Sunteți pe pagina 1din 111

M/s .Rawest Power Pvt.Ltd.

Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
1
Doshion Veolia
WATER SOLUTION

OPERATION & MAINTENANCE
MANUAL
FOR
DM SYATEM

PLANT SUPPLI ED TO:

M/S RAJWEST POWER PVT LTD
BADMER


PLANT SUPPLIED BY:

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



PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
2
OPERATION MANUAL


Sr.No. Section Page
01. Introduction 3
02. Cautions 5
03. Description 8
04 Technical Specification ( Mechanical ) 30
05 Technical Specification ( Elect / Inst ) 31
06. Operation & Control Philosophy 32
07. Chemical & Power consumption. 56 & 58
08 Maintenance & Trouble Shooting 59
09 Water analysis & Test methods 81
10. Lab. Equipment list & Equipment History
Card
104







PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
3



I NTRODUCTI ON
























PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
4
INTRODUCTION:

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

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

The specific method adopted for conventional treatment such as
flocculation/coagulation , filtration and disinfection, lime soda softening process,
electro dialysis, demineralization, reverse osmosis and others are depends upon the
product quality requirement .








PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
5







CAUTIONS
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
6
CAUTIONS

READ THIS MANUAL:-
Prior to operating or servicing this plant, this manual must be read and understood. If any
doubt exists, call for assistance before proceeding. This manual and other associated
manuals are desirable to keep with operators and service people of the plant.

USE PROPER POWER CONNECTION:-
Use proper wiring and connection methods to satisfy industrial electrical code.

SHOCK HAZARD:-
Connect this device to a properly grounded connection in accordance with the National
electrical code. DO NOT under any circumstances remove the ground wire or ground
prong from any power plug / connection. Do not use extension cords without proper
consideration.

DO NOT REMOVE COVER OR PANEL:-

To avoid electrical shock hazard, do not remove covers or panel when power is supplied to
the electrical equipments when covers or panels are removed.

DEVICE LABELING:-

Under any circumstances, do not remove any caution, warning or other descriptive labels
from the plant until the conditions warranting the label are dominated.

DO NOT OPERATE UNDER AN INFLAMMABLE ATMOSPHERE:-

To avoid fire or explosion, do not operate this plant in an explosive environment.

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
7
WARRANTEE / GUARANTEE:-

DOSHION, Guarantees the proposed product to be free from defects in material
or workmanship when operated in accordance with written instructions for a
period of three years from commissioning or three & half years from receipt,
whichever is shorter. Parts not manufactured by DOSHION are covered by their
manufactures warranties which are normally one year.

It is the obligation of the User to maintain regular operating data record.
DOSHION may request these records in the warranty claim evaluation. User
must notify DOSHION at the very first sign of change in performance of the
DOSHION unit. Such notification should be in writing and should include all data
requested on the operating log sheets.

AFTER SALES TECHNICAL SERVICES:

If you wish to return goods for repair, warranty evaluation and / or credit,
please have your original sales order or invoice available. Customer should
send their written complain / claim to customer care division at,

M/s. DOSHION VEOLIA WATER SOLUTION PVT.LIMITED.
Plot no. 24, 25, 26, Phase - II, G.I.D.C. estate, Vatva,
Ahmedabad 382 445, Gujarat,
Phone no. : 091 - 079 - 2583 1156, 2589 1916, 2589 3586
Fax no. : 091 - 079 - 2583 3302

Or send electronic mail to,

wecare@doshion.com.

DOSHION customer care representative will provide necessary instructions.



PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
8



DESCRI PTI ON






PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
9

Sr.No. NAME OF ITEM
1. FEED WATER PUMP
2. ACTIVATED CARBON FILTER
3. STRONG ACID CATION EXCHANGER
4. DG TOWER
5. DEGASSED WATER STORAGE TANK
6. DG BLOWER
7. DEGASEED WATER TRANSFER PUMP
8. STRONG BASE ANION EXCHANGER
9. MIXED BED
10. MIXED BED BLOWER
11. BULK ACID STROGE TANK
12. BULK CAUSTIC STORAGE TANK
13. ACID UNLOADING PUMP
14. CAUSTIC UNLOADING PUMP
15. ACID MEASURING TANK FOR SAC
16. ACID MEASURING TANK FOR MB
17. CAUSTIC DILUTION TANK FOR MB
18. CAUSTIC DILUTION TANK FOR SBA
19. CAUSTIC FEED PUMP
20. N-PIT
21. AMT FOR N-PIT
22. LIME DOSING TANK FOR N-PIT
23. NEUTRALIZATION WATER TRANSFER PUMP
24. REGENRATION WATER PUMP
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
10
25. PRIMING TANK
26 INTERMEDIATE TANK
27 BASKET SRAINER
28 DOSING TANK
29 NAOCL DOSING PUMP
30 NAOH DOSING PUMP
31 HCL DOSING PUMP
32 ULTRA FILTRATION MODULE
33 UF FEED PUMP
34 UF BACK WASH PUMP


















PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
11
FEED WATER PUMP: FWP- 1101/ A/B/C
The Vertical Turbine Type capacity 100M3/Hr raw water transfer pump
(2W + 1S) MOC CI is incorporated in the system to transfer the raw water from
raw water storage tank to Activated Carbon Filter.


ACTIVATED CARBON FILTER (ACF):

Activated carbon filter is provided in order to remove colour, odour free
chlorine & organics to some extent. The activated carbon media is a very good
adsorbent which adsorbs the free chlorine from filtered water. It is a MSEP(2W+1S)
Vertical pressure vessel.
This unit is charged with an activated carbon bed, which is supported on a layer of
silex and pebbles.
Free chlorine, colour & Organics to some extent from filtered water are removed by
activated carbon.
Chlorine reacts with Activated Carbon as follows
C + 2Cl
2
+ 2H2O = 4HCl + CO
2

STRONG ACID CATION UNIT: -

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

It is an MSRL (2W+1S) vessel fitted with top header piping fitted with
nozzles/strainers for inlet water uniform distribution, bottom distribution plate with
nozzles/strainer for water outlet as well as to prevent slippage of the resin, chemical
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
12
header pipe works fitted with nozzles/strainers for regeneration of the resin bed and
vessel frontal pipe work with valves for normal & back wash, regeneration and rinse
operation. The vessel is filled with cation resin for a calculated volume as per the
water quality and ionic load with sufficient height of free board as a provision for bed
expansion. All the piping inside the vessel is rubber lined for adequate thickness to
prevent corrosion as well as to safe guard the quality of water.

The chemical reactions given below illustrate the process of demineralization.



CATION EXCHANGER:

NaCl + R-H = R - Na + HCl
Sodium Hydrogen Sodium Hydrochloric
Chloride Exchanger Exchanger Acid.

MgSO
4
+ 2R-H = R
2
Mg + H
2
SO
4

Magnesium Hydrogen Magnesium Sulphuric
Sulphate Exchanger Exchanger Acid.

Ca (HCO
3
) + 2R-H = R
2
Ca + 2CO2 + 2H
2
O
Calcium Hydrogen Calcium Carbon Water
Bicarbonate Exchanger Exchanger Dioxide






PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
13
REGENERATION:

R Na HCl
OR Hydrochloric Acid
R
2
Mg +
OR OR RH +NaCl OR MgCl
2

R
2
Ca H
2
SO
4
= OR CaCl
2

Sodium sulphuric acid sodium, magnesium or
Magnesium calcium chloride
Or calcium or CaSO
4

Exchanger



DEGASIFICATION SYSTEMS:

DEGASSER TOWER

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

DEGASSER WATER STORAGE TANK:

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



PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
14

DEGASSER BLOWER:

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

DEGASSER WATER TRANSFER PUMP:

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



STRONG BASE ANION EXCHANGER:

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

It is an MSRL(2W+1S) vessel fitted with inlet bell mouth for uniform water
distribution, bottom distributor for water outlet as well as to prevent slippage of the
resin, chemical header pipe works fitted with nozzles/strainers for regeneration of
the resin bed and vessel frontal pipe work with valves for normal & back wash,
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
15
regeneration and rinse operation. The vessel is filled with SBA resin for a calculated
volume as per the water quality and ionic load with sufficient height of free board as
a provision for bed expansion. All the pipings inside the vessel are rubber lined for
adequate thickness to prevent corrosion as well as to safe guard the quality of water.

The chemical reactions given below illustrate the process of demineralization.
H
2
(SO
4
)
2
(SO
4
)
2

2HCl 2Cl
2(HSiO
3
) + R - OH = 2(HSiO
3
) R + H
2
O
2(HCO
3
) 2(HCO
3
) Water
Sulphuric Acid, Hydroxide Sulphate
Hydrochloric Acid Exchanger Chloride
Sililic Acid Salilic
carbonic Acid Carbonic


REGENERATION :
(SO
4
)
2
SO
4

2(Cl) Cl
2

2(HSiO
3
) R + 2NaOH = R - OH + Na
2
(HSiO
3
)
2

2(HCO
3
) (HCO
3
)
2

Sulphate, Chloride Sodium Hydroxide Sodium Sulphate
Salilic, Carbonic Hydroxide Sodium Chloride
Exchanger Sodium
Silicate
Sodium Bi-carbonate




PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
16

06. MIXED BED UNIT:

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

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





PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
17
MIXED BED BLOWER:
For through mixing of Cation and anion resins after MB regeneration, two nos.
twin lobe type positive displacement type air blowers (one working and the other
as standby) are provided in the system for supplying the required air at sufficient
quantity and pressure for effective mixing of the resin bed.



BULK ACID STORAGE TANK


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


BULK CAUSTIC STORAGE TANK

To store the caustic from the outside tankers a separate MSRL vessel with
all necessary associated pipe works, valves, level indicators, inlet, outlet and

overflow nozzles has been incorporated to receive as well as to supply caustic
to CDT for carrying out the regeneration of the MB & SBA units. A suitable
centrifugal pump of adequate head and capacity of recommended MOC
has been provided of recommended material of construction for unloading caustic acid from
the outside tankers as well as to supply acid to the plant for regeneration purpose.















PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
18
10. ACID MEASURING TANK FOR SAC:

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

11. CAUSTIC DILUTION TANK FOR SBA:-

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



12. ACID MEASURING TANK FOR MB:

This comprises of separate tanks in MSRL for acid, incorporating all nozzles for
chemical inlet, service water inlet, level gauge, overflow, drain, fume absorber etc.
Also included with the associated pipe works and valves in MSRL for connecting the
tank and the power water source via ejector for creating the necessary vacuum for
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
19
injection of chemical at 4 to 6% w/v for the resin bed. The concentration of the
chemicals in the solution tank is maintained at 30 to 32 % w/v. For proper
regeneration the flow rates recommended at different stages to be maintained
properly as well as quantity of chemicals for each cycle of regeneration.

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

14. NEUTRALISATION SYSTEM:

Neutralization pit operation:-

Auto / Manual selection will be provided for Disposal and
recirculation valves.

Pre condition for Neutralization pit pump starting:-

1. Pump Module Ready ( MCC not Disturbed ) feedback from MCC
should be available.

Pump will be operated by the operator through PLC soft button
Control Desk push Buttons.





PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
20
Interlock:-


A soft button will be provided for operator selection of Neutralisation Pit
compartment.

Logic of N-Pit operation:-

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




Condition:- 1.

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



Condition 2

If pH value is higher than pre set range for more than 30 seconds
then Recirculation valve will open and then discharge valve will
close automatically. Operator will manually open Acid dosing valve
and start dosing. After the pH value reaches the preset range
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
21
operator will manually close the dosing valves. If pH value remains
within limits for 10 minutes discharge valve will open and then
recirculation valve will close automatically.
INTERMEDIATE STROGE TANK.
The final product from MB vessel is stored in tank of adequate
capacity to distribute water further for process, for UF system.

UF FEED PUMP:
UF Feed pumps 2 Nos having a capacity of 50 m
3
/hr @ 2.5 Kg/cm2
along with necessary suction , discharge piping , pressure gauges for
pumping the DM water to the UF system through basket filter

BASKET FILTER:

For removing the fine suspended particles from the water and particles due to
non performance of Sand filter. On line Basket Filter with 100 micron absolute
rating is provided to removes the suspended particles down to 100 micron.
The basket filter is provided with local pressure gauges for monitoring
pressure drop and choking of filter.

UF SYSTEM:

Cross flow membrane filtration technique is for the separation of suspended
or dissolved materials by molecular weight & size. Application of a pressure
difference causes the membrane to act like a sieve. Substances smaller than
pore size of the membrane passes through with solvent as permeate, while
larger solutes or particles are retained as concentrate. This separation
technique is easy to handle and requires no phase change no addition of
chemicals and little energy.

Ultra filtration and Nano filtration membranes are high density micro porous
skin cast onto a highly porous substructure. The substructure acts only as
support for the extremely thin active layer and generally has no effect on the
filtration characteristics of the membrane. Since the actual discriminating
barrier is extremely thin, very high flux can be easily achieved. Due to the
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
22
highly asymmetric structure, all rejected material is retained on the membrane
surface and internal pore fouling is virtually eliminated.

08. UF BACK WASH PUMP:

A Horizontal centrifugal pump of SS 316 has been provided in the system to
supply UF treated water from DM water storage tank for supplying the
required quantity water for back washing and flushing the UF module at the
required head and capacity. The pump is provided with necessary piping
connections, pressure gauge, valves and control interlocks. For details,
please refer the technical data sheets for all mechanical equipments.


.



DM WATER STRORAGE TANK:

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

DM WATER REGENRATION PUMP:

Permissive for starting of pump:-

1. MODULE READY (MCC not Disturbed) feedback should be available from the
MCC.
2. DM Water storage Tank level should not be Low.

The Regeneration Pumps will be provided with following selections:

AUTO / MANUAL
RWP- 3101/3102

In Manual mode of operation the Pumps can be started using soft buttons from
Operator
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
23

Workstations.

In Auto mode of operation Pump selected MAIN pump will start when any SAC /
SBA / MB are put in Regeneration. STANDBY pump will start automatically if the
MAIN pumps trips electrically or MAIN pump fails to start. If one SBA / MB is in
Service and another SAC / SBA / MB is taken in Regeneration / Backwash then
the Standby pump will start automatically. That is if one stream is running and
another vessel is taken in Regeneration / Backwash then both the Regeneration
Pumps will be in operation. On completion of Regeneration / Backwash cycle the
STANDBY pump will switch OFF automatically.

The inlet valve of the DM Storage Water Tank selected for filling will be opened
Manually from the Operator workstations.

Regeneration pumps will TRIP on any of the following conditions:
Electrical TRIP
DM Water Storage tank Level Low

Both pumps status (Running/Electrically healthy/stop) will be displayed in PLC
Workstation graphics. Operator alarms will be generated for Low and High level of
DM tanks.
.
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
24

BASIS OF DESIGN:


A) FEED WATER ANALYSIS:

Sr. No. Parameter Uni t Data
1.
CALCIUM as CaCO3 Mg/l 90
2.
MAGNESIUM as CaCO3 Mg/l 70
3.
SODIUM as CaCO3 Mg/l 49
4.
TOATL HARDNESS as CaCO3 Mg/l 160
5.
SULPHATE as CaCO3 Mg/l 9.00
6.
CHLORIDE as CaCO3 Mg/l 20.00
7
Total Dissolved Solids Mg/l 210-370
8
Silica Mg/l 30.0
9
Alkalinity(Total) Mg/l 180.00
10.
Turbidity NTU 3000
11.
PH 8.5-8.8



Out put water Quality

DM WATER QUALITY

Na+ K
<0.1 ppm
Ca
< 1 ppm
CL + F
< 0.1 ppm
SILICA ACID ( SIO2Nh2O)
<0.05 ppm
PH
<8.8

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
25
GUARANTEED WATER QUALITY

# CLARIFLOCCULATOR


Turbidity Less than 15 NTU
KMnO4 No. O2 absorbed
Mg/I, 4 hours at 37 Deg. C Nil

# GRAVITY FILTERS

Turbidity 1 NTU (max)

EFFLUENT QUALITY FOR D.M. PLANT

ACF

Turbidity Nil
Free Chlorine Content Nil

SAC

Sodium (Na) 1 ppm

SBA

SiO2 < 0.2 ppm






PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
26
MB

Total dissolved solids, (max) < 0.05 ppm
Total Hardness Nil
Chloride Nil
Total Silica as SiO2, (max) < 0.01 ppm
Iron as Fe, (max) Nil
Conductivity at 20 deg. C
(max) 0.1 S/cm
PH
7 0.2 at 20 Deg C
ambient
Turbidity Nil




























PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
27











PROCESS
DESCRIPTION
AND
DESIGN BASIS





PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
28
BRIEF DESCRIPTION OF DM PLANT:

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

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

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

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

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
29



B. TREATED WATER QUALITY:

Sr. No. PARAMETERS OUTLET
1 Conductivity @ 25 C <1 micro S / cm after MB outlet
(Before pH correction)
2 Reactive Silica as SiO2 0.02 ppm max
3 PH 6.8 to 7.2 after pH correction
dosing


Note:
The treated water quality is subjected to following

1 The feed quality is same as specified in your inquiry. In case of any change
in the quality of raw water the same may have implications on operating
parameters or on end results of the system.
2 The feed limiting conditions mentioned as below are strictly maintained. The
operation of demineralization so strictly done as per reports should be sent to
us for monitoring of system and to suggest suitable actions for better and
smooth operation of the system.
3 Pure chemicals, original spares and consumable specified by us are used in
DM plant. Sufficient inventory of spares for at least 1 year is to be maintained.




PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
30






TECHNICAL
SPECIFICATIONS
MECHANICAL
AS PER ATTACHED
ANNEXURE: 1




PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
31





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

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
32




OPERATION
AND
CONTROL
PHILOSOPHY










PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
33
BRIEF SYSTEM DESCRIPTION:
A. SYSTEM OPERATION

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

A.1 BASIC OPERATION GUIDE LINES

A.1.1 All the system pipe work are to be lined up properly before commissioning operation
of any part of the system such as pre treatment, ACF SAC, DGWST,SBA,Mixed Bed
& UF . All the valves are tagged for easy identification for closing and opening as
per the guidelines provided in our comprehensive Operation & Maintenance Manual

A.1.2 Activated carbon filters are to be backwashed for 25 minutes at the rated flow once
in a day or if the pressure drop across the vessel exceeds 0.8 kg/cm2 whichever is
earlier.

A.1.3 All the chemical solution for pretreatment dosing, SAC, SBA & MB such as Acid &
Alkali are to be prepared at the right concentration and dosage at the right capacity
to achieve desirable water quality.

A.1.4 All the equipments are to be started after ensuring the systems pipe work and
vessel is full of water and free of air.

A.1.5 Water samples from different stages of the treatment plant are to be taken regularly
for checking Hardness, TDS & Conductivity of water from SAC outlet, SBA outlet &
MB outlet water to assess the performance level

A.1.6 Detailed recording of the plant parameters in standard log sheets, to check and
review the performance of the plant as well as to observe for any abnormalities.

A.1.7 Mixed bed is to be put on regeneration for Cation and Anion resin bed upon
completion of OBR period as per the guidelines provided in our Operation &
Maintenance Manual. The rated quantity of Acid & Caustic Soda is to be used with
correct concentration in the solution Tank (30%). The final solution inlet to the
vessel will be at 5 to 6%.

A.1.8 Thorough air mixing of Cation & Anion after regeneration and final rinsing of the bed
is required for achieving rated quality of water.


PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
34
OPERATION SEQUENCE

Pre Treatment

Select the filter water pump, after ensuring adequate head of water
in the DM Clarified water storage tank. Keep the pump discharge kept throttled.
Check the free rotation of the shaft and direction. Start the pump to maintain the
flow of 90 M^3/hr at adequate discharge head.

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



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


STATUS (Now pre treated, filtered water is available for subsequent treatment scheme.
Refer the attached Timing scheduled for back washing procedure of the
ACF

Ensure partial opening of the back wash inlet valve V-1105,2105,3105 and full
opening of air release valve V1108,2108,3108 the SAC vessel before taking ACF
in to the service cycle to prevent sudden pressurization of the vessel. After taking
ACF in to the service, fill up the vessel with water and to remove the air
completely from the vessel.

Line up the SAC vessel after regeneration of the resin by opening the Header &
service inlet and outlet of the vessel V-1109,2109,3109 & V-1110,2110,3110 and
outlet valve V-1118,2118,3118 All the other valves of the vessel are to be fully
closed. Keep the flow rate across SAC at 90 m^3/hr for each stream (2S+1S) at
the inlet of the SAC.

Now SAC, treated process water is available at the rate of 90 M^3/hr. SAC to be
subjected to regeneration after completion of OBR value after the specified
duration of operation at the rated flow. Please refer the regeneration procedure for
the SAC attached. Check the outlet parameters of the SAC water at the outlet of
the vessel before commencing the regeneration.

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
35
Ensure partial opening of the Header & service inlet V-1121,2121,3121 & V-
1122,2122,3122 and air release valve V-1132,2132,3132 of the SBA to fill the
water in the vessel and to remove the air completely.


Line up the SBA by opening inlet and outlet valves fully opened V-1122, 2122,
3122 & V-1130, 2130, 3130 maintain the flow rate across the system 90 M^3/hr
per stream ( 2W+1S).

Ensure partial opening of the Header & service inlet V- 1133,2133,3133 & V-
1134,2134,3134 and air release valve V- 1145,2145,3145 of the MB to fill the
water in the vessel and to remove the air completely.

Start to fill the MB vessel full of water and free of air

Line up the MB by opening inlet and outlet valves fully opened V-
1134,2134,3134 & V-1143,2143,3143 to maintain the flow rate across the vessel
90M^3/hr for each vessel (2W+1S),. The above operation is to be done after
ensuring the following :

- Thorough mixing of cation and anion resin after regeneration
- Status of the resin . It should be fully in regenerated condition or in completion
of OBR after completion of last regeneration.)
- Check the conductivity of MB outlet water for within the specified limits.

Demineralised water at the rate of 90M3/hr is available please refer the
attached sheet for regeneration procedure of the mixed bed. Also refer the field
instruments for conductivity and flow at the outlet of mixed bed.

Note: All the frontal valves for ACF, SAC, SBA and MB are operated
according to the operation as per the sequence mentioned above.
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
36
BACKWASHING


BACKWASHING OF THE ACTIVATED CARBON FILTER

Backwashing of the ACF is to be carried out in case of observing the pressure drop
across the vessel as 0.8kg/cm or once in 20 hours of operation whichever is earlier.

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


BACKWASHING PROCEDURE OF ACF

The procedure as under.

1]. Close the service inlet and outlet valve fully closed (V-1102, 2102, 3102&V-
1106,2106,3106),

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

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

4]. Ensure the vessel is full of water and free of air

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

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

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

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

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
37

STRONG ACID CATION REGENERATION PROCEDURE & NORMAL OPERATION

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

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

NORMAL STOPPING:

Switch off the conductivity meter, and close conductivity isolation valve. Close the inlet
(V-1110, 2110, 3110) and outlet (V-1119, 2129, 3129) valve. Release pressure by opening
air release valve (V-1120, 2120, 3120).

SAC REGENERATION DATA TABLE - I FOR TIMINGS:

01. SAC Backwash 05 mins
Middle collector flush 05 mins
Pre injection 03 mins
Acid injection 20 mins
Acid slow rinse 28 mins
Final rinse 09 mins


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


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
38



REGENERATION:

For the first six months of operation, the SAC unit is regenerated at its rated output between
regeneration. If the quality of the treated water is satisfactory, the output between two
regenerations may be stepped up after the initial six months. If the treated-water quality is still
satisfactory then the run should be terminated on Sodium breakthrough. Note in case of
longer operation of the plant if the product water quality from SAC unit is not as per the
requirement after regeneration; we recommend doing the double quantity regeneration of
SAC unit after 8-10 regeneration.

PREPARATION OF REGENERANTS:

Pour the Hydrochloric Acid for the cation regeneration in the acid measuring tank to prepare
30-32% by w/v HCL solution.

The quantity of HCL (30%) per regeneration for one SAC unit: 1390.98 Kg.

BACK WASH:

Open slowly backwash inlet valve (V-1116, 2116, 3116) and backwash outlet valve (V-1111,
2111, 3111). Maintain the required flow rate by adjusting the outlet valve (V-1111, 2111,
3111). After ten minutes of backwashing close the valves (V-1116, 2116, 3116 & V-1111,
2111, 3111). Recommended flow rate 44.2 M3/Hr.. This operation is to ensure loosing of the
resin bed to remove fines and any other impurities.

MIDDLE COLLECTOR FLUSHING

This operation is to ensure clearing of the middle collector piping for any traces of resin and
other impurities, before commencing the acid injection. To operate the following valves for five
minutes. The flow rate is to be maintained as 44.2 m3/hour for 5 minutes.

ACID PREINJECTION / DOWN FLOW :

This step is carried out to set the flows for injection. The middle collector outlet valve, service
inlet valve, acid inlet valve, power water inlet valve are opened for stabilizing the flow rates.


PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
39
ACID INJECTION ( CCR)

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

Acid solution inlet to vessel - V1117, 2117, 3117
Acid ejector suction valve - V5076
Rinse outlet valve - V-1119, 2119, 3119


ACID SLOW RINSE

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

Acid solution inlet to vessel - V-1117, 2117, 3117
Rinse outlet valve - V-1119, 2119, 3119

FINAL RINSE:

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

Service Inlet V-1110, 2110, 3110
Rinse outlet V-1119, 2119, 3119
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
40

STRONGE BASE ANION REGENERATION PROCEDURE & NORMAL OPERATION

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

NORMAL STOPPING:

Switch off the conductivity meter, and close conductivity isolation valve. Close the inlet (V-
1122, 2122, 3122) and outlet (V-1130, 2130, 3130) valve. Release pressure by opening air
release valve (V-1132, 2132, 3132)

SBA REGENERATION DATA TABLE - I FOR TIMINGS

01. SBA Backwash 05 mins.
Middle collector in 03 mins.
Caustic injection 20 mins.
Slow rinse 32 mins.
Final rinse 20 mins.




Note- Please note , during the normal operation & regeneration of the DM Plant vessels
as explained below the valves other specified should be kept in closed condition.
REGENERATION :

For the first six months of operation, the SBA unit is regenerated at its rated output between
regeneration. If the quality of the treated water is satisfactory, the output between two
regenerations may be stepped up after the initial six months. If the treated-water quality is still
satisfactory then the run should be terminated on conductivity breakthrough. Note in case of
longer operation of the plant if the product water quality from SBA. Unit is not as per the
requirement after regeneration; we recommend to do the double quantity regeneration of
SAC. unit after 8-10 regeneration.

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
41
PREPARATION OF REGENERANTS:

Fill the caustic dilution tank with water and gradually add Noah (100%) to make 30-32%
solution. The concentration of diluted regenerant may be confirmed either by checking the
specific gravity or by titration.

The quantity of NaoH (48%) per regeneration per SBA unit: 547.30 kg.

BACK WASH:

Open slowly backwash inlet valve (V-1128, 2128, 3128) and backwash outlet valve (V-1123,
2123, 3123). Maintain the required flow rate 19 M3/Hr. by adjusting the outlet valve (V-2123,
1123, 3123). After five minutes of backwashing close the valves (V-1128, 2128, 3128 &V-
1123, 2123, 3123 ) . Recommended flow rate 19M^3/hr. This operation is to ensure loosing of
the resin bed to remove fines and any other impurities.

MIDDLE COLLECTOR FLUSHING

This operation is to ensure clearing of the middle collector piping for any traces of resin and
other impurities, before commencing the acid injection. To operate the following valves for five
minites. The flow rate is to be maintained as.19 m3/hour.

Middle collector inlet valve V-1126, 2126, 3126
Backwash outlet valve V-1123, 2123, 3123

CAUSTIC PREINJECTION (CCR)
Open service inlet valve, caustic inlet valve, power water inlet valve, and SBA middle collector
outlet valve to set the flow rates.

CAUSTIC INJECTION (CCR)

Caustic injection is being carried out at the rated flow for a period of 25 minutes by operating
the following valves & all other valves should be kept closed.
(Recommended flow rate 27.3 M^3/hr)

Balance water (service inlet) - V-1125, 2125, 3125
Power water for Caustic ejector - V-5170, 5171
Caustic solution inlet to vessel - V-1129, 2129, 3129
Caustic ejector suction valve - V- 5150, 5155
Rinse outlet valve - V-1131, 2131, 3131
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
42

CAUSTIC SLOW RINSE

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

Balance water (service inlet) - V-1125, 2125, 3125
Power water for Caustic ejector - V- 5170, 5171
Caustic solution inlet to vessel - V-1129, 2129, 3129
Rinse outlet valve - V-1131, 2131, 3131


FINAL RINSE:

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

Service Inlet V-1122, 2122, 3122
Rinse outlet V-1131,2131,3131
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
43

MIXED BED REGENERATION PROCEDURE & NORMAL OPERATION

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

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

Open M.B. inlet valve (V-1134, 2134, 3134) and air release valve (V-1145, 2145, 3145).
When water starts coming through air release pipe. Close (V-1145, 2145, 3145) and
open/adjust rinse outlet valve (V-1166, 2166, 3166). Rinse the unit at final rinse flow rate
11.4M3/Hr. for 15 minutes. Open conductivity isolation valve and switch on the
conductivity meter. Check the conductivity, if satisfactory (conductivity should be less
than<1.0 s/cm) then close rinse outlet valve and open and adjust M.B. outlet valve (V-
1143, 2143, 3143) to the required service flow rate.

NORMAL STOPPING:

Switch off the conductivity meter, and close conductivity isolation valve. Close the inlet (V-
1134, 2134, 31346) and outlet (V-1143, 2143, 3143) valve. Release pressure by opening air
release valve (V-1145, 2145, 3145).

REGENERATION:

For the first six months of operation, the mixed-bed unit is regenerated at its rated output
between regeneration. If the quality of the treated water is satisfactory, the output between
two regenerations may be stepped up after the initial six months. If the treated-water quality is
still satisfactory then the run should be terminated either on silica or conductivity
breakthrough. Note in case of longer operation of the plant if the product water quality from
M.B. unit is not as per the requirement after regeneration, we recommend to do the double
quantity regeneration of M.B. unit after 8-10 regeneration.

PREPARATION OF REGENERANTS:

Fill the caustic dilution tank with water and gradually add NaOH (100%) to make 48% BY W/V
solution. The concentration of diluted regenerant may be confirmed either by checking the
specific gravity or by titration. Pour the sulfuric acid for the cation regeneration in the acid
measuring tank after filling water in tank to prepare 30-32% by w/v HCL solution.


The quantity of NaoH (48%) per regeneration - 177.55 Kg.

The quantity of HCL (30%) per regeneration - 284.7 Kg.
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
44

BACK WASH:

Open slowly backwash inlet valve (V-1141, 2141, 3141) and backwash outlet valve (V-1135,
2135, 3135). Maintain the required flow rate by adjusting the outlet valve (V-1135, 2135,
3135). Continue for the backwashing for the period of five or more till the physical separation
of cation & anion bed as well as removal fines and other impurities from the bed. Close the
valves (V-1141, 2141, 3141 & V-1135, 2135, 3135).

MIDDLE COLLECTOR FLUSHING

This operation is to ensure clearing of the middle collector piping for any traces of resin and
other impurities, before commencing the acid injection. To operate the following valves for five
minites.

Middle collector inlet valve V-1138, 2138, 3138
Backwash outlet valve V-1135, 2135, 3135

CAUSTIC INJECTION (CR)

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


Suction valve for Caustic Ejector - V-5160, 5165
MB Vessels caustic inlet valve - V-1146, 2146, 3146

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
45

CAUSTIC SLOW RINSE:

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

MB Vessels caustic inlet valve - V-1146, 2146, 3146


ACID INJECTION:

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

Acid Balance water - V-1140, 2140, 3140
Suction valve for Acid Ejector - V-5077, 5078
MB Vessels Acid inlet valve - V-1137, 2137, 3137
Balance Water in service inlet valve - V-1136, 2136, 3136
MB rinse outlet valve - V-1166, 2166, 3166

ACID SLOW RINSE

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

MB Vessels Acid inlet valve - V-1137, 2137, 3137
Balance Water in service inlet valve - V- 1136, 2136, 3136
MB rinse outlet valve - V-1166, 2166, 3166

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
46

DRAIN DOWN:

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

AIR MIXING:
Open air release valve (V-1145, 2145, 3145) and then open air inlet valve (V-1142, 2142,
3142) and start the air blower for air mixing the anion and cation bed. This operation is
continued for 10 minutes & then close air inlet valve (V-1142, 2142, 3142) after stopping the
air blower and blower discharge valve.

REFILLING AND FINAL RINSE:

This operation should be done immediately after air mix to avoid any separation of resins
inside the unit. Open inlet valve fully (V-1134, 2134, 3134) and air release valve (V-1145,
2145, 3145). When water starts coming through air release pipe close air release valve (V-
1145, 2145, 3145) and open/adjust rinse outlet (V-1166, 2166, 3166) valve. Rinse the unit for
04 minutes at the service flow rate. Open the conductivity isolation valve to check the MB
outlet conductivity, if it is satisfactorily, close the rinse outlet (V-1166, 2166, 3166) valve and
open service outlet valve (V-1143, 2143, 3143). The unit is ready for next service run.


ULTRAFILTRATION UNIT

UFFP PUMP: UFFP-1001 A/B

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

The UFFP Supply Pumps will be provided with following
selections:
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
47
1. AUTO / MANUAL
2. PUMP-A / PUMP-B
In Manual mode of operation The Pumps can be started if
permissive 1 to 3 are met.
In Auto mode of operation Selected Pump will start when any of
the UF 2101 A/B is put in Service Mode. Standby pump will start
automatically if the selected pump TRIP. An alarm will also
generate due to Electrical Tripping. An alarm will be generated if
Discharge header pressure reached HIGH set point.

UFFP supply pumps will TRIP on any of the following conditions:
1 Electrical TRIP
2 Both UF 2101A/B out of service (In AUTO mode of operation)
3 Intermediate Water Storage Tank level Low (In AUTO mode of
operation)
4 UF product water storage tank level High (In AUTO mode of
operation)

Both pumps status (Running/Electrically Tripping) will be
displayed in PLC work station graphics.

UF Operation:

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

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

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

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
48
1. UF Operation Cycle (Service + Backwash + Fast Flush)
2. UF Chemical Cleaning Cycle

Operator has select two pumps for service cycle and then start UF
stream through display.
1. UF Operation Cycle:

Initial Fast Flush:
At every first start of UF system, valve related to Fast flush will be
opened and then UFFP-1001 A/B will be started. This cycle will be
continued for set time for Initial Fast Flush cycle.

Service Cycle:
After Fast Flush cycle, PLC will check following conditions before
starting Service cycle.
1. Level of UF product water storage tank shall not be high
2. UFFP selected for Service cycle shall be electrically healthy.

If these conditions found healthy all valves related to first half of
service cycle will be opened, this cycle will be continued for set time
for First half of Service Cycle.
At completion of first half of service cycle, valve related to second
half of service cycle will be opened, this cycle will be continued for
set time for Second half of service Cycle.

Service cycle will be terminated incase of following interlocks,
1. Level of IDMWST storage tank low.
2. Level of DM product water storage tank High.
3. UF Feed pressure high
4. Diff. Pressure across UF Modules is high

Incase of one of UFFP feed pump tripped during service cycle,
standby UFFP feed pump will be started by PLC.

Respective message will be displayed indicating fault and stream,
and hooter will sound.

Back-wash Cycle:
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
49
After completion of service cycle, PLC will check following
conditions,
1. Level of UF product water storage tank shall not be low.
2. UFBP Back wash pumps UFBP-1001 A & B shall be electrically
healthy

If these conditions found healthy PLC will open valve required for
first half of backwash cycle. Then Backwash pumps UFBP-1001 A &
B will be started. This cycle will be continued for set time for first
half of back-wash.
At completion of first half, valves related to second half will be
opened and after 3 sec valves for first half will be closed. This will
be continued for second half of backwash.

UF backwash cycle will be terminated incase of following interlock
1. Level of DM product water storage tank low
2. UF backwash pump UFBP-4101 A or B electrically tripped.
3. UF backwash pressure high.

Fast Flush:
After completion of backwash cycle, valves related to Fast Flush will
be opened. After 3 sec UFFP pumps UFFP-1001 A or B will be
started. This cycle will run for set time of Fast Flush.

These three cycles (i.e. Service, backwash and fast flush) will be
continued one by as per time set automatically.

Incase of power failure during Service cycle or Fast Flush, PLC will
start fast flush cycle first with power on.

Incase of power failure during Backwash, PLC will start backwash
cycle first with power on.

Timers of UF service cycle, fast flush cycle & backwash cycle shall
be retentive.


2. CHEMICAL CLEANING OF UF SECTION:
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
50

Chemical Cleaning will be selected and performed manually by
Chemical Cleaning pump. Levels of the tank will be monitored by
Low level switch provided at CIP tank. Respective Auto valves will
be opened as per valve sequence when Chemical Cleaning is
started. Then after 3sec message for CIPRP start will come. This
cycle will be performed till operate stop it.

Interlocks:
1. If any neutralization pit level goes high then backwash will be
stopped.
2. A Hold soft button will be provided to prolong the current step
at operator discretion.
3. At every step control system will check for the required drive /
valve feedbacks. In case any of the feedback is not received
within the set time, an operator alarm will be raised and the
Service / Backwash / Fast Flush cycle will pause. An over ride
soft button will be provided for the Operator to reset the alarm
and continue with the cycle.

If backwash cycle stopped due to any reason backwash cycle timer
will pause but not reset. Operator has to reset the timer manually.

Valve sequence Chart for UF 2101 A/b

Valve Sequence is as per attached Annexure.

Attachment:
1. PLC Control Interlocks
2. Valve Sequence For Vessels








PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
51
Acid and Caustic Handling Area:-

Filling operation of Acid Tanks

Acid Tank AMT (SAC) ( 1001A ), AMT (MB) ( 1001B ) filling operation will be
done by operator through PLC work station soft button. When level of the
respective tank becomes high acid inlet valve will close automatically.

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

Filling operation of Caustic tanks

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

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

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

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



PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
52
1. Neutralization pit operation:-

Pump shall be started and stopped manually.

Pre condition for Neutralization pit pump starting:-

2. Neutralization Pit level should not be low low.
3. Neutrally influent disposal pump starter should not be tripped.

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

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

Logic of N-Pit operation:-

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

Condition: - 1.

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

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
53
Condition 2

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
























PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
54




CHEMICAL
&
POWER
CONSUMPTION



PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
55



CHEMICAL
CONSUMPTION









PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
56
CHEMICAL CONSUMPTION:



Client M/s.Rajwest Power Pvt Ltd.

CHEMICAL CONSUMPTION DATAS

Sr.
No. ITEM
Consumption
/ Day
No. of Stream


1
Hydrochloric Acid for SAC
30% 1390.98 2
2
Hydrochloric Acid for MB
30 % 284.07 2
3
Caustic Soda for SBA
48% 570.30 2
4
Caustic Soda for MB
48 % 177.55 2












PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
57






POWER
CONSUMPTION







PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
58

POWER CONSUMPTION:
POWER CONSUMPTION DATA
FOR THE DRIVES IN OUR SCOPE OF SUPPLIES
Sr.
No. ITEM
Qty.
Offere
d
Qty
Workin
g
Motor
load
connecte
d Load
kW
(Rated
power)
Power
absorbed
kW /
DRIVE
(Actual
Power)
Operation
Details Flow

1
Clarified Water
pump 03 02 15 Continuous
100M3/hr @
35MWC
2 DGWTP 03 02 22 Continuous
1846M3/hr @
55MWC
3
DGB
03 02 0.75 Intermittent
100M3/hr @
35MWC
4
Acid Unloading
Pump 02 01 2.2
Intermittent 10M3/hr @
15MWC
5 MBB 02 01 0.75
Intermittent 4.54M3/hr @
4000MWC
6 RWP 02 01 7.5
Intermittent 30M3/hr @
30MWC
7
Caustic
Unloading
Pump 02 01 2.2
Intermittent 10M3/hr @
15MWC
8
N-Pit transfer
Pump 02 01 15
Intermittent 100M3/hr @
30MWC
9 UF Feed Pump 02 01 7.5 Continuous
55M3/hr @ 2.5
Kg/Cm2
10
UF back wash
pump 02 01 15
Intermittent 96M3/hr @ 2.5
Kg / Cm2
11 Agitator 03 03 1.5 Continuous
12 Agitator 03 03 0.75 Continuous
Note:
1
There may be slight variation in the Power Consumption of +/- 2% over the values
provided above depending on the Voltage / Current / Frequency etc supplied to the system


PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
59






MAINTENANCE
&
TROUBLE
SHOOTING





PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
60




SYSTEM MAINTENANCE:

This section consists of summary of system maintenance tasks which include
scheduled maintenance, trouble shooting and repairs. This section is to be read in
conjunction with the detailed maintenance/trouble shooting/repair instructions in the
respective manuals supplied by various manufacturers. All maintenance should be
documented in a maintenance log, as to maintain a chronological history of all
maintenance tasks performed. While attempt has been made to make this section as
exhaustive as possible, site specific problems are not included here. Need to evolve
and establish detailed maintenance schedule specific to the site may exist and
instruction for handling such situations may be added to this section, in consultation
with the manufacturer, where necessary.

SCHEDULED MAINTENANCE:
Regular preventive maintenance tasks are recommended on a periodic basis. The
critical aspects are summarized below.

INSTRUMENT CALIBRATION:
Recommend intervals for calibration tasks as recommended on a periodic basis. The
critical aspects are summarized below to serve as guide.






PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
61


INSTRUMENT RECOMMENDED INTERVAL




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

ALSO REFER VENDORS OPERATION MANUALS.

PRESSURE SAND FILTER:-

TROUBLE SHOOTING

SR.
NO.
SYMPTOM POSSIBLE CAUSE ACTION
01. Pressure drop across
the bed & reduction in
outlet flow rate.
(a) Media bed may be
fouled.
(b) Media is not
backwashed
properly.
Clean up media bed and
carry out backwash.


02. (a) Fine sand coming
out of filter plant.
(a) Fine gravel under
bed may have
Re- bed the unit.
Conductivity instruments 90 days
Flow indicator 30 days
Pressure indicators 100 days
Pressure switch 30 days
pH instrument 90 days
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
62
(b) High turbidity at
outlet.

shifted.
(b) Channelisation of
filter bed.
03. Drain flow is less than
what is listed in the
specifications.
a) Backwash flow
control plugged.
b)Drain line is restricted.
a) Clean backwash flow
control.
b) Clear any
obstructions in
drain line.
c) Air scouring for 20-30
Minutes.



PRESSURE SAND FILTER

Once a week, backwash the filter for about one hour, in order to minimize
accumulation of solids in the filter bed.

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

CHARGING THE MEDIA

[1] Unpack the under bed materials, comprising four grades of pebbles and one
grade of crushed gravel. Wash each separate grade thoroughly with water to make it
free from dust, dirt and other impurities.

[2] Open the backwash inlet valve to fill up water upto a small level in the vessel.
Charge the first (coarser) layer of pebbles into the vessel with extreme care, so as to
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
63
avoid damaging the laterals or nozzles/strainers, and arrange the pebbles properly
around the laterals. Level the layer and note its depth.

[3] charge the remaining layers of pebbles and gravels successively in a similar
manner, first increasing the water level stepwise to cover each successive layer(by
opening backwash inlet valve), then charging and leveling each layer, and noting the
bed depth at each stage. Check and note the total depth of the under bed.

[4] Unpack the mixed sand media and wash it thoroughly with water, to make it
free from dust, dirt and other impurities.

[5] Open the service inlet valve and fill up about half the vessel with water.
Charge the mixed sand media and level the top surface uniformly. Check the bed
depth.

[6] Fit the inverted bell mouth distributor by bolting. Using a rubber gasket for
jointing.

WASHING THE MEDIA
[1] Open the backwash outlet valve fully, and open the backwash inlet valve
ensuring that sand is not carried over to drain. Continue backwashing until the
effluent is completely clear, and then close both the valves.
[2] Open the rinse outlet valve and drain the water level in the vessel to just
below the surface of the filter bed. Scrape the top surface and remove any fines and
dust collected on the surface.
[3] Close the vessel by bolting (manhole cover), using a rubber gasket for joining.
[4] Connect the air release pipe work.


CLEANING OF FILTER BED:-
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
64

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

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

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

ACTIVATED CARBON UNIT
CHARGING THE MEDIA (ACTIVATED CARBON):

[1] All the activated carbon washed with clean water to removing dust particles
and other impurities upto the effluent is clear.

[2] Open the backwash inlet valve to fill up water upto a small level in the vessel.
Charge the activated carbon into the vessel with extreme care. Check and note the
total depth of the underbid.

[3] Unpack the activated carbon wash it thoroughly with water, to make it free
from dust, dirt and other impurities.
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
65

[4] Fit the inverted bell mouth distributor by bolting. Using a rubber gasket for
jointing.

[5] Close the vessel by bolting (either the manhole cover or the top body flange
joint), using a rubber gasket for joining.

[6] Connect the air release pipe work.



WASHING THE MEDIA (ACTIVATED CARBON):

[1] Open the backwash outlet valve fully, and open the backwash inlet valve,
ensuring that activated carbon particles are not carried over to drain. Continue
backwashing until the effluent is completely clear, and then close both the valves.

[2] Open the rinse outlet valve and drain the water level in the vessel to just
below the surface of the filter bed. Scrape the top surface and remove any fines and
dust collected on the surface.



CLEANING OF FILTER BED :

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

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
66
If oil-free compressed air is available, it can be used for air scouring of the filter bed
after the backwashing as above. For this purpose, connect an M.S. Pipe ( 1 - 1.5
meters long) to a flexible base. Drain the water level in the filter to 70-80 mm above
the bed level and insert the M.S. pipe into the filter bed to the extent of about one
meter. Connect the flexible hose to the source of compressed air and start the air
supply. Continue air scouring of the bed for about 20-30 minutes. Then remove the
M.S. pipe from the filter bed and backwash the filter bed until the effluent is clear.
Drain the water level and again scrape the top surface to remove any fines or dust
collected.

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


ROUTINE MAINTENANCE :

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

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








PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
67
SAC/SBA UNIT :

CAUSE ACTION

Poor backwashing




Cation resin bed depth
increase in multi bed.




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

Under drain failure
Resin passing to unit which follow.

Low pressure
drop
Reduce flow P. decreases with flow
Increased temperature A) lower viscosity
B) check wash rate at higher
temperature.
Resin loss, reduced bed
depth
Check for loss to sewer during wash
Under drain failure
Resin decross-link reduces density :
A) resin attrition due to age
B) oil contamination.
Flotation due to released gases if wash
inlet valve used to throttle.
HYDROGEN CATION
Loss of capacity Increased loading and / or
distribution
A) increase regenerant
B) add resin
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
68
C) investigate pretreatment
Over run capacity, previous
run
A) normal regenerant does not restore.
Double regenerant qty. For next cycle.
B) adjust end of run determination.
Iron, manganese,
aluminium coating &
precipitates
A) check water supply quality.
B) check regenerant chemicals for
contaminants.
C) chemically cleaned resins.
D) pretreatment for removal
Channeling, poor
distributions.
A) s.s. Loading
B) iron and other metals
C) low flow
D) poor distribution
E) broken or clogged distributors.
Resin age Upto 3-5 years loss in capacity consider
normal check resin moisture to show
decross-link analysis resin to determine
remaining useful life.
Resin loss Excessive wash
Under drain failure
Regenerant concentration
and quality
A) check pumps, ejectors, drawdown
etc.
B) check dilution flows, time settings,
apply correct amount at correct
concentration.
Excessive rinsing A) analysis for end or recycle
B) adjust rinse period to suit time cycle.


Resin oxidation A) pressure of oxidants (chlorine) and
oxygen.
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
69





























B) in presence of catalyst (iron) decross-
linking which reduce capacity and
eventually high pressure drop.
C) replace if 60 % moisture or higher
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
70



Calcium Sulphate
precipitation (barium
sulphate precipitation)
Sulphuric acid regenerant unit calcium in
treated water.
Remove with chemical cleaning readjust
acid concentration
Calcium Phosphate
colloidal silica, zirconium,
titanium oxides, oils
grease.
Chemically clean pre-treatment for
removal before exchanger.
Poor quality Valve leakage Check bed. Bed sample v/s. Outlet pipe
sample (before and after valving special
caution on was inlet valve check limit
stops on electric valves check air
pressure.
CAUSE ACTION
Excessive flow Insufficient reaction time reduces flow.










Low flow rates Poor distribution channeling place one
or more units in stand by recycle treated
water to inlet.
Improper regeneration Set regeneration cycle as
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
71




recommended.

Loss of capacity
Chemical precipitation Hardness in regenerant water and


/ or leakage from cation unit or silica
precipitation.
Organic fouling Pretreatment for removal chemically
clean resin oxidation of cation resin can
foul anion.
Resin age, resin loss,
channeling poor distribution
regenerant concentration,
quantity over exhaustion.
As in weak base and previous notes
(excessive caustics concentration
reduce capacity)
Heavy metal fouling Check cation for fouling check
regenerant for iron chemically clean.
Excessive Chemically clean pretreated to control
organisms.
Poor quality High silica in treated water Organics fouling, chemical clean, check
regenerant concentration and quantity,
check regenerant temperature
Low temperature Slow reaction rates reduce flow rates
pre-heat feed.
Iron in treated

























Resin fouled, chemically clean, pretreat
for removal prior to exchange additives
during each regeneration.
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
72


CAUSE ACTION

Calcium in treated water (should be
zero)
Calcium sulfate, precipitation on
sulfuric acid regenerates clean.
Adjust acid concentration and time
of application. Calcium Phosphate
or other complexes you feed.
Hardness in treated water (should
be zero)
Valve leakage high flow channeling
poor distribution.

Excessive sodium in treated water. Over run capacity, check
regenerant concentration and
quantity investigate up flow or
hydrochloric acid regenerant.
High Pressure
Drop
Valve Partially closed Check and adjust all valve
Internal distributor Backwash
Blockage with resin, iron, debris Inspect, repair / clean distributor
Increased flow rate P. Increases with flow
Increased S.S. Loading Mid cycle backwash
Bed Compaction Air Or mechanical stir to
supplement backwash
Resin fines Remove with backwash
Cation resin decross link. Analyze resin. Replace if 60% or
higher moisture.
Lower water temperature P. Increases with higher viscosity
at low temperature
Broken under drain, resin OR sub fill
in collectors OR outlet pipe.
Inspect internals
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
73
Channeling. Backwash
Check Collectors
Check valve operating speeds.
Check support bed upset.
Poor backwashing Regular check of flow and duration
adjust with changes in water
temperature and pressure.
Anion resin bed depth increase in
multi bed
Under drain failure
Biological growths Chemically clean pretreat to control
organisms
Low pressure
Drop
Reduce flow P.Decrease with flow
Increased temperature Lower viscosity check wash rate at
higher temperature
Resin loss, reduced bed depth Check for loss during wash under
drain failure.
Resin decors-link reduces density.
Resin attrition due to age oil
contamination.
Flotation due to released gases if
wash inlet valve used to throttle.
Loss of capacity
(Strong Acid
Cation MB)
Increased loading and / or
distribution
Increase Hcl regenerant, add CSA-
9 resin investigate pre-treatment.
Over run capacity, previous run. Normal regenerant does not
restore double regenerant adjust
end of run determination.
Excess sodium in treated water. Over run capacity
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
74
check regenerant
Concentration and quantity
investigate up flow or hydrochloric
acid regenerant.
Iron, Manganese, Aluminum coating
& precipitates
Check water supply
Check wash
Check regenerant chemicals for
contaminates.
Chemically clean resins pretreat for
removal.
Channeling, poor distribution Check wash
SS loading
Iron and other metals
Low Flow
Poor distribution
Broken or clogged distributors.
Resin age Up to 5 yrs loss in capacity
considered normal check resin
moisture to show decors-link
analyze resin to determine
remaining useful life.
Resin loss Excessive wash over drain failure.
Regenerant concentration and
quantity
Check Pumps, Ejectors, Drawdown
etc.
Check dilution flows, time setting
apply correct amount at correct
concentration.
Excessive rinsing. Analyze for end OR rinse
determination adjust rinse period to
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
75
suit.
Resin oxidation Pressure of oxidants (chlorine) and
oxygen in presence of catalysis
(iron) decors-linking which reduce
capacity and eventually high
pressure drop.
Replace if 60% moisture or higher.
Calcium Phosphate colloidal Silica,
Zirconium, Titanium, Oxides, Oils
Chemically clean pre-treatment for
removal before exchanger.
Poor Quality Valve Leakage. Check bed sample v/s outlet pipe
sample (before & after valving
special caution on was inlet valve.
Check limit stops on electric valves
check air pressure.
Excessive flow Insufficient reaction time reduces
flow.
Low Flow Rates. Poor distribution channeling place
one or more units in stand by
recycle treated water to inlet.
Loss of capacity
(Strong Base
Anion MB)
Increased loading of exchangeable
Ions
Add ASB-108 resin increase
regenerant check degassifier for
carbon dioxide removal check for
change in % anions.
Organic fouling Pretreat for removal chemically
clean resin oxidation of cation resin
can foul anion.
Resin age, resin loss, channeling
poor distribution regenerant
concentration, quantity over
See in previous section.
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
76
exhaustion.
Heavy Metal fouling Check cation for fouling.
Check regenerant for iron
chemically clean.
Poor Quality High silica in treated water. Organic fouling.
Chemical clean.
Check regenerant concentration &
quantity.
Check regenerant temp.
Low temperature Slow reaction rates reduce flow
rates pre-heat feed.
Iron in treated Resin fouled.
Chemically clean
Pretreat for removal prior to
exchanger additives during each
regeneration.













PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
77
ALKALI BRINE TREATMENT FOR ANION RESIN

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

SODIUM HYDROXIDE SOLUTION AT 22C

SPECIFIC GRAVITY GRAMS / 100 ML PRECENT NAOH
1.0095 1.010 1.010
1.0207 2.041 2.041
1.0318 3.095 3.095
1.0428 4.171 4.171
1.0538 5.269 5.269
1.0648 6.389 6.389
1.0758 7.531 7.531










PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
78
MB UNIT :

TROUBLE SHOOTING

Loss of capacity
(SAC MB)
Increased loading and / or
distribution
Increase Hcl regenerant, add CSA-
9 resin investigate pre-treatment.
Over run capacity, previous run. Normal regenerant does not
restore double regenerant adjust
end of run determination.
Excess sodium in treated water. Over run capacity
check regenerant
concentration and quantity
investigate up flow or hydrochloric
acid regenerant.
Iron, Manganese, Aluminum
coating & precipitates
Check water supply
Check wash
Check regenerant chemicals for
contaminates.
Chemically clean resins pretreat
for removal.
Channeling, poor distribution Check wash
SS loading
Iron and other metals
Low Flow
Poor distribution
Broken or clogged distributors.
Resin age Up to 5 yrs loss in capacity
considered normal check resin
moisture to show decors-link
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
79
analyze resin to determine
remaining useful life.
Resin loss Excessive wash over drain failure.
Regenerant concentration and
quantity
Check Pumps, Ejectors,
Drawdown etc.
Check dilution flows, time setting
apply correct amount at correct
concentration.
Excessive rinsing. Analyze for end OR rinse
determination adjust rinse period
to suit.


Resin oxidation Pressure of oxidants (chlorine) and
oxygen in presence of catalysis
(iron) decors-linking which reduce
capacity and eventually high
pressure drop. Replace if 60%
moisture or higher.
Calcium Phosphate colloidal
Silica, Zirconium, Titanium,
Oxides, Oils
Chemically clean pre-treatment for
removal before exchanger.
Poor Quality Valve Leakage. Check bed sample v/s outlet pipe
sample (before & after valving
special caution on was inlet valve.
Check limit stops on electric valves
check air pressure.
Excessive flow Insuf. reaction time reduce flow.
Low Flow Rates. Poor distribution channeling place
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
80
one or more units in stand by
recycle treated water to inlet.
Loss of capacity
(Strong Base
Anion MB)
Increased loading of
exchangeable Ions
Add ASB-108 resin increase
regenerant check degassifier for
carbon dioxide removal check for
change in % anions.
Organic fouling Pretreat for removal chemically
clean resin oxidation of cation
resin can foul anion.
Resin age, resin loss, channeling
poor distribution regenerant
concentration, quantity over
exhaustion.
See in previous section.
Heavy Metal fouling Check cation for fouling.
Check regenerant for iron
chemically clean.
Poor Quality High silica in treated water. Organic fouling.
Chemical clean.
Check regenerant concentration &
quantity. Check regenerant temp.
Low temperature Slow reaction rates reduce flow
rates pre-heat feed.




PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
81





ANALYSIS






PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
82
CHEMICAL CONTROL

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


CATIONS UNITS :


(1) The water leaving the cation unit will be acid to methyl orange indicator, the
extent of the acidity depending on the total dissolved solids in the raw water. The
exchange of calcium, magnesium and sodium ions takes place in strick chemical
equivalence and the raw water analysis is given in the description.

(2) In practice it will be found that the actual acidity of the cation treated water -
known as the free mineral acidity (FMA) - will approach very closely to the EMA, with
most waters, the FMA should be within 3 to 5 ppm of the EMA.

(3) The higher the EMA of the raw water the greater will be the difference
between it and the FMA. This will be reflected in higher conductivity and chloride
figures in the dematerialized water.

(4) The chemical composition of many waters is liable to vary from time to time,
and in consequence there will be an equivalent variation in the amount of good
quality water produced by the cation unit.. When this occurs the unit should be
rinsed till two successive tests give the same figures for FMA.




PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
83

ANION UNIT :

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


(2) If the present of silica and co
2
is objectionable the anion unit must then be
regenerated, other wise the unit can remain in service until a rise in conductivity
indicates that the anion exchange material is exhausted the amount of Sodium
Hydroxide in the dematerialized water, is dependent on the analysis of the raw water
and on the cation leakage from the cation unit. The latter is partly a function of the
raw water quality, and partly a function of the type and quality of acid used for
regeneration.

(3) The Phenolphthalein alkalinity of the dematerialized water during the silica
free part to the run will normally be about 2 to 5 ppm, but will also increase will
increasing dissolved solids in the raw water.

(4) The conductivity variation is rather indefinite. 1.0 ppm of Nacl results in a
conductivity of 1.8 micromohs. Hence when the conversion to NaoH stops there will
be a decrease in conductivity but at the same time there will be on increase due to
non-removal of co
2
.

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
84
The following analytical test methods are included in the attached sheets.

E.M.A.

F.M.A.

Chloride

Free CO
2
(cation water)

Free CO
2
(raw water)

Silica (0-1 ppm)

Silica (0-1 ppm)

Alkalinity

Hardness
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
85

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

REAGENTS :
1. DOSHION CSA - 9, STRONGLY ACIDIC, CATION EXCHANGE RESIN.
2. APPROXIMATELY 2N HYDROCHLORIC ACID.
3. SCREENED METHYL ORANGE INDICATOR.
4. 0.02 N SODIUM HYDROXIDE SOLUTION.

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

MLS OF TITRATION (B)
-------------------------------- X 1000 = PPM E.M.A. AS CaCO
3

MLS OF SAMPLE (A)

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


PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
86
NOTE :
1. The column prepared in the above manner may be used for several
determinations before it is exhausted. It is capable of exchanging the equivalent of
5000 mgm. Of calcium carbonate, when exhausted it need simply be washed,
regenerated and rinsed again.

2. This test actually determines the acidity equivalent to the dissolved neutral
salts in the water (Sulphate + Chloride + Nitrate).


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

REAGENTS AND APPARATUS :

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







PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
87
METHOD :

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

2. Add three drops of screened methyl orange indicator. The sample should
turn.

3. Run in 0.02n sodium hydroxide solution a few drops at a time until the
sample turns Smokey-grey. Mix thoroughly while adding the solution.

CALCULATION :

Free mineral acidity = BURETTE READING X 20 PPM AS caco
3
.

NOTE :

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

TEST : 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)
100 ml. Graduate cylinder
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
88
10 ml. Graduated pipette (for boiler water or water with a high chloride
content).
150 ml. Conical flask.



METHOD :

1. Measure a 100 ml. Sample of the water to be tested in the graduated
cylinder, then pour sample into the conical flask.

2. Add five drops of Phenolphthalein indicator; if the sample turns pink run in
0.02N Nitric acid until the pink colour is just discharged.

3. Add five drops of potassium chromate indicator.

4. Run silver nitrate into the sample, drop by drop, with constant shaking until
the yellow colour begins to acquire a faint orange tint.

5. Note the burette reading - 'A'
measure out 100 ml. Of distilled (or deionised) water, pour into the flask and
repeat the test procedure. Note the burette reading - 'B'.








PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
89
CALCULATION :

Chloride content = ('A' - 'B') ml. Of 0.02N silver nitrate used x 10 expressed in parts
per million (ppm) as caco3.

NOTE :

In the case of boiler water or waters with a high chloride content a smaller sample
should be taken e.g., 10 ml. The result should then multiplied accordingly e.g. if a 20
ml. Sample is used multiply the burette reading by 50.





CHLORIDES

Mercuric nitrate method for determination of chloride

REAGENTS AND APPARATUS :

Burette for Mercuric Nitrate
0.02N Mercuric Nitrate Hg (N03)2 solution.
concentrated Nitric acid.
distilled water.
0.02N sodium chloride solution.
0.1% w/v solution DiPHenylcarbazone.
Nickel Nitrate (buffer solution)
100 ml. Graduated pipettes.
250 ml. Conical flasks.
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
90

REAGENTS :

1. 0.02N Mercuric Nitrate Hg (No
3
)
2
:

Dissolve 3.24 gms Hg (No
3
)
2
or 3.42 gms Hg (N
3
)
2
in approximately 500 ml. Of
deionised or distilled water which contains 3 ml. Of concentrated nitric acid. When
totally dissolved make up to 1 litre standardize as under procedure against standard
sodium chloride solution.

2. Standard sodium chloride solution (0.02N) :-

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

3. 0.1% w/v solution of DiPHenylcarbozone in Iso-Propanol or Ethanol. This
solution is unstable and should be renewed monthly.


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

PROCEDURE :

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


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
91
mercuric nitrate until a faint but persistent violet colour is observed (i.e. The end
point).

CALCULATION :

Chloride content = ml. Of titration solution x 1000
--------------------------------
ml. Of sample

Expressed in ppm chloride as caco
3
.
TEST RESIDUAL CO
2
IN CATION EXCHANGER TREATED (H.I.) WATER

REAGENTS AND APPARATUS : -

Sodium hydroxide 0.02 N (N/50)
Phenolphthalein indicator solution.
Methyl orange indicator solution.
Burette for standard alkali.
Co
2
flasks
10 ml graduated cylinder



PROCEDURE :-

1. 100 ml. Samples of H.I. Water are measured into two 250 ml. Co
2
flask.

2. The first is carefully titrated with N/50 NaoH to M.O. End point and the
heading (A) noted.

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
92
NOTE :

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

CALCULATION :

(B) - (A + 0.8) x 8.8 = ppm co
2



REAGENTS AND APPARATUS :

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

PROCEDURE :
1. Fill the nessler cylinder to the 100 ml. Mark with the water being tested,
avoiding splashing and add 2 tablets or 20 drops of Phenolphthalein indicator.

2. Run in 0.04 N sodium carbonate, a few drops at a time with gentle stirring
until a pale pink colour is produced which persists for one minute. Take the burette
reading.
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
93

INTERPRETATION OF RESULT :

Free carbon dioxide content= burrette reading x 10 (expressed in parts/ million)
(ppm) as CaCO
3
.

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

REAGENTS :

1. ACID MOLYBDATE SOLUTION :

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

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

2. 10% w/v tartaric acid solution (or 10% oxalic acid solution).

3. Reducing agent.

A) 90 gms. Sodium metabisulPHite are dissolved in 800 ml. Of silica free water.
B) 7 gms. Anhydrous sodium sulPHite are dissolved in 10 ml. Silica-free water.
Together with 1.5 gms. Of 1 - amino, 2 - naphthol, 4 - sulPHonic acid. Solution (b) is
mixed with solution (a) and the total volume made up to 1 litre with silica-free water.


PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
94
APPARATUS :
Lovibond nessleriser
Disc for silica 0.2 - 1.0 ppm
Two 50 ml. Graduated tubes for nessleriser.
Pipettes
Alternatively a spectrophotometer may be used at the wave length corresponding to
a maximum absorption (approx. 800 mu. But the exact wave length will have to be
checked on each individual instrument.)


METHOD :

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

NOTE :

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


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
95

TEST SILICA (0-20 PPM) - MOLYBDENUM BLUE METHOD.
REAGENTS AND APPARATUS :
BDH lovibond nessleriser.
Disc with colour standards 0.05 mg. To 1.0 mg Sio
2
.
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 25-30c. 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 Sio
2
. 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.




PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
96
NOTE :
Most colourless salts, even when present in relatively large quantities are without
influence upon the colour produced in the test provided the concentration of free
acid is not unduly disturbed. Phosphates, however, must be absent, since they
respond to the test and yield a yellow colour similar to that produced by silica.
Phosphates maybe removed by treating 100 cc. Of the solution under test with 50
ml. Of Sorensens 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 Sorensens
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.
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
97
TEST ALKALINITY -(TOTAL METHYL ORANGE AND PHENOLPTHALEIN)
REAGENTS AND APPARATUS :

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

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

1. Transfer the appropriate amount of sample to the conical-flask and add 5
drops of Phenolphthalein indicator.
2. Run in 0.02 N Nitric Acid from the burette until the pink colouration is just
discharged.
3. Note the volume of acid used multiply by the appropriate factor (see table)
and record as 'p'.

MLS OF SAMPLE TAKEN FACTOR
100 x 10
20 x 50
10 x 100


PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
98


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

5. Read the burette again note the total amount of acid used in both titration
and mutiply by the appropriate factor (see the table above) record result as 'm'.

INTERPRETATION OF RESULTS :

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

BICARBONATE CARBONATE CAUSTIC

P=nil m nil nil
P<1/2 m m-2p 2p nil
P=1/2 m nil 2p nil
P>1/2 m nil 2(m-p) 2 p-m
P = m nil nil p

The above results are expressed in parts/million (ppm) as CaCO
3


NOTE :
1. Screened Methyl Orange Indicator solution.
preparatian of indicator solution-dissolve 0.2g of crystalline Methyl range in
mixture of 25 ml. Methylated spirits and 25 ml. Deionised water. Dissolve 0.28 g
Xylene Cyanol ff in a mixture of 25 ml. Methylated spirits and 25 ml. Deionised
water. Mix the two solutions together.
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
99
2. For most raw water samples, as also lime softened waters a 100 ml. Sample.
3. Use Sodium Thio-sulPHate solution before addition of Methyl Orange only if
water has been chlorinated e.g.from bottling precipitators.

TEST HARDNESS
REAGENTS AND APPARATUS

1. N/50 E.D.T.A.
4.0 grams of disodium dihydrogen ethylene diamine tetra acetate are dissolved in
800 mis. Of water and standardised and adjusted a standard hardness solution unit
1 ml.=1 m.gm. Caco
3



2. AMMONIA BUFFER
(a) Dissolve 16.9 g Ammonium Chioride, NH4C in 143 ml. Conc ammonium
hydroxide, NH4OH; add 125 g of Magnesium salt of EDTA (this salt is available
commercially) water.
(b) A buffer containing the Magnesium salt of EDTA may also be made as follows
:

Dissolve 16.9 g NH
4
CL in 143 ml. Conc nh
2
oh. Weigh out 0.25 g MgSo
4
.

7H
2
O.
Transfer qnantitativly to a 100 ml. Volumetric flask. And make up to colume with
distilled water. Pipet 50.0 ml. Of this solution into a porcelain dish; add a few drops
of the NH
4
cl-NH
4
oH solution (sufficient to achieve a PH of 10.0-10.1); add 2-3 drops
of indicator solution and titrate with edta with continucus stirring until a steel-blue
colour with no tinge of red is present. To the 50 ml. Of solution remaining in the
volumetric flask add exactly the volume of edta required in the above titration. Add
this solution to the NH
4
cl-NH
4
oH mixture and make up to 200 ml. With distilled water.

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
100
Keep the solution (A or B) in a plastic or resistant glass container, tightly
stoppered to prevent loss of nh3 or pickup of Co
2
.


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

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

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





PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
101
CHLORINE TEST PROCEDURE

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




COLOUR PRODUCED CHLORONIDE
WHITE MILKY FLUORESCENT NONE
FOINTLY PINK & MILKY 0.1 PPM
PINK 0.2 PPM
RED 0.5 PPM
PURPLE 0.6 PPM
VIOLET 0.8 PPM
BLUE 1.0 PPM


CHEMICAL ANALYSIS OF WATER FOR TSS, TDS & TS

TS TOTAL SOLIDS
TSS TOTAL SUNSPENDED SOLIDS
TDS TOTAL DISSOLVED SOLIDS
TS TDS + TSS

Total solids are considered to be the sum of dissolved and suspended solids. In
water sources the dissolved solids which usually pre dominate, consist mainly of in
organic salts, small amount of organic matter and dissolved gases. The suspended
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
102
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 its performance.

The determination of total solids is made of evaporation and drying of measured
sample water in a pyrex beakor (or) China Dish. Since water may contain small
amounts of suspended matter it is usual; these to be determined separately as the
total solids in filtered and unfiltered of water sample. The difference between the
total solids in unfiltered and filtered sample is then taken as a measure of suspended
solids present.

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

PROCEDURE :

1] Weigh accurately a thoroughly cleaned and dried evaporating dish of 250ml -
say m1 gram on laboratory physical balance.

2]. Take 100 ml of water sample in it

3]. Evaporate the water carefully to dryness

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

5]. When residual water is removed completely, cool it at a desiccators to room
temperature and find the mass of residual along with the dish - say m
2
gram

Mass of the residual = (m2 - m1) = X gram
PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
103

The Total solids in the sample = X x 106
--------- = 104 x ppm
102
Note: Repeat the above for filtered and unfiltered of the sample to determine TSS
separately.


























PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
104








LIST OF
ABBREVIATION














PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
105

LIST OF ABBREVIATIONS

1. BOD : Bio-Chemical Oxygen Demand

2. CDI : Continuous Deionization

3. cfu : Colony Forming Unit

4. cm : Centimeter

5. COD : Chemical Oxygen Demand

6. DM Water : Dematerialized Water

7. ETP : Effluent Treatment Plant

8. IDR : Indion Duo Rapide

9. ms : Microsiemens

10. ml : Milliliter

11. MSRL : Mild Steel Rubber Lined

12. ppm : Parts per Million

13. ppb : Parts per Billion

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
106
14. RO : Reverse Osmosis

15. SDI : Silt Density Index

16. TDS : Total Dissolved Solid

17. TOC : Total Organic Carbon

18. UF : Ultra Filtration

19. SMBS : Sodium Meta bi Sulphate

20. UV : Ultra Violet

21. FRP : Fiber Reinforced Plastic

22. PP : Poly Propylene

23. MS : Mild steel

24. SS : Stainless Steel

25. CI : Cast Iron

26. PVC : Poly Vinyl Chloride

27. OBR : Output Between Regeneration

28. SAC : Strong Acid Cation

PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
107
29. SBA : Strong Base Anion

30. SPM : Stroke Per Minute

31. ROSA : Reverse Osmosis System Analysis

























PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
108

M/s RAJWEST POEWR PVT LTD

EQUIPMENT HISTORY LIST

EQUIPMENT :
MODEL :
MAKE :

Date Service Carried Out Spares Replaced Remarks by
Maint. Engineer


























PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
109
Note: To enter all the detail of services carried out and spares replaced and to
periodically review the status of the equipment.
BRANCH OFFICES / AGENTS / REPRESENTATIVES AVAILABLE IN ALL MAJOR
CITIES; FOR MORE INFORMATION PLEASE CONTACT:

REGD. OFFICE & FACTORY :

M/s DOSHION VEOLIA WATER SOLUTION
Plot Nos : 24-25-26, G.I.D.C. Estate,
Phase - II, Vatva, AHMEDABAD - 382 445
Phone No. : 583 1156 / 589 1916
Fax No. : 30406229

MUMBAI OFFICE:
OFFICE NO.3, II FLOOR
AWING,GODREJ COLLISEUM,
EASTERN EXPRESS HIGHWAY,
B/H. EVERAD NAGAR ,SION (E)
MUMBAI - 400 022
Phone No : 022 24043189 , 24081193
Fax No. : 022 - 24072611









PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
110
DELHI OFFICE:
C-147, MADUBAN ,
NR.UNIVERSAL PUBLIC SCHOOL,
NEW DELHI - 110 092.

Phone No. : 011 22502064,22022175,32910195
Fax No. : 011 - 22044979





CHENNAI OFFICE :
V-3. 1
ST
Floor 4
TH
MAIN ROAD,
ANNANAGAR
CHENNAI - 600 040
Phone No. : 044 26221401,26220591
Fax No. : 044 - 2622 0591












PDF created with pdfFactory Pro trial version www.pdffactory.com


M/s .Rawest Power Pvt.Ltd.
Prepaid By : Mahendra
PROJECT: Rawest Power Pvt Ltd
POC NO : 1954
Checked by :

Document: Operation and Maintenance Manual


M/ s. Rawest Power Pvt Ltd POC 1954 PAGE
111

Can Do For You .......


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


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

SPARE PARTS

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

PDF created with pdfFactory Pro trial version www.pdffactory.com

S-ar putea să vă placă și