Electrochlor Ination System Operating and Maintenance

OPERATING & MAINTENANCE MANUAL
2 X 8.0 KG/HR HYPOPAC-M ELECTROCHLORINATION PACKAGE

Page No : 1 of 50
PIPA II DEVELOPMENT
Dynamic Producer Inc.
01
10-DEC-2009
For Information
Dinesh
Murali
Murugan
Rev.
Date
Reason for issue
Prepared
Checked
Approved
Document Status Code (CODE MUST BE IDENTIFIED)
Owner Company Name / Logo
Code
IDC X FI FA FC F AB
Document status
For IDC For Information For Approval For Construction Final / Certified As built
Dynamic Producer Inc.

I
Sub Supplier Company Name / Logo
Code
FI A B
Approval status
For Information Approved without Comments Approved with Comments
Titanium Tantalum Products Ltd

Chennai- 600 073, India.
TiTaN Document Number:
C Not Approved, Re-submit for Approval Originator/Contractor Company Name/Logo
TTPL/TLSX010/ENG/PD/100000060/042-00
Originator / Contractor Document Number:
Document Title Project No Originator no. Contract/PO no
PS-05
System 47 Area N/a Discipline Z
80
Doc. Type MB
P080102
HYPOPAC - M Electrochlorination Package 2 x 8.0 Kg/hr OPERATING & MAINTENANCE MANUAL No of Sheets 50 Doc.Status FI Revision 01
Client Doc. Number DPI -80-Z-47-MB-0001

2 x 8.0 KG/HR HYPOPAC-M ELECTROCHLORINATION PACKAGE
Sheet No: 2 of 50
OPERATING AND MAINTENANCE MANUAL

RT MARINE-S
2 X 8.0 KG/HR ELECTROCHLORINATION PACKAGE

Sheet No: 3 of 50
REVISION RECORD
REV 0
DATE 10.08.09
PREPARED MD
CHECKED GM
APPROVED GM
DESCRIPTION FOR INFO

Sheet No: 4 of 50
INDEX
S.NO 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11
INTRODUCTION
CONTENTS
PAGE NO 5 5 10 16 19 28 30 32 35 40 42
DESIGN BASIS
GENERAL DESCRIPTION
OPERATING PROCEDURE
PACKAGE OPERATION
STARTUP PROCEDURE
SHUTDOWN PROCEDURE
MAINTENANCE
HEALTH AND SAFETY
DOS & DONTS
ELECTROLYSER PERFORMANCE TESTING
ANNEXURE I ANALYSIS PROCEDURE ANNEXURE II REFERENCE DOCUMENTS

Sheet No: 5 of 50
1.INTRODUCTION Seawater is used extensively on offshore marine platforms, oilrigs and FPSO vessels for a variety of different applications. Seawater causes biological growth and algae formation on wetted walls of the Sea chests, cooling water pipe lines and inner surfaces of vessels. To control the biological growth and algae formation, chlorine in the form of sodium hypochlorite shall be dosed at all the Sea chests of A, B, C, D, E, F & G which is going to be installed at A1 Ship Shaped Oil production Storage and Drilling Unit, DYNPOS-AUTR, E0, Heldeck. Sodium hypochlorite will be produced from seawater by electrolyzing the Seawater, which predominantly has sodium chloride. The produced chlorine will be in the form of sodium hypochlorite, which is a good disinfectant, and anti bacterial agent. To achieve this, new electrochlorination package with inbuilt generating facility will be installed to generate sodium hypochlorite and dose in seawater flowing area to control the biological growth in Sea chest. RT MARINE-S is the most advanced TiTaNs MGPS (Marine Growth Preventing system) comprising an HYPOPAC- M electrolyser that produces on-site generation of chlorine in the form of safe sodium hypochlorite solution (equivalent chlorine) the active ingredient required for anti fouling. Sodium hypochlorite solution will be used for the disinfections of seawater to prevent bio fouling by destroying the growth of marine organisms in the seawater facilities. This package has been designed to supply suitable capacity of the sodium hypochlorite as per contract requirement, which consists of all required equipments, instruments, valves, piping its accessories, etc for safe and smooth operation. This manual covers all the necessary design, sizing basis, operating sequence, start-up & shutdown procedures, maintenance, troubleshooting, instrumentation and its control logics sequences provided for safe and effective operation of electrochlorination package. The 2 X 8.0 Kg/hr HYPOPAC M Skid Based Electrochlorination System is supplied to: Owner : Dynamic Producer Inc., (DPI)

Sheet No: 6 of 50
2.0 DESIGN BASIS Project : MALAYAMPA PHASE 2 ASSET INTEGRITY DEBOTTLENECKING DPI Project No. TiTaN Job No. Package : : : PS-05 TLSX010 2 x 8.0 kg/hr HYPOPAC - M Electrochlorination package (RT MARINE-S) Type of the system Operating mode Installation location Filtered / Oil free seawater inlet supply No. of hypochlorite generator units No. of electrolytic cell modules of each unit Sodium hypochlorite production capacity of each unit Concentration of available chlorine at each unit outlet No. of transformer rectifier unit Each transformer rectifier unit output No. of degassing tank Capacity of degassing tank No. of air dilution blower Air dilution blower capacity : : : : : : : : : : : : : : Seawater based Continuous Ship-indoor 11.0 m3/hr @ 11 bar.g 2 Nos (1W + 1S) 2 Nos 8.0 kg/hr 727 ppm 2 Nos (1W + 1S) 60 V DC, 1000 A DC 1 No. 1 m3 2 Nos ( 1W + 1S ) 300 m3/hr

Sheet No: 7 of 50
2.1
PROCESS DESIGN CALCULATION
2.1.1. PACKAGE CAPACITY Quantity of seawater to be treated (as per contract) Continuous hypochlorite dosing concentration Amount of hypo required to treat above quantity of seawater = 2,610 m3/h = 3 mg/l = 2,610x 1000 x 3 = 7830000 mg/h = 7830000/10-6 kg/hr = 7.83 kg/hr Design capacity of the package = 8.0 kg/hr
2.1.2. HYPOCHLORITE CONCENTRATION

Design capacity of Hypochlorite generator unit = 8.0 kg/hr = 8000 g/h Seawater flow rate Hypochlorite concentration in seawater = 11 m3/h = 8000/(11 x 1000) = 0.727 g/l = 0.727 x 1000 mg/l = 727 mg/l

Sheet No: 8 of 50
2.1.3 BLOWER CAPACITY:
The electrolysis process, which will take place inside the electrolytic cell, will be as follows NaCl + H2O NaOCl + H2
From the above equation, When 1 mole of sodium hypochlorite generates, 1 mole of hydrogen will also generate. In electrochlorination process, sodium hypochlorite will be measured in terms of equivalent chlorine. Hence, When 1 mole of chlorine generates, 1 mole of hydrogen will also generate. Or When 71 grams of chlorine generates, 2 grams of hydrogen will also generate. Unit capacity is 2 X 8 kg/hr, 8 kg/hr or 8000 grams/hr will be in operation continuously.
Hence, 8000 gm/hr of equivalent chlorine generates
= 2/71 x 8000 = 225.35 g/h of Hydrogen.
Density of hydrogen Volume of hydrogen generates
= 0.08 kg/m3 = 0.22535 / 0.08 = 2.8168 m3/h
This hydrogen will be diluted using air to its 25% of LEL and vented to atmosphere.

Sheet No: 9 of 50
25% of LEL of hydrogen is Hence, we are diluting the above quantity of hydrogen with 100% (v/v) air. Therefore, the volume air required
= 1% (v/v) in air
= 2.8168 x 100 = 281.68 m3/h
Design capacity of blower
= 300 m3/h
2.1.4
DEGASSING TANK CAPACITY:

The Design flow rate of seawater + hypochlorite coming to tank = 11.0 m3/h
Generally, 5 minutes minimum hold up volume of the flow rate will be considered for capacity sizing of hypo storage tank in seawater based electro chlorination system. Hence, Volume of the tank = 11 x 5 / 60 = 0.9166 m3 = 1 m3 Design capacity of degassing tank = 1 m3

Sheet No: 10 of 50
3.0 GENERAL DESCRIPTION The on-site generation of sodium hypochlorite solution from filtered seawater is performed by electrochemical process providing electrolysis of sodium chloride contained in seawater, as it flows through direct current energizing anodic and cathodic tubular electrodes. Filtered and Oil free seawater is fed to the sodium hypochlorite generators (electrolyser) of HYPOPAC-M unit. During normal operation, TiTaNs electrolyser produces designed sodium hypochlorite solution by means of electrolysis via DC power supplied from transformer rectifier and collected in the degassing tank. The amount of hydrogen gas generated along with sodium hypochlorite disengages from the liquid phase in the upper part of the tank and it is diluted with airby air dilution blower in order to keep hydrogen concentration at about 1% v/v (25% LEL) when it is vented to atmosphere. Finally sodium hypochlorite solution is delivered to the dosing point of seachests by means of gravity flow from the degassing tank. The basic operations of electrochlorination package is controlled / monitored in the Transformer rectifier and local control panel.
Seawater at Battery Limits:

1. Seawater enters the package at the flow rate of 11.0 m3/hr at 11.0-bar.g pressure. 2. Seawater at the package inlet should be filtered free from suspended solids and oils.

Sheet No: 11 of 50
3.1 PACKAGE EQUIPMENT DESCRIPTION The HYPOPAC-M Electrochlorination package consists of the following major equipments, which are erected in two skids (to be fixed together at site) and it is to be placed in a well-ventilated closed room. 3.1.1 3.1.2 3.1.3 3.1.4 3.1.5 Hypochlorite generator Degassing tank Air Dilution Blowers Transformer-Rectifier Local Control Panel
3.1.1
Hypochlorite Generator The heart of the electrochlorination package is TiTaNs proprietary concentric tubular
HYPOPAC-M electrolyser (hypochlorite generator), which is suitable for installation in Offshore, FPSO, commercial vessels, Oilrigs, drilling units and other ship-based applications. The 2 X 8.0 kg/hr HYPOPAC - M electrochlorination package provides onsite generation of sodium hypochlorite by electrolysis of seawater. There are two numbers of hypochlorite generator (one operating [47-XQ-0001-A & 47-XQ-0002-A] mounted at the two side bottom and one standby [47-XQ-0001-B & 47-XQ-0002-B]) at the two-side top, which are connected hydraulically parallel with each other having equivalent chlorine production capacity of 8.0 kg/hr each. Each hypochlorite generator is having two electrolytic cell modules of electrolytic cells connected electrically and hydraulically in parallel. Each electrolytic cell module having an operating capacity of 4.0 kg/hr equivalent chlorine which is fed with the DC power via individual transformer rectifier unit. All the
four numbers (two operating and two standby) of electrolytic cell modules are assembled in a

Sheet No: 12 of 50
separate metallic enclosure fixed in horizontal position, which will form continuous flow path through electrodes. The electrodes are constructed from titanium seamless / welded tubes. The two outer tubes are separated by an outer union and electrically insulated from each other one outer tube is an anode (+) and the second is a cathode (-). The inner tube is bipolar serving as a cathode for the outer anode and an anode for the outer cathode. The seawater flows in the cylindrical shaped annular space between the inner and outer tubes acting as an electrolyte. The anodes of each cell are coated with precious metal oxide coating, which is for excellent efficiency in the electrolysis process and long durability. Inter electrode Gap between inner and outer electrodes is maintained with the TEFLON spacer buttons in order to avoid the short circuit. Complete electrode assembly is fixed inside a SS316L enclosure suitable for installing in harsh marine environment. This enclosure is having required inlet and outlet process connections, DC power cable entry holes and suitable vent & drain connections with plugs at the side and the bottom of the enclosures respectively. 3.1.1.1 SALIENT FEATURES OF HYPOPAC -M ELECTROLYSER High and Uniform velocity at fully turbulent flow No acid cleaning required Non corroding titanium electrodes with Platinized metal coating Metallic Enclosure housing protection for harsh marine environment suitability 5 year warranty for anode life Low Maintenance Design Compact, adaptable installation

Sheet No: 13 of 50
3.1.2. Degassing Tank: The degassing tank is an atmospheric vessel made out of FRB, sized for 1000 liters up to overflow so that the hypochlorite received from the electrolyser at the nominal flow rate has a residence time sufficient to dilute the entrained hydrogen with air and vented to atmosphere via vent line provided at the top of the tank. The tank is vertical cylindrical design with integral flattop and bottom. The tank is provided with a transparent level gauge, overflow, drain, vent, discharge / outlet, hand hole, level switch and additionally one spare nozzle as well as transparent level gauge.
Design temperature of tank is 600 C, which is higher than the maximum temperature that any part of the tank is likely to attain in course of operation. The tank is mechanically designed as per BS 4994 1987 standard.
3.1.3 Air Dilution Blower: Two horizontal centrifugal hydrogen air dilution blowers (one working + one standby) are connected to the degassing tank. The blower is rated at 100% of flow and will provide 300 m3/hr @ 150 mm WC discharge pressure and it is used to dilute the hydrogen gas to reduce the hydrogen concentration in the atmosphere to 25% of its LEL. Both impeller and casing are made of SS316L. The motor is a foot-mounted type with IP 55 protection with F class and direct on line starting at 690V, 3 ph and 60 Hz.

Sheet No: 14 of 50
3.1.4 Transformer Rectifier: Transformer rectifiers (47-ET/ER-0001-A / 47-ET/ER-0001-B) are specifically designed to feed HYPOPAC-M hypochlorite generators, which are continuously and automatically controlled. Direct current can be adjusted within the range of 20% to 100 % of the fully rated current. The Transformer rectifiers are provided with an automatic control system, which stabilizes the direct current value. The transformer rectifier is a forced air cooled type of thyristor based constant current controlled unit with DC output of 1000 A DC and 60 V DC at input power supply of 690 V, 3 ph and 60 Hz. Unit is designed as per a IEC 600146 standard which is having efficiency of more than 80% at rated output with a ingress protection of IP 44 rating. Local potentiometer provided at the rectifier front panel is used to control the DC current and the digital DC voltmeter is used to measure the voltage across the hypochlorite generator. The Voltage may vary depending on the resistance and temperature of the seawater. The readings of the DC voltmeters are periodically taken, checked and recorded as they reflect the working conditions of the hypochlorite generators and an early warning of the exhaustion of the anode coating catalytic properties. Should the voltage across any hypochlorite generator deviates from its normal operating value and approach a level which is dangerous to the electrode metal structure, an automatic device installed in the transformer rectifier (47-ET/ER-0001-A/ 47-ET/ER-0001-B) will signal the fault and/or shut off the electric power supply to the hypochlorite generator before any damage occurs. Transformer rectifier enclosure is manufactured from Mild steel with a grey color (RAL 7032) powder coated.

Sheet No: 15 of 50
3.1.5 Local Control Panel Local Control Panel (47-IB-0001-A) has been specifically designed for continuous controlling/monitoring the electrochlorination package through HMI with a battery back up from UPS (Uninterrupted Power Supply), also it contains DOL feeders and power feeders which feeds AC power to corresponding Motors and Transformer-Rectifiers. These units are supplied as loose items. The operator interface to the process will be mainly provided via graphics pictures on the monitor of HMI screens. Main screens in HMI are, Overall view Seawater inlet section Hypochlorite generator section Hypo Tank & Blower section Alarms Parameter settings Touching the graphical picture on the particular device on screen in which has sufficient buttons like auto/manual, open/close, and feedbacks can control all equipments/instruments in this electrochlorination package. Local control panel provides the basic dry contacts of the following for client (DPI) DCS interfacing signals, 47-SDV-0001 (ON-OFF valve) OPEN/CLOSE 47-SDV-0002 (ON-OFF valve) OPEN/CLOSE 47-SDV-0003 (ON-OFF valve) OPEN/CLOSE 47-ET/ER-0001-A (Transformer Rectifier- working) RUNNING / STOP 47-ET/ER-0001-B (Transformer Rectifier- standby) RUNNING / STOP 47-ET/ER-0001-A (Transformer Rectifier -working) COMMON FAULT ALARM 47-ET/ER-0001-B (Transformer Rectifier- standby) COMMON FAULT ALARM

Sheet No: 16 of 50
4.0 OPERATING PROCEDURE Seawater is allowed to feed into the electrochlorination package by opening the inlet on off valve 47-SDV-0001.The selfactuated pressure control valve placed at the inlet of the package reduces and controls the incoming pressure to 2.0 3.0 bar.g to suit the operation requirement. In case of abnormal high pressure surge on electrochlorination system feed header, equipment/lines are protected from damage by means of pressure relief valve set at 4.5 bar.g. Pressure gauge provided at the inlet of package helps to monitor the controlled incoming pressure. The electrolyser operates normally under constant seawater flow rate, while DC load is manually adjusted so as to meet the required production of 8.0 kg/hr active chlorine.
The filtered/oil free seawater is fed into the hypochlorite generator (47-XQ-0001/0002-A/B). The flow switches 47-FS-0001/0002 or 47-FS-0003/0004 monitors the set flow to the hypochlorite generator. The required seawater flow through each hypochlorite generator shall be set through respective flow meter and manual diaphragm control valve by operator manually. As a safety precaution, once the minimum flow is passed through hypochlorite generator (electrolyser) by sensing the flow in flow switches which are at the inlet of each electrolytic module, 47-FS-0001&0002 / 47-FS0003&0004, air dilution blower is started during start up and it is the last equipment which has to be switched-off during shutdown.
The operator has to set the required amperage (up to 900 ADC) gradually from zero for the production of sodium hypochlorite from the local control panel through HMI or from Transformer rectifier panel (by local potentiometer). The Voltage may vary depending on the resistance in the electrodes and temperature of the seawater.

Sheet No: 17 of 50
The production of sodium hypochlorite (available chlorine) is based on passing a direct current through an aqueous solution of sodium chloride (NaCl) which is totally dissociate into Na+ and Clthe following chemical and electrochemical reactions occur
Free Chlorine is generated at the anode: 2 Cl---------------- Cl2 + 2e-
Hydrogen is evolved at the cathode with the corresponding formation of hydroxyl ion: 2H2O + 2e--------- 2OH- + H2
The overall electrochemical reaction is: 2Cl- + 2H2O --------- Cl2 + H2 + 2OHThen chlorine and hydroxyl ions react chemically producing hypochlorite and chloride: 2OH- + Cl2 ---------- ClO- + Cl- + H2O The overall chemical reaction can be expressed as follows: 2NaOH + Cl2 --------- NaOCl + NaCl + H2O
In the chemical literature hypochlorite concentration are commonly referred to in term of available or active chlorine, i.e., the quantity of chlorine having the same oxidizing effect as the hypochlorite when analysed by standard methods.

Sheet No: 18 of 50
When the Hypochlorite outlet temperature is more than 50C, then it will be detected by the Temperature switch (47-TS-0001). High temperature in Electrolyser outlet of hypochlorite solution will give an alarm and trips the transformer rectifier supply. The hypo solution from the hypochlorite generator outlet is fed to the degassing tank (47-TA-0001A). The hydrogen generated with the hypochlorite gets separated in the tank where the hydrogen evolved during the process will be safely disposed to atmosphere. Air dilution blower supplies required air to dilute the hydrogen stream, so as to get a non-flammable mixture (25% of LEL). The hypochlorite level in the tank is sensed/monitored by the level indicator (47-LI-0001) and level switch (47-LS-0003). The hypochlorite solution from the degassing tank is to be dosed through the dosing location of sea chests by gravity flow from the tank. The local mounted flow meter at the hypo outlet line helps to monitor the hypochlorite dosing flow.
REMARKS: MGPS (Electrochlorination) Package cannot operate unless it is full of liquid, and also cannot operate unless there is liquid flow through it; In case of such mis-operation equipment will get damage. Therefore isolation valve in the seawater inlet/outlet lines must be fully opened. Also drain valves shall be tightly closed during normal operation.

Sheet No: 19 of 50
5.0 PACKAGE OPERATION 5.1 PACKAGE OPERATING MODE: The electrochlorination package-operating modes of MANUAL, SEQUENCE & AUTO modes, and START/ STOP and FAULT/TRIP signals are being controlled from the local control panel. This electrochlorination package is usually started in MANUAL mode and put into AUTO / SEQUENCE mode for process control parameters. In MANUAL mode, equipments are to be controlled manual switching ON and OFF from the control panel pushbuttons & HMI screens with minimum interlocks. In AUTO mode, all devices can be controlled switching ON and OFF from the HMI screens with sequence full interlocks. In SEQUENCE mode, all devices are controlled automatically as per the sequence with full interlocks. Skid mounted instruments continuously monitor the system and in the event of an abnormality / fault is being reported to the operator via local control panel. Required feed amperage for the Electrolyser shall be set from the control panel or transformer rectifier by the operator gradually. When start up in manual mode, all the devices can be switched ON/OFF as per the pre-defined sequence.
5.2 SYSTEM PRE-START CHECK LIST Conduct visual checks to see that all components of the system including electrical connections and instruments are in place and in tact.
The area is safe, clean, and well illuminated.
Supply to the Transformer rectifier and local control Panel is available.
Flush the line before start of the unit.

Sheet No: 20 of 50
5.3 System Line up
STEP 1:
Before start up the following manual valves are to be kept in CLOSE condition for the normal operation of the unit.
S. No.
1 2 3 4 5 6 7 8 9 10 11 12
Valve No.
47-BA-0002 47-BA-0004 47-BA-0007 47-BA-0010 47-BA-0011 47-BA-0017 47-BA-0018 47-BA-0024 47-BA-0025 47-BA-0028 47-BA-0036 47-BA-0037
Description
Manual Ball Valve Manual Ball Valve Manual Ball Valve Manual Ball Valve Manual Ball Valve Manual Ball Valve Manual Ball Valve Manual Ball Valve Manual Ball Valve Manual Ball Valve Manual Ball Valve Manual Ball Valve
Position
Close Close Close Close Close Close Close Close Close Close Close Close

Sheet No: 21 of 50
Before start up the following manual valves are to be kept in OPEN condition under the normal operation of the package,
S. No.
1 2 3 4 5 6 7 8 9 9 10 11 12 13 14 15 16 17 18 19 20 21
Valve No.
47-BA-0001 47-BA-0003 47-SDV-0001 47-BA-0005 47-BA-0006 47-BA-0008 47-BA-0008 47-SDV-0002/0003 47-XX-0001/0002 47-BA-0012/0019 47-BA-0013/0020 47-BA-0014/0021 47-BA-0015/0022 47-BA-0016/0023 47-BA-0017/0024 47-BA-0026 47-BA-0027 47-BF-0001/0002 47-BF-0003 47-BA-0029 47-BA-0030 47-BA-0031
Description
Manual Ball Valve Manual Ball Valve Shut down Valve Manual Ball Valve Manual Ball Valve Manual Ball Valve Manual Ball Valve Shut down Valve Manual Diaphragm Valve Manual Ball Valve Manual Ball valve Manual Ball Valve Manual Ball Valve Manual Ball Valve Manual Ball Valve Manual Valve Manual Valve Manual Butterfly Valve Manual Butterfly Valve Manual Ball Valve Manual Ball Valve Manual Ball Valve
Position
Open Open Open Open Open Open Open Open Open Open Open Open Open Open Open Open Open Open Open Open Open Open

Sheet No: 22 of 50
22 23 24 25 26 27 28 29 30 31 32
47-BA-0032 47-BA-0033 47-BA-0034 47-BA-0035 47-XX-0003 47-XX-0004 47-XX-0005 47-XX-0006 47-XX-0007 47-XX-0008 47-XX-0009
Manual Ball Valve Manual Ball Valve Manual Ball Valve Manual Ball Valve Manual Diaphragm Valve Manual Diaphragm Valve Manual Diaphragm Valve Manual Diaphragm Valve Manual Diaphragm Valve Manual Diaphragm Valve Manual Diaphragm Valve
Open Open Open Open Open* Open* Open* Open* Open* Open* Open*
- Shall be opened and set the required dosing flow once after hypochlorite is collected in the
degassing tank.
STEP 2:
Seawater inlet Flow, Allow the oil/grease free seawater flow into the package. Set the required pressure and flow for the package by adjusting the allrespective valves. Set the required flow in the Rota meter flow meter 47-FI-0001 / 0002 by throttling the diaphragm valve 47-XX-0001 / 0002
STEP 3:
Air Dilution Blower 47-KF-0001-A/B, The selected Air dilution blower shall start. Once flow through Electrolyser is ensured, start the air dilution blower. The blower will off automatically with time delay when the transformer rectifier / local control panel tripping is occurred during operation.

Sheet No: 23 of 50
If the air flow switch (47-FS-0005) senses low airflow from running blower, it will START the stand - by air dilution blower.
STEP 4:
Transformer Rectifier (47-ET/ER-0001-A/B) ON Transformer rectifier will be switched ON from its front panel or from local control panel under AUTO mode. Required feed amps are slowly raised based on the set point in the local control panel HMI screen or using potentiometer located in the TR panel (in case of in local mode). It will trip when the following conditions are occurred, Electrolyser inlet flow Low Electrolyser outlet temperature high Hypo Tank level high
ALARMS
Alarms are made to annunciate the fault conditions to the operator. The following conditions are referred to generate the alarms in the hooter. 47-XQ-0001/0002-A/B Hypochlorite generator (Electrolyser) inlet flow is low 47-PDS-0001/0002 differential pressure is High 47-XQ-0001/0002-A/B hypo outlet temperature is High 47-TA-0001-A Hypo tank level is high 47-KF-0001-A/B air dilution blower flow is low 47-ET/ER-0001-A/B Transformer-rectifier trip

Sheet No: 24 of 50
47-KF-0001-A/B Air dilution blower trips When phase loss occurs in the Transformer Rectifier panel When over temperature indication in the TR panel Package shut down
Manual Mode
For commissioning / maintenance purposes the system can be run in Manual Mode. Fully trained and authorized personnel should only undertake this manual operation. Individual Package Item can be started and stopped using the relevant push buttons on the HMI / PLC panel.
Operator Interface
All operator controls and indications are via the touch screen type Human Machine Interface (HMI). Selection of screens is performed via the push buttons provided in the touch panel. For the above conditions, operators have to acknowledge the fault first, and find the reason and cause for the alarm, Rectify the fault and restart the system cautiously.
Following Indications / Push Buttons / Selector Switches / Meters are available in the Transformer Rectifier (47-ET/ER-0001-A/B) front panel, S.No
1 2 3 4
Indication Buttons
R, Y & B Lamp Rectifier unit Trip Phase Loss DC Overload/over current
Description
Three phase Lamp indication Transformer Rectifier trip indication Incoming three phase status indication Indication for Over load/current

Sheet No: 25 of 50
5 6
DC Over Voltage Rectifier Over temperature
Output DC over voltage indication Indication while Over temperature occurred
S.No 7 8 9
Illuminating Push Buttons Fault / Fault Reset

Rectifier Start Rectifier stop
Description
For acknowledge the faults and to reset the faults Transformer Rectifier START illumination To stop the transformer rectifier unit
S.No 10 11
Push Buttons
Emergency stop Hooter accept
Description
Lockable Push Button to stop the complete Unit For accept the fault alarm hooter
S.No 12 13 14
Selector Switches
Auto / Manual Ammeter Selector Mains ON/OFF
Description
Switch for selection mode of auto or manual Switch for measuring amps between two phases Power ON/OFF the TR panel
S.No 15 16 17
Meters
AC Voltmeter AC Ammeter DC Voltmeter
Description
Digital Meter - Incoming Voltage indication Digital Meter - Incoming Current indication Digital Meter DC Voltage indication

Sheet No: 26 of 50
18 19
DC Ammeter SET Current Value
Digital Meter - DC Current indication Potentiometer for adjusting amps
Following Indications / Push Buttons / Selector Switches / Meters are available in the Local Control Panel ( 47-IB-0001-A), S.No
1 2 3 4 5 R, Y & B 47-KF-0001-A BLOWER-A TRIP 47-KF-0001-B BLOWER-B TRIP 47-ET/ER-0001-A RECTIFIER A TRIP 47-ET/ER-0001-B RECTIFIER B TRIP
Indication Buttons
Description
Three phase Lamp indication Air dilution Blower A trip indication Air dilution blower B trip indication
Transformer Rectifier A unit trip indication

Transformer Rectifier B unit trip indication
S.No 6 7 8 9 10 11 12 13 14
Illuminating Push Buttons

47-KF-0001-A BLOWER-A START 47-KF-0001-A BLOWER- A STOP 47-KF-0001-B BLOWER-B START 47-KF-0001-B BLOWER-B STOP 47-ET/ER-0001-A RECTIFIER-A START 47-ET/ER-0001-A RECTIFIER-A STOP 47-ET/ER-0001-B RECTIFIER-B START 47-ET/ER-0001-B RECTIFIER-B STOP SEQUENCE START
Description
Air Dilution blower A START illumination Air Dilution blower A STOP illumination Air Dilution blower B START illumination Air Dilution blower B STOP illumination Transformer Rectifier unit A START illumination Transformer Rectifier unit A STOP illumination Transformer Rectifier unit B START illumination Transformer Rectifier unit B STOP illumination Cycle START illumination

Sheet No: 27 of 50
15
SEQUENCE STOP
Cycle STOP illumination
S.No 16 17 18 EMG STOP RESET TEST
Push Buttons
Description
Latchable Push Button to stop the complete Unit To reset the fault condition For testing the local control panel
S.No 19 20 21 22
Selector Switches
MANUAL/AUTO /SEQUENCE 47-KF-0001 BLOWER A/B 47-ET/ER-0001 RECTIFIER A/B Mains ON/OFF
Description
Switch for selection mode of manual/auto/sequence Switch for selecting air dilution blower A / B Switch for selecting transformer rectifier A/B Switch ON/OFF the local control panel
S.No 23 24 AC Voltmeter AC Ammeter
Meters
Description
Analog Meter - Incoming Voltage indication Analog Meter - Incoming Current indication

Sheet No: 28 of 50
6.0 START UP PROCEDURE 6.1. MANUAL START UP SEQUENCE:
Before start up of the system ensure the TR and local control panel is in manual selection. All the main process line valves should be kept in open condition as listed above (section 5.3) also ensure all the drain valves and vent valves are kept in closed condition. The startup operation of this HYPOPAC M electrochlorination package involves the following steps: Allow the seawater into the package by opening the inlet manual valve 47-BA-0001 slowly. Ensure the required pressure 2.0 3.0 bar.g is set in the self-actuated pressure control valve (47-LC-0001) by monitoring the inlet pressure in the pressure gauge 47-PI-0003 provided at the inlet of the package. Set the process required flow of 11.0 m3/hr in the Rota meter flow meter by throttling the manual diaphragm valve 47-XX-0001/0002 Hypochlorite generator (electrolyser) is then lined up by ensuring the inlet and outlet valves are kept in open condition. At initial start up Electrolyser outlet vent valve is kept in open condition for few seconds so that air lock or air bubbles in the line will be released completely. Line up the seawater flow to the Electrolyser outlet line to the degassing tank ( 47-TA-0001-A) Ensure that sample point valve and vent valves 47-BA-0025 and 47-BA-0017/0024 are in closed.
ENSURE THAT THERE IS NO AIR POCKETS OR AIR LOCKS IN THE PIPING. CHECK THIS BY OPENING THE RESPECTIVE VENT VALVES.
Once adequate flow into Electrolyser is ensured start the air dilution blower 47-KF-0001-A/B Allow seawater flow into the package through the pressure control valve, Pressure relief valve and seawater strainers.

Sheet No: 29 of 50
Switch on the TR and Switchgears for Blowers in the Local Control panels; check for the normalcy of Input supplies Voltage conditions and direction of rotation of the Motors. Check the normalcy of the Rectifier by observing fault indications are getting off. If any fault indication is ON, press fault RESET PBs. Also, check phase sequence of the equipment. If any phase loss observes, change the any two input phase lines. (RB into YR or YB into BR or other possibilities). If all fault indications are getting off. Press Start PB in the Rectifier panel. Adjust the current setting between 0 and 100% using the potentiometer knob provided in the front panel of the TR. Always start with an initial setting not more than 50% Amperage Load. Set the required amperage (it should not exceed 900 ADC) by gradually under normal operating conditions. Taking a sample from the sample line provided at the outlet of electrolyser and analyze by iodometric laboratory analysis (as per the annexure), which ensures the concentration of the sodium hypochlorite and accordingly hypochlorite production rate. 6.2. AUTOMATIC SEQUENCE: Once the plant is started in the manual mode, stabilizing the process and can be put in the automatic mode to govern all safety interlocks for the package process parameter. Seawater inlet pressure as per preset value (47-PS-0001) Hypochlorite generator outlet temperature is High (47-TS-0001) Differential Pressure across Hypochlorite generators is high (47-PDS-0001/0002) Seawater flow through Electrolyser as per preset value (47-FS-0001/0003 & FS0002/0004). Set required DC amperage from the HMI panel. Dosing flow by earths gravity

Sheet No: 30 of 50
6.3. NORMAL OPERATION: Once the package is steady after start up, increase the amps setting from 50% to 100% or as required for production. Regularly monitor the following conditions to ensure proper condition of the Package. Monitor the flow in 47-FS-0001/0003 & FS0002/0004 for proper throughput of feed through the Electrolyser. (Once in shift) Check the transformer rectifier Voltage and Amperage values (Once in shift). Check the hypochlorite generator (electrolyser) outlet stream temperature ( Once in shift) Monitor the tank level in level gauge (47-LI-0001) Monitor the dosing flow Periodic change over to the standby pumps by stopping the running pumps and clean the strainer. This practice shall ensure tactfulness and availability of the standby system in operation. Daily check the hypochlorite generation concentration at the electrolyser outlet solution as per given procedure in annexure.
7.0 SHUT DOWN PROCEDURE Electrochlorination package having two shutdown processes 7.1. NORMAL SHUTDOWN: Reduce the amperage setting to Zero by rotating the POT (which is in front panel of TR) in anti-clockwise direction or decreasing the amps in HMI panel. Stop the DC power supply by pressing Stop PB in the Rectifier panel.

Sheet No: 31 of 50
Switch OFF the transformer rectifiers power from local control panel. After 20 minutes, switch OFF the air dilution blower (47-KF-0001-A/B) Switch OFF the AC power to local control panel and transformer rectifier panel. Ensure that all electrical drives are switched OFF. Close the seawater supply to the Electrochlorination package, by closing the inlet valve 47BA-0001 after few minutes from TR stop. Open all the manual Drain valves and vent valves. Drain the system completely. Clean the Y-Strainer (47-ST-0001) filter and kept in functional for the subsequent startup. Completely isolate the all-electrical feeder to the electrochlorination package. Now the package shall be declared to be under complete shutdown and ready for maintenance.
7.2. EMERGENCY SHUTDOWN Under emergency condition, please shutdown the transformer rectifier immediately by pushing the emergency push button (while pressing the Emergency PB, keep the key provided for E-Stop PB safely, for next operation this key will open the E-Stop Pushbutton) safeguard the package which will cut D.C current to electrolyser, thus stopping hydrogen production also. Maintain air dilution blower in operation to ensure hydrogen is completely removed from degassing tank.
Following steps carried out in emergency shutdown. TR Trips with alarm.

Sheet No: 32 of 50
Air dilution blower switched off with time delay. Operator to close the inlet manual valve 47-BA-0001 after few minutes Then operator to acknowledge the fault by resetting the fault alarm push button and release the emergency push button.
If the package needs to remain shutdown for longer period of more than 5 days, the above planned shutdown procedure may be followed for draining out the system.
8.0 MAINTENANCE Preventive Maintenance is a major step in the right direction for reducing non-scheduled downtime and the following practices have been demonstrated as being useful. Establish and enforce regular inspection schedules Keep records of operating data, maintenance works and inspections Accumulation of dust, dirt and corrosion, particularly on stand-by equipment may cause faulty operation of many devices. Therefore, a periodic routine of cleaning and inspections should be established. Remove debris from electrical components. Heat build-up can occur when electrical devices are covered with dust or concrete. Ensure the normal operations of all instruments and equipments through HMI screen. Ensure the direction (clockwise) of blower motor and cooling fan rotation in Transformer rectifier / local control panel when the door is in closed condition. Maintain the proper earthing of the junction box, transformer rectifier and local control panel. The same will be connected to the instrument earth pit not with power earth pit.

Sheet No: 33 of 50
On a monthly basis, check all electrical connections and keep them tight. A loose wire either in a panel or on the field instruments will cause electrical arching
For establishing a sound preventive maintenance is determining the frequency of inspection and testing.
MAINTENANCE TOOLS No special tools are required.
8.1 Inspection Schedule Though, Hypochlorite generator (electrolyser) is designed, as a free of maintenance, schedule of inspection for electrolyser should be followed under normal operations as follows, DAILY S.No 1 2 CHECKING PARAMETERS REMARKS
Ensure that daily log sheets are reporting to TiTaN

Check visually for any physical damage or leakage if any Test Alarm lights on TR/PLC panel and rectify/troubleshoot the same as per the operating & maintenance manual.
OK OK
Not OK Not OK
OK
Not OK
WEEKLY S.No 1 CHECKING PARAMETERS Check the healthiness of the power cable visually for any physical damage. Check the healthiness of instruments like pressure gauge, flow switch, temperature switch, level gauge, and flowmeter for any physical damage visually. REMARKS
OK
Not OK
OK
Not OK

Sheet No: 34 of 50
MONTHLY S.No 1. CHECKING PARAMETERS

Ensure that monthly log sheets are reporting to TiTaN
REMARKS OK Not OK
YEARLY S.No 1 CHECKING PARAMETERS

Check the tightness of all bolted connections Check for correct operation of all protective devices (actuate them manually)
REMARKS OK Not OK
OK
Not OK
5 YEARLY S.No 1
CHECKING PARAMETERS Refurbish / Replace the electrodes if required
REMARKS OK Not OK

Sheet No: 35 of 50
8.2 TROUBLE SHOOTING
EQUIPMENT
DEFECT
CAUSE
REMEDY
a. Trouble in Rectifier b. Loose connection of copper strip. 1. Over Voltage c. Anode life
a. Refer TR manual b. Stop the operation of package. Check the tightness of copper Strip Connection after opening the door. c. In case the voltage is still
HYPOCHLORITE GENERATOR (ELECTROLYSER) UNIT a. High temperature Of feed seawater
higher than normal, contact TiTaN technical support. Ph : 044-22781210,0211,0212 a. Find out cause of increase in temperature. After reducing the temp 2.Sodium Hypochlorite Solution temp high b. Insufficient flow of feed seawater b. Check & ensure the all main line manual valve open. Also check all the drain valves are kept in close condition so that there wont be any flow through drain lines. to normal level restart operation.

Sheet No: 36 of 50
a. Check all the manual valves are kept in fully open condition without openings. 3.Seawater low or no flow flow Low pressure of feed seawater b. Check and ensure sufficient flow pressure into to the package is sufficient by monitoring the inlet pressure in the 47-PI-0001. b. Find out the cause of low pressure. After the pressure normal level, resume operation. a. Check AC input voltage at transformer rectifier terminals. b. Push Fault RESET button. to clogging or partial
a. Input fuse blown 1. Will Not Start b. If equipped with overload, and tripped
PACKAGE
a. DC fuse blown b. SCR not firing c. Current control knobs adjusted to zero
a. Check DC Fuse b. Check for faulty SCR and replace if necessary. c. Adjust current control knobs to selected output voltage and current.
2. No output

Sheet No: 37 of 50
a. Discharged hypochlorite solution flow rate down. 1. Tank level High b. Stuffing in discharge line. c. High flow rate of feed seawater. HYPO TANK
a. Check the outlet dosing valves are not closed in condition, which should be kept open.
b. Blow out stuffing by opening the vent valve 47-BA-0017 and 47-BA-0023 c. Check normal inlet flow rate in the Rotameter flow meter.
a. Low flow rate of a. feed seawater.
Find
out
the
cause
of
Insufficient flow and rectify.
2. Tank level low
b. Leakage from the connections and/or piping. of
b. Check the tank and outlet
tank piping and rectify.
AIR DILUTION BLOWER
Air Flow Low
a. Noise or other problem in the blower
Refer
blower
manufacturers
manual and rectify the problem.

Sheet No: 38 of 50
9.0 HEALTH AND SAFETY

9.1. DATA FOR SODIUM HYPOCHLORITE
Substance Identification
Substance Chemical family Molecular formula : : : Sodium hypochlorite solution 1000 ppm Inorganic Cl-O-Na
Components and Contaminants

Component Other contaminants : : Sodium hypochlorite + Seawater None
Physical Data
Description Odor Boiling point Specific gravity Solubility : : : : : Clear, light greenish-yellow liquid Bleach Decomposes 1.025 Soluble in water
Fire and Explosion Data

Negligible fire hazard when exposed to heat or flame.
TOXICITY Sodium Hypochlorite Irritation Rate Carcinogen status Local effects Toxic level : : : : 10 mg/kg eye-rabbit moderate. Skin rabbit moderate. None Corrosive, inhalation, skin, eye. Slightly toxic by ingestion

Sheet No: 39 of 50
9.2 HEALTH EFFECTS AND FIRST AID
A. Inhalation Effects:
Acute exposure may cause severe bronchial irritation, sore throat with possible blistering, coughing, stomatitis, nausea, laboured breathing, shortness of breath and Pulmonary Edema (extreme condition).
First Aid:
Removal from exposure area to fresh air immediately. If breathing has stopped, give artificial respiration. Maintain airway. Administer oxygen if available. Keep warm. Obtain medical attention immediately.
B. Skin Contact Effects:

Extent of damage depends upon concentration and duration of contact. May cause redness, pain, blistering in worst case. Prolonged exposure may cause Dermatitis.
First Aid:
Wash affected area with large amounts of water. Treat as for chemical burns if severe.

Sheet No: 40 of 50
C. Eye Contacts Effects:

May cause redness, pain or blurred vision.
First Aid:
Wash eyes immediately with large amounts of water, occasionally lifting upper and lower lids, until no evidence of chemical remains (at least 10-15 minutes). Continue irrigating with normal saline until pH has returned to normal (20-40 minutes). Get medical attention as soon as possible.
D. Ingestion Effects:
May cause irritation and erosion of the mucous membranes, vomiting and abdominal pain/spasm, drop in blood pressure, shallow respiration, Edema of Pharynx, larynx and glossitis, confusion, convulsions, delirium. Gyamasis and circulatory collapse are possible in extreme cases.
First Aid:
If conscious, give milk, melted ice cream or beaten eggs. Do not use antiemetic, acid antidotes or sodium bicarbonate. Antacids such as Milk of Magnesia or aluminium hydroxide are also useful. Maintain airway, respiration and blood pressure. Get medical attention immediately.
Antidote:
In severe cases only, hypochlorite poisoning may occur. A few ounces of 1% sodium thiosulphate solution may be ingested and left in the alimentary tract. However contact a physician immediately.

Sheet No: 41 of 50
9.3. HAZARD PREVENTION

9.3.1 EXPLOSION HAZARD:
During normal operation the safety instruction of cell room and storage tank area, no smoking and no use free flames are to be kept in mind.
Before maintenance, be sure that hydrogen has been previously and completely removed from the area.
9.3.2
ELECTRICAL HAZARD:
The danger is minimized since the electric connection are covered by protection panels, but since the electrolytic cell in operation are supplied with D.C voltage, the operators must wear rubber shoes and rubber gloves for safety even in case of a hand touch. The energized parts shall not be touched.
Therefore no personnel except the operators shall be permitted to enter into the package area. During the operation of the MGPS system no work except for switching, valve handling and sampling shall be carried out. If metal tools or other conductive tools must be used near the electrolytic cells for maintenance purposes, the supply of power to the electrolytic cells shall be stopped in advance to prevent short circuit trouble and safety signal Do not operate unit under maintenance placed on rectifier control cubicle.
9.3.3
SAFETY PRECAUTIONS:

Sheet No: 42 of 50
A first aid infirmary is to be foreseen. Before doing any preventive maintenance service, think about your own safety and the safety of other people involved in doing the preventive maintenance service of the equipment. Periodic preventive maintenance will extend the life of the equipment and reduce the necessity of shutdown due to component failure. Before entering the equipment, for such maintenance as fuse replacement, etc., be sure the external disconnect is in the OFF position.
NOTE: Do Not Service Unit With Power ON 9.4 SAFETY DEVICE

9.4.3 GENERAL SAFETY DEVICE:
The following safety apparatus should be foreseen in the area: Safety shower provided with eyewash and drinking water. Protection against fire. For fire see local rules. Within the unit it must be strictly forbidden to smoke or to handle flames, welding machine etc.,
9.4.4 PERSONAL SAFETY DEVICE:
The individual protection equipment is essentially following: Safety goggles in order to preserve completely eyes. Hardhat or helmet. Working dress with buttoned neck and cuffs. Rubber gloves. Rubber boots or shoes with rubber sole.

Sheet No: 43 of 50
The equipment must be always efficient and readily available for immediate use.
9.4.5 SITE SAFETY:
The installer must keep the electrochlorination package, surrounding area and all access routes free from the accumulation of waste material and debris caused by the operations performed during the work. Care must be taken not to include necessary items of equipment in those materials taken for disposal during erection work.
Site safety rules shall be adhered to at all times.
10 DOS AND DONTS 10.1 Dos: Always ensure the recommended or required flow through the Electrolyser. Always check the inlet seawater pressure. During package starts/restarts gradually increase the amps load from 0 to max. It shall reach the maximum load after 10 mins from the package starts / restarts.
Always ensure that the system has been connected with appropriate AC power source. Check / Analyze the concentration of hypochlorite in every shift by taking sample from sampling point.

Sheet No: 44 of 50
Always ensure that the respective suction valves are in open position when switch ON the hypo dosing pumps, discharge valves can open once pump is started.
Always ensure that the respective inlet and outlet valves are in open position when the TR cum Control panel switched ON. Always follow the instructions in the operating and maintenance manual for starting / restarting the system. Always record the operating parameters like amps load, cell voltage, seawater flow rate and hypochlorite concentration in every shift.
10.2
DONTS: Do not operate the system without any seawater or very low flow seawater. Do not operate the system at very low amps load. Do not switch ON the Transformer-rectifier cum Control panel with inlet / outlet valves closed position. Do not increase or decrease the DC amps load suddenly when start / restart the system. Do not leave the system un-operated for longer duration. Do not operate the pumps at dry conditions. Do not handle any electrical items without safety tools during charged.

Sheet No: 45 of 50
11. ELECTROLYSER PERFORMANCE TESTING: 11.1. DAILY REPORT: Seawater DATE inlet Flow rate m3/hr Outlet Available Chlorine Concentration gpl
Feed Amps A DC
Operating Voltage VDC
Production Capacity Kg/hr
Power Consumption kWhr
Remarks
Efficiency %
Seawater Flow rate (m3/hr) * hypo Concentration (ppm) * 100 1.323 * Actual Feed Current (ADC) * 8
Important Note: This Daily report shall be forwarded to TiTaN for review and continuous monitoring to ensure healthiness of the electrolysers. Otherwise, warranty given for electrolyser will be null and void.

Sheet No: 46 of 50
ANNEXURE I - ANALYSIS PROCEDURE

Sheet No: 47 of 50
DETERMINATION OF AVAILABLE CHLORINE CONCENTRATION Aim: To analyze the available chlorine concentration in the sodium hypochlorite solution. Reagent And Indicator: 0.1 N Sodium thiosulphite solution (Na2S2O3) 10% Potassium Iodide Solution (KI) 30% Acetic Acid solution (CH3COOH) Distilled water One Litre in Bottle 200 ml in Bottle 200 ml in Bottle 5 Litres in container
Apparatus Required:
Burette 25 ml with stand Conical Flask 200 ml Pipette 20 ml Pipette 10 ml Measuring Flask 250 ml
2 Nos; 2 Nos; 2 Nos; 2 Nos; 1 No.

Sheet No: 48 of 50
Procedure: Pour 10 ml of 10% KI solution into a 200 ml flask. Add 50 ml of distilled water. Pour exact 20 ml of sample into 200 ml flask using a pipette Add 10 ml of 30% acetic acid. Titrate with 0.1 N sodium Thiosulphite. The end point will be indicated by the stray yellow color solution turning colorless. To identify the end point exactly for color change, add starch solution before the expected end point. (With starch the end point is blue color changing colorless)
Calculation: Concentration of available chlorine is obtained by the following equation. Available chlorine concentration in gpl = 35.45 x V x N / S
Where, V N S : : : Titer volume, ml The factor of 0.1 N Na2S2O3 ( = 0.1) Sample volume, ml (= 20 ml)
Result: Available Chlorine in the Hypochlorite solution =.. gpl.

Sheet No: 49 of 50
ANNEXURE II REFERENCE DOCUMENTS

Sheet No: 50 of 50
S.No. 1. 2. 3. 4 5. 6. 7. 8. 8. 9. 10. 11.
REFERENCE DOCUMENT
PIPING AND INSTRUMENTATION DIAGRAM CAUSE & EFFECT DIAGRAM PLOT PLAN SKID LAYOUT & ARRANGEMENT DRAWING HYPOCHLORITE GENERATOR DATASHEET TRANSFORMER RECTIFIER DATASHEET DEGASSING TANK DATASHEET AIR DILUTION BLOWER DATASHEET SINGLE LINE DIAGRAM TRANFORMER RECTIFIER MANUAL AIR DILUTION BLOWER MANUAL ALL INSTRUMENTS MANUAL
REFERENCE DOCUMENT No.

DPI - 80-P-47-XB-0001 DPI -80-P-47-XR-0001 DPI-80-P-47-XF-0001 DPI -80-L-47-XE-0001 DPI -80-R-47-DS-0001 DPI -80-E-47-DS-0001 DPI -80-R-47-DS-0003 DPI -80-R-47-DS-0002 DPI -80-E-47-XJ-0001 -

Electrochlor Ination System Operating and Maintenance

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OPERATING & MAINTENANCE MANUAL

2 X 8.0 KG/HR HYPOPAC-M ELECTROCHLORINATION PACKAGE

Reason for issue

Document Status Code (CODE MUST BE IDENTIFIED)

Owner Company Name / Logo

Dynamic Producer Inc.

Sub Supplier Company Name / Logo

Titanium Tantalum Products Ltd

C Not Approved, Re-submit for Approval Originator/Contractor Company Name/Logo

Document Title Project No Originator no. Contract/PO no

Client Doc. Number DPI -80-Z-47-MB-0001

OPERATING & MAINTENANCE MANUAL

OPERATING AND MAINTENANCE MANUAL

OPERATING & MAINTENANCE MANUAL

DESCRIPTION FOR INFO

OPERATING & MAINTENANCE MANUAL

DOS & DONTS

ELECTROLYSER PERFORMANCE TESTING

ANNEXURE I ANALYSIS PROCEDURE ANNEXURE II REFERENCE DOCUMENTS

OPERATING & MAINTENANCE MANUAL

OPERATING & MAINTENANCE MANUAL

OPERATING & MAINTENANCE MANUAL

PROCESS DESIGN CALCULATION

2.1.2. HYPOCHLORITE CONCENTRATION

OPERATING & MAINTENANCE MANUAL

2.1.3 BLOWER CAPACITY:

Hence, 8000 gm/hr of equivalent chlorine generates

= 2/71 x 8000 = 225.35 g/h of Hydrogen.

Density of hydrogen Volume of hydrogen generates

= 0.08 kg/m3 = 0.22535 / 0.08 = 2.8168 m3/h

OPERATING & MAINTENANCE MANUAL

= 2.8168 x 100 = 281.68 m3/h

Design capacity of blower

DEGASSING TANK CAPACITY:

OPERATING & MAINTENANCE MANUAL

Seawater at Battery Limits:

OPERATING & MAINTENANCE MANUAL

OPERATING & MAINTENANCE MANUAL

OPERATING & MAINTENANCE MANUAL

OPERATING & MAINTENANCE MANUAL

OPERATING & MAINTENANCE MANUAL

OPERATING & MAINTENANCE MANUAL

OPERATING & MAINTENANCE MANUAL

Free Chlorine is generated at the anode: 2 Cl---------------- Cl2 + 2e-

OPERATING & MAINTENANCE MANUAL

OPERATING & MAINTENANCE MANUAL

The area is safe, clean, and well illuminated.

Supply to the Transformer rectifier and local control Panel is available.

Flush the line before start of the unit.

OPERATING & MAINTENANCE MANUAL

5.3 System Line up

OPERATING & MAINTENANCE MANUAL

OPERATING & MAINTENANCE MANUAL

OPERATING & MAINTENANCE MANUAL

OPERATING & MAINTENANCE MANUAL

OPERATING & MAINTENANCE MANUAL

DC Over Voltage Rectifier Over temperature

Output DC over voltage indication Indication while Over temperature occurred

Illuminating Push Buttons Fault / Fault Reset

OPERATING & MAINTENANCE MANUAL

DC Ammeter SET Current Value

Digital Meter - DC Current indication Potentiometer for adjusting amps

Transformer Rectifier A unit trip indication

Illuminating Push Buttons