where the methods predicting pHs are different for LSI and S&DSI.

To control calcium carbonate scaling by acid addition alone, the LSI or S&DSI in the concentrate

stream must be negative. Acid addition is useful to control carbonate scale only.

Facilities provided for Acid Dosing System: The system consists of 200 liters MSRL tank (DOT-53002) with over flow drain arrangement,

magnetic level switch provided for low-level alarm, and level indicator also provided for visible level

observation.

2 Nos of electronic operated Diaphragm pump (DOP-53002) of capacity 0-6 LPH is provided for

chemical dosing in to the pipeline.

SMBS DOSING SYSTEM : DOT-53003Filtered water may contain free residual chlorine depending upon the utilization of chlorine dosed.

Since free residual chlorine is strong oxidizing agent hence it has to be decomposed before

entering in to the RO membrane made by polyamide highly oxidizing material. Being a strong

oxidizing agent causes damage to the polyamide thin film composite membranes. Hence

necessary to remove the free chlorine prior to feeding in to the RO system.

Na2 S2O5 + H2O 2 NaHSO3

2NaHSO3 + 2HOCl H2SO4 + 2HCl + Na2SO4

FACILITIES PROVIDED FOR ANTI SCALENT DOSING SYSTEM :Sodium Meta Bi Sulphite dosing system consists of 100 liters MSRL tank (DOT-53003) with over

flow drain arrangement, One magnetic level switch is provided for low-level alarm, and level

indicator for visible level observation. One Agitator is provided at the top of the tank for proper

chemical mixing with water.

2 Nos of electronic operated Diaphragm pump (DOP-53003A/B) of capacity 0-2 LPH is provided

for chemical dosing in to the pipeline.

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SPECIAL ANTI-SCALANT DOSING SYSTEM : DOT-53004 Scale inhibitors (Antiscalant) can be used to control carbonate scaling, sulfate scaling and calcium

fluoride scaling. There are generally three different types of scale inhibitors like Sodium hexa Meta

phosphate (SHMP), organophosphonates and polyacrylates. SHMP is inexpensive but unstable

compared to polymeric organic scale inhibitors. Minor amounts adsorb to the surface of micro

crystals, preventing further growth and precipitation of the crystals. Food-grade quality SHMP

should be used. Care must be taken to avoid hydrolysis of SHMP in the dosing feed tank.

Hydrolysis will not only decrease the scale inhibition efficiency, but also create a calcium

phosphate scaling risk. Therefore, SHMP is generally not recommended. Organophosphonates

are more effective and stable than SHMP. They act as antifoulants for Insoluble aluminum and iron,

keeping them in solution. Polyacrylates (high molecular weight) are generally known for reducing

silica scale formation via a dispersion mechanism.

Polymeric organic scale inhibitors are also more effective than SHMP. Precipitation reactions may

occur, however, with negatively charged scale inhibitors and cationic Polyelectrolyte or multivalent

cat ions (e.g., aluminum or iron). The resulting gum-like products are very difficult to remove from

the membrane elements. For dosage rates on all antiscalants, contact the antiscalant

manufacturers. Overdosing should be avoided. Make certain that no significant amounts of cationic

polymers are present when adding an anionic scale inhibitor.

In RO plants operating on seawater with TDS in the range of 35,000 mg/L, scaling is not as much

of a problem as in brackish water plants because the recovery of seawater plants is limited by the

osmotic pressure of the concentrate stream to 30-45%. For safety reasons, however, a scale

inhibitor is recommended when operating above a recovery of 35%.

FACILITIES PROVIDED FOR SPECIAL ANTI SCALENT DOSING SYSTEM :The system consists of 100 liters MSRL tank (DT-53004) with over flow drain arrangement, One

magnetic level switch is provided for low-level alarm, and level indicator provided for visible level

observation.

2 Nos of electronic operated Diaphragm pump (DOP-53004A/B) of capacity 0-2 LPH is provided

for chemical dosing in to the pipeline.

MICRON CARTRIDGE FILTER : MCF–13001The Pre-treatment stream shall have one Primary Cartridge Filter. It consists of a MSRL vessel

installed with Poly Propylene disposable Cartridge. This helps to reduce the Silt Density Index to

acceptable level and hence safe guard the R.O. Membranes. The MCF shall be equipped with

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necessary pressure gauges for monitoring the pressure drop across the cartridges. Capacity of the

cartridge 29.4m3/Hr.

HIGH PRESSURE PUMP : WPP13006 A/BThe RO Feed Water from the Outlet of MCF is feed to the High-pressure pump suction, which

increases the pressure in feed water and then the water can be feed into the Membrane with

design pressure. The Feed Pressure must be greater than the osmotic pressure of the feed water,

and then only the reverse osmosis will take place. By adjusting the brine control valve the required

system pressure is achieved and the recovery is set. Two numbers of high-pressure pump

provided one is working and another will standby.

REVERSE OSMOSIS TREATMENT SYSTEM.Reverse osmosis is the finest level of filtration available. The RO membrane acts as a barrier to all

dissolved salts and inorganic molecules, as well as organic molecules with a molecular weight

greater than approximately 100 in the water, on the other hand, pass freely through the membrane

creating a purified product stream. Rejection of dissolved salts is typically 95 -99%.

The applications for RO are numerous and varied and include desalination of seawater or brackish

water for drinking purposes, wastewater recovery, food and beverage processing, biomedical

separations, purification of home drinking water and industrial process water.

Also, RO is often used in the production of ultra pure water for use in the semiconductor industry,

power industry (boiler feed water), and medical/laboratory applications. Utilizing RO prior to ion

exchange (IX) dramatically reduces operating costs and regeneration frequency of the IX system.

The membrane feed pressure can be varied with respect model usage of water source. Normally

brackish water membrane maximum feed pressure will be 10 kg/cm2 and seawater membrane

pressure will be 84 kg/cm2.

Basic principles of reverse osmosis:The phenomenon of osmosis occurs when pure water flows from a dilute saline solution through a

membrane into a higher concentrated saline solution. A semi-permeable membrane is placed

between two compartments. Assume that this membrane is permeable to water, but not to salt.

Then, place a salt solution in one compartment and pure water in the other compartment. The

membrane will allow water to permeate through it to either side. But salt cannot pass through the

membrane.

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As a fundamental rule of nature, this system will try to reach equilibrium. That is, it will try to reach

the same concentration on both sides of the membrane. The only possible way to reach equilibrium

is for water to pass from the pure water compartment to the salt-containing compartment, to dilute

the salt solution.

Figure shows that osmosis can cause a rise in the height of the salt solution. This height will

increase until the pressure of the column of water (salt solution) is so high that the force of this

water column stops the water flow. The equilibrium point of this water column height in terms of

water pressure against the membrane is called osmotic pressure.

If a force is applied to this column of water, the direction of water flow through the membrane can

be reversed. This is the basis of the term reverse osmosis. Note that this reversed flow produces

pure water from the salt solution, since the membrane is not permeable to salt.

REVERSE OSMOSIS PROCESS

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In practice, reverse osmosis and nanofiltration are applied as a cross flow filtration process. The

simplified process is shown in Figure

With a high-pressure pump, feed water is continuously pumped at elevated pressure to the

membrane system. Within the membrane system, the feed water will be split into low saline and

purified products. The product water is called permeate and high saline or concentrated brine is

called concentrate or reject. Water feed to the RO system and back pressure to be created by flow

control valve it is called brine control valve.

The key terms used in the reverse osmosis process are defined as follows. RECOVERY - the percentage of membrane system feed water that emerges from the system as

product water or “permeate”. Membrane system design is based on expected feed water quality

and recovery is defined through initial adjustment of valves on the concentrate stream. Recovery is

often fixed at the highest level that maximizes permeate flow while preventing precipitation of

super-saturated salts within the membrane system.

REJECTION - the percentage of solute concentration removed from system feed water by the

membrane. In reverse osmosis, a high rejection of total dissolved solids (TDS) is important, while

in nanofiltrations the solutes of interest are specific, e.g. low rejection for hardness and high

rejection for organic matter.

PASSAGE - the opposite of “rejection”, passage is the percentage of dissolved constituents

(contaminants) in the feed water allowed to pass through the membrane.

PERMEATE - the purified product water produced by a membrane system.

FLOW - Feed flow is the rate of feed water introduced to the membrane element or membrane

system, usually measured in gallons per minute (gpm) or cubic meters per hour (m3/h).

Concentrate flow is the rate of flow of non-permeated feed water that exits the membrane element

or membrane system. This concentrate contains most of the dissolved constituents originally

carried into the element or into the system from the feed source. It is usually measured in gallons

per minute (gpm) or cubic meters per hour (m3/h).

FLUX - the rate of permeate transported per unit of membrane area, usually measured in gallons

per square foot per day (gfd) or liters per square meter and hour (l/m2h).

FACTORS AFFECTING REVERSE OSMOSIS PERFORMANCEPermeate flux and salt rejections are the key performance parameters of a reverse osmosis or a

nanofiltration process. Under specific reference conditions, flux and rejection are intrinsic

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properties of membrane performance. The flux and rejection of a membrane system are mainly

influenced by variable parameters including

• Pressure

• Temperature

• Recovery

• Feed water salt concentration

Pressure: With increasing effective feed pressure, the permeate TDS will decrease while the

permeate flux will increase as shown in Figure 1.1.

Temperature: If the temperature increases and all other parameters are kept constant, the

permeate flux and the salt passage will increase (see Figure 1.2)

Recovery: Recovery is the ratio of permeates flow to feed flow. In the case of increasing recovery,

the permeate flux will decrease and stop if the salt concentration reaches a value where the

osmotic pressure of the concentrate is as high as the applied feed pressure. The salt rejection will

drop with increasing recovery (see Figure 1.3)

Feed water Salt Concentration Figure 1.4 shows the impact of the feed water salt concentration

on the permeate flux and the salt rejection.

`Figure 1.1 Performance vs. Pressure Figure 1.2 Performance vs. temperature

Figure 1.3 Performance vs. recovery Figure 1.4 Performance vs. feed water salt concentration

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RO CHEMICAL CLEANING SYSTEM :

CHEMICAL CLEANING TANK : CCT530011000 Ltr MSRL tank (Ø1000 x 1500 Ht) has been provided to store the Chemicals solution. This

tank size has been arrived based on the requirement of stage wise cleaning of RO Membranes,

level indicator has been provided for visible level monitoring. Low level switch also provided to

avoid the dry run of the pump. Recirculation line has been provided for proper mixing of chemical

with water.

CHEMICAL CLEANING PUMP : WPP53003Two (1W+1S) numbers of Chemical cleaning Pumps are provided to clean the RO Membranes.

Suitable flow of pump 22.5m3/hr @ 3.5kg/cm2. Suitable valves are provided suction and delivery

piping for flow controlling.

MICRON CARTRIDGE FILTER : MCF53002The system shall have one Primary Cartridge Filter. It consists of a MSRL vessel installed with

Poly Propylene disposable Cartridge. This helps to reduce the Solid partials to acceptable level

and hence safe guard the R.O. Membranes. The MCF shall be equipped with necessary pressure

gauges for monitoring the pressure drop across the cartridges. Capacity of the cartridge 22.5 m3/

Hr.

SODIUM BI CARBONATE DOSING SYSTEM : DOT- 53005The RO Permeate water from the output is little acidic in nature. Hence a pH correction dosing

system is incorporated in the system to boost up the water pH to a desired acceptable level

especially for Potable application.

Facilities provided for Sodium Bi Carbonate Dosing System:The system consists of 100 liters MSRL tank (DOT-53005) with over flow drain arrangement,

magnetic level switch provided for low-level alarm, and level indicator provided for visible level

observation.

Two nos of electronic operated Diaphragm pump (DOP-53005A/B) of capacity 0-2 LPH is provided

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for chemical dosing in to the pipeline. One Agitator is provided for proper chemical mixing with

water.

DE-GASIFICATION SYSTEM : DGT-13001RO treated water is allowed to pass through a de gasification tower (DGT-13001) & the free carbon

dioxide is removed from the water. It is fitted internally with a top distributor & bottom collector.

Degasser tower is a forced draft type of atmospheric tower Polypropylene pall rings are charged in

the tower to increase the contact area of air & water for efficient stripping of Co2 from the incoming

water. The size of the DG tower is 700 mm in diameter and 3300 mm height and its capacity is 20

m3/Hr has been provided with MSRL construction.

DG BLOWER : DGB-83001 A/BTwo numbers Centrifugal type air blowers in M.S. construction one working and one stand by has

been provided for blowing high flow of 7.7 m3//min @, low pressure of 55 mm water column for de

gasification. Forced air by degasser blower is passed in counter current direction while the RO

product water is sprayed from the top, thus removing the free carbon dioxide produced during

splitting of alkaline salts.

DG WATER STORAGE TANK : DGS-1300120 m3 MSRL tank (Ø2700 x 3800 Los) has been provided to store the RO permeate water.

Degasser tower is placed over the tank by fasteners. RO permeate from RO system will be

collected in DGWST after passing through DG tower. Level switch is provided to monitor low level

and high level of tank and also to avoid dry run of pump (WPP-13007A/B). level indicator has been

provided for visual observation of the tank level.

DG WATER TRANSFER PUMP : WPP-13007 A/BThis pump is used to transfer the water from degasser tank to DM Plant. 2 nos of pumps, one is

working and another is standby. The pump provided to suit service and back wash of DM Plant.

Necessary valves, pressure gauges and flow indicator has been provided in inter connecting pipe

lines to monitor the safe operation.

STRONG ACID CATION : SAC-13001& 13002The Strong Acid Cation unit embodies a single column of AMBERJET 1000H resin. When water

comes in contact with these resins, the positive ions are taken up by the resins and H+ is released

thus producing low hardness water.

Strong Acid Cation vessels (20 m3 Capacity ) is made up of MSRL and the size of 1000 mm dia

and 2000 mm Height has been arrived based on the input cation load to the Strong Acid Cation.

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ACID MEASURING TANK FOR SAC: AMT-53001& 53003 Strong Acid Cation resins shall be regenerated by Hydro Choleric Acid (HCL).

The system consists of 200 liters MSRL tank with over flow drain arrangement. Level gauge is

provided for visible level observation. Level switch has been provided for low level alarm.

Service Cycle Reaction

Ca CL/SO4 Ca H2SO4

Mg (Hco3) + 2HR Mg R2 + 2H2CO3

Na2 CL/SO4 Na2 HCL

Regeneration Cycle Reaction Ca Ca

Mg R2 + 2Hcl 2HR + Mg Cl2

Na2 Na2

STRONG BASE ANION : SBA- 53001& 53002 The Strong Base Anion unit embodies a single column of AMBERJET 4200CL (Strong Base Anion

Exchange) resin. When water comes in contact with these resins, the negative ions are taken up

by the resins OH- are released thus producing Less Conductivity water.

Before regenerating the resins, the resins have to be backwashed. The resins are regenerated with

caustic. After the regeneration the resins are rinsed thoroughly with service water.

Strong Base Anion vessel is made-up of MSRL ,Capacity of 20 m3/Hr Size of vessel 1000 mm dia

and 2000 mm height has been arrived based on the input Anion load to SBA.

CAUSTIC DLUTION TANK FOR SBA: CDT-53001& 53003Anion exchange resins shall be regenerated by Sodium Hydroxide.

The system consists of 200 liters tank with over flow drain arrangement, and Level gauge is

provided for visible level observation. Level switch has been provided for low level alarm. Agitator

is provided for each tank for proper mixing chemicals with service water.

Service Cycle ReactionH2SO4 + 2ROH R2So4 + 2H2O

HCL + ROH RCL + H2O

CO2 + ROH RHCO3

SiO2 + ROH RHSIO3

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Regeneration Cycle ReactionRSO4 + 2NaOH 2ROH + Na2SO4

RCl + NaOH ROH + NaCl

RHCO3 + NaOH ROH + NaHCO3

RHSiO3 + NaOH ROH + NaHSiO3

MIXED BED : MDB-53001 & 53002The Mixed Bed unit embodies a single column of AMBERJET 1000H (Strong Acid Cation) and

AMBERJET 4200CL (Strong Base Anion Exchange) resin mixed intimately together. When water

comes in contact with these resins, the resins take up the positive and negative ions and H+ and

OH- are released thus producing high purity water. Before regenerating the resins, the resins have

to be separated by carrying out the backwash. During backwash, the lighter anion resin is carried

to the top and the heavier cat ion resin settles at the bottom. After the resin separation, the resins

are regenerated with caustic and hydrochloric acid.

Mixed Bed vessels are made up of MSRL and the size of 1000 Dia X 2800 Ht capacity of vessel

20m3/Hr has been arrived based on ionic load.

ACID MEASURING TANK FOR MDB: AMT- 53002 & 53004Cation resins shall be regenerated by Hydrochloric Acid (HCL).

The system consists of 100 liters capacity MSRL tank size of 400mm Dia x 1000mm Height with

over flow drain arrangement. Level gauge is provided for visible level observation. Level switch has

been provided for low level alarm.

Service Cycle ReactionCa CL/SO4 Ca H2SO4

Mg (Hco3) +2HR Mg R2 + 2H2CO3

Na2 CL/SO4 Na2 HCL

Regeneration Cycle Reaction Ca Ca

Mg R2 +2Hcl 2HR + Mg Cl2

Na2 Na2

CAUSTIC DLUTION TANK : CDT-53002 & 53004Anion resins shall be regenerated by Sodium Hydroxide. The system consists of 200 liters capacity

MSRL tank size of 600mm Dia x 1000mm height with over flow drain arrangement, and Level

gauge is provided for visible level observation. Level switch has been provided for low level alarm.

19 Of 62

Agitator is provided for each tank for proper mixing chemicals with service water.

The Reaction during service cycle of anion Resin

H2SO4 +2ROH R2So4 + 2H2O

Hcl + ROH RCl + H2O

CO2 + ROH RHCO3

SiO2 + ROH RHSIO3

The Reaction during Regeneration of Anion Resin

RSO4 + 2NaOH 2ROH + Na2SO4

RCl + NaOH ROH + NaCl

RHCO3 + NaOH ROH + NaHCO3

RHSiO3 + NaOH ROH + NaHSiO3

MIXED BED AIR BLOWER : MBB-83001The twin lobe air blower is provided for thorough mixing of cation and anion resins in mixed bed.

The system is provided with 1 nos of blower. The capacity of the blower is 2.0m3/min @ 4.5 meter

water column.

PH CORRECTION DOSING SYSTEM : DOT- 53006The well polished dematerialized water from the MB output is little acidic in nature. Hence a pH

correction dosing system is incorporated in the system to boost up the water pH to a desired

acceptable level especially for boiler feed.

Facilities provided for pH Dosing System:The system consists of 100 liters capacity SS304 tank size of 400mm Dia x 1000mm Height with

over flow drain arrangement. Level gauge is provided for visible level observation. One level switch

has been provided for low level alarm.

Two nos of Stainless steel electronic operated Diaphragm Auto dosing pump (DOP53006A/B) of

capacity 0-2 LPH is provided for chemical dosing in to the pipeline. One Agitator is provided for

proper chemical mixing with service water.

BULK ACID STORAGE SYSTEM : BAT-53001Facilities provided for safe and easy chemical filling of Acid dosing tank & Acid measuring

tanks.15m3 capacity MSRL tank has been provided for bulk HCL chemical storage for continuous

plant operation. Over flow and drain line is provided. One set of level indicator is provided for visible

level observation.

20 Of 62

Two nos. of PP Acid unloading pump (WPP-53010A/B) is provided for chemical unloading from

chemical carrying trucks (capacity 14m3/[email protected]/cm2) One pump is working another pump will be

standby.

BULK CAUSTIC STORAGE SYSTEM : BCT-53001Facilities provided for safe and easy chemical filling of Caustic dilution tanks.15m3 capacity MS tank

has been provided for bulk NaOH chemical storage for continuous plant operation. Over flow and

drain line is provided. One set of level indicator is provided for visible level observation.

Two nos. of SS316 caustic unloading pump (WPP-53011A/B) is provided for chemical unloading from

chemical carrying trucks (capacity 14m3/[email protected]/cm2) One pump is working another pump will be

standby.

NEUTRALIZATION PIT : NEP-63001 Effluent collection system consists of a collection pit, which has been provided to collect the water

from rejects of Water Treatment System. The closed pit is made up of Reinforced cement concrete

85m3 Volume has been arrived based on the effluent collection and transfer rate.

Two numbers of pump (WPP63009A/B) is provided MOC of the pump is SS316 And capacity

56.0m3/hr@ 3.5kg/cm2 has been provided. One pump is working and other pump will be standby.

The pump will transfer the neutralized water to Guard pond.

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5. SYSTEM OPERATION – BOILER MAKEUP FILTER FEED PUMP

Before starting the pump make sure the RWST has sufficient water. Close the delivery valve and

Start the Raw Water transfer Pump. Open the delivery valve gradually and adjust up to the required

flow and pressure to the Multi Grade Filter Inlet.

CHLORINE DOSING SYSTEMBefore starting the pump ensure the level of Sodium hypo chlorite solution, and fill the solution if

the level is insufficient. Start the dosing pump and adjust the sodium hypo chlorite doing as per the

free residual chlorine requirement at before dechlorination dosing point.

Sodium hypochlorite dosage has to be optimized depending upon the chlorine demand generally

the range of dosing will be 2.0 – 3.0 ppm. It forms hypochlorous acid which liberates free chlorine

which kills micro organisms and breaks long chain polymers of organics. Thus water is disinfected.

Caution : Never run the pump with air lock to avoid the damage of diaphragm.

MULTI GRADE FILTER

• Before starting the pump open the service inlet valve and air vent valve ensure the complete air

release through air vent pipe.

• Open Service inlet valve and the Rinse outlet Valve and drain the water for few minutes.

• Check the quality of rinse out let if water quality found OK.

• Close the rinse outlet valve and open the Service outlet Valve.

• If the Pressure drop across the filter exceeds 0.8 kg/cm2 Isolate the filter and proceed for

Backwash.

V13024 : SERVICE INLET VALVEV13025 : BACK WASH OUTLET VALVEV13026 : BACK WASH INLET VALVEV13027 : SERVICE OUTLET VALVEV13028 : RINSE OUTLET VALVE V63029 : AIR RELEASE VALVE

Ensure the Multi Grade Filter is backwashed daily, irrespective of the no. of hours of service or

pressure drop across the filter bed.

Open backwash has to be done once in 6 months.

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Procedure for Open BackwashOpen the top manhole of body flange as per the MGF design and drain the water from the filter and

maintain water level of 100 mm above the top layer of the filter media. Observe the media

condition. if the media condition is worst add HCL acid and maintain 5% concentration in the filter

and continue for soaking of 6-8 hrs. Start the filter feed pump and open backwash inlet valve and

maintain backwash flow velocity of 24-30 meter/hr. Continue this open backwash for 15-20 minutes

still the clear water from the backwash overflow. Now check the media condition if necessary

continue the above process for till getting satisfactory result. From the above treatment if the media

is not cleaned perfectly remove the media and replace the worst portion of the media.

Washing The Media

• Open the backwash outlet valve fully, and open the backwash inlet valve ensuring that sand is not

carried over to drain. Continue backwashing until the effluent is completely clear, and then close

both the valves.

• Open the rinse outlet valve and drain the water level in the vessel to just below the surface of the

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

• Close the vessel manhole.

• Connect the air release pipe.

Charging The Media

• Unpack the under bed material comprising of four grades of pebbles and Silex, fine sand by

opening side man hole if provided. Wash each separate grade thoroughly with Water to make it

free from dust, dirt and other impurities.

• Open the backwash inlet valve to fill up water in the vessel. And clean the vessel inside surface

area then charge the First (coarser) layer of pebbles into the vessel with extreme care, so as to

avoid damaging the laterals or nozzles/strainers, and arrange the pebbles properly around the

laterals. Level the layer and note its depth.

• Charge the remaining layers of pebbles and gravels successively in a Similar manner, first

increasing the water level stepwise to cover each successive layer (by opening backwash inlet

valve), then charging and leveling each layer, and noting the bed depth at each stage. Check and

note the total depth of the under bed.

• Open the service inlet valve and fill up about half the vessel with water. Charge the mixed sand

media and level the top surface uniformly. Check the bed depth. Carry out open backwash for 10

minutes or until the clear water from backwash overflow.

• Fit the inverted bell mouth distributor.

• Close the manhole then fill the water by opening the service inlet valve ensure the complete air

release. Then carry out the backwash and rinsing before service cycle.

23 Of 62

Do's and Don't s of Filtration

Do:

• Perform thorough filter inspections and correct problems as needed.

• Monitor peak turbidities, particle counts, backwash water turbidity, media % expansions, run times,

head loss, filtration rates, surface wash pressure and flow rates, etc.

• Adjust backwash rates & times as needed to properly clean the filters. - observe backwash for

signs of air and other problems. - continue to optimize backwash procedures by implementing step

backwash procedures or backwash water treatment (polymer or coagulant).

• Record keeping is very important for monitoring filter performance. If numbers are out of range,

they should trigger a maintenance work order or corrective action. Be specific on work order

requests since problems may occur on off-hours.

Don't:

• exceed filtration rate maximum for the filters (~ 3.0 MGD)

• make sudden and significant filtration rate changes. At my plant, no more than 0.1 MGD per filter in

30 minutes.

• re-start "dirty or off-line filters without backwashing first.

• keep poor performing filters, based on high effluent turbidity or particle counts, in service. Take bad

filters out of service.

ULTRA FILTRATION

UF –AUTO CYCLESR. NO PROCESS VALVE OPEN IN UF PUMP IN OPERATION TIME IN MIN

a UF - SERVICE PSV13002,

PSV13005WPP13001A/B -Run 58

b UF- BACK WASHPSV13006,


c UF- FAST FLUSHPSV13003,


PSV13001 – UF FAST FLUSH TANK INLET VALVE.PSV13002 – SERVICE INLET VALVE.PSV13003 – FAST FLUSH INLET VALVE.PSV13004 – REJECT OUTLET VALVE.PSV13005 – PRODUCT OUTLET VALVE.PSV13006 – BACK WASH INLET VALVE.

24 Of 62

A) SERVICE CYCLE:

• Select the UF system in auto mode then the sequence of operation will be as follows.

• If the RWST level is not low Ensure the MGF service cycle valve open then automatically the MGF

feed pump will start, and also UF Feed valve and Permeate valve will open (Before Start the pump

UF feed valve should be open condition).

• Operator has to make sure the Service inlet and outlet valve of MGF has to be opened after air

release from the MGF to feed the water in to the UF system.

• Now the operator has to adjust the MGF feed valve and UF reject valve (Manual) to maintain the

feed flow of 33.7 cum/hr in the UF feed and 30.3 cum/hr in the UF permeate and 3.4 cum/hr in the

UF reject.

• Maintain the FRC of 0.5 ppm in the UF feed to avoid biological growth in the UF membrane.

• This service cycle continues for 58 min.

B) UF BACK WASH CYCLE:

• After completion of Service cycle for 58 min the back wash cycle will continue for 1 min.

• Filter feed pump will get shutdown automatically and also UF Feed & Product valve will get closed

automatically.

• UF fast flush inlet valve should be in closed condition.

• UF back wash inlet valve and UF reject outlet valve will get open automatically, then UF back wash

pump will get start automatically.

• This cycle will continue continuously, subjected to the satisfaction of the following interlocks.

No low level in UST-13001

No High pressure at UF Back wash Inlet.

C) UF FAST FLUSH CYCLE:

• After completion of back wash cycle for 1 min the fast flush cycle will continue for 1 min.

• UF service inlet valve should close automatically.

• UF Fast flush inlet valve and UF reject valve will get open automatically, and then UF fast flush

pump will get start automatically.

• This cycle will continued 1 minutes after that fast flush inlet valve get close automatically. And also

fast flush pump will get stop automatically.

• This cycle will continue continuously, subjected to the satisfaction of the following interlocks.

No low level in UFT-13001

No High pressure at UF feed Inlet.

• Now service cycle will start automatically.

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D) NORMAL SHUT DOWN

• Stop the UF auto mode switch and Open the MGF air release valve and close the MGF service

inlet and service outlet valves.

UF CHEMICAL CLEANING

CAUSTIC / CHLORINE WASH

• Take 5000 liter of Filter water in UF fast flush tank. Add caustic slowly to achieve 10-12 pH (0.5 wt

% sodium hydroxide addition).

• Add liquid sodium hypo chlorite (NaOCl) to achieve the total chlorine concentration of 200 mg/lit

max.

• Circulate the caustic and chlorine solution for 20 – 30 minutes.

• Check and chlorine solution and NaOCl as required to maintain the chlorine concentration

• Drain and completely flush with UF permeate water to get normal pH and chlorine concentration.

NOTE : Always add caustic before chlorine never adds chlorine to the neutral or acid solution. process line

must be completely flushed between each caustic chlorine wash and acid wash.

ACID WASH

• Take 5000 liter of Filter water in UF fast flush tank, add citric acid (solid) Slowly to achieve the pH

2.5 (0.5 wt. % of citric acid addition)

• Circulate the citric acid solution for 20 – 30 minutes.

• Drain and completely flush with UF permeate water to get normal pH.

Ultra Filtration system Maintenance:Operational safety measure:

• Maintain minimum 0.5 ppm residual chlorine in the UF feed water.

• Extended back wash and fast flush once in a week with 2-3 ppm chlorine.

• Maintain the recovery as per design.

Scheduled Maintenance:

• Check the tightness of electrical connection of solenoid valves.

• Check the tightness of support U clamps to avoid vibration.

• Chemical cleaning has to be done once in 3 months

• Check the condition of compressor air hose and replace if necessary.

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Preventive maintenance

• Chemical cleaning has to be done if the differential pressure increases more than 0.8-1 bar.

• Chemical cleaning has to be done once the feed pressure increased to 2kg/cm2.

Events for break down maintenance.

• Failure of solenoid coil.

• Increase feed pressure or differential pressure.

• Failure of UF module.

• Failure of pipelines.

Do's and Don't s of UF System.

Do

• Daily monitor the feed pressure and differential pressure.

• Maintain minimum 0.5 ppm FRC in UF feed.

• Maintain recovery as per design

• Run the system only in auto mode.

Don't s

• Don’t run the system in manual mode.

• Not to run the system with out FRC.

• Never run the system with more than 2.5 Kg/cm2 feed pressure.

• Never run the system with with differential pressure more than 0.8 kg/cm2.

RO SYSTEMRO FEED PUMP

Before start the RO feed pump SMBS & Antiscalant dosing should be ON condition. Close the

delivery valve of RO feed pump and ensure the sufficient level in UST-13001 then start the RO

feed pump and gradually open the Discharge valve and maintain the flow & suction pressure at

High pressure pump suction.

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ACID DOSING SYSTEMCheck the level of Hydrochloric acid solution, and fill the solution if the level is insufficient. Start the

dosing pump. The dosing pump will adjust the stroke to maintain the RO feed pH of 6.5 – 6.8

based on pH transmitter signal.

CAUTION : Never run the pump with air lock to avoid the damage of diaphragm.

SMBS DOSING SYSTEMCheck the level of Sodium meta bi-sulphite solution, and fill the solution if the level is insufficient.

Start the dosing pump and adjust the sodium meta bi-sulphite dosing as per quantity required to

decompose the free residual chlorine available in the RO feed water.

Sodium meta bi-sulphite dosage has to be optimized depending upon the FRC load and also

maintain the ORP value between +200mV to +350mV to avoid excess Sodium meta bi-sulphite

dosing.

Caution: Never run the pump with air lock to avoid the damage of diaphragm.

Note: Use Agitator for chemical preparation for proper mixing of chemical with water.

SPECIAL ANTISCALANT DOSING SYSTEM

Check the level of Antiscalant solution, and fill the solution if the level is insufficient. Start the

dosing pump and adjust the antiscalant dosing rate to desired value by means of the stroke-

frequency knobs provided in the pump.

The antiscalant dosing rate has to be arrived based on the membrane manufacturer scaling

calculation and antiscalant manufacturer dosing calculation.

Caution: Never run the pump with air lock to avoid the damage of diaphragm.

MICRON CARTRIDGE FILTEROpen the Air Release Valve to escape all the air. While the filter is in service, the product water

quality and the pressure drop across the filter should be regularly monitored and recorded with inlet

and outlet pressure gauges. When the pressure drop across the unit reaches 0.8 -1.0 kg/cm2 or

when the unit outlet water quality deteriorates, the cartridges have to be replaced.

REVERSE OSMOSIS SYSTEMSDI TESTING

Before feed the water to RO Module SDI Value To be Checked. SDI testing provision provided at

MCF Outlet. During SDI testing 2 Kg/Cm2 pressure will be maintained. SDI Value maintain as

follows.

For Bore Well Water SDI value : < 3, For Surface Water SDI Value : < 4

28 Of 62

SDI is a test normally carried out on water to assess the extend of particulate (suspended)

contamination in it. It yield a non-dimensional figure, so called SILT DENSITY INDEX (SDI), also

referred to at times as Fouling Index. High index water is dirty and contaminated, low index water

is clean and indicates suitability for the process.

The index is influenced by the presence of colloidal/fine particulate (undissolved or suspended). It

is not affected by the large sticks and stoned (unlike the total suspended) solids figure which is

reported in mg/liters, and is influenced by the large or heaver particles. This makes the test very

useful to users to the process like reverse osmosis, where the membrane is more dangers in

fouling from the smaller contaminant species.

The test takes around fifteen minutes to carryout and the test sample volume is around 15-20 lts.

Thus SDI is fairly representative of the actual conditions and comparatively less affected by

sampling error.

Real utility the test should be carried out once a day. This yield the user valuable information about

the quality of his process water. This will also help in diagnostics and protect downstream

equipment from particulate fouling.

TEST PROCEDUREBefore starting clear the SDI Kit of any debris by opening the lower part of the filter and running

water drain.

Assemble the filter holder without any filter paper. Then connect it to the sampling point, where the

water would be drawn from for testing. In case of pressurized lines care should be taken to avoid

injury or losses due to drenching of near by equipment.

Set the pressure and flow conditions by adjusting the sapling valve and regulator. Turn the back

knob on the regulator to adjust the pressure. The flow should be adjusted to approximately 100 ml

in 5 second.

Shut the valve, open the filter holder and place a new filter paper into the filter assembly. Place the

O-Ring on top of the filter and loosely screw the lower filter holder into position. Remove all the air

from the filter holder by slowly. Opening the valve, and allowing a small amount of water to flow out

from around the filter holder threads.

When all the air has been expelled quickly shut the valve and tightens the filter holder. It is

important that the filter holder is not over tightened, as this may crack the top threaded portion.

Hold the top of the assembly whenever tightening or lessening the unit.

Open the valve, and if necessary adjust the test pressure once again to maintain 30 psi and using

the stopwatch time the collection of 1200 ml. This should be carried out quickly and accurately as

this time interval measure is recorded as to. The stop watch is to be started at the time of

beginning of this operation. SDI Kit should be held in such a way so as to ensure that the filter

29 Of 62

holder always horizontal. Holding the stop watch next to the measuring cylinder enables both the

collection and timing to be observed at the same time. Use the lap time feature of the stop watch to

monitor both to and the total test time T.

The water is kept flowing the unit and at regular intervals of one or two minutes, the time taken to

measure a 100 ml sample is measured. When this time is five times the initial value or 15 minute of

test time has been reached the test is stopped.

Unscrew the filter holder and remove the filter membrane. Examining the membrane under a light

microscope will give you a visual idea of the kind of contaminants present in your water.

Record the data in an SDI record sheet and calculate the SDI of the water.

CALCULATING SDI

The Slit Density Index Is Calculated Using the Following Formula

SDI = (1-To/Tf) T/f x 100

Where,

To = time (in seconds) for the collection of initial 100ml

Tf = time (in seconds) for the collection of the final 100mlsample, at time Tf

T/f = the time (in minutes) at which the final 100ml samples collected (usually 15 minutes)

REVERSE OSMOSIS :IMPORTANT INSTRUCTIONS TO OPERATE THE R.O PLANTPlease check the following before you start the R.O. Plant.

• Check the high pressure pump suction pressure it has to be minimum 2 Kg/cm2.

• Check the High pressure pump suction valve is fully open and discharge valve 30% open.

• 5-10 minutes flush the membrane with raw water. This has to be done every startup and shut down

of the plant.

• Ensure RO Product water tank is not full.

• Ensure Brine control valve is full open.

• Open the drain valve of RO permeates.

R.O. NORMAL START UP

• Select the pump which is going to start then start the pump and monitor the flow and pressure

slowly open the HPP discharge valve and make sure the HPP suction pressure should not be less

than 0.5 kg/cm2 to avoid low suction tripping of HPP.

• Continue for 2-3 minutes without controlling the brine valve.

• Throttle brine control valve and maintain brine flow and product flow as per the design. Monitor

R.O. system pressure and control it.

30 Of 62

• Initially drain the product water for 5 minutes then start closing the brine control valve very slowly.

SHUT DOWN

• Open the brine control valve fully and continue for 3 - 5 minutes and also make sure the minimum

suction pressure of 0.5 kg/cm2 to avoid tripping of HPP due to low suction.

• Stop High Pressure Pump.

• Continue for 5-10 minutes with RO feed pump flow & then shut down the following.

RO feed pump

Dechlorination dosing pump(SMBS)

Antiscalant dosing pump

• This flushing cycle is to ensure that any scaling formation taken place during desalination of water

because of high concentration and precipitation, which settle on the membrane surface, should get

dissolved in low salinity water and get away in reject. This precipitation may cause Scaling of

membranes which reduce the life of membrane and increase the pressure drop across the system.

The flushing should be followed daily and by passing of that may void the guarantee of

performance.

GENERAL RO CHEMICAL CLEANING TIPS :During chemical cleaning of RO system the following procedure to be carried out, Biological fouling

in the RO system to be removed first. Hence we have preferred high pH, Chemical cleaning then

low pH cleaning. It will give better results.

• Normalized Permeate flow drops 10%

• Normalized Salt Passage increases 5 -10 %

• Normalized Pressure Drop (feed - reject increased to 5 -10%

• Chemical solution water temperature to be maintained < 25 deg c.

• Chemical cleaning solution temperature to be maintained with respect to the pH.

• For BW membrane 1-12 pH @35 Deg c and 1 -10.5 pH @45 deg c.

• For SW membrane 1-12 pH @35 Deg c and 1 -10.5 pH @45 Deg c.

• Pressure (20 - 60 PSI) and flow 6 - 9.1 m3/Hr/Pressure tube, to be maintained during chemical

cleaning.

• Membrane supplier strongly recommended stage wise cleaning tube done separately. This will give

effective results.

• Fist cleaning to be done with alkaline pH then proceed acetic pH.

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RO MEMBRANE CLEANING PROCEDURE, CHEMICAL REQUIREMENT & SPECIFICATIONSRO CHEMICAL CLEANING

• During chemical cleaning of RO system the following procedure to be carried out.

• Biological fouling in the RO system to be removed first. Hence we have preferred high pH chemical

cleaning then low pH cleaning. It will give better results.

CAUSTIC SODA + DSS CLEANING (INCASE OF BIOLOGICAL FOULING) :

• Chemical cleaning tank should be cleaned with water.

• Take 900 liter of RO permeate water in chemical cleaning tank and should be free of oxidizing

agent.

• Start the chemical cleaning pump & open the recirculation valve and add DSS (Dodecyl Sodium

Sulfate) slowly with RO permeate water for 900 Liter of solution 2.16kg DSS are used.

• Monitor the pH value and should be maintained within the limit of 7 -10. If not maintained add

NaoH (Max of 0.87kg) for maintaining the pH.

• Before chemical circulation ensure pump flow/chemical cleaning inlet line connection/return line /

permeate return connection to be made.

• When starting the chemical circulation first 10-15 % of solution should be drained out. That means

high concentration of contaminants should not be re – used.

• Circulate the solution 30 minutes check Feed flow, pH and temperature of solution and record the

same.

• Soak the chemical 30 minutes in the RO and both side (inlet /out let) should be closed during

soaking.

• Repeat the procedure if required.

• Drain out the chemical solution and flush the RO with RO permeate water up to the pH reaches

neutral.

CAUTION

• Temperature should not increase to more than 35 deg.

• pH should be maintained 7 -10.

32 Of 62

CITRIC ACID CLEANING (INCASE OF INORGANIC FOULING)



agent.

• Start the chemical cleaning pump & open the recirculation valve, add Citric Acid and make Citric

Acid solution.

• To prepare 900 liters of cleaning solution are needed 8.74 kg of Citric Acid solution.

• Monitor the pH value and should be maintained within the limit of 2 - 4. If not maintained add

Ammonia (NH3) for maintaining the pH.






same.


soaking.


• Drain out the chemical solution and flush the RO with RO permeate water Up to the pH reaches

neutral.

CAUTION

• Temperature should not increase to more than 35 deg.

• pH should be maintained 2 - 4.

33 Of 62

SODIUM HEXA META PHOSPHATE +HYTROCHLORIC ACID CLEANING (INCASE OF COLLIODAL FOULING) :



agent.

• Start the chemical cleaning pump & open the recirculation valve and add Sodium Hexa Meta

Phosphate(SHMP) slowly with RO permeate water. Ensure SHMP dissolved completely in the

chemical cleaning tank.

• To prepare 900 liter of cleaning solution are needed 8.74 kg of SHMP chemical powder.

• Add HCL (Max of 0.44 Kg) to the SHMP solution until pH value is reached 2. If it is going below 2

pH add caustic soda for maintaining pH is 2.






same.


soaking.


• Drain out the chemical solution and flush the RO with RO permeate water up to the pH reaches

neutral.

CAUTION:

1. Temperature should not increase to more than 35 deg.

2. pH should be maintained 2 -3.

NOTE : The specified chemical quantity is was considered as 100% concentration.

34 Of 62

Do's and Don't s of Reverse Osmosis System

Do

· Maintain ORP between +200 TO +350 MV.

· Maintain minimum 0.5 Kg/cm2 pressure in RO HPP suction.

· Maintain recovery as per design

· Maintain the reject recirculation and reject drain as per design.

· Replace the MCF if the differential pressure crosses more than 0.8 Kg/cm2.

· Stop the HPP after full open of Brine control valve.

· Flush the RO with feed water for 5-10 min with RO feed pump before every startup and shutdown.

Don't s

· Don’t start the HPP with out full open of Brine control valve.

· Not to run the system with ORP more than +350 Mv.

· Never run the RO system with by pass of ORP meter and Dechlorination dosing.

· Never run the system with more than 2.5 Kg/cm2 differential pressure.

· Never run the system with permeate valve closed condition.

· Don’t start the system with out ensuring the Nil FRC in RO feed water.

· Never run the HPP with out minimum suction pressure of 0.5 Kg/cm2.

DE GASIFICATION SYSTEMStart the De gasser blower immediately after startup of HPP pump. RO Permeate water is routed

to pass through a De gasification tower & the free carbon dioxide is removed from the water.

DEMINERALIZATION SYSTEMThe Operation can be performed Through Manually.

The above service cycle will perform with the fulfillment of following conditions/Interlocks.

1. OBR of SAC/SBA/MDB

2. pH of SAC

3. Conductivity of SBA

4. Conductivity & Silica of MDB

If any one of the above condition is not satisfied the particular system will go for regeneration

mode. All other units remaining idle.

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REGENERATION CYCLE:Regeneration process calls for anyone of the following reasons.

A) Regeneration of SAC & SBA

▪ OBR of SAC exceeds 400m3/hr.

▪ SAC outlet pH increases above 4.5

▪ OBR of SBA exceeds 400m3/hr.

▪ SBA outlet Conductivity exceeds above 10.0 microsiemens/cm.

B) Regeneration of MB

▪ OBR of MB exceeds 6000 m3 /hr.

▪ MB outlet Conductivity exceeds above 0.5 microsiemens/cm

C) Regeneration of SAC, SBA & MB

▪ MB outlet Conductivity exceeds above 0.5 micro siemens/cm and the SBA outlet

Conductivity exceeds above 10.0 micro siemens/cm.

▪ MB outlet Silica exceeds above 0.02 ppm.

REGENERATION PROCEDURE FOR SAC:Following operation can be done during SAC regeneration cycle. And The total time of

regeneration of a Strong Acid Cation shall not exceed 3 hours.

• Back Wash

• Middle collector Flushing

• Acid Injection

• Slow rinsing

• Final rinsing

During Regeneration cycle Flow and time should be followed as per the enclosed“WTP - DM Regeneration design” sheet.

ACID INJECTION FOR SAC:

Cation resins shall be regenerated by Hydrochloric Acid (HCL). Check the level of Acid Measuring

tank and fill the Acid if the level is insufficient. Open the Power water valve and open the Acid outlet

valve up to achieve the required specific gravity. Chemical Injection time should be followed as per

the enclosed “WTP - DM Regeneration design” sheet.

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REGENERATION PROCEDURE FOR SBA:Following operation can be done during SBA regeneration cycle. and The total time of regeneration

of a Strong Base Anion shall not exceed 3 hours.

• Back Wash


• Caustic Injection

• Slow rinsing

• Final rinsing


CAUSTIC INJECTION FOR SBA:Anion resins shall be regenerated by Sodium Hydroxide. Check the level of Caustic Dilution tank

and fill the Caustic if the level is insufficient. Open the Power water valve and open the Caustic

outlet valve up to achieve the required specific gravity. Chemical Injection time should be followed

as per the enclosed “WTP - DM Regeneration design” sheet.

REGENERATION PROCEDURE FOR MDB:Following operation can be done during MB regeneration cycle. And The total time of regeneration

of a Mixed Bed shall not exceed 3 hours.

• Back Wash


• Caustic Injection

• Slow rinsing

• Acid Injection

• Slow Rinsing

• Water Drain for Air Scoring

• Air Scoring

• Final Rinsing


ACID INJECTION FOR MDB:Cation resins shall be regenerated by Hydrochloric Acid (HCL). Check the level of Acid Measuring

tank and fill the Acid if the level is insufficient. Open the Power water valve and open the Acid outlet

valve up to achieve the required specific gravity. Chemical Injection time should be followed as per

the enclosed “WTP - DM Regeneration design” sheet.

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CAUSTIC INJECTION FOR MDB:Anion resins shall be regenerated by Sodium Hydroxide. Check the level of Caustic Dilution tank

and fill the Caustic if the level is insufficient. Open the Power water valve and open the Caustic

outlet valve up to achieve the required specific gravity. Chemical Injection time should be followed

as per the enclosed “WTP - DM Regeneration design” sheet.

After completion of the regeneration cycle, the DM stream is goes to service cycle.

SERVICE CYCLE:DG WATER TRANSFER PUMP : WPP-13007A/B

Before starting the pump make ensure the DG water Storage tank level has sufficient water and

Open the suction and delivery valve. The delivery valve opening position adjust manually to

achieve the desired flow (service flow).

Caution: Never run the pump with air lock to avoid the damage of Pumps.

PH DOSING SYSTEM : DOT-53006Check the level of pH dosing solution, and fill the solution if the level is insufficient. Start the dosing

pump and adjust the dosing rate as per required pH boost up. The dosing has to be optimized,

depending upon the required pH to avoid increase in TDS in the DM water. The same operation will

be done by automatically by auto - pH dosing pump.

Caution: Never run the pump with air lock to avoid the damage of diaphragm.Note : Use Agitator for chemical preparation for proper mixing of chemical with water.

TROUBLE SHOOTING OF STRONG ACID CATION UNITS

Problem Cause Action

Loss of Capacity Improper regenerationCarry regeneration as per

specificationsChange in raw water

characteristics, Increase in

Na/TC.

Increase acid quantity

Over exhaustion of unitNormal acid will not restore capacity

increase acid quantity.

Channeling

Remove resin fines Replace broken

strainer or laterals Faulty distribution

system-check and rectify.

Loss of ResinInspect resin bed depth

Control Backwash flowResin fouling 1. Get Resin analyze

2. Clean with acid

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3. Replace if analyze too much

decross linking and broken

beads.

Poor Quality of treated

waterValve leakage Arrest the leakage

Higher flow greater than

normal design range

increases leakage

Increase Na/TC has more profound

effect on leakage from increased

flow rate

Low flow rateThe flow rate should be maintained

above 0.5 GPM/ft3 of resin.

TemperatureDoes not have much effect except

for very low temperature

Increased TDSIncreased leakage (Analyze and

correct).Add resin if required.

Hardness in Raw water

Valve leakage, High flow rate,

change in Raw water composition .

Inefficient regeneration

High sodium slip in treated

water

Over exhaustion (Double injection)

Improper regeneration (Correct)

TROUBLE SHOOTING OF STRONG BASE ANION UNITS


Loss of capacity Increase in Ionic load

Put more resin, use more

regenerant. Check for Degasser

functioning.

Long Rinsing timeCation not working, Organically

fouled resin. Give brine treatment.Increase in Alkalinity Check. Add resin or reduce output

Fouled Resin

Chemically clean with hot caustic for

silica & brine treatment for organic

fouling

Precipitation by Ca, Mg

Check Regeneration for Ca/Mg etc.

Check cation if regenerated by

H2SO4. Use Decationized or DM

water for dilution.

Resin ageingUse specified concentration of

NaOH

Bacterial contamination

Unit idle. Do not keep unit idle. Very

important where high purity water

required.

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Heavy metal fouling

Iron in regeneration or through

leakage from cation. Damaged

Rubber lining.Poor treated water

qualityHigh pH, high conductivity

Check cation. Do more Rinsing

Check conductivity meter

Low pH, High conductivity

Check anion. Regeneration not

carried. properly. Organic fouling,

check pH meter

High silica

Resin organically fouled. (Clean

chemically). Carry regeneration as

per specification. Regeneration

temperature low (carry regeneration

by hot caustic). High service water

temperature, check.

Chloride leakage

Valve leakage, chloride in

regenerant WBA not working silica

precipitation in WBA. Rectify.

HardnessCheck cation. Use cation or DM

water for dilution and rinsing.

Sodium leakage

Check raw water for sodium, check

cation for sodium slip, Na slip give

rise conductivity.

TROUBLE SHOOTING OF MIXED BED UNITS


Loss of capacity Organic fouling of anion

loss of resin.

Check and rectify. Give Brine wash

Excessive Rinsing Organically fouled, clean.Improper regeneration Channeling poor distribution. Check

laterals and strainers Use correct

quantity of regenerant.Exhaustion of preceding

cation / anion unit

MB need not be considered to be

exhausted. Most MB’s are designed

for 3-4 runs of Anion and cationPressure drop Valve not opened fully. Broken or

blocked internals. High flow rate or

Resin fine etc.Bacterial growth Unit idle. Check, Recycle water.

Poor Treated Water

quality

Low pH Anion resin organically fouled Clean,

Check Blower, Air Mixing not proper,

See note on acid leakage from MB.High pH Cation/Anion not working, check,

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Regeneration not proper, check

Increase in ionic load.Silica leakage Organic fouling clean. Improper

regeneration. Over exhaustion.Clumping Happens with new resin, Give Brine

treatment.High conductivity Air mix not proper, Insufficient air,

Fouled resin, Back wash not proper,

Improper regeneration, Channeling /

poor distribution.General poor quality Loss of inert resin, Loss of cation

resin if no inert resin, Middle

collector not in proper position,

Backwash not proper. Air mixing not

proper

Do's and Don't s of MDB System.Do

• Air Release and rinsing has to be done before every startup of service cycle.

• Maintain designed flow rate.

• Use clear MB water for regeneration solution preparation.

• Keep the AMT and CDT in closed condition.

Don't

• Don’t backwash with excess flow.

• Not to allow any oxidizing agent in to MB.

• Never use excessive chemical for regeneration.

• Never run the system with intermediate operation.

BULK ACID STORAGE SYSTEM :Before starting the pump make ensure the connection between pump and tanker. The delivery

valve opening position adjust manually.


BULK CAUSTIC STORAGE SYSTEM :Before starting the pump make ensure the connection between pump and tanker. The delivery

valve opening position adjust manually.


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NEUTRALIZED WATER TRANSFER PUMP :Before starting the pump make sure the water level in Neutralization pit. Close the delivery valve

and then start the pump after priming. Open the delivery valve gradually to transfer the neutralized

water to guard pond.


6) SYSTEM DESCRIPTION – COOLING TOWER MAKEUPFILTER FEED PUMP FOR CT MAKEUP : WPP-13002A/B

To feed the raw water from Raw Water Storage Tank to CT-filtration system, Two numbers (1W+1S)

of Filter feed pumps are provided. The capacity of pumps are 22.5 m3/hr @ 3.5 kg/Cm2. The same

pumps shall be used for CT-multi grade filter backwash. Suitable valves are provided for suction and

Delivery line for flow controlling.

MULTI GRADE FILTER : MGF-13002After the dosing Multi Grade Filter is installed for primary filtration of raw water. It is Dead end

Filtration and there is no rejection. Some residual iron, manganese, clay, inert solids, bacteria, and

other constituents are still present in the water.




end construction provided for primary filtration of raw water. Raw water is passed through a Multi

Grade Filter (MGF) unit in order to remove suspended matters & turbidity present in raw water. It is

an MSRL vertical pressure vessel. Internally it is fitted with inlet top distributor and bottom

collecting system. Externally this unit is fitted MSRL frontal piping with butterfly valve for operation.

Inlet outlet pressure gauges and sampling valves also provided for performance observation of

filter.

This unit is charged with various sizes of pebbles, quartz sands of various sizes as per standard bed

height. Size of the media will be arranged such that the bottom contains larges size of pebbles and

top layer will be fine sand. Suspended matters & turbidity gets removed when raw water is passed in

downward direction through this filter bed under pressure. The Multi Grade Filter is capable to filter

up to particles size of 10 micron to 1 mm.

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ACTIVATED CARBON FILTER : ACF-13001Activated carbon filter is installed for primary filtration of raw water. It is Dead end Filtration and

there is no rejection. Some residual iron, manganese, clay, inert solids, oder, chlorine, bacteria,

and other constituents are still present in the water.




end construction provided for primary filtration of raw water. Raw water is passed through a

Activated Carbon Filter ACF unit in order to remove suspended matters,oder, smell, & turbidity

present in raw water. It is an MSRL vertical pressure vessel. Internally it is fitted with inlet top

distributor and bottom collecting system. Externally this unit is fitted MSRL frontal piping with

butterfly valve for operation. Inlet outlet pressure gauges and sampling valves also provided for

performance observation of filter.

This unit is charged with various sizes of pebbles, quartz sands of various sizes as per standard bed

height Size of the media will be arranged such that the bottom contains larges size of pebbles and

top layer will be fine sand and activated carbon is used. Suspended matters & turbidity chlorine oder

gets removed when raw water is passed in downward direction through this filter bed under pressure.

SOFTNER SYSTEM : SOF 13001The softening process consists of passing raw water containing hardness through a bed of cation

resin in sodium form. The hardness ions Ca & Mg are taken up by resin and in exchange sodium

ions are relinquished from the resin. Raw water will continue to get softened till the resin gets

exhausted. Bringing back the resin to it original form is called regeneration. Softener resin is

regenerated by sodium chloride of 10—15 % Concentration.

Softening is the process used for removal of hardness. The feed water containing hardness is

passed through the sodium form Cation resin. Calcium and magnesium both being divalent

displace the monovalent sodium and gets attached to the resin. The treated water coming out of

the unit contains the Na ions which has been displaced by Ca and Mg. As more and more

untreated water passes the unit the resin goes on getting converted to Ca and Mg form. The

selectivity of resin for divalent compound is more than that for monovalent ion. Higher

molecular weight ion is preferred if both ions are of same valence. Ca ions having higher molecular

weight is preferred over Mg ions and thus displaces the Mg ions further down the resin bed. Thus

the top of the resin is enriched with Ca ion. Ca ions pushes the Mg ions down the column

which in turn pushes the Na ions. This cycle continues till the hardness starts leaching out of the

unit. This is known as Exhaustion. The ions which appears first at the end of service cycle is

predominantly is Mg ions. Being dependent on flow rate and uniformity of flow distribution the

band may not be totally distinct. The effluent hardness is less than 5 ppm for low TDS water but

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is about 1% of the total influent hardness in a co-flow regenerated unit depending upon the

regenerant level.

Softner vessel - SOF13001 (20.2 m3/hr Capacity) is made up of MSRL and the size of 1500 mm

dia and 2500 mm Height has been arrived based on the input cation(Ca & Mg) load to the Softner.

BRINE MEASURING TANK FOR SOFTNER : BMT-53001 Softener resins shall be regenerated by Sodium Chlorite (NaCl).

The system consists of HDPE and Capacity of 2m3 sizes 1350mm DIA and 1600mm HOS tank

with over flow drain arrangement, One level indicator provided for visible level observation. One

agitator provided for brine solution preparation, salt proper mixing with water.

Service Cycle

Ca (HCO3)2 Ca NaHCO3

SO4 + Na2 R R + Na2 SO4

Mg Cl2 Mg NaCl

Regeneration CycleCa CaCl2R + NaCl Na2 R +Mg Mg

7) SYSTEM OPERATION – COOLING TOWER MAKEUPFILTER FEED PUMP FOR CT MAKEUP

Before starting the pump make sure the RWST has sufficient water. Close the delivery valve and

Start the Raw Water transfer Pump. Open the delivery valve gradually and adjust up to the required

flow and pressure to the Multi Grade Filter Inlet.

MULTI GRADE FILTER

• Before starting the pump open the service inlet valve and air vent valve ensure the complete air

release through air vent pipe.





Backwash.

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V13287 : SERVICE INLET VALVEV13288 : BACK WASH OUTLET VALVEV13289 : BACK WASH INLET VALVEV13290 : SERVICE OUTLET VALVEV13291 : RINSE OUTLET VALVE V63292 : AIR RELEASE VALVE

Ensure the Multi Grade Filter is backwashed daily, irrespective of the no. of hours of service or

pressure drop across the filter bed.


Procedure for Open BackwashOpen the top manhole of body flange as per the MGF design and drain the water from the filter and



and continue for soaking of 6-8 hrs. Start the filter feed pump and open backwash inlet valve and





Washing The Media



both the valves.





Charging The Media





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Do:










Don't:



30 minutes.




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ACTIVATED CARBON FILTER

• Before open the MGF service Outlet valve open the service inlet valve and air vent valve ensure

the complete air release through air vent pipe





Backwash.

V13297 SERVICE INLET VALVEV13298 BACK WASH OUTLET VALVEV13299 BACK WASH INLET VALVEV13300 SERVICE OUTLET VALVEV13301 RINSE OUTLET VALVE V63302 AIR RELEASE VALVE

Ensure the Activated Carbon Filter is backwashed daily, irrespective of the no. of hours of service

or pressure drop across the filter bed.


Procedure for Open BackwashOpen the top manhole of body flange as per the ACF design and drain the water from the filter and



and continue for soaking of 6-8 hrs. if available blower Start the air scouring blower and continue

air scouring for 15-30 min. Then start the filter feed pump and open backwash inlet valve and





Washing The Media



both the valves.



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Charging The Media



















Do:










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Don't:



30 minutes.




SOFTENER

Service cycle

• Before open the ACF service Outlet valve open the service inlet valve and air vent valve ensure the

complete air release through air vent pipe





Backwash.

V13307 SERVICE INLET VALVEV13308 BACK WASH OUTLET VALVEV13309 BACK WASH INLET VALVEV13310 SERVICE OUTLET VALVEV13311 RINSE OUTLET VALVE V63312 AIR RELEASE VALVEV13315 POWER WATER INLET VALVEV53316 EJECTOR SUCTION VALVE

Regeneration After the unit has given specified quantity of treated water, it has to be regenerated.

Backwash and brine injection

• Open back wash inlet valve and back wash out let valve for 10 minutes.

• After back washing close the back wash inelt out let valve and start the injection.

• Before starting the brine injection open the rinse outlet valve and power water inlet valve and brine

ejector suction valve for 20 – 30 minutes.

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• After completion of brine solution close the ejector suction valve and continue the slow rinsing 20 –

30 minutes or upto brine tracing come out from the water. Close the Power water inlet valve and

start the final rinsing

Final rinse

• Open the service inlet valve and rising out let valve. Start the feed pump this operation continued

20 -30 minutes or outlet water hardness less than 30ppm.

• Then service cycle to continued. open the service outlet valve and close the rinsing outlet valve.

8. PERFORMANCE GUARANTEED WATER PARAMETERS AT THE OUTLET OF MIXED BED PERFORMANCE GUARANTEE

• pH @ 25 Deg. C : 8.8 – 9.2 (After pH correction Dosing)

• Conductivity @ 25 Deg. C : < 0.5 Micro Siemens/cm (Before pH Correction Dosing)

• Total silica : < 0.02 ppm

• Net output at the outlet of MDB : 20 m3 /hr.

9. TOPUP RESIN REQUIREMENT FOR SAC, SBA, MB & SOFTNER

S. NO APPILICATION MAKE TYPETOTAL QTY.(Liters)

TOPUP QTY.(Liters)

1 SAC-01 RESIN (Cation) Rohm & Hass AMBERJET 1000H 800 40

2 SBA-01 RESIN (Anion) Rohm & Hass AMBERJET 4200CL 800 40

3 MB-01 RESIN (Cation) Rohm & Hass AMBERJET 1000H 400 20

4 MB-01 RESIN (Anion) Rohm & Hass AMBERJET 4200CL 600 30

5 SAC-02 RESIN (Cation) Rohm & Hass AMBERJET 1000H 800 40

6 SBA-02 RESIN (Anion) Rohm & Hass AMBERJET 4200CL 800 40

7 MB-02 RESIN (Cation) Rohm & Hass AMBERJET 1000H 400 20

8 MB-02 RESIN (Anion) Rohm & Hass AMBERJET 4200CL 600 30

9 SOFTENER RESIN Rohm & Hass AMBERLITE 120Na 2250 Liters 125

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10. CHEMICAL ANALYSIS PROCEDURE METHODS OF WATER ANALYSIS

CHEMICAL CONTROL

CHLORIDES

Reagents and apparatus

Burette for silver Nitrate

Silver Nitrate solution 0.02N (N/50)

Potassium Chromate indicator solution

Phenolphthalein indicator solution

Nitric acid 0.02 (n/50)

10 ml. Graduate cylinder

10 ml. Graduated pipette (for boiler water or water with high chloride content).

150 ml. conical flask

METHOD

e) Measure a 100ml. Sample of the water to be tested in the graduated cylinder, then pour sample

into the conical flask.

f) Add five drops of Phenolphthalein indicator, if the sample turns pink run in 0.02N Nitric Acid until

the pink color is just discharged.

g) Add five drops of potassium chromate indicator.

h) Run silver nitrate into the sample, drop by drop, with constant shaking until the yellow color begins

to acquire a faint orange tint.

i) Note the burette reading – ‘A’

Measure out 100ml. Of distilled (or deionized) water, pour into the flask and repeat the test procedure note

the burette reading – ‘B’.

CALCULATION

Chloride content = (‘A’ – ‘B’) ml. Of 0.02N Silver Nitrate used x 10 expressed in parts per million (ppm) as

CaCO3.

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CHLORIDES

Mercuric Nitrate method for determination of chloride

REAGENTS AND APPARATUS

Burette for Mercuric Nitride

0.02N Mercuric Nitrate Hg (NO3)2 solution.

Concentrated Nitric Acid.

Distilled water.

0.02N Sodium Chloride solution.

0.1% w/v solution Diphenylcarbazone.

Nickel Nitride (buffer solution)

100 ml. Graduated pipettes.

250ml. conical flasks.

REAGENTS

(1) 0.02N MERCURIC NITRATE Hg (NO3)2

Dissolve 3.24 gms Hg (NO3)2 or 3.42 gms Hg (NO3)2 in approximately 500 ml. Of deionized or distilled

water which contains 3 ml. Of concentrated Nitric Acid. When totally dissolved make up to 1 liter

standardize as under procedure against standard Sodium Chloride solution.

(2) Standard Sodium Chloride solution (0.02N)

Dissolve 1.17 gms of pre-dried granular Sodium Chloride in 1 ltr. O distilled or deionized water (i.e. 1ml

0.02N NaCl = 1 MgCl as CaCO3).

(3) 0.1% w/v solution of Diphenylcarbazone in Iso-Propanol or Ethanol this solution is unstable and should

be renewed monthly.

(4) Nickel Nitrate (buffer solution)

4 molar crystalline nickel nitrate solution containing 5 ml of concentrated Nitric acid per 10 ml. Of solution.

PROCEDURE

Measure 100ml. Of sample into a 250 ml. Flask, add 2 ml. Diphenylcarbazone solution and mix and of

Nickel Nitrate buffer solution and mix again. The resulting solution should be a pale green color if the

solution has an orange tint, add Nitrate drop wise until the green tint is achieved. Titrate the solution with

Mercuric Nitrate until a faint but persistent violet color is observed (I.e. the end point).

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CALCULATION

Chloride content = Ml. Of titration solution x 1000 ml. Of sample expressed in ppm

chloride as caco3.

TEST SILICA (0-1 PPM) – MOLYBDENUM BLUE METHOD.

REAGENTS

(1) ACID MOLYBDATE SOLUTION

75 gms of Ammonium Molybdate annular are dissolved in 50 ml of distilled water. 322 ml of 10/n Sulphuric

acid are added gradually with constant shaking the solution is then made up to 1 liter with Silica free water.

NOTE

(1) Approx. 10/n Sulphuric acid is prepared by mixing 10 ml of conc. Silica-free water.

(2) 10% w/v Tartaric acid solution (or 10% Oxalic acid solution).

(3) REDUCING AGENT

[A] 90 gms Sodium Meta bisulphite are dissolved in 800 ml of silica free water.

[B] 7 gms Anhydrous Sodium Sulphate is dissolved in 10 ml. Silica free water. Together with 1.5gms of

1- Amino, 2- Naphthol, 4-Sulphonic acid solution (b) is mixed with solution (a) and the total volume made

up to 1 litre with silica-free water.

APPARATUS

LOVIBOND NESSLERISER

Disc for silica 0.2-1.0 ppm

Two 50 ml. Graduated tubes for nessleriser pipettes.

Alternatively a spectrophotometer may be used at the wave length corresponding to a maximum

absorption (approx. 80 mu But the exact wave length will have to be checked on each individual

instrument.

METHOD

50 mls of the water under test is treated with 2.0 ml. Acid Molybdate solution and allowed to stand for 5

mins. At a temperature of 20 – 300C if a tinge of yellow appears, 4 ml. Of 10% Tartaric (or Oxalic) acid is

added to the sample followed by 1.0 ml. Of reducing agent and the sample allowed to stand for 20 mins.

The blue colour of the sample is compared with that of a blank comprising the same water without

reagents, using either a B.D.H. lovibond nessleriser or a previously calibrated absorption meter.

53 Of 62

SILICA FREE WATER

Prepare and store in a polythene bottle a large batch of water containing not more than 0.005 SiO2

determine the silica content of the water by treating it as a sample as under ‘method’. This water is used to

prepare reagents and standards and to dilute samples when necessary – distilled water from an all metal

‘still’ or water which has been passed successively through a mixed bed deionization unit regenerated with

NaOH at a level of 20 lbs./cu.ft has been found to meet this specification.

TEST SILICA (0-1 PPM) – MOLYBDENUM BLUE METHOD.


BDH Lovibond nessleriser.

Disc with colour standards 0.05 mg. To 1.0 mg SiO2.

10% w/v aqueous solution of Ammonium Molybdate.

2N Sulphuric Acid solution.

METHOD

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

compartment of the nessleriser.

2. Fill the other nessler glass with the sample at 25-300C. Add 4 ml. Of the 2N Sulphuric acid and 2 ml

of the Ammonium Molybdate solution. Mix thoroughly, place in the right hand compartment and

allow to stand for 10 minutes.

3. Fit the glass standard disc in the hinged lid.

4. Stand the nessleriser facing a uniform source of light, looking north if possible and compare the

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

INTERPRETATION OF RESULT

Silica content in parts/million (ppm) = disc Reading x 20 as SiO2. Should the Colour in the test solution be

deeper than the deepest standard, a fresh test should be carried out using a smaller quantity of sample

and diluting to 50 ml. With distilled water before adding the reagents.

NOTE

Most colorless salts, even when present in relatively large quantities are without influence upon the Colour

54 Of 62

produced in the test provided the concentration of free acid is not unduly disturbed. Phosphates, however,

must be absent, since they respond to the test and yield a yellow Colour similar to that produced by silica.

Phosphates maybe removed by treating 100c. Of the solution under test with 50ml of Sorensen’s borate

buffer solution (pH – 10.0) and 2 ml of 2N Calcium Chloride solution; after mixing and allowing to stand for

2 Hours the mixture is filtered. The test is made on 50 ml of the filtrate by the method described above. As

Sorensen’s borate buffer invariably contains silica derived from the glass bottle, a blank test should be

carried out and the necessary correction made. The result must be multiplied by 1.5.

TEST ALKALINITY

(TOTAL METHYL ORANGE AND PHENOLPTHALEIN)


f) Burette for standard acid.

g) Nitric acid 0.02N (N/50).

h) Ml.graduated measuring cylinder

i) Conical flask (150 ml).

j) Phenolphthalein indicator solution

k) Screened Methyl Orange indicator solution

l) Ml. graduated pipette

m) Sodium ThioSulphate 10% q/v solution.

METHOD

If the alkalinity of the water is low, 100 ml. of sample should be measured using the graduated cylinder.

Otherwise a 10 or 20 ml. portion of sample should be taken with the pipette.

• Transfer the appropriate amount of sample to the conical – flask and add 5 drops of

Phenolphthalein indicator.

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

• Note the volume of acid used multiply by the appropriate factor (see table) and record as ‘P’.

MLS OF SAMPLE TAKEN FACTOR

100 X 10

20 X 50

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10 X 100

• If the water is chlorinated add 2 drops of Sodium ThioSulphate solution. Add 2 drops of screened

methyl orange indicator add continue the addition of acid until the solution just turns to Smoke

Grey.

• Read the burette again note the total amount of acid used in both titration and multiply by the

appropriate factor (see the table above) record result as ‘M’.

INTERPRETATION OF RESULTS

The relative quantities of Bicarbonate and Carbonate and Caustic Alkalinity can then be obtained from the

following table

BICARBONATE CARBONATE CAUSTIC

P = Nil M=Nil Nil

P>1/2M M-2P 2P Nil

P=1/2M Nil 2P Nil

P>1/2M Nil 2(M-P) 2(P-M)

P=M Nil Nil P

NOTE

The above results are expressed in Parts/Million (PPM) as CaCO3.

CI) Screened Methyl Orange indicator solution. Preparation of indicator solution-dissolve 0.2g of

crystalline Methyl Orange in mixture of 25 ml. Cyanol FF in a mixture of 25 ml. Methylated spirits

and 25 ml deionized water. Mix the two solutions together.

CII)For most raw water samples, as also lime softened waters a 100 ml. sample.

CIII) Use Sodium Thiosulphate solution before addition of Methyl Orange only if water has been

chlorinated e.g. from bottling precipitators.

TEST HARDNESS


1. N/50 E.D.T.A.

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4.0 Grams of Di sodium Di hydrogen Ethylene Di amine Tetra Acetate are dissolved in 800 ml of

water and standardized and adjusted a standard hardness solution unit 1 ml. = 1m. gm. CaCO3

2. AMONIA BUFFER

(a) Dissolve 16.9 g Ammonium Chloride, NH4H in 143 ml Conc. Ammonium Hydroxide, NH4OH; add

125 g of Magnesium salt of EDTA (this salt is available commercially) water.

(b) A buffer containing the Magnesium salt of EDTA may to be made as follows

Dissolve 16.9 g NH4Cl in 143 ml conc. NH2OH. Weigh out 0.25 g MgSO4 7H2O. Transfer

quantitatively to a 100 ml. volumetric flask and make up to column with distilled water. Pipette 50.0

ml of this solution into a porcelain dish; add a few drops of the NH4Cl-NH4OH solution (sufficient to

achieve a pH of 10.0-10.1); add 2-3 drops of indicator solution and titrate with EDTA with

continuous stirring until a steel-blue Colour with no tinge of red is present. To the 50 ml. of solution

remaining in the volumetric flask add exactly the volume of delta required in the above titration add

this solution to the NH4Cl-NH4OH moisture and make up to 200 ml. with distilled water.

Keep the solution (A or B) in a plastic or resistant glass container, tightly stopper to prevent loss of

NH3 or pickup of CO2.

3. INDICATOR

Mix 0.5g of Erichrome black T with 4.0 g Hydroxylamine Hydrochloride. Dissolve this mixture in 100

ml. of 95 per cent ethyl or isopropyl Alcohol.

• BURETTE FOR N/50 EDTA.

• 250 ml beaker.

• 50 ml measuring cylinder

• Stirring rod

• For soft water use 750 ml. evaporating dish and magnetic or electric stirrer.

• 50 ml. measuring cylinder.

FOR RAW WATER

A 50 ml quantity of the water is measured out in a measuring cylinder. 40 ml. of this are placed in a 250

ml. beaker 1 ml. of buffer solution and 6-8 drops indicator are added. The titration is then carried out by

adding delta solution from the burette, until the last tinge of red disappears. The last 10 ml. of water are

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then added and the titration completed to the same end-point. The liquid in the beaker is stirred and

supported on a stand, through which the beaker is illuminated from underneath by a blue light.

CHLORINE TEST PROCEDURE

Measure 5 ml. of the reagent in to a glass cylinder to this add rapidly 50 ml. of the water under test mix

thoroughly allow to stand for 1 minute and then compose the Colour with the Colour chart.

COLOUR PRODUCED FRC

WHITE MILKY FLUORESCENT NONE

FOINTLY PINK & MILKY 0.1 PPM

PINK 0.2 PPM

RED 0.5 PPM

PURPLE 0.6 PPM

VIOLET 0.8 PPM

BLUE 1.0 PPM

CHEMICAL ANALYSIS OF WATER FOR TSS, TDS & TS

Total solids are considered to be the sum of dissolved and suspended solids. In water sources the

dissolved solids which usually pre dominate, consist mainly of in organic salts, small amount of organic

matter and dissolved gases. The suspended solids contain much of the organic matter. Any increase of

these tends to increase the degree of pollution of water if used for public health purposes. Moreover this

parameter is very important for analysis especially in Reverse Osmosis plants as a measure of it’s

Performance.

Hence, to carry out the following analysis for unfiltered and filtered sample to determine TDS & TSS as

ppm for a water sample from s particular source.

PROCEDURE

• Weight accurately a thoroughly cleaned and dried evaporating dish of 250ml say ‘m1’ gram on

laboratory physical balance.

• Take 100ml of water sample in it.

• Evaporate the water carefully to dryness.

• When it is almost dried, keep the dish in a hot air over for 110-1000C

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• When residual water is removed completely, cool it at a desiccators to room temperature and find

the mass of residual along with the dish – say '2' gram

Mass of the residual = (m2 – m1) = x gram

The total solids in the sample X x 106/102=104 ppm

Note repeat the above for filter and unfiltered of the sample to determine TSS separately.

SYSTEM MAINTENANCE AND TROUBLE SHOOTINGSYSTEM MAINTENANCE

In every section of The WTP system standby drives had been provided to overcome unexpected

shutdown. Regarding the process equipment standby is not provided and the same has to be

taken care by scheduled preventive maintenance. This section consists of summary of system

maintenance tasks which include scheduled maintenance, trouble shooting and repairs. This

section is to be read in conjunction with the detailed maintenance/trouble shooting/repair

instructions in the respective manuals supplied by various manufactures. All maintenance should

be documented in a maintenance log, so as to maintain a chronological history of all maintenance

tasks performed.

TYPE OF MAINTENANCE :SCHEDULED MAINTENANCE

Regular preventive maintenance tasks are recommended on a periodic basis. The critical aspects

are summarized below.

INSTRUMENT CALIBRATIONRecommend intervals for calibration tasks as recommended on a periodic basis. The critical

aspects are summarized below to serve as quite.

INSTRUMENT RECOMMENDED INTERVAL

Conductivity Indicator 90 days

PH Indicator 90 days

Silica Analyzer 90 days

Pressure Gauge 100 days

Pressure Switch 30 days

Flow Indicator 60 days

Flow Transmitter 30 days

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ROUTINE MAINTENANCEOpen the valve bodies periodically and check the condition of internal parts and lubricate the seats/

spindles.

11. P&ID DIAGRAM FOR WATER TREATMENT PLANTENCLOSED.

12. POWER CONSUMPTION DETAILS ENCLOSED.

13. TENTATIVE CHEMICAL REQUIREMENTS ENCLOSED.

14. VENDOR'S MANUALS ENCLOSED.

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14. TECHNICAL SUPPORTContact CL personnel in the following cases :

• When the module is preserved longer duration.

• For any failure of the system.

• For any up gradation of the system.

• For expansion of the system.

• Degrade in salt rejection.

• High differential pressure across the membrane system.

Do & Don’t Guide Line

• To follow the guide lines provided in O&M Manual for proper starting and shutdown of the plant.

• The plant to be operated by the trained and experienced personnel.

• To check the SDI of the feed water everyday before the HP Pump.

• To check the pressure difference of the MCF and to closely monitor the same.

• Change the MCF cartridges if the pressure difference exceeds more than 1.0 kg/cm2 OR once in

three months whichever earlier.

• Before starting HPP, keep the system full of water and free of air.

• Check for any abnormality of HPP.

• Correctly balance the RO Product and reject flow rate as per the plant design and specifications.

• Ensure system interlocks are in line as a protection to the plant equipments.

• Closely observe the pressure difference across the RO Module, quality of product water produced.

• Carry out minimum 15 min. flushing before starting and shutdown of the plant.

• Calibrate all the instruments for accuracy and reliability of data’s for ensuring overall integrity and

efficiency of the plant at regular intervals as per our recommendation.

• Keeps proper record of daily operational log sheets review the plant status, recording of daily

events, activities carried out and to maintain the equipment history record to carry out necessary

service in time.

• Always maintain minimum inventory of original spares and regular consumables to reduce down

time of the plant equipments.

Do Not

• Not to operate the plant when the SDI of the feed water is more than the limiting factor specified.

• Not to operate the plant when the pressure difference across MCF is more than 1.0 kg/cm2.

• Not to operate the plant when the feed water conductivity is more than the limiting factor specified.

• Not to run the HPP with LPS by passed and with insufficient suction pressure.

• Not exceed the product recovery rate more than the specified value.

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• Not to open and dismantle and HPP during the Guarantee Period without prior information to M/s.

CL.

• Not to open the RO module in case of any deviations of the plant parameters without prior

information to Ms/. CL during the Guarantee Period.

• Not to carry out any chemical cleaning during the guarantee period without prior information to Ms/.

CL as well as without the presence of M/s. CL’s representatives.

• Not to operate the plant without checking the presence of any oxidizing agents such as ozone,

chlorine before the RO feed.

• Not to use duplicate spare parts/regular consumables this may impair the long life of system and

equipments.

BRANCH OFFICES/AGENTS/REPRESENTATIVES AVAILABLE IN

ALL MAJOR CITIES; FOR MORE INFORMATION PLEASES CONTACT

REGD. OFFICE & FACTORY

M/s CETHAR LIMITED

No 4, Dindigul Road,

Tiruchirapalli

Tamil Nadu 620 001

Phone No. : 0431-2484000

Fax No. : 0431-2481079

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Mtpcl - Wtp o&m Manual

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