YUGADANAVI POWER PLANT Water Treatment S

YUGADANAVI POWER PLANT
Document Type: OPERATION PROCEDURE Document No. WCP-OP-025
Water Treatment System

Operation Procedure
Prepared by Nazrul Islam [From KEMA]

Revision Rev. Date Reviewed By Approval Signature Date
Senior Operations
00 24-11-2010 Plant Manager
Engineer
Water Treatment System Operation Procedure WCP-OP-025
AMENDMENT RECORD
Revision # Description Date Approved By

TABLE OF CONTENTS
Part Description Page Number
AMENDMENT RECORD
OVERALL TABLE OF CONTENT
ABBREVIATIONS
GLOSSARY OF TERMS
1 PURPOSE AND SCOPE 05
2 PREREQUISITE 06
3 SYSTEM DESCRIPTION 08
4 SCHEMATIC FLOW DIAGRAM 39
5 P & ID 41
6 TECHNICAL DATA 42
7 START UP 54
8 NORMAL OPERATION 59
9 SHUTDOWN 65
10 EMERGENCY PROCEDURES 70
11 ALARMS AND TRIPS 72
12 FAULT & TROUBLESHOOTING 73
13 PERFORMANCE ANALYSIS 76
14 APPENDICES 77
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ABBREVIATIONS
Terms Description
DMF Dual Media Filter
UF Ultra Filtration
SWRO Sea Water Reverse Osmosis
BWRO Brackish Water Reverse Osmosis
TDS Total Dissolved Solid
TSS Total Suspended Solid
BOD Biological Oxygen Demand
COD Chemical Oxygen Demand
SDI Silt Density Index
TOC Total Organic Carbon
GLOSSARRY OF TERMS
Terms Description
Coagulation Destabilization of colloidal and suspended matter by the reduction of
electrostatic repulsive forces between particles with chemicals.
Flocculation The water treatment process following coagulation, which uses
gentle stirring to bring suspended particles together so they will form
larger, more settle able particles called floc.
Hardness characteristic of water, caused primarily by the salts of calcium and
magnesium
Sedimentation The water treatment process that involves reducing the velocity of
water in basins so the suspended material can settle out by gravity.
Ion Exchange A reversible process where ions of a given species are exchanged
between a solid (ion-exchange resins) and a liquid for an ion of
another species.
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1.0 PURPOSE AND SCOPE
The purpose of this procedure is to provide the system alignment settings and operation
procedure for the Water Treatment System at YUGADANAVI POWER PLANT.
This procedure is provided for the operations people at YUGADANAVI POWER PLANT and
should be used as a guide for aligning and operating the equipment on a regular basis.
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2.0 PREREQUISITES
2.1 System Verification
2.1.1 There is no Lock-Tagout existing in the system.
2.1.2 Sea Water Intake system is ready
2.1.3 Flash Mixer, Flocculation system and Tube Settler are ready
2.1.4 Dual Media Filters are ready
2.1.5 Ultra Filters are ready
2.1.6 SWRO System is ready
2.1.7 BWRO System is ready
2.1.8 Demineralization System (MBP) Water System is ready
2.2 Electrical Energize
2.2.1 Flash Mixer (AM-101) motor breaker has been energized
2.2.2 Flocculator Drive (AM-102) motor breaker has been energized
2.2.3 Flocculant Dosing Tank Agitator (AM-103) motor breaker has been energized
2.2.4 Coagulant Dosing Tank Agitator (AM-104) motor breaker has been energized
2.2.5 Coagulant Dosing Pumps (AP-103A/B) motor breakers have been energized
2.2.6 Flocculant Dosing Pumps (AP-102A/B) motor breakers have been energized
2.2.7 Filter Feed Pumps (AP-101A/B/C) motor breakers have been energized
2.2.8 DMF Blowers (AN-401A/B) motor breakers have been energized
2.2.9 DMF Backwash Pumps (AP-403A/B) motor breakers have been energized
2.2.10 UF Back-flush Pumps (AP-402A/B) motor breakers have been energized
2.2.11 SWRO Feed Pumps (AP-401A/B/C) motor breakers have been energized
2.2.12 SWRO HP Pumps (AP-601/602/603) motor breakers have been energized
2.2.13 BWRO Feed Pumps (AP-701A/B/C) motor breakers have been energized
2.2.14 Degasser Blowers (AN-701A/B) motor breakers have been energized
2.3 DCS / PLC Alignment
2.4 System Alignment/ Lined Up

2.4.1 Pretreatment system has been lined up according to the P&ID
LTL-NISM-PID-001 P&I DIAGRAM FOR PRETREATMENTA
2.4.2 Dual Media Filters have been lined up according to the P&ID:
LTL-NISM-PID-002 P&I DIAGRAM FOR DUAL MEDIA FILTERS
2.4.3 Ultra Filtration System has been lined up according to the P&ID:
LTL-NISM-PID-003 P&I DIAGRAM FOR ULTRA FILTRATION SYSTEM

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2.4.4 Back-wash/SWRO Feed Pumps have been lined up according to the P&ID:
LTL-NISM-PID-004 P&I DIAGRAM FOR BACKWASH/ RO FEED PUMPS
2.4.5 SWRO Chemical dosing system has been lined up according to the P&ID:
LTL-NISM-PID-005 P&I DIAGRAM FOR SWRO CHEMICAL DOSING SYSTEM
2.4.6 SWRO System has been lined up according to the P&ID:
LTL-NISM-PID-006 P&I DIAGRAM FOR SWRO System
2.4.7 DGT, SWRO & BWRO Permeate Tank system has been lined up according to
the P&ID:
LTL-NISM-PID-007 P&I DIAGRAM FOR DGT, SWRO & BWRO PERMEATE TANK
2.4.8 BWRO System has been lined up according to the P&ID:
LTL-NISM-PID-008 P&I DIAGRAM FOR BWRO SYSTEM
2.4.9 Mixed Bed Exchangers have been lined up according to the P&ID:
LTL-NISM-PID-009 P&I DIAGRAM FOR MIXED BED EXCHANGERS
2.4.10 Acid/ Alkali Storage Tanks have been lined up according to the P&ID:
LTL-NISM-PID-010 P&I DIAGRAM FOR ACID/ ALKALI STORAGE TANK
2.4.11 RO Cleaning System has been lined up according to the P&ID:
LTL-NISM-PID-011 P&I DIAGRAM FOR RO CLEANING SYSTEM
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3.0 SYSTEM DESCRIPTION

3.1 Water Treatment Basics
3.1.1 Molecular Structure of Water
Water is a colorless, tasteless and odorless transparent liquid at ambient temperature.
The molecular formula of water is expressed as H2O.
Figure 1.1 (a) shows the molecular structure of water. The atomic distance between the H and
O is 0.96 Å, and the angle of H-O-H is 104° 5'. Water molecular has four electrical charges of
two positive and two negative ones as shown in Figure 1.1 (b). As the four electrical charges
occupy symmetrical positions, a water molecule behaves like a bar magnet as shown in Figure
1.1 (c), that is, it has the dipole moment.
Because of the water molecule structure shown in Figure 1.1 (b), a water molecule has four
arms making hydrogen bonds.
The hydrogen bond is a kind of atomic bond which a hydrogen atom interposes, like O-H··O, O-
H··N, N-H··O and so on. Thus a water molecule combines the other water molecules, alcohols,
amino acids, etc.
These dipole moment and hydrogen bond of water give very unique properties to water
comparing with the other organic and inorganic substances.
This large latent heat of water is utilized for various industrial and air-conditioning processes,
etc. A typical example of such utilization is the recooling of circulation water by the partial
evaporation in a cooling tower. The evaporation of the 1% of circulation water reduces the
temperature of remaining 99% water by around 5.8°C at an ambient temperature.
As water has the dipole structure, water dissolves most of inorganic substances and some
organic substances having ionic bonds by dissociating and hydrating them.
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Some organic compounds without ionic bonds, such as sugar, dissolve into water if their
molecular sizes fit in the spaces between water molecules.
3.1.2 pH: Acidity and Alkalinity

Probably the most fundamental concept in the approach to understanding water chemistry is the
acidity-alkalinity relationship. The first step in grasping this is an understanding of the
dissociation of the water molecule itself into hydrogen ions and hydroxyl ions, according to
equation:
H2O ↔ H+ + OH-
The pH indicates the concentration of hydrogen ion in an aqueous solution and is used as an
index showing the acidity or alkalinity of water.
This ion product of water is a constant and it is 1 x 10–14 at 25°C.
[H+] [OH–] = 1 X 10–14
Where,
[H+], [OH–] = molar concentration of H+ and OH- at 25°C
The pH is calculated from the H+ concentration by using the equation as below
In case of pH 7, [H+] and [OH–] are equal at 1 x10–7 and this water is said to be neutral. Water
with pH of lower than 7 is acidic and higher than 7 is alkaline.
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3.1.3 M-Alkalinity and P-Alkalinity

When the pH drops below approximately 5, the hydrogen ion begins to reach milligrams per liter
levels, concentrated enough to be determined by titration, using the correct organic dye
indicator. The chemical indicator originally selected by the water chemist for this purpose was
methyl orange, changing color at pH 4.2 to 4.4. The color change of this indicator was so
subtle—orange on the alkaline side to salmon pink on the acid side—that researchers looked for
a substitute to give a more pronounced color change. The one they developed produces a blue
color on the alkaline side and red on the acid side, with gray at the endpoint. Even though this
special indicator has replaced methyl orange, the water chemist still defines alkalinity as methyl
orange alkalinity ("M" alkalinity) which exists above the approximate pH range of 4.2 to 4.4.
The water chemist is also concerned with P alkalinity (phenolphthalein alkalinity), which exists
when the pH is over a range of 8.2 to 8.4, corresponding to the change in phenolphthalein
indicator from a colorless condition below 8.2 to pink or red above 8.4. In most natural water
supplies, the pH is less than 8.2, so there is no P alkalinity. Very few natural waters have a pH
below about 5.0, so it is seldom that strong mineral acids are found in fresh water. The pH
range between the M endpoint and the P endpoint defines the alkaline range in which
bicarbonate alkalinity exists and weak acids may be present, the most prominent of which is
carbonic acid—carbon dioxide in solution.
Fig: Acidity and various types of alkalinity and their pH
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3.1.4 General Contaminants/ Impurities of Water:

Physical Contaminants:
 Suspended Solids
 Turbidity
 Oil & Grease
Dissolved Contaminants:
 Inorganic Salts : Ca, Mg, Alk, Cl, SO4, Si
 Organic: TOC, COD etc
3.1.5 IDENTIFYING IMPURITIES

Turbidity:
Turbidity consists of suspended material in water, causing a cloudy appearance. This cloudy
appearance is caused by the scattering and absorption of light by these particles. The
suspended matter may be inorganic or organic. Generally the small size of the particles
prevents rapid settling of the material and the water must be treated to reduce its turbidity.
Correlation of turbidity with the concentration of particles present is difficult since the light-
scattering properties vary among materials and are not necessarily proportional to their
concentration.
Turbidity can be measured by different optical systems. Such measurements simply show the
relative resistance to light transmittance, not an absolute level of contamination.
A candle turbidimeter is a very basic visual method used to measure highly turbid water. Its
results are expressed in Jackson Turbidity Units (JTU). A nephelometer is more useful in
lowturbidity water, with results expressed in Nephelometric Turbidity Units (NTU) or Formazin
Turbidity Units (FTU). JTU and NTU are not equivalent.
Suspended matter can also be expressed quantitatively in parts per million (ppm) by weight or
milligrams per liter (mg/L). This is accomplished by gravimetric analysis, typically filtering the
sample through a 0.45-micron membrane disc, then drying and weighing the residue.
The Silt Density Index (SDI) provides a relative value of suspended matter. The measured
values reflect the rate at which a 0.45-micron filter will plug with particulate material in the
source water. The SDI test is commonly used to correlate the level of suspended solids in
feedwater that tends to foul reverse osmosis systems.
pH:
The relative acidic or basic level of a solution is measured by pH.
The pH is a measure of hydrogen ion concentration in water, specifically the negative logarithm
(log) of the hydrogen ion concentration.
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The measurement of pH lies on a scale of 0 to 14 (Figure 2), with a pH of 7.0 being neutral (i.e.,
neither acidic nor basic), and bearing equal numbers of hydroxyl (OH-) and hydrogen (H+) ions.
A pH of less than 7.0 is acidic; a pH of more than 7.0 is basic.
Total Solids
Total Solids (TS) is the sum of Total Dissolved Solids (TDS) and Total Suspended Solids (TSS).
In water analysis these quantities are determined gravimetrically by drying a sample and
weighing the residue. In the field, TDS is commonly measured by a conductivity meter which is
correlative to a specific salt solution; however, this measurement is only an approximation most
often based on a multiplication factor of 0.66 of the electrical conductivity.
Example Total Solids (TS)

TDS TSS
Organic Inorganic Organic Inorganic
humic acid reactive silica algae silt
tannin (dissolved) fungi rust
pyrogens salt ions bacteria floc
clays
Conductivity/Resistivity
Ions conduct electricity. Because pure water contains few ions, it has a high resistance to
electrical current. The measurement of water’s electrical conductivity, or resistivity, can provide
an assessment of total ionic concentration. Conductivity is described in micro-Siemens/cm (μS)
and is measured by a conductivity meter and cell. Resistivity is described in mega ohm-cm, is
the inverse of conductivity and is measured by a resistivity meter and cell.
Bacterial Contamination
Bacterial contamination is quantified as “Colony Forming Units” (CFU), a measure of the total
viable bacterial population. CFU’s are typically determined by incubating a sample on a
nutritional medium and counting the number of bacterial colonies that grow. Each colony is
assumed to have grown from a single bacterial cell. This is called a “Standard Plate Count” and
is the most common method.
Total Organic Carbon (TOC)
TOC is a direct measure of the organic, oxidizable, carbon-based material in water. TOC is a
vital measurement used in sophisticated water treatment systems – such as electronics grade –
where any amount of contamination can adversely affect product quality and yield.
Biochemical Oxygen Demand (BOD)
BOD is a measure of organic material contamination in water, specified in mg/L. BOD is the
amount of dissolved oxygen required for the biochemical decomposition of organic compounds
and the oxidation of certain inorganic materials (e.g., iron, sulfites).
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Typically the test for BOD is conducted over a five-day period.
Chemical Oxygen Demand (COD)
COD is another measure of organic material contamination in water specified in mg/L. COD is
the amount of dissolved oxygen required to cause chemical oxidation of the organic material in
water.
Both BOD and COD are key indicators of the environmental health of a surface water supply.
They are commonly used in waste water treatment but rarely in general water treatment.
Silt Density Index (SDI)
The SDI test is performed by measuring the time T1 to collect 500 mL of filtrate through a 0.45-
μm filter at exactly 30 psi. The filter is allowed to flow for 15 min, then the time T2 for another
500 mL is measured.These times are compared in the formula given below. If the filter plugs
before 15 min, the feedwater needs additional treatment before going to the RO.
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Some Problems Caused by Water Impurities

Process water Boiler water Cooling water
Industries
affected How affected Deposits Corrosion Other Deposits Corrosion Other
Hardness (Ca,
Mg) All Scale and deposits M* M
Paper and textile Deposits on fibers Soap

Laundries scum on fabrics
Paper, textile, Destroys acid reagents,
Alkalinity beverages dyes, alum, flavors M(1) M
Electronics, Adds to cost of making high- High blow- High blow-
Dissolved solids utilities purity water down C down
Suspended
solids All Deposits, wear M M M
Dissolved
oxygen All Major cause of corrosion M M
May flash at well pump and
Carbon dioxide All (3) cause scaling M(1) Affects pH
Iron and
manganese All Deposits and discoloration M M
Paper, textile Stains fibers
Foods,
Organic matter beverages Tastes and odors May cause May cause
Food for bacteria foaming foaming
All Fouls ion-exchange resins
Silica C M(2) C
Microorganisms All Produce slimes and odors M
Code: (1) in steam condensate system;

M - major factor in problem; (2) in steam turbine;
C - contributor to problem; (3) deep well water supply.
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3.2 Description of the Treatment Process

3.2.1 Pre Treatment Plant
Clarification (Flash Mixer  Flocculator  Tube Settler)
Clarification is a mechanical/physical process to remove the suspended solids (Silts, Dirt,
Microorganisms etc.) which requires chemical conditioning to enhance clarifier performance
Coagulation process is again comprised of 3 steps as follows:

Coagulation  Flocculation  Sedimentation
Coagulation - The electrochemical process of neutralization of surface charges (usually
negative) to allow small colloidal particles to collide and form larger masses capable of settling
or withstanding pressure.
Flocculation - The physical process of the formation of larger masses, often enhanced by the
addition of long-chain polymeric compounds
Sedimentation - settling of particles by gravity.
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Dual Media Filter:
Media filters are used to remove Suspended solids (Silt, Turbidity, TSS etc). They cannot
remove dissolved solids (Ions and Organics).
A stacked media bed or two layers (dual media) is one answer to providing coarse to fine
filtration in a downflow pattern. The two materials selected have different grain sizes and
different specific gravities. Normally, ground anthracite is used in conjunction with silica sand.
The anthracite grains with a specific gravity of 1.6 and a grain size of 1 mm settle slower than
sand with a specific gravity of 2.65 and a grain size of 0.5 mm, so the coarse anthracite rests on
top of the fine sand after backwashing. In a typical dual media bed, 20 in of anthracite is placed
above 10 in of sand. The coarse anthracite allows deeper bed penetration and provides longer
filter runs at higher filter rates. The finer sand polishes the effluent. Under normal conditions,
this dual media can produce acceptable effluent at flow rates up to 5 gal/min per square foot of
bed area.
Flow rate through a filter is critical, since it limits the throughput and dictates the number of
filters required. Generally, as flow rate increases, penetration into the filter increases. The flow
rate is limited by the head available and the media size. As the media starts to load with solids,
the net velocity at a given flow rate increases until shear forces tear the solids apart and they
escape into the effluent.
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Most filters are designed to be backwashed before this breakthrough occurs at a point
determined by head loss. Typically, single media filters are backwashed when the head loss
reaches about 10 ft. In deep bed filtration, a terminal head loss of 15 to 20 ft is tolerable.
Backwash Initiation based on any of the following condition:
 Turbidity Breakthrough
 Terminal Head loss
 Timer
 Particle Counter
Design Features:
 Service Flow Rate*

o Pre-RO: 12-15 M/hr
o Non-RO: 15-20 M/hr
 Service flow rate too high
o High dP
o Deep impregnation of filter bed by suspended matter
o Shortened runs
o Poor water quality
 Service flow rate too low
o Channeling
o Unpredictable water quality
 Backwash at 20 M/hr *
o Frequency: Daily or when dP ≥ 10 psi
o Bed expansion: 40% minimum
o Duration: 10-20 minutes or until water is clear
 Backwash Flow rate too high
o Media loss
 Backwash Flow rate too low
o Shortened runs
o Poor water quality
o Plugging (resulting in equipment damage)
o Channeling
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Operation Practice
 Monitor Filter Influent (Clarifier Effluent)

 Monitor Filtered Water Turbidity From Each Filter Cell or Filter
 Adequate Flow Control To Prevent Surges
 Pre-chlorinate Filter Influent
 Are Filters Being Thoroughly Backwashed
 Inspect Media Regularly
 At least once per year for pressure filters
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3.2.2 Ultra filtration

Processes using small pore-size membranes and increased pressure, called ultrafiltration (UF),
generally require pressure differentials greater than 20 lb/in2 (1.4 kg/cm2). The purpose of using
a smaller pore size is to remove colloids and certain high molecular weight organic materials
from water. However, this small pore size makes the membranes even more susceptible to
clogging or blinding than microfiltration membranes
More pronounced than in straight filtration, the character and form of the UF membrane is
critical to the results obtained. To obtain suitable flow rates, the UF semipermeable membrane
usually has an extremely thin skin incorporated on the surface of a more porous, thicker
substrate. This type of membrane is said to be anisotropic. The skin may be less than 0.1 µm
thick, while the substrate may be 25 to 50 µm in depth. Additional mechanical support is usually
necessary. The skin and the substrate are often the same material, the skin being modified on
the surface of the bulk membrane by treating the surface thermally, mechanically, chemically, or
by some combination of these.
In microfiltration and depth or septum filtration, the water flow path is perpendicular to the
filtration surface, and all of the water to be processed passes through the barrier and is
recovered. By contrast, in both ultrafiltration and reverse osmosis, the flow of water to be filtered
is cross-flow, or parallel to the membrane surface, with only a portion of this peeling off the
mainstream to pass through the membrane. The high rate of cross-flow is maintained either by
recycle or by excessive wastage, and this procedure of maintaining high surface velocity
effectively minimizes surface fouling by its scouring action and reduces concentration
polarization effects. Because of this operating procedure, not all of the original liquid to be
processed becomes filtrate. The ratio of permeate (the term applied to product water instead of
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"filtrate" where semipermeable membranes are used) to applied feed water is the recovery ratio,
R.
Back Flush
KPI for Ultra Filter
 Turbidity
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 Silt Density Index
Parameter Feed Treated Water

Turbidity, NTU 1~2 0.1 ~ 0.2
Silt Density Index 6 ~ UM <4
Trans-membrane Pressure, psi 10 ~ 15 Max 20
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3.2.3 Reverse Osmosis

Osmosis is the process in which a solvent flows across a membrane separating a stronger from
a weaker solution; the solvent flows in the direction that will reduce the concentration of the
stronger solution. The flow of solvent between solution compartments can be observed as the
liquid in the compartment of stronger solution increases in volume.
In reverse osmosis (RO), a driving force, the differential pressure across the membrane, causes
water to flow from the stronger solution to the weaker. Therefore fore, the pressure required
must exceed the osmotic pressure. The differential pressure (trans-membrane pressure) is often
greater than 300 lb/in2 (21 kg/cm2), depending on concentration differences. It averages about
10 lb/in2 for each 1000 mg/L difference in total dissolved solids. From this, it is apparent that a
large portion of the operating cost is pumping energy; the other major cost factors are the cost
of disposal of the reject stream (usually about 25% of the volume of feed stream), depreciation,
and membrane replacement.
Transmembrane pressure differences are influenced by the types of membranes used. In

reverse osmosis, transport of water through the membrane is not the result of flow through
definitive pores, at least not pores as commonly conceived.
It is the result of diffusion, one molecule at a time, through vacancies in the molecular structure
of the membrane material. The vacancies in amorphous polymers are in a state of flux, or are
not fixed, while in crystalline materials the vacancies are voids in lattice structures and are
essentially fixed in number, position, and size. RO membranes are made of amorphous
polymers, but usually contain some crystalline or less amorphous regions.
The most widely used membrane materials are cellulose acetate, triacetate, and polyamide
polymers. A condensed tabulation of their most important characteristics is given in Table
below. Operating temperature must be carefully monitored, since failure occurs if the
temperature limit is exceeded, and flow is restricted as the temperature drops. Polysulfone
membranes are used at higher temperatures. For wider operating pH ranges, polyethylenimine
and polyfurane membranes may be used.
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RO Membrane Characteristics
(Based on 90% rejection)
Type membrane
Triacetate Polyamide Cellulose
acetate spiral
hollow fibers hollow fibers wound
Flux at 400 lb/in² 1.5 1 15-18
Back Pressure, lb/in² 75 50 0
pH range 4-7.5 11-Apr 4-6.5
Maximum temperature, °F 100° 110° 100°
Cl2, maximum mg/L 1 0.1 1
Bioresistance Good Excellent Fair
Backflushing Ineffective Ineffective Effective
Silt density index (SDI) 4 4 7
Because the membranes have such small pores, it is extremely important to provide a feed
stream free of crud and stabilized to prevent precipitation or scaling reactions. The use of high
velocity to scour the surface is a design feature that helps keep the surface from fouling, but it
cannot solve the problem completely.
The susceptibility of the membrane to fouling by water-borne debris is measured by a special

filtration technique that determines the Silt Density Index (SDI).
In this test, a sample of feed water at a constant pressure of 30 lb/in2 is passed through a 0.45
µm membrane filter. The filtrate is collected in a 500-mL graduate, and the time for collection of
the first 500-mL sample is recorded as t15. From the data, the SDI is calculated as follows:
𝒕𝟏𝟓 −𝒕𝟎
SDI = ( ) x 6.7
𝒕𝟏𝟓
(The factor 6.7 applies to the 15-minute test period only.)
Usually spiral-wound membranes can tolerate a higher SDI than the hollow fiber-type RO
membranes. If the SDI exceeds 10, prefiltration is always needed, but may be required for
hollow-fiber membranes even when the SDI exceeds 4.
Even with prefiltration and control of the Langelier index, fouling may still occur from such things
as heavy metals (Fe, Mn), silica (SiO2), and organic matter. The latter may provide food for
microbes, so disinfection is frequently required.
Some membranes cannot tolerate more than 0.1 mg/L chlorine, so non-oxidizing biocides must
be used. Formaldehyde has sometimes been used for batch disinfection.
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Typical RO process:
Two stage RO at 75% Recovery:
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Factors which affect RO:
 Sparingly Soluble Salts.

 Silica.
 Iron.
 Organic Matter.
 Hardness.
Typical RO System Problems
Iron Fouling Microbiological Fouling
Silica Fouling Mineral Scale
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RO System Monitoring
 Pretreatment monitoring
 Silt Density (SDI), Turbidity, pH, oxidants
 Temperature, pressure, TDS
 Foulants (bacteria, metals, hardness, silica)
 Performance monitoring
 Percent salt rejection
 Normalized permeate flow rate
 Differential pressure
 Feedwater flow rate
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3.3 Ion Exchange

Ion exchange removes unwanted ions from raw water by transferring them to a solid material
(resin), called an ion exchanger, which accepts them while giving back an equivalent number of
a desirable species stored on the ion exchanger skeleton.
The ion exchanger has a limited capacity for storage of ions on its skeleton, called its exchange
capacity; because of this, the ion exchanger eventually becomes depleted of its desirable ions
and saturated with unwanted ions. It is then washed with a strong regenerating solution
containing the desirable species of ions, and these then replace the accumulated undesirable
ions, returning the exchange material to a usable condition. This operation is a cyclic chemical
process, and the complete cycle usually includes backwashing, regeneration, rinsing, and
service.
The ion exchangers used in water conditioning are skeleton like structures having many ion
exchange sites. The insoluble plastic skeleton is an enormously large ion that is electrically
charged to hold ions of opposite charge. As such, the ion exchanger is related to the
polyelectrolytes used for coagulation and flocculation, but deliberately made so high in
molecular weight as to be essentially insoluble. Exchangers with negatively charged sites are
cation exchangers because they take up positively charged ions. Anion exchangers have
positively charged sites and, consequently, take up negative ions. The plastic structure is
porous and permeable, so the entire ion exchange particle participates in the process.
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Most commercial ion exchangers are synthetic plastic materials, such as copolymers of styrene
and divinyl benzene .There is a fine balance between producing a loosely cross-linked polymer
that has free access to water for rapid reaction but is slightly soluble, and a tightly cross-linked
resin, which would be insoluble, but more difficult to use because of restricted rates of exchange
both in exhaustion and regeneration. Water treatment ion exchangers are essentially insoluble
and can be expected to last for 5 to 10 years.
Resin Material:
BACKBONE: STYRENE –DIVINYLBENZENE COPOLYMER
CROSSLINKING (DVB): – 2% - 25% DVB
FUNCTIONAL GROUPS: Ion Exchange Functionality
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Resin Types:
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Cation Exchange Resin
 Strong Acid Cation (SAC)

 Hydrogen or sodium form
 Sodium form removes hardness (Ca/Mg) only
 Hydrogen form removes nearly all cations
 Functional group: sulfonic acid group - HSO3
 Weak Acid Cations (WAC)

 Removes only hardness associated with alkalinity
 More efficient regeneration than SAC
 Functional group: carboxylic group – COOH
Reactions:
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Anion Exchange Resin
 Strong Base Anion (SBA)

 Removes all anions: SO4, Cl, NO3, HCO3, SiO2, CO2, Organics
 Less efficient regeneration than WBA
 Functional group: quaternary ammonium group
 Type I RN(CH3)3
 Greater stability,
 Effective for Silica and CO2 removal
 Type II RN(CH3)2C2H5OH
 Greater capacity
 Efficient Regeneration
Selectivity: PO4 3+> SO4= > NO3- > Cl- > HCO3- > HSiO3- > CO2 > OH-
 Weak Base Anion (WBA

 Removes only SO4, Cl, NO3, PO4 (strong acids)
 More efficient regeneration
 Better at releasing organics (elution) upon regeneration
 Used ahead of SBA to protect from fouling
 Functional groups: amine groups R-NH2
 Acts as an “acid sponge”
Anion Resin Reactions:
Page 33 of 77
Mixed Bed Exchanger
Intimate mixing of cation and anion resins - acts as an infinite series of cation/anion exchangers
to achieve very low leakage
Page 34 of 77
Demineralization Process:
Cation Bed: Exchanges Cations for H+
Anion Bed: Exchanges Anions for OH-
H+ + OH-  HOH
Demineralizers Turn Salt into Water (H2O)
Page 35 of 77
Regeneration of Cation Resin: 5% Hydrochloric Acid (HCl) solution is used for regeneration of
the cation resin
Regeneration of Anion Resin: 4% Caustic Soda (NaOH) solution is used for regeneration of
the cation resin
Page 36 of 77
Mixed-Bed Regeneration Steps:
 Exhaustion rinse 10 minutes water

 Blowdown air 3 minutes air
 Backwash 15 minutes water
 Settle 5 minutes
 Caustic 1/Acid 1 35 minutes 4%NaOH / blocking water
 Caustic 2/Acid 2 25 minutes 4%NaOH / 5%HCl
 Anion/Cation Slow rinse 30 minutes water / water
 Combined rinse 25 minutes water
 Blowdown 3 minutes air
 Air/water mix 3 minutes air & water
 Air mix 3 minutes air
 Drain 3 minutes air
 Fill 5 minutes water
 Final rinse 15 minutes water
Total time: 180 minutes
Page 37 of 77
3.4 Scheme/ Arrangements of the Treatment Process

The water treatment plant comprises of three sections namely:
 Pre Treatment Plant Comprising of

 Flash Mixer
 Flocculator
 Tube Settler
 Dual Media Filter
 Ultra filtration plant
 Desalination Plant Comprising of
 Sea Water RO System
 Sea Water RO Permeate Storage tank
 Brackish Water RO System
 Brackish water RO Permeate tank
 Demineralizing Plant Comprising of
 Mixed Bed Units
 DM Water Storage Tanks
 Regeneration System
Process Step Purpose

Pre – Treatment Clarification Removal of Suspended Solid
Coagulation Dosing Coagulation of Particulate Matter
Agglomeration Particulate Matter Agglomeration and
flocculation of
Coagulant Aid Dosing Particulate Matter
Dual Media Filtration
(Fine Sand & Anthracite ) Removal of Fine Suspended Solid
Ultra Filtration System Removal of Colloidal matters
Removal of Chlorine to Protect RO
De-Chlorination Dosing membrane
Anti scalant Dosing To Prevent Scaling of Membrane
Acid Dosing To reducer the feed water pH
Cartridge Filtration 5 Microns Removal of Suspended Solid to range 5 Microns
RO (Reverse Osmosis) Process Removal of Dissolved Salt
Post pH adjustment To adjust the product water pH
De gasification Removal of Carbon dioxide
Mixed Bed system Final polishing unit, removal of traces of Ions
Page 38 of 77
4.0 SCHEMATIC FLOW DIGRAM
Page 39 of 77
Water Balance Diagram:
Page 40 of 77
5.0 P & ID
Vendor Name P&ID Number P&ID Description

NALCO LTL-NISM-PID-001 PROCESS AND INSTRUMENTATION DIAGRAM FOR PRETREATMENT
NALCO LTL-NISM-PID-002 PROCESS AND INSTRUMENTATION DIAGRAM FOR DUAL MEDIA FILTERS
NALCO LTL-NISM-PID-003 PROCESS AND INSTRUMENTATION DIAGRAM FOR ULTRA FILTRATION SYSTEM
NALCO LTL-NISM-PID-004 PROCESS AND INSTRUMENTATION DIAGRAM FOR BACKWASH / RO FEED PUMPS
NALCO LTL-NISM-PID-005 PROCESS AND INSTRUMENTATION DIAGRAM FOR SWRO CHEMICAL DOSING SYSTEM
NALCO LTL-NISM-PID-006 PROCESS AND INSTRUMENTATION DIAGRAM FOR SWRO SYSTEM
NALCO LTL-NISM-PID-007 PROCESS AND INSTRUMENTATION DIAGRAM FOR DGT, SWRO & BWRO PERMEATE TANKS
NALCO LTL-NISM-PID-008 PROCESS AND INSTRUMENTATION DIAGRAM FOR BWRO SYSTEM
NALCO LTL-NISM-PID-009 PROCESS AND INSTRUMENTATION DIAGRAM FOR MIXED BED EXCHANGERS
NALCO LTL-NISM-PID-010 PROCESS AND INSTRUMENTATION DIAGRAM FOR ACID / ALKALI STORAGE TANKS
NALCO LTL-NISM-PID-011 PROCESS AND INSTRUMENTATION DIAGRAM RO CLEANING SYSTEM
NALCO LTL-NISM-PID-012 LEGENDS AND VALVES
NALCO LTL-NISM-PID-013 PROCESS AND INSTRUMENTATION DIAGRAM FOR EFFLUENT TREATMENT PLANT
NALCO LTL-NISM-PID-014 PROCESS AND INSTRUMENTATION DIAGRAM FOR CHEMICAL DOSING SYSTEM FOR ETP
NALCO LTL-NISM-PID-015 PROCESS AND INSTRUMENTATION DIAGRAM FOR SEWAGE TREATMENT PLANT
Page 41 of 77
6.0 TECHNICAL DATA

6.1 Plant Design Capacity
The plant requires 1200 m3/day of DM water. Accordingly the DM water plant is designed to
produce 1200 m3/day of DM water at an average flow rate of 50 m 3/hr. The capacity of various
stages of the plant is brought out below:
6.1.1 Tube Settler Clarifier

The tube settlers are designed to produce 250 m3/hr of clarified water. There are two streams
both working producing 125 m3/hr each.
6.1.2 Dual Media Filters

The Dual Media Filtration system will produce filtered water at 221.2 m3/hr to feed to the SWRO
systems. The DMF system will have six streams with five working and one standby.
Each stream will produce 50 m3/hr of filtered water.
6.1.3 Ultra Filtration Systems

The Ultra Filtration system will produce permeates at 199.1 m3/hr to feed to the SWRO systems.
The recovery of the sea water system will be 90% and hence the feed flow to the UF system will
be 221.2 m3/hr. The UF system will have three streams with two working and one standby. Each
stream will produce 99.55 m3/hr of permeate water.
6.1.4 Sea Water RO Units

The seawater RO system will produce permeates at 74.2 m3/hr (64 m3/hr for BWRO and 10
m3/hr for Drinking Water). The recovery of the sea water system will be 35% and hence the feed
flow to the sea water system will be 211.9 m3/hr.
The reject water from the BWRO system will be fed to the SWRO system. Hence feed flow from
pre treatment plant will be 211.9 m3/hr. The seawater RO system will have three streams with
two working and one standby. Each stream will produce 37.15 m3/hr of permeate water.
6.1.5 Brackish Water RO Units

The brackish water RO system will produce permeate at 51.3 m3/hr at a recovery of 80% to feed
to the mixed bed units. The feed flow to the brackish water system will be 64.2 m3/hr.
The brackish water RO system will have three streams with two working and one standby.
Each stream will produce 25.6 m3/hr of permeate water.
6.1.6 Mixed Bed Units

The mixed bed unit of designed to produce 50 m3/hr of useful DM water and 1200 m3 between
regeneration. The unit will be regenerated once in a day. There will two units with one working
and one on standby. The gross output from the unit will be net useful output plus the
regeneration water required.
Page 42 of 77
6.2 Design Data of Feed Water

The feed water to the plant is pre-chlorinated sea water. The physical and chemical
characteristics for the feed water are as below. The below analysis is used for the design of the
plant:
Sr# Parameters Unit Value

1 Source of water Sea Water
2 pH 7.8
3 TDS ppm 36800
4 Calcium As CaCO3 1000
5 Magnesium As CaCO3 5000
6 Sodium ppm 10000
7 Iron ppm 0.1
8 Strontium ppm 5
9 Barium ppm 2
10 M Alkalinity As CaCO3 4000
11 P Alkalinity As CaCO3 800
12 Sulphate ppm 2584
13 Chloride ppm 18824
14 Fluoride ppm 2
15 Silica ppm 5
16 TSS ppm <150
6.3 Treated Water Quality at different Stages:

The feed water to the plant is pre-chlorinated sea water.
Sr. # Parameter SWRO BWRO MB

1 TDS in ppm < 500 < 20
2 Conductivity, µS/cm < 0.1
3 Silica in ppm as Si < 0.01
4 pH 7.0 + 0.2
5 Hardness ppm as CaCO3 Nil Nil
Page 43 of 77
6.4 Process Sizing calculation
Tag Description Unit Value

No
1.0 Flash Mixer (AG- 01)
Design Flow m3/hr 250
Quantity provided Nos. 1
Contact Time required sec 30
Volume required m3 2
Volume provided m3 4
Size provided 2.0m x 2.0m x 1.0m
LD
Mixer MOC SS316
2.0 Flocculation Tank (AG- 02)
Quantity provided Nos. 1
Contact time min 20
Volume m3 80
Size provided 5.0m x 5.0m x 3.5m
LD
Mixer MOC SS316
3.0 Tube Settler (T-03/04)
No of units provided Nos. 2
Capacity per unit m3/hr 125
Type Tube Settler
Settling velocity in the pack (Rise rate) m/hr 1
Depth of pack m 0.75
Settling area of pack m2/m3 11
Design Settling area m2 120
Quantity of media m3 10.9
Surface area required m2 14.53
Surface Overflow Rate to be provided m3/m2/hr 2.5
based on plan area
Plan area required m2 48
Plan area provided mxm 7x7
Overall Size 7.0m x 7.0m x 3.5m
LD
MOC PVC
4.0 Clarified Water Tank (T-05)
No of tanks provided Nos. 1
Page 44 of 77

No
Contact time hr 1
Volume Provided M3 250
Size Provided 8.0m x 8.0m x 4.0 LD
MOC RCC – Epoxy
lined/GRP panel tank
Scope By Purchaser
5.0 Filter Feed Pumps , (P-01-A/B/C)
No of Pumps Nos. 2w+1s
Type Centrifugal
Capacity m3/hr 125
Head kg/cm2 3.5
MOC SS 316
6.0 Dual Media Filters (DMF-01/02/03/04/05/06)
Total Flow m3/hr 250
Number Offered Nos. 5w + 1s
Capacity / Filter m3/hr 50
Filtration Velocity m/hr 15
Filtration Area Required m2 3.33
Diameter required m 2.0
Size provided Φ2.2m x 1.8m HOS
MOC CSRL, inside rubber
lined
Media: Sand + Anthracite
Sand 0.35 ~0.5mm size 400mm bed 1.52 m³
Anthracite 0.8 ~1.2mm size 600mm bed 2.28m³
Operating/Design Pressure Kg/cm² 3.5 / 6.0

7.0 Backwash Pumps (P-04 -A/B)
Filtration area provided m2 3.8
Back Wash Velocity m3/m2/hr 21
Back Wash Flow m3/hr 80
Type Centrifugal
Capacity m3/hr 115
Head kg/cm2 1.5
Back Wash Duration min 20
Back Water Quantity m3 27
Page 45 of 77

No
MOC SS 316
8.0 DMF Blowers( K- 01- A/B)
Filtration area provided m2 3.8
Air scour velocity m3/m2/hr 40
Air flow rate required m3/hr 152
No of Blowers Nos. 1w+1s
Type Roots
Capacity m3/hr 155
Head kg/cm2 0.4
MOC Cast Iron
9.0 Ultra Filtration System (UF-01/02/03)
No of trains Nos. 2w+1s
Permeate Capacity m3/hr 218
Permeate Capacity/Train m3/hr 109
System Recovery % 90
Membranes per Train Nos. 36
Membrane Make Hydranautics
Membrane Model Hydracap60
Membrane Area sqft 500
System Flux l/m2/hr 59.8
Back Wash Flow m3/hr 150
MOC SS/PP
Outlet water SDI <3
Disc Filters 100 um
Qty of disc filters 2 nos
Make & Model Azud- 3 NW
UF Module Specification
Model no : Hydracap60
Size : Dia. 8” x 48” long
Membrane material : Polysulfone
Outer shell : FRP
Feed/concentrate connection : 2-1/2” victaulic
Permeate connection : 2” tubing
Maximum feed pressure : 73 psi
Tran membrane Pressure : < 20 psi
Maximum operating temperature : 40 °C
Chlorine Tolerance :100 ppm @pH 10
Operating pH Range : 4-10
Cleaning pH Range : 1.5 -13
10.0 UF Permeate Tank (T-08, BB401)
Page 46 of 77

No
Retention Time Required min 30
Volume Provided M3 150
Size Provided 7.0m x 7.0m x 3.5m
LD
Material Construction RCC – Epoxy lined
Scope By Purchaser
11.0 UF Back flush Pumps (P-05 -A/B)
Type Centrifugal
Capacity m3/hr 150
Head kg/cm2 1.5
MOC SS 316
12.0 Sea water RO Feed Pumps (P –08- A/B/C)
Type Centrifugal
Capacity m3/hr 109
Head kg/cm2 3.5
MOC SS 316
13.0 SWRO Micron filter ( MF- 01/02/03)
Quantity Nos. 2w+1s
Flow m3/hr 109
Cartridge Length inch 40
No. Of Cartridges each 30
Material of construction PP
Filter MOC SS 304
14.0 Sea water RO HP Pumps (SWRO – 01/02/03)
Type Centrifugal/Eq
Capacity m3/hr 108
Head kg/cm2 65
MOC SS 316/2205
15.0 Sea water RO SYSTEM ( SWRO –01/02/03)
No of Trains Nos. 2w+1s
Total Permeate Flow m3/hr 76
Page 47 of 77

No
Permeate Flow per Train m3/hr 38
Operating Pressure Bar 60 to 65
Feed water Temperature deg C 25-35
Membrane Make Dow, USA
Membrane Model Filmtec SW30HR LE-
400
No of stages 1
No of pressure vessels 10
No of membranes per vessel 6
Total number of membranes 60
Average Permeate Flux Lit/m2/hr 17.04
Pressure Vessel MOC FRP
HPB Energy Recovery Turbine Model HPB-120
HPB MOC Duplex2205
Brine Flow m3/Hr 70.2 m3/Hr
Brine Pressure bar 63
Feed Flow m3/Hr 108
Feed Pressure bar 39
Outlet Pressure bar 65
Suck back tank ( Common for three skids) M3 5
16.0 Degasser Tower (T-20)
Total Flow m3/hr 76
Number Working Nos. 1
Capacity / Tower m3/hr 76
Degassing Velocity m/hr 80
Degassing Area Required m2 0.95
Diameter required mm 1100
Diameter Provided mm 1200
Total height mm 3000
Fill Media Pall Rings
Media Depth mm 1500
Media MOC PVC / PP
Tower MOC FRP
17.0 Degasser Air Blowers (K-02-A/B)
Degassing area provided m2 1.13
Air scour velocity m3/m2/hr 40
Air flow rate required m3/hr 45
Page 48 of 77

No
Type Centrifugal
Capacity m3/hr 45
Head mmWG 100
MOC Cast Iron
18.0 SWRO Permeate Tank (T-13)
Retention Time Required Hrs. 12
Capacity Required m3 1272
Capacity Provided m3 1500
Size Provided 20.0m x 18.0m x
4.5m LD
Material Construction RCC – Epoxy
lined/GRP
Scope By Purchaser
19.0 Micron filter
Flow m3/hr 66
Quantity No. 2w+1s
Quantity No. 1
Capacity m3/hr 33
No. Of Cartridges Nos. 12
Length of Cartridge Inch 30
Filter MOC SS 304
20.0 BWRO Feed Pumps (P-15-A/B/C)
Type Horizontal Centrifugal
Capacity m3/hr 35
Head kg/cm2 3.0
MOC SS 304
21.0 BWRO HP Pumps ( BWRO –01/02/03)
Pump Capacity m3/hr 33
Type Multistage Centrifugal
MOC SS 304
Head kg/cm2 15
22.0 Brackish water RO SYSTEM (BWRO –01/02/03)
No of trains Nos. 2w+1s
Page 49 of 77

No
Total Permeate Flow m3/hr 53
Permeate Flow/Train m3/hr 26.5
No of Stages 2
Array 3:2
No of pressure vessels 5
No of membranes per vessel 6
Total number of membranes 30
Membrane Make Dow, USA
Membrane Model Filmtec BW30-400
Membrane Flux Lit/m3/hr 23.77
Pressure Vessel MOC FRP
23.0 BWRO Permeate Tank (T-14)
Retention time hrs 3.5
Volume Provided m3 200
Size Provided Under Hold
Material of Construction GRP
Type of Tank Sectional bolted type
24.0 MB Feed Pumps (P-10-A/B)
Type Horizontal Centrifugal
Capacity m3/hr 50
Head kg/cm2 3.0
MOC SS 304
25.0 MB Unit (MB –01/02)
Quantity Nos. 1w+1s
Capacity m3/hr 50
Diameter mm 1400
HOS mm 2500
Resin Quantity Cation: 800 Anion:
1200
Regenerant Quantity Kg/regn Acid: 64
Alkali: 96
Operation Automatic
MOC CSRL
26.0 MB Blowers ( K-03-A/B)
Page 50 of 77

No
Type Turbo blower
Capacity m3/hr 185
Head kg/cm2 0.4
MOC Cast Iron
27.0 MB Regeneration System ( P-11- A/B)
MB Regenerant day Tanks Acid Alkali
No offered One One
Capacity 300 Lit 550 Lit
MOC MSRL MSRL
Diameter 600 mm 800 mm
Height 1200 mm 1200 mm
Mixer No Provided
Bulk Chemicals Tank Acid Alkali
No offered One One
Capacity 10 m3 10 m3
MOC MSRL MSRL
Diameter 2000 mm 2000 mm
LOS 5000 mm 5000 mm
Unloading Pumps Acid Alkali
No offered Two Two
Capacity 1.5 m3/hr 1.5 m3/hr
Type Barrel Pump Barrel Pump
MOC PP PP
28.0 DM Water Storage Tank (T-18)
Volume Specified m3 1200
Tank MOC GRP
Type of Tank Sectional Bolted Type
Dimensions Under Hold
29.0 CIP SYSTEM ( T-21)
Volume Specified m3 2000
Tank MOC PE
Mixer MOC SS316
30.0 Micron filter- CIP
Page 51 of 77

No
Flow m3/hr 90
Quantity No. 1
No. Of Cartridges Nos. 22
Length of Cartridge Inch 40
Filter MOC SS 304
31.0 CIP Pump ( P-12-A/B)
No of Pumps Nos. 2
Type Verticle Centrifugal
Capacity m3/hr 90
Head kg/cm2 4
MOC SS 304
32.0 Coagulant Dosing System ( N 8185/Eq) (T-07)
Concentration % 10%
Dosage Required (max) ppm 5
Dosing Capacity Required LPH 12.5
Dosing Capacity Provided LPH 30
No Offered Nos. 2
Required Tank Capacity Lit. 300
Provided Tank Capacity Lit. 500
No Offered Nos. 1
Tank MOC HDPE
Dosing Tank Agitator (AG- 04) MOC SS316
33.0 Flocculant Dosing System (T-06)
Concentration % 0.1
Dosage Required ppm 0.5
Dosing Capacity Required LPH 125
No Offered Nos. 2
No Offered Nos. 1
Tank MOC HDPE
Dosing Tank Agitator MOC SS316
(AG –03)
34.0 Anti-Oxidant (SMBS) Dosing System ( T-12)
Page 52 of 77

No
Concentration % 10
Dosage Required ppm 5
No Offered Nos. 2
No Offered Nos. 1
Tank MOC HDPE
Dosing Tank Agitator MOC MOC SS316
(AG-06)
35.0 PC191 Dosing System (T-11)
Concentration % 10
No Offered Nos. 2
No Offered Nos. 1
Tank MOC HDPE
Dosing Tank Agitator MOC MOC SS316
(AG-05)
36.0 ACID Dosing System (T-10)
Concentration % 33
No Offered Nos. 2
No Offered Nos. 1
Tank MOC HDPE
Page 53 of 77
7.0 START UP
7.1 Pre-start Checks
# Checklist Item Remarks (Okay?)
Pretreatment System
1 Coagulant Dosing system is Ready
2 Flocculant Dosing system is Ready
3 Flash Mixer drive is Ready
Dual Media Filter

1 Filter has been filled with water
2 Feed Pump discharge valve is open and Inlet water
Turbidity is <xx NTU
3 Root valve of the Pressure Gauges are open
4 Drain valves are closed
Ultra Filtration System
SWRO System
1 pH should be less than 6.5
2 SDI < 5
3 Turbidity <1 NTU
4 Temperature < 45°C
5 Free Chlorine < 0.1 ppm
Mixed Bed Exchanger
Page 54 of 77
7.2 Normal Startup

7.2.1 COAGULANT DOSING SYSTEM
The operation of coagulant feed system shall be coordinated with the operation of the TUBE
SETTLER (BB - 103). While the tube settler in operation, the coagulant should be fed through
flash mixer reaction zone.
AUTO OPERATION
 Ensure that coagulant dosing tank is full of chemical

 Switch two dosing Pump in auto mode, open the isolation valve in the suction and
discharge lines for the in – service injection pumps.
 As soon as the raw water influent flow is established. The service injection pump will
start automatically.
7.2.2 FLOCCULANT DOSING SYSTEM
The operation of Flocculant feed system shall be coordinated with the operation of the TUBE
SETTLER (BB - 103). While the tube settler in operation, the Flocculant should be fed through
flash mixer reaction zone.
The Flocculant dosing system comprises of one Flocculant tank (BB -106) and 2 x 100
% Coagulant dosing pumps (AP- 102 A/B). The Coagulant is injected at the flocculation
chamber. The concentration of Flocculant solution may be around 0.5 -1 % at Flocculant tank.
AUTO OPERATION
 Ensure that Flocculant dosing tank is full of chemical

 Switch two dosing Pump in auto mode, open the isolation valve in the suction and
discharge lines for the in – service injection pumps.
 As soon as the raw water influent flow is established. The service injection pump will
start automatically.
7.2.3 Dual Media Filters (DMF-01/02/03/04/05/06)
Ensure that feed water is at sufficient flow and Pressure. Feed shall be pretreated.
The changeover to service mode shall be automatic in auto mode. In semi automatic mode
select the SERVICE mode and press the “SERVICE START” PB configured on the SCADA.
The PLC will issue a command to open the valves.
The changeover to backwash mode based on time shall be automatic. However, in case DP
across filter increases beyond set value before 24 hours, an alarm shall be given.
Page 55 of 77
On receipt of “DP ACROSS FILTER HIGH” alarm on the PLC, the filter will be isolated by
closing its inlet and outlet valves automatically and goes in Backwash mode. The subsequent
steps shall then be followed automatically.
The various steps of operation namely Service, Backwash etc. are carried out according to the
logical sequences programmed in the PLC. The Logical sequences are programmed based on
the Valve-Timing chart.
7.2.4 Ultra Filters

 Switch all UF modules to run position.
 Open the inlet water supply to the UF system
 Record all the pressure and flow.
 Check and record the water temperature
 Observe the backwash sequence and valve operation.
 Check the backwash outlet water condition.
 Regulate the Recirculating flow is necessary.
7.2.5 ANTI OXIDANT - SODIUM META BISULPHATE DOSING SYSTEMS

Operation of de-chlorination system shall be coordinated with the operation of the feed water
and RO system as well as the ORP reading at the outlet of the cartridge filter.
The sodium bi-sulphate is injected at the cartridge filter inlet. Under normal operating condition
one of pump shall be in operation, whereas one pump is a common standby.
7.2.6 ANTI SCALANT DOSING SYSTEM: Auto Operation

- Ensure that Anti scalant dosing tank is full chemical.
- Switch one dosing pumps in automatic mode. Open the isolation valve in the suction and
discharge lines for in service injection pump.
As soon as the clarified water pump start, and in service injection pump will start automatically.
7.2.7 SWRO SYSTEM

Start up and shutdown of the RO system shall be coordinated with the RO product tank level.
The RO system is completely automated and is operated from control panel. It can not be
operated locally.
Auto Operation
- Switch pump in automatic mode. Open the isolation valves in the suction & discharge lines of
the cartridge filter.
Page 56 of 77
- Switch the filters and complete RO system in automatic mode. Press the start button for the
RO system.
- High pressure pump will start automatically as per the start up sequence.
The system will start with the following steps:
 The system R.O start

 If this ORP parameter is good the RO sequence will start.
 Valve will open according to the pre set sequence.
 Valve V1( feed inlet) & V2( product outlet) will open.
 The RO feed pump will start.
 After 15 sec, the HPP will start.
7.2.8 Degasser System

The SWRO permeate is further passed through the degasser tower for degasification & then
stored in SWRO permeate tank.
Two Degasser Blowers K-02A/ B have been provided. The operation of degasser blowers is
possible either from the Control room or from Local. The operation of the blowers from the
Control room, select the LOCAL / REMOTE selector switch configured in the PLC system to
REMOTE mode.
The degasser blower K-02A/ B trips in case the SWRO Pump trips and starts when the SWRO
Pump starts.
7.2.9 BWRO
The De-gassed feed water flows through Micron Filters into the BWRO membranes through HP
Pumps AP 801 to AP803. The permeate water is then fed in to BWRO Permeate tank BB703.
Three nos. of BWRO- skids (2 W+1SB) are provided for the Purpose. Whenever the high DP is
sensed the Micron filters are taken out of operation for replacement of cartridges.
The BWRO feed pumps are being provided with the AUTO / MANUAL & REMOTE / LOCAL
options on the SCADA.
In case the pumps are selected in “REMOTE” mode, the pumps can be operated using the soft
buttons configured on the PLC. In case the pumps are selected in “LOCAL” mode, the pumps
can be operated from the Local Push Button Stations.
Set point for conductivity analyzer is 30 µS/cm at 250 C
Page 57 of 77
7.2.10 Mixed Bed Exchanger

Each MB is being provided with various selective options like SERVICE / REGENERATION /
STANDBY on Scada Screen.
The start permissive for service mode of MB can be listed as:
 The MB Feed pumps shall be running (P-10A/B)

 The MB vessel should be in standby mode.
Operator shall select either through PLC logic or SERVICE mode by pressing the SERVICE
START PB configured on the CRT. The PLC will issue a control output to open the Service inlet
valve and the Service outlet valve
The MB feed pumps selected in remote mode will start automatically. (The standby pump will
start in case the main selected pump trips or does not start within 10 secs after the issue of the
command by PLC).
Starting Sequence:
1. Open inlet Valve V1 & Air release valve V7 to remove trapped air inside the column.
2. Close air release valve
3. Open inlet Valve V1 & final rinse (acid Rinse) outlet valve V5 and maintain the level in the
drain sump at the final rinse level marker if orifice or V notch board is provided.
4. Open valve v13 so that sufficient water flows through conductivity cell
5. Switch on the conductivity indicator
6. When the conductivity of the rinse effluent is satisfactory level, close rinse outlet valve and
open outlet valve V2 and the unit is in service.
7. The rate of flow to service is controlled by outlet valve V2.
Page 58 of 77
8.0 NORMAL OPERATION
8.1 Pretreatment System
The pre-chlorinated seawater shall be fed in the Flash mixer tank and a flow meter is provided
to monitor the flow at the inlet. The control valve will adjust the flow rate with the help of flow
meter feed back signal. A High mixer is provided in the tank and the running indication shall be
provided in PLC. Coagulant is injected into Flash mixer zone to achieve an effective coagulation
The Flash Mixer drive is started from the soft buttons on the Scada Screen
The seawater from Flash mixer tank will flow to flocculator tank by gravity and flocculent is
dosed to achieve the flocculation.
The Flocculator drive is started from the soft buttons on the Scada Screen.
Flocculator mixer (AM - 102) is operated by manually from HMI, and during auto mode the mixer
shall be operated continuously. The Flocculator is functioned during the flocculation step of the
coagulation – flocculation process, to destabilize particles grow and agglomerate to form large,
settle able flocks. Through gentle prolonged mixing, chemical bridging and / or physically
enmeshment of particles occur
Tube settlers (BB –103/104)

Two numbers working settling tanks with tubes are provided for removal of suspended solids.
The treated water will flow to clarify water tank by gravity. The capacity of each tube-settling
tank is 120 Cu. M. Operation of the tube settlers shall be coordinated with the operation of the
seawater intake flow, coagulant feed system, and flocculent feed system.
Clarified water storage tank (BB - 105)
The treated water from tube settlers will flow to clarified water tank by gravity. The capacity of
clarified water tank is 240 m³.
8.2 Dual Media Filter
MANUAL OPERATION
 Manual selection is provided for each filter. In manual mode each filter valve is controlled
through an open / close switch on the panel.
 If any filter is full of water but has been out of service for two days or longer, it should be
run through the backwash sequence before being put online.
 To bring the filter on line that is set in manual, switch the master selector switch in
automatic. The filter will go into service automatically.
AUTO OPERATION
 Each filter has an automatic setting. In automatic the backwash sequence is initiated by
PLC program function. Automatic backwash is initiated from 08 hours time.
Page 59 of 77
 Keep all the filters, feed dump and feed isolation valves in automatic mode.
 If the filter is full of water but has been out of service for two days or longer, it should be
run through the backwash sequence before being put online. At the end of backwash
filter will automatically go into standby.
 To bring the filter online that it set automatically, semi automatic and in the standby
mode, place the selector switch in service. Press the push button and the filter will go
into service automatically.
8.3 Ultra Filtration System
The filtered water shall then pass through Basket Strainers & UF membranes for the removal of
colloidal impurities.
Three (2W + 1S) UF skids are provided for ultra filtration. The complete UF operation is
automatic except for integrity testing which shall be manual. FIT is provided to measure the
back flush flow.
The operation of UF comprises of four processes:
Processing: It is the mode in to ultra filtration takes place. During this operation, the service
inlet and service outlet valves of UF are automatically opened and will be closed at a pre
requisite time for back wash operation.
Fast Flush: During processing solids accumulate on the membrane surface hence cleaning by
means of fast flush and backwash is essential. During this mode the total feed water forced from
one feed end of the membrane and comes out from other feed end hence flushing out loosely
attached particles on membrane surface. During this mode feed pump shall start, inlet valve and
flush outlet valve shall be open also fast flush isolation valve shall be closed.
Backwash: After fast flush wherein loosely attached particles are remove backwash of
membrane is done. Backwash is necessary to restore the membrane performance. Backwash
operation is carried out after pre requisite time or in case outlet turbidity exceeds the preset
value. During this operation, backwash pumps shall start, service inlet & outlet valves will close
and B/W inlet & outlet valves will open.
VALVE OPERATING SEQUENCE

The valves situation explained as table
Valve Run V1 V2 V3 V4 V5 V6 V7
Service- 1 Hour • • •
Page 60 of 77
Fast flush-10 Sec • •
Backwash-60 Sec • • •
Fast flush –10 Sec • •
NOTE: Manual Valve Reject Valve (V6) is open for all the operations.
8.4 SWRO PLANT
Normal operation of R.O System involves pre-treatment units. The operator shall keep attention
to monitor the operation and change feed water condition. The membranes shall be protected
against chlorine and high pressure
The membranes must never be exposed to feed water contained chlorine to avoid rapid
deterioration.
The operator shall regularly check all of above parameter.
Fill the data in the various operation Logs. The daily check should consist of the following.
a. Carry out daily routine jobs and checklist.
b. Check and record all R.O system instrumentation including Flow meters and pressure gauges
and carry out SDI test of R.O feed water.
Be aware of any drastic changes from previously readings.
c. Records media filter Inlet and Outlet Pressure. Backwash if the pressure drip more than 1
Bars. Record Cartridge filter pressure, read from the gauge on the filter. Change the cartridge
filter if delta pressure is more than ( 14,5 PSI ) by opening the housing and replace with the new
one.
d. Check and record the product raw water and filtered water test.
e. Check and record the product water quality. Be aware of any significant changes from
previous reading.
Note : A change in product quality accompanied by a change in quantity could indicate

problems developing – Refer to trouble shooting guide.
After the above log entries are made, check the following:
- Anti scalant dosing tank level : If there is no sufficient chemical to last until next check , the
system may shut down.
- Acid dosing tank level : If there is no sufficient chemical to last until next check, the system
may shut down on the pH out of range.
Page 61 of 77
- De chlorination dosing Tank level : If there is no sufficient chemical to last until next check,
the system may shut down on the ORP out of range.
- Coagulant dosing Tank level : If there is no sufficient chemical to last until next check, the
system may shut down.
- Level in other chemical : If there is no sufficient chemical to last until next check, the system
may shut down
General Operating Requirements:
Feed water temperature shall be in range 25oC – 35oC while the system is operated.
Feed water pressure at inlet to high pressure pump should be least than 150 kPa ( 1,5 Bars ).
This low limits is required in order to overcome the pressure drop of the filters and to prevent
activation of the low feed pressure switch ( still not starve the high pressure pump.
Pre – filtration equipment is included within the system. The cartridge filter will retain particle
down to 5 microns in the feed water and protect the high pressure pump.
The SDI at the membrane shall be checked during RO plant operation and the SDI shall be held
below than 5 ( if possible below than 3 at all times ).
The pH level is governed by the amount of caustic injected in the pretreatment.
The pH is displayed on the panel mounted indicator. The feed water pH shall be maintained at
al level between 7.5 – 8.5.
Scale inhibitor ( Anti scalant ) is automatically injected when the high pressure pump is run.
Ensure that there is an adequate quantity of scale inhibitor in the storage tank.
8.5 BWRO Operation
8.6 Mixed Bed Exchanger Operation
Page 62 of 77
The degassed water is fed to MB Exchanger units to get the required output. The regeneration
of MB shall be by Hydrochloric Acid in countercurrent and by caustic in co-current mode.
The effluent from a mixed bed is extremely pure deminaralized water. The pH of water is around
7 (between 6.8 to 7.2) . Conductivity less than 1 µS/cm is obtained; silica value of 0.02 ppm is
normal. Total electrolyte is less than 0.5 ppm. The silica in MB effluent is dependent on the
regeneration level, the temperature of regeneration and silica loading. The water produced by
MB is ultra pure and hence an excellent solvent. Utmost care in sampling & estimation must be
taken must be taken to avoid errors. Necessary blank test must also be carried out side by side.
For conductivity & pH measurement online meters are suitable. Atmospheric CO2 may
contaminate and vitiate the result if suitable precaution is not taken.
The selected MB unit will go out of service automatically if:
1. The conductivity of the MB outlet water AT 901/ 902 exceeds the pre set limit
2. On achieving the pre set total output between regenerations
The operator will need to put take the exhausted MB out of service, put the standby MB into
service and initiated regeneration of the exhausted MB
Page 63 of 77
8.7 Normal Operating Data Log
During normal operation following data should be checked recorded at least once in a shift to
monitor the operating condition and to make data history.
Water Treatment System

Tag Description KKS # Unit Limit
Value
Page 64 of 77
9.0 SHUTDOWN
9.1 Pre-Treatment
Coagulation Dosing: Automatic Shutdown
 If the filter water pumps (AP- 101 A/B/C) tripped Off, the coagulant dosing system will
stop automatically since the feed water flow reach the low flow set point.
 If the dosing Tank (AM - 104) reaches low – low level the dosing pump will stop
automatically.
 If the Shutdown condition will be more than two (2) days, close the suction and
discharge valves on the injection dosing pumps.
Flocculant Dosing: Automatic Shutdown
 If the filter water pumps (AP- 101 A/B/C) tripped Off, the coagulant dosing system will
stop automatically since the feed water flow reach the low flow set point.
 If the dosing Tank (AM - 102) reaches low – low level the dosing pump will stop
automatically.
 If the Shutdown condition will be more than two (2) days, close the suction and
discharge valves on the injection dosing pumps.
9.2 Dual Media Filter
Control shutdown.
One of the filters will stop automatically with the following condition:
 If one of the filter select to manual mode.

 If one of the filter goes to backwash mode.
 If the filter water tank level is high.
Automatic shutdown:
All of three filters will go to stand by mode if UF permeates water tank level is high-high.
If the shutdown condition will be more than two days, flush the suction and discharge line and
close the discharge valves on the valve on the pumps.
9.3 SWRO PLANT SHUT DOWN.
Control shutdown.
- If the RO system is selected to stop mode.
Automatic shutdown:
Page 65 of 77
RO unit will automatically shutdown with the following condition:
 If the product water tank (PU T51) reaches high – high level.
 If the ORP is higher than the set point.
 If the high pressure pump suction pressure is low and is high.
 If the shutdown condition will be more than two days, flush the suction and discharge
line and close the discharge valves on the pumps.
9.4 Procedure For The Extended Shutdown
Preservation of RO/NF/UF membranes and RO/NF/UF plants (TFC membranes)

It is recommended to preserve when the plant is out of production more than 24 hours.
Methods of preservation:
1. Preservation with sodium bi sulfite (1%).
It is recommended to measure the pH regularly. A fresh solution is needed when the pH <
3.A fresh solution is also needed when the liquid becomes turbid or changes colours.
Regular inspections (weekly) are recommended. It has to be verified that the plastic
materials (including pressure vessels) used in the membrane plant are resistant to
sodiumbisulfite. Otherwise cracks might occur in the plastic materials.
2. Preservation with PermaClean® PC-56
Preservation period Concentration PermaClean® PC-56
< 2 days 0.018% (180 ppm)
2 - 7 days 0.036% (360 ppm)
1 - 4 weeks 0.054% (540 ppm)
1 - 6 months 0.09 % (900 ppm)
> 6 months drain and refill
This preservation method can be applied when the membranes have been in operation for
a minimum of 1 month.
3. Preservation with formaldehyde
0.5% - 3% (w/w) formaldehyde solutions can be applied dependent on the membrane
supplier’s recommendations. The preservation solution needs to be renewed latest after
12 months. Formaldehyde handling requires more precautions due to its suspected
cacogenic. Please stick to the relevant safety regulations.
4. Preservation with gluteraldehyde and other aldehydes
It is strongly recommended not to use gluteraldehyde or other aldehydes as it can reduce
Page 66 of 77
the permeate flow of the membranes dramatically.

5. Preservation with PermaClean® PC-11 is not recommended as to the very
short half
life of this chemistry
NOTE: Prior to shutdown, the RO/NF/UF needs to be cleaned (dependent on the operation
parameters) and be flushed with Respective permeate (a MUST). Then the preservation
solution can be pumped in the RO/NF/UF (low pressures
Page 67 of 77
9.5 Mixed Bed Shutdown and Regeneration
Stopping the plant:

1. Switch off the feed pump
2. Close the inlet valve, conductivity cell valve and outlet valve.
3. Open air release valve and release pressure
4. Close all valves
Page 68 of 77
Selective options for various regeneration steps like BACKWASH / INJECTION / SLOW RINSE
/ AIR MIX / REFILL / FAST RINSE are also provided.
The operator can do regeneration of vessel in AUTO / SEMI AUTO / MANUAL mode by making
suitable selections on the SCADA Screen.
A) The following Soft Buttons are configured on the Scada Screen:
 START PB – To start the REGENERATION operations.

 STOP PB – To STOP the regeneration.
 HOLD / RELEASE PB – Press to HOLD the step and RELEASE to proceed to next step.
 SKIP PB – To skip the step
SEMI AUTO REGENERATION MODE FOR MB:
In this mode of operation, the regeneration mode (SEMI AUTO / MANUAL) has to be selected
from the Scada and once the mode is selected and the Pre requisites are met, in auto mode
PLC process the control output to Valves and Drives as per the logic requirement. During Semi
Auto mode of regeneration, following Soft PB’s shall be operative through Scada.
START PB – To start the REGENERATION operations and the regeneration will stop after the
completion of all the steps.
STOP PB – To stop the REGENERATION operations.
SKIP PB – To SKIP the step
HOLD / RELEASE PB – Press to HOLD the step and RELEASE to proceed to next step.
Page 69 of 77
10.0 EMRGENCY PROCEDURES
Emergency which occurs in the units shall be recognized and acted upon immediately. Operator
and Supervisor personnel should become thoroughly familiar with the action to be done in such
situations. Some emergency can not be resulted in unit shutdown only, but if not handled
properly can cause injury to personnel and serious damage to equipment. In some
circumstances emergency condition can be tolerated for a short time, (provided that proper
measures are taken). It is something possible to maintain the unit in operating during a localized
emergency, (e.q. during out of service a control valve, by operating in manual control through its
by – pass until repairing is completed).
In emergency, the following guidelines shall be observed by operating personnel:
- Determine the extent of emergency conditions.
- Arrange to notify the emergency to other unit if required.
- Decide how to face emergency to other unit if required.
- Deal with the localized condition without shutting down whole unit.
- Shutdown the whole unit according to normal shutdown procedure.
- Shutdown the whole unit order emergency procedure.
- Perform all operation to prevent immediate or future dagger, which may damage equipment (
e.q. Pump running dry, Vacuum inside vessel or over pressure
10.1 Total Air Failure
In the event of total air failure, operator should perform the following:
- Stop all the running drives from the panel.
- Isolate the vessel by closing the inlet and outlet manual valve.
10.2 Total power failure
- In the event of total power failure, the running drives will stop and the auto valves that are
open will close.
Page 70 of 77
- The operator should put the switch from normal service to off position and the plant can be
restored as per normal start up on restoration of power.
10.3 Local electric failure
These may be traced back to fuse generally, however there are other sources of local problems,
which may include overload relays for drive motors low voltage trios if they are employed. In all
case of failure it is advisable to consult the electrical maintenance department to determine the
reason for these failures.
Page 71 of 77
11.0 ALARM AND TRIPS

Normal Remarks
Description Tag Number Alarm Trip
Value
Page 72 of 77
12.0 FAULTS AND TROUBLE SHOOTING
12.1 Ultra Filtration
 High pressure drop - Clean the membrane

 Valves not open - Check the solenoid valve
 Flow rate small - Some UF drain not in operation, Switch the UF drain to auto operation
 Pressure drop cannot be recovered by back flushing
o Normal back flushing time not enough
o Set the back flushing time longer.
 Normal back flushing interval too long
o Set the back flushing interval shorter.
 Concentrate flow too small
o Adjust the flow bigger
 Recycle flow not enough
o Adjust the recycle flow bigger
 Pressure drop increase too much before back-flushing
o Back flushing flow too small
o Adjust the back flush flow bigger
 Back flushing pressure & flow too high
o Adjust the flow smaller
 Membrane leakage - Replace the UF membrane
 Flow rate too high - Lower the flow rate
 Permeate SDI high & Pressure drop too high
o Clean the membrane
Page 73 of 77
12.2 SWRO System
CHECK VERIFY EFFECT

More than 15% indicates
Pressure drop fouling of feed path and
between feed and Has not increased by more membrane surface. Requires
reject. than 15%. cleaning
Pressure drop More indicates fouling of
between feed and Has not increased by more membrane surface. Requires
permeate than 15%. cleaning
Permeate Has not increased by more than More indicates fouling of membrane
conductivity 15%. surface. Requires cleaning.
More can cause membrane damage
or sulfate scaling. Less can cause
carbonate scaling or metal oxide
Acid dosing Is within recommended value. fouling.
Verify by calibration and carryout of
lab check of the parameters the Wrong operation False sense of
Instruments Reading instrument is monitoring. security that everything is OK.
PH controller generally controls acid
dosing pumps. pH controller Should
be calibrated periodically and More or less acid dosing than
pH meter calibration tripping of dosing pump to the set required. Effect of this as already
& control point should be checked. been mentioned earlier.
Probing with ¼ ‘ plastic tube and by Failure can lead to increase salt
measuring how far it has been passage, increase permeate flow.
O ring inserted. Decrease pressure drop.
If fully closed, 100% recovery will
result and cause membrane damage
Brine valve Should not be closed fully. due to precipitation of inorganic salt.
Page 74 of 77
12.3 Mixed Bed Exchanger
Problem Cause Action

Organic fouling of anion
Check and rectify. Give Brine wash
loss of resin.
Excessive Rinsing Organically fouled, clean.
Channeling poor distribution. Check laterals and
Improper regeneration
strainers Use correct quantity of regenerants.
Loss of capacity
Exhaustion of preceding MB need not be considered to be exhausted. Most
cation / anion unit MB’s are designed for 3-4 runs of Anion and Cation
Valve not opened fully. Broken or blocked
Pressure drop
internals. High flow rate or Resin fine etc.
Bacterial growth Unit idle. Check, Recycle water.
Anion resin organically fouled Clean, Check
Low pH Blower, Air Mixing not proper, See note on acid
leakage from MB.
Cation/Anion not working, check,
High pH Regeneration not proper,
check Increase in ionic load.
Organic fouling clean.
Silica leakage Improper regeneration.
Over exhaustion.
Happens with new resin,
Poor Treated Clumping
Give Brine treatment
Water quality
Air mix not proper,
Insufficient air,
Fouled resin,
High conductivity
Back wash not proper,
Improper regeneration,
Channeling / poor distribution.
Loss of inert resin, Loss of Cation resin if no inert
resin,
General poor quality Middle collector not in proper position,
Backwash not proper.
Air mixing not proper
Page 75 of 77
13.0 PERFORMANCE ANALYSIS
Treated water quality for the different process steps should as follows:
Pretreatment
Parameter Value
Turbidity < 1 NTU
Suspended Solids < 1 ppm
Silt density Index < 4.0
Flow Capacity 217 m3/hr
SWRO
Parameter Value
pH 6.5 to 8.0
Suspended Solids < 1 ppm
Turbidity < 1 NTU
Total Dissolved Solids < 500 ppm
SWRO Permeate Flow 76 m3/hr
Recovery 0.35
BWRO
Parameter Value
pH 6.5 to 7.0
Total Disolved Solids < 20 ppm
Permeate Flow Rate 53 m3/hr
Recovery 0.8
DM Water System
Parameter Value
pH 6.8 to 7.2
Conductivity @ 25 Deg. C < 0.1 µS/cm
Silica (Reactive) <0.01 ppm
Total Hardness BDL
DM Water flow 50 m3/hr
Output Between regeneration 1200 m3
Page 76 of 77
14.0 APPENDICES
14.1 Pre-start checklist

S/N Checklist Item Remarks (Okay?)
14.2 Water Treatment P&ID
WT System-All
P&ID.pdf
14.3 VALVE OPERATING SEQUENCE for SWRO, BWRO and MB System
Page 77 of 77

YUGADANAVI POWER PLANT Water Treatment S

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YUGADANAVI POWER PLANT Water Treatment S

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YUGADANAVI POWER PLANT

Document Type: OPERATION PROCEDURE Document No. WCP-OP-025

Water Treatment System

Prepared by Nazrul Islam [From KEMA]

Revision # Description Date Approved By

Part Description Page Number

OVERALL TABLE OF CONTENT

1 PURPOSE AND SCOPE 05

4 SCHEMATIC FLOW DIAGRAM 39

11 ALARMS AND TRIPS 72

12 FAULT & TROUBLESHOOTING 73

1.0 PURPOSE AND SCOPE

2.3 DCS / PLC Alignment

2.4 System Alignment/ Lined Up

LTL-NISM-PID-001 P&I DIAGRAM FOR PRETREATMENTA

LTL-NISM-PID-002 P&I DIAGRAM FOR DUAL MEDIA FILTERS

LTL-NISM-PID-003 P&I DIAGRAM FOR ULTRA FILTRATION SYSTEM

LTL-NISM-PID-004 P&I DIAGRAM FOR BACKWASH/ RO FEED PUMPS

LTL-NISM-PID-005 P&I DIAGRAM FOR SWRO CHEMICAL DOSING SYSTEM

2.4.6 SWRO System has been lined up according to the P&ID:

LTL-NISM-PID-006 P&I DIAGRAM FOR SWRO System

2.4.8 BWRO System has been lined up according to the P&ID:

LTL-NISM-PID-008 P&I DIAGRAM FOR BWRO SYSTEM

LTL-NISM-PID-009 P&I DIAGRAM FOR MIXED BED EXCHANGERS

LTL-NISM-PID-010 P&I DIAGRAM FOR ACID/ ALKALI STORAGE TANK

2.4.11 RO Cleaning System has been lined up according to the P&ID:

LTL-NISM-PID-011 P&I DIAGRAM FOR RO CLEANING SYSTEM

3.0 SYSTEM DESCRIPTION

The molecular formula of water is expressed as H2O.

3.1.2 pH: Acidity and Alkalinity

This ion product of water is a constant and it is 1 x 10–14 at 25°C.

[H+] [OH–] = 1 X 10–14

[H+], [OH–] = molar concentration of H+ and OH- at 25°C

The pH is calculated from the H+ concentration by using the equation as below

3.1.3 M-Alkalinity and P-Alkalinity

Fig: Acidity and various types of alkalinity and their pH

3.1.4 General Contaminants/ Impurities of Water:

3.1.5 IDENTIFYING IMPURITIES

The relative acidic or basic level of a solution is measured by pH.

Example Total Solids (TS)

Total Organic Carbon (TOC)

Biochemical Oxygen Demand (BOD)

Typically the test for BOD is conducted over a five-day period.

Chemical Oxygen Demand (COD)

Silt Density Index (SDI)

Some Problems Caused by Water Impurities

Paper and textile Deposits on fibers Soap

Code: (1) in steam condensate system;

3.2 Description of the Treatment Process

Coagulation process is again comprised of 3 steps as follows:

Dual Media Filter:

Backwash Initiation based on any of the following condition:

 Service Flow Rate*

 Monitor Filter Influent (Clarifier Effluent)

3.2.2 Ultra filtration

KPI for Ultra Filter

 Silt Density Index

Parameter Feed Treated Water

3.2.3 Reverse Osmosis

Transmembrane pressure differences are influenced by the types of membranes used. In

The susceptibility of the membrane to fouling by water-borne debris is measured by a special

(The factor 6.7 applies to the 15-minute test period only.)

Two stage RO at 75% Recovery: