2010

BALANCE OF
PLANT
TRAINING REPORT

SUBMITTED BY: MUHAMMAD UZAIR

TRAINEE ENGR.
 BOP Training Report

TABLE OF CONTENTS

Chapter 01:

PRE TREATMENT OF INTAKE WATER ……………………………….3

Chapter 02:

WATER DEMINERALIZATION…………………………………………19

Chapter 03:

COOLING TOWERS………………………………………………………39

Chapter 04:

HYDROGEN GENERATION SYSTEM &

WASTE WATER DISPOSAL…………………………………………….50

APPENDIX………………………………………………………………..62

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CHAPTER # 01

PRE TREATMENT OF
INTAKE WATER

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PRE TREATMENT OF INTAKE WATER

The Balance of Plant section is responsible for providing water according
to desired specifications for the entire needs of plant and safe disposal of waste
water after proper treatment.

At AES Lalpir Thermal Power Plant raw water is taken from Canal. Canal
Water from suction pit passes through bar screen whose primary purpose is to
remove the prominent or large debris, which can cause damage. Then canal
water passes through traveling bar screen, having 22 baskets which continuousl y
revolve in such way that water has to pass through their centre, band screen has
the sieve size of 1 mm with the same purpose as of bar screen but is for smaller
debris. The waste collected in these screens is sprayed away to waste collecting
pit and is pumped back to the canal. The raw water is then pumped to the power
plant with the help of canal water pump having 1200m 3 /hr discharge rate, each
pump is supplied with pneumaticall y controlled valve which when open,
recirculates the water back to the bar screen. There are total 4 Canal Water
pumps, two pumps for each unit, when one pump is in service, the other is
standb y.

The intake s ystem consists of following main components;

Canal intake
Canal water pumps
Well water pumps
Settling basins
Clarifier suppl y pumps
Clarifier
Clear well
Dual media filters (DMF)

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Suction
Pit LALPIR
CANAL PUMPS

Suction
Pit

BAR TRAVELLING
SCREEN BAND
SCREEN
WELL
PUMPS

CANAL PAKGEN
PUMPS

Suction
Pit

BAR TRAVELLING
SCREEN BAND
SCREEN
WELL
PUMPS

CANAL INTAKE SYSTEM

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SETTLING BASINS
There are three types of objects which can be found in water. In order from smallest to largest,
these objects are chemicals in solution, colloidal solids, and suspended solids. The settling basins
are designed to provide ample retention time for settling of heavy suspended particles, debris and
uncharged particles. Coagulation/flocculation will remove colloidal and suspended solids from
water.

All sedimentation basins have four zones - the inlet zone, the settling zone, the sludge zone, and
the outlet zone. Each zone should provide a smooth transition between the zone before and the
zone after. In addition, each zone has its own unique purpose. Zones can be seen most easily in a
rectangular sedimentation basin, such as the one shown below:

CLARIFICATION
COAGULATION AND FLOCCULATION
In a clarifier, water typically enters the basin from the center rather than from one end and flows
out to outlets located around the edges of the basin. But the four zones can still be found within
the clarifier:

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All waters, especially surface waters, contain both dissolved and suspended particles.
Coagulation and flocculation processes are used to separate the suspended solids portion from
the water.

The suspended particles vary considerably in source, composition charge, particle size, shape,
and density. Correct application of coagulation and flocculation processes and selection of the
coagulants depend upon understanding the interaction between these factors. The small particles
are stabilized (kept in suspension) by the action of physical forces on the particles themselves.
One of the forces playing a dominant role in stabilization results from the surface charge present
on the particles. Most solids suspended in water possess a negative charge and, since they have
the same type of surface charge, repel each other when they come close together. Therefore, they
will remain in suspension rather than clump together and settle out of the water.

PURPOSE

The primary purpose of the coagulation/flocculation process is the removal of turbidity from the
water. Turbidity is a cloudy appearance of water caused by small particles suspended therein.
Water with little or no turbidity will be clear.

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Turbidity is not only an aesthetic problem in water. Water with a high turbidity can be very
difficult or impossible to properly disinfect. As a result, the maximum allowable level of
turbidity in water is 0.5 NTU, while the recommended level is about 0.1 NTU. (NTU, or TU,
stands for nephelometric turbidity units, a measurement of the turbidity of water.)

In addition to removing turbidity from the water, coagulation and flocculation is beneficial in
other ways. The process removes many bacteria which are suspended in the water and can be
used to remove color from the water.

Turbidity and color are much more common in surface water than in groundwater. As surface
water flows over the ground to streams, through streams, and then through rivers, the water picks
up a large quantity of particles. As a result, while aeration is more commonly required for
groundwater, treatment involving coagulation and flocculation is typical of surface water.

LOCATION IN THE TREATMENT PLANT

After the source water has been screened and has passed through the optional steps of pre-
chlorination and aeration, it is ready for coagulation and flocculation.

In theory and at the chemical level, coagulation and flocculation is a three step process,
consisting of flash mixing, coagulation, and flocculation. However, in practice in the treatment
plant, there are only two steps in the coagulation/flocculation process - the water first flows into
the flash mix chamber, and then enters the flocculation basin.

STEPS OF CLARIFICATION

The chemistry of coagulation/flocculation consists of three processes - flash mix, coagulation,

and flocculation. Each of these processes is briefly explained below.

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PHENOMENON

The chemistry of coagulation and flocculation is primarily based on electricity. Electricity is the
behavior of negative and positively charged particles due to their attraction and repulsion. Like
charges (two negatively charged particles or two positively charged particles) repel each other
while opposite charges (a positively charged particle and a negatively charged particle) attract.

Negatively charged particles repel each other due to electricity.

Most particles dissolved in water have a negative charge, so they tend to repel each other. As a
result, they stay dispersed and dissolved or colloidal in the water, as shown above.

The purpose of most coagulant chemicals is to neutralize the negative charges on the turbidity
particles to prevent those particles from repelling each other. The amount of coagulant which
should be added to the water will depend on the zeta potential, a measurement of the magnitude
of electrical charge surrounding the colloidal particles. You can think of the zeta potential as the
amount of repulsive force which keeps the particles in the water. If the zeta potential is large,
then more coagulants will be needed.

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Coagulants tend to be positively charged. Due to their positive charge, they are attracted to the
negative particles in the water, as shown below.

Positively charged coagulants attract to negatively

charged particles due to electricity.

The combination of positive and negative charge results in a neutral, or lack, of charge. As a
result, the particles no longer repel each other.

The next force which will affect the particles is known as Van der Waal's forces. Van der
Waal's forces refer to the tendency of particles in nature to attract each other weakly if they
have no charge.

Neutrally charged particles attract due to van der Waal's forces.

Once the particles in water are not repelling each other, van der Waal's forces make the particles
drift toward each other and join together into a group. When enough particles have joined
together, they become floc and will settle out of the water.

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Particles and coagulants join

together into floc.

COAGULANT SELECTION
The choice of coagulant chemical depends upon the nature of the suspended solid to be removed,
the raw water conditions, the facility design, and the cost of the amount of chemical necessary to
produce the desired result.

Final selection of the coagulant (or coagulants) should be made following thorough jar testing
and plant scale evaluation. Considerations must be given to required effluent quality, effect upon
down stream treatment process performance, cost, method and cost of sludge handling and
disposal, and net overall cost at the dose required for effective treatment.

INORGANIC COAGULANTS
Inorganic coagulants such as aluminum and iron salts are the most commonly used. When added
to the water, they furnish highly charged ions to neutralize the suspended particles. The inorganic
hydroxides formed produce short polymer chains which enhance microfloc formation.
Inorganic coagulants usually offer the lowest price per pound, are widely available, and, when
properly applied, are quite effective in removing most suspended solids. They are also capable of
removing a portion of the organic precursors which may combine with chlorine to form
disinfection by-products. They produce large volumes of floc which can entrap bacteria as they
settle. However, they may alter the pH of the water since they consume alkalinity. When applied
in a lime soda ash softening process, alum and iron salts generate demand for lime and soda ash.
They require corrosion-resistant storage and feed equipment. The large volumes of settled floc
must be disposed of in an environmentally acceptable manner.

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INORGANIC COAGULANT REACTIONS

Common coagulant chemicals used are alum, ferric sulfate, ferric chloride, ferrous sulfate, and
sodium aluminate. The first four will lower the alkalinity and pH of the solution while the
sodium aluminate will add alkalinity and raise the pH. The reactions of each follow:

ALUM
A12(SO4)3 + 3 Ca(HCO3)2 -------> 2 Al(OH)3 + 3CaSO4 + 6 CO2
Aluminum + Calcium Aluminum + Calcium + Carbon
Sulfate Bicarbonate Hydroxide Sulfate Dioxide

FERRIC SULFATE
Fe2(SO4)3 + 3 Ca(HCO3)2 --------> 2 Fe(OH)3 + 3CaSO4 + 6 CO2
Ferric + Calcium Ferric + Calcium + Carbon
Sulfate Bicarbonate Hydroxide Sulfate Dioxide

FERRIC CHLORIDE
2 Fe Cl3 + 3 Ca(HCO3)2 ----------> 2 Fe(OH)3 + 3CaCl2 + 6CO2
Ferric + Calcium Ferric + Calcium + Carbon
Chloride Bicarbonate Hydroxide Chloride Dioxide

FERROUS SULFATE
FeS04 + Ca(HCO3)2 ----------> Fe(OH)2 + CaS04 + 2CO2
Ferrous + Calcium Ferrous + Calcium + Carbon
Sulfate Bicarbonate Hydroxide Sulfate Dioxide

SODIUM ALUMINATE
2 Na2A12O4 + Ca(HCO3)2 ---------> 8 Al(OH)3 + 3 Na2CO3 + 6 H20
Sodium + Calcium Aluminum + Sodium + Water
Aluminate Carbonate Hydroxide Carbonate

Na2Al2O4 + CO2 -------> 2 Al(OH)3 + NaCO3

Sodium + Carbon Aluminum + Sodium
Aluminate Dioxide Hydroxide Carbonate

Na2Al2O4 + MgCo3 --------> MgAl2O4 + Na2CO3

Sodium + Magnesium Magnesium + Sodium
Aluminate Carbonate Aluminate Carbonate

POLYMERS
Polymers--long-chained, high-molecular-weight, organic chemicals--are becoming more widely
used, especially as coagulant aids together with the regular inorganic coagulants. Anionic
(negatively charged) polymers are often used with metal coagulants. Low-to-medium weight

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positively charged (cationic) polymers may be used alone or in combination with the aluminum
and iron type coagulants to attract the suspended solids and neutralize their surface charge. The
manufacturer can produce a wide range of products that meet a variety of source-water
conditions by controlling the amount and type of charge and relative molecular weight of the
polymer.
Polymers are effective over a wider pH range than inorganic coagulants. They can be applied at
lower doses, and they do not consume alkalinity. They produce smaller volumes of more
concentrated, rapidly settling floc. The floc formed from use of a properly selected polymer will
be more resistant to shear, resulting in less carryover and a cleaner effluent.
Polymers are generally several times more expensive in their price per pound than inorganic
coagulants. Selection of the proper polymer for the application requires considerable jar testing
under simulated plant conditions, followed by pilot or plant-scale trials.

FLOCK
The end product of a well-regulated coagulation/flocculation process is water in which the
majority of the turbidity has been collected into flock, clumps of bacteria and particulate
impurities that have come together and formed a cluster. The flock will then settle out in the
sedimentation basin, with remaining flock being removed in the filter.

FACTORS INFLUENCING COAGULATION

In a well-run water treatment plant, adjustments are often necessary in order to maximize the
coagulation/flocculation process. These adjustments are a reaction to changes in the raw water
entering the plant. Coagulation will be affected by changes in the water's pH, alkalinity,
temperature, time, velocity and zeta potential.

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The effectiveness of a coagulant is generally pH dependent. Water with a color will

coagulate better at low pH (4.4-6) with alum.
Alkalinity is needed to provide anions, such as (OH) for forming insoluble compounds to
precipitate them out. It could be naturally present in the water or needed to be added as
hydroxides, carbonates, or bicarbonates. Generally 1 part alum uses 0.5 parts alkalinity
for proper coagulation.
The higher the temperature, the faster the reaction, and the more effective is the
coagulation. Winter temperature will slow down the reaction rate, which can be helped
by an extended detention time. Mostly, it is naturally provided due to lower water
demand in winter.
Time is an important factor as well. Proper mixing and detention times are very
important to coagulation.
The higher velocity causes the shearing or breaking of floc particles, and lower velocity
will let them settle in the flocculation basins. Velocity around 1 ft/sec in the flocculation
basins should be maintained.
Zeta potential is the charge at the boundary of the colloidal turbidity particle and the
surrounding water. The higher the charge the more is the repulsion between the turbidity
particles, less the coagulation, and vice versa. Higher zeta potential requires the higher
coagulant dose. An effective coagulation is aimed at reducing zeta potential charge to
almost 0.

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OPERATING PROCEDURES

CANAL WATER PUMP

There are total 4 Canal Water pumps, two pumps for each unit, when one pump
is in service, the other is standb y. Each pump is supplied with pneumaticall y
controlled valve which when open, re-circulate the water back to the suction
pit. All four pumps lubricating oil and rubber bearings at shaft are cooled b y
cooling water.

PRE CHECKS FOR STARTING THE CANAL WATER PUMP:

Check breaker of the pump. It should be (rack-in close position) ON.
Canal water level should be more than 60%(greater than -500 level).
Check the lube water tank level. It should be full and the make up water pump
selection on AUTO
Start Bar Screen
Start travelling bar screen. It should be ON.
Checks lube oil level. It should be within the max. and min. limits in
the view glass.
Checks lube water pressure. It should be around 4.0 bar.
Check instrument air. It should be present.

After checking all these, ask to CCR start the canal water pump and finall y
Verify that pump discharge pressure is about 2.4 kg/cm 2

WELL WATER PUMPS

For dry period the continuous demand for water is met with 12 well water pumps having
240m3/hr/pump discharge rate (6 for each unit).

TAKING WELL WATER PUMPS IN SERVICE

Verify that electric, instrument and control system is available.

Verify that its system line valve arrangement is completed.

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Canal water pump's outlet valves should be close,

Settling basin inlet level control valve is auto condition.
Settling basin inlet isolation valve should be opened for selected basin.
Start the well water pump.
Open the pump discharge valve.
Verify that pump discharge pressure is available about 1.5kg/cm2
Verify that other pumps are on auto and their discharge valves should be opened.

CLARIFIER SUPPLY PUMP

PRE-CHECKS FOR STARTING OF CLARIFIER SUPPLY PUMPS
Check the breaker. It should be (in rack-in close position) ON.
Check the level of settling basin; it should be above 60% (above -500
levels).
Check the Settling basin outlet valve. It should be open.
Check the clarifier pump cooling water flow. The cooling water valve
must be open and the flow physicall y present.
Check the Clarifier supply pump discharge valve. It must be open.
Check the minimum flow valve for the clarifier suppl y pump. It should
be on Auto.
Verify that pump discharge pressure is 2.3kg/cm 2 g.
Verify that pump suction strainer diff pressure is lower than
0.5kg/cm 2 g.

When its suction strainer differential pressure becomes higher than 0.5kg/cm 2 g,
strainer should be cleaned after stopping the Pump.

DUAL MEDIA FILTERS

The filter media is the part of the filter which actually removes the particles from the water being
treated. Filter media is most commonly sand, though other types of media can be used, usually
in combination with sand. The gravel at the bottom of the filter is not part of the filter media,
merely providing a support between the under drains and the media and allowing an even flow of
water during filtering and backwashing.

The sand used in rapid sand filters is coarser (larger) than the sand used in slow sand filters. This
larger sand has larger pores which do not fill as quickly with particles out of the water. Coarse
sand also costs less and is more readily available than the finer sand used in slow sand filtration.

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In many cases, multiple types of media are layered within the filter. Typically, the layers
(starting at the bottom of the filter and advancing upward) are sand and anthracite coal, or garnet,
sand, and anthracite coal. The picture below shows a cross-section through a dual media filter.

Photo Credit: Christie Shinault

The media in a dual or multi-media filter are arranged so that the water moves through media
with progressively smaller pores. The largest particles are strained out by the anthracite. Then
the sand and garnet trap the rest of the particulate matter though a combination of adhesion and
straining. Since the particles in the water are filtered out at various depths in a dual or multi-
media filter, the filter does not clog as quickly as if all of the particles were all caught by the top
layer.

DMF CLEANING/BACKWASHING
After 2 hours of running DMF Filters are cleaned/backwashed to remove the carryover
suspended particles. Clear well Level should be above 70%.

DRAIN DOWN(5 min)

Here the air outlet valve and drain down valves are opened so that an y
previous reserve is drained because standing water in DMF is rich in
silica. Flow rate is 90 m 3 /hr
AIR MIX(5 min)
In this step air mix inlet valve (air from the DMF air blowers) and air
outlet valve are opened this steps evens the DMF surface same as air
scouring. Flow rate is 1380 m 3 /hr

FILL(5 min)

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In this step service inlet of water and air outlet valve opens in this step
DMF fills itself with water. Flow rate is 225 m 3 /hr

BACKWASH(5 min)
Here back wash inlet and outlet valves opens and the water goes to
Settling Basin. Flow rate is 680 m 3 /hr

RINSE(5 min)
Service inlet and rinse outlet valves open and the waste water goes to
distribution chamber. Flow rate is 170 m 3 /hr.
After these steps DMF is ready for service
DMF Backwash and cl ear well overflow goes to settling basin A&B.

BY-PASSING THE PRE-TREATMENT SYSTEM

Close the inlet FCV of clarifier manuall y from P LC.
Open the clarifier bypass valve.
If PG Unit is operating then clarifier pump C discharge bypass valve to
cooling tower would be opened.
DMF pumps should be OFF and DMF bypass valve must be open.

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CHAPTER # 02

WATER DEMINERALIZATION

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The demineralization system is designed to produce demineralized treated water with a

conductivity of less than 0.1 mmhos/cm and silica content of less than 0.01 mg/L.

MULTIMEDIA FILTERS
The media in a dual or multi-media filter must have varying density as well as varying pore size
so that they will sort back into the correct layering arrangement after backwashing. Anthracite
coal is a very light (low density) coal which will settle slowly, ending up as the top layer of the
filter. Garnet is very dense sand which will settle quickly to the bottom of the filter.

Pre-treated water from the filtered water basin is directed to two (2) Multi-Media Filters which
remove residual turbidity and suspended solids from the water. Following multi-media filtration,
the water is injected with sodium bisulphate to remove trace quantities of free chlorine. Multi-
Media filter backwash and rinse water is directed to the inlet distribution box. A portion of the
multi-media filtered water is directed to the potable water tank and chlorinator. If the raw water
source is canal water, the multi-media filtered water effluent is directed to the permeate tank .If
the raw water source is well water, the multi-media filtered water is directed to the reverse
osmosis system. Each multi-media filter is designed to treat 97m3/hr of pre-treated water.

The largest particles are removed by the coal, the medium particles by the sand,
and the smallest particles by the garnet.

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Like DMF gravel layer is also used here for supporting the media. The arrangement of media
from top to bottom is as follows:

Materials Quantity(m3) mm(average size)

Garnet 1.06 0.35
Anthracite 1.5 0.9-1.0
Filter Sand 1.45 .45-0.55
Fine Gravel 0.5 3.35-1.7
Medium Gravel 0.5 12.7-6.3
Coarse Gravel 1.9 19-12.7

BACK WASHING OF FILTERS

Backwash and rinse waste water is returned to the distribution box. With one (I) filter in service
and the other in backwash, a second filter feed pump will be activated. Treated water is fed to the
reverse osmosis system when a high total dissolved solids raw water is utilized. Under normal
circumstances, the R.O. system is bypassed and the multimedia filter effluent is directed to the
R.O. permeate tank. Sodium bisulphate is injected into the multimedia filter effluent at a
constant, manually set rate. A flow switch will control the start/stop operation of the bisulphate
pumps.

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Pi
Filter Water
Basin B
Pi
Filter Water
Basin A
From Filter Water

Back Wash to Distribution

MMF MMF
A B

Back
Wash

RINSE LINE

BAG
FILTERS

TO RO SYSTEM

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REVERSE OSMOSIS SYSTEM

Osmosis is a natural process involving the fluid flow of across a semi-permeable membrane
barrier. Consider a tank of pure water with a semi-permeable membrane dividing it into two
sides. Pure water in contact with both sides of an ideal semi-permeable membrane at equal
pressure and temperature has no net flow across the membrane because the chemical potential is
equal on both sides. If a soluble salt is added on one side, the chemical potential of this salt
solution is reduced.

Osmotic flow from the pure water side across the membrane to the salt solution side will occur
until the equilibrium of chemical potential is restored. In scientific terms, the two sides of the
tank have a difference in their “chemical potentials,” and the solution equalizes, by osmosis, its
chemical potential throughout the system. Equilibrium occurs when the hydrostatic pressure
differential resulting from the volume changes on both sides is equal to the osmotic pressure. The
osmotic pressure is a solution property proportional to the salt concentration and independent of
the membrane.

REVERSE OSMOSIS
Application of an external pressure to the salt solution side equal to the osmotic pressure will
also cause equilibrium. Additional pressure will raise the chemical potential of the water in the
salt solution and cause a solvent flow to the pure water side, because it now has a lower chemical
potential. This phenomenon is called reverse osmosis.

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OPERATING PROCEDURES

PRE- START CHECKS FOR RO SYSTEM

Ensure all the elements are properly loaded.
Check the filtered water basin level. It should be above normal.
Check filtered water pumps. A/B should be in service.
Check Multimedia filters. Multimedia filters A or B should be in service.
Check 5 micron filters manual isolation valves.
Open micron filters isolation valves
Check RO Booster pump & manual isolation valves.
Open RO Booster pump manual isolation valves One RO booster pump should be on
AUTO mode from breaker and PLC.
Check the reject valve.
Open the reject valve.
Check the RO 4% acid solution tank level and pump. RO 4% acid level should be normal
and pump on Auto mode.
Check RO antiscalant solution tank level and pump.
RO antiscalant level should be normal and pump on Auto mode.
Check the product drain manual isolation valve.
Manual product dump valve should be in close position.

START-UP
Put RO bank A or B on Auto mode from PLC.
Flush the RO bank until the permeate conductivity falls below 90 micromhos/cm.
RO 4% acid pump should be in service.
RO antiscalant pump should be in service.
Adjust the reject valve flow.

SHUT DOWN
Put RO bank on Manual from PLC and observe the following;

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RO bank inlet and out let valves will close

RO anti scalant pump will stop.
RO 4% acid pump will stop.
Flush RO bank for 15 minutes with low pressure feed water OR permeate water by
manually opening the RO bank inlet and dump valves.

RO PRESERVATION
RO preservation is for periods where an RO plant must remain out of operation for more than
thirty days with the RO elements in place. Prepare each RO train as follows.

Clean the RO membrane elements in place.

Flush the RO section with biocide (PC 55) 100 ppm solution.
When the RO section is filled with this solution (make sure that it is completely filled),
close the valves to retain the solution in the RO section.
Repeat Steps 2 and 3 with fresh solution every thirty days if the temperature is below
80°F (27°C), or every fifteen days if the temperature is above 80°F (27°C).
When the RO system is ready to be returned to service, flush the system for
approximately one hour using low-pressure feed water with the product dump valve
open to drain; then flush it at high pressure for 5 to 10 minutes with the product dump
valve open to drain. Before returning the RO system to service, check for any residual
biocide in the product.

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DEMINERALIZATION
WATER DEIONIZATION PROCESS

The process used for removal of all dissolved salts from water is referred to as
demineralization/deionization. Deionization requires the flow of water through two ion exchange
materials in order to effect the removal of all salt content.

The passage of water through the first exchange material removes the calcium and magnesium
ions just as in the normal softening process. Unlike home equipment, deionization units also
remove all other positive metallic ions in the process and replace them with hydrogen ions
instead of sodium ions.

As the metallic ions in the water affix themselves to the exchange material, the latter releases its
hydrogen ions on a chemically equivalent basis. A sodium ion (Na+) displaces one hydrogen ion
(H+) from the exchanger; a calcium ion (Ca++) displaces two hydrogen ions; a ferric ion
(Fe+++) displaces three hydrogen ions, etc. (Recall that home softeners also release two sodium
ions for every calcium or magnesium ion they attract.)

This exchange of the hydrogen ions for metallic ions on an equivalent basis is chemical necessity
that permits the exchange material to maintain a balance of electrical charges.

Now because of the relatively high concentration of hydrogen ions, the solution is very acid.

At this point the deionization process is just half complete. While the positive metallic ions have
been removed, the water now contains positive hydrogen ions, and the anions originally in the
raw water.

The partially treated water now flows through a second unit, this time an anion exchange
material normally consists of replaceable hydroxyl anions and fixed irreplaceable cations.

Now the negative ions in solution (the anions) are absorbed into the anion exchange
material. Released in their place are hydroxyl anions.

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WATER CONTAINING VARIOUS MINERAL CONTAMINANTS ENTERING HERE

All that emerges from such a two unit system is ion-free water. It still contains the positive
hydrogen ions released in the initial exchange plus the negative hydroxyl ions released in the
second exchange.

What has become of these two ions? Through the magic of chemistry they have combined
(positive to negative) to produce water molecules which are in no way different from the water in
which they were produced.

The result of this two-stage ion exchange process is water that is mineral-free.

Equipment for use in the deionization process may be of several types. Available are both
multiple bed and single bed units. Multiple bed units have pairs of tanks, one for the cation
exchanger, the other for the anion exchanger. Single bed units incorporate both the cation and
anion exchangers, mixed in a single tank.

Deionized water has a wide range of uses in industry. Chemical production, pharmaceuticals,
electroplating, television tube production and leather goods processing are among the many
diversified applications for deionized water

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OPERATING PROCEDURE
PRE-START CHECKS
Check the level of RO permeate. RO permeate level should be above low level.
Both Demin trains and mixed beds must be in standby mode.
Check demineralizer feed pump. Pump A or B should be on Auto mode.
Decarbonator water forwarding pump and blower A or B should be on Auto mode.
Check the valve line-up of train A or B.
Demineralizer pump suction and discharge manual isolation valve should be open.
Cation inlet and outlet manual isolation valve should be open.
Decarbonator water forwarding pump inlet and outlet manual isolation valve should
be open.
Anion inlet and outlet manual isolation valve should be open.
Mixed bed inlet and outlet manual isolation valve should be open.
Demin water storage tank A or B filling line manual isolation valve should be open.
Demin water storage tank A or B level should be below 80%

START-UP
Start Demin train by pressing ‘Train service’ from PLC.
Wait for pre-service rinse the train will come in service after pre-rinsing.
When the level of Decarbonator is above low level, Decarbonator water forwarding
pump will cut in automatically
Start mixed bed by pressing ‘mixed bed service’ from PLC.
Wait for pre-service rinse the train will come in service after pre-rinsing.
After some time of train operation check the silica of Anion and mixed bed from
laboratory OR from online analyzer.

SHUTDOWN
Demin train will go on standby after reaching the maximum level in the Demin storage tanks,
OR carry out as mentioned below

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Stop Decarbonator water forwarding pump.

Stop demineralizer water pump.
RO will stop automatically at RO permeate tank low level.

REGENERATION OF DEMINERALIZER TRAINS

The resin beads used for ion exchanger have thousands of sites available for exchanging ions.
However, once the hydrogen or hydroxyl ions have been depleted, the beads are no longer useful
for ion exchange. In the exhausted state, the resin bed cannot remove ions from the incoming
water. There are two parameters to monitor resin exhaustion, silica monitoring & Conductivity
monitoring. Demineralized trains are exhausted after cleaning particular amount of water. They
are regenerated with injecting fresh ions of Hydrogen & hydroxyl. Regeneration is pushbutton
initiated. Initiation of a primary train regeneration sequence will automatically regenerate a
Cation unit and its corresponding anion unit concurrently. Following regeneration of a primary
train and/or a mixed bed unit, the units are placed in standby and return to service is pushbutton
initiated. The standby regenerated train may be placed in service during the regeneration
procedure when in the semi-auto mode. Both trains may be placed in service together only in the
semi-auto mode. During normal operation, one train will be in service and one train in standby.
During the regeneration of a Demineralizer train, the other train will be in standby.

Regeneration of the Demineralizer system is normally performed on a “train” basis by

regenerating the Cation and anion units of the same train concurrently or a mixed bed unit.
Interlocks are provided to ensure that only one train or a mixed bed unit can be regenerated at
any given time. To initiate regeneration, both trains must first be placed into “Standby” and then
press the appropriate regeneration key(s).

The Cation and anion units are regenerated in a split flow counter current manner and therefore
will not be given a full backwash every regeneration. When these units are backwashed
(approximately every 20 regenerations), a double chemical injection will be automatically
provided to recondition the resin at the bottom of the bed.
Regeneration controls are programmed for each Cation and anion unit to totalize the number of
regenerations without a full backwash. When the preset value is reached, the unit will be given a
backwash and double chemical injection during its next regeneration cycle and the appropriate
regeneration tantalizers will be reset to zero after this upset regeneration.
Provisions have been made to override the regeneration if necessary; however, under normal
operating conditions the regeneration cycles should be allowed to time out and sequence through
to completion. Dilution water for the acid and caustic regenerate solutions is demineralized water
delivered by the diluents water pumps. Interlocks are provided to ensure that the acid and caustic
regenerate solutions are delivered at the correct flow rates and chemical strength. A heat

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exchanger is provided to heat the dilution water during preheat caustic injection and
displacement steps of the anion and mixed bed regeneration procedure. Interlocks are provided to
ensure that the minimum anion dilution water temperature is at 35 oC and the mixed bed dilution
water is at 49oC. Dilution water flow is controlled by rate set valves provided for Cation acid
dilution, mixed bed acid dilution, anion caustic dilution and mixed bed caustic dilution.

REGENERATION OF DEMIN. TRAIN

STRONG ACID CATION UNITS

Sub-Surface Wash

Rate 36.3 m3/hr

Time 10 minutes

Backwash (after 20 Regeneration)

Rate 42.0 m3./hr

Time 10 minutes

Acid Injection - 2% H2SO4

98% H2SO4 Required 16 kg.(0.303 m3.)

98% H2SO4 Rate 0.3 64 m3/hr

Dilution Rate 6.6 m3/hr

Total 2% H2SO4 Rate 7.0 m3/hr

2% H2SO4 Up flow Rate 13.5 m3/hr

2% H2SO4 Down flow Rate 3.5 m3/hr

Time 50 minutes

Displacement

Up flow Rate 13.3 m3/hr

Down flow Rate 13.3 m3/hr

Time 15 minutes

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Fast Rinse

Rate 65 m3/hr

Time 20 minutes

NOTE:

If a full backwash cycle is selected, the 2% H2SO4 injection time is extended to 75 minutes

Times and flow rates may be adjusted to suit operational experience to achieve maximum
efficiency

STRONG BASE ANION UNITS

Sub-Surface Wash

Rate 5.9 m3./hr

Time 10 minutes

Backwash (when required)

Rate 20.0 m3.Ihr

Time 10 minutes

Preheat@35C

Up flow Rate 0.5 m3./1ir

Down flow Rate 4.5 m3.fhr

Time 20 minutes

Caustic Injection - 4% NaOH

NaOH Req’d/Regen 95kg.(0.39m3. 50% NaOH)

50% NaOH Rate 0.52 m3./hr

Dilution Rate .0 m3./hr

Total 4% NaOH Rate .52 m3./hr

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4% NaOH Up flow rate 4.76 m3/hr

4% NaOH Down flow rate 0.76 m3/hr

Time 45 minutes

Displacement

Up flow Rate 0.5 m3./hr

Down flow Rate 4.5 m3./hr

Time 45 minutes

Fast Rinse

Rate 65 m3./hr

Time 20 minutes

Note:

If a full backwash cycle is selected, then 4% caustic injection time is extended

MIXED BED UNITS

Backwash
Rate 13.6 cu.m./hr

Time 15 minutes

Settle
Rate NIL

Time 5 minutes

Anion Preheat @ 49oC

Anion Preheat flow rate 4.3 m3./hr

Time = 15 minutes

4% Caustic Injection / 4% Acid Injection

NaOH required/regen. 108 kg (0.14m3. 50% NaOH)

50% NaOH flow rate 0.2m3./hr

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Dilution water flow rate 4.3 m3/hr

4% NaOH flow rate 4.5 m3 /hr

93% H required/regen 108 kg (0.064 m3 .)

93% H flow rate 0. I m3./hr

Dilution water flow rate 4.4 m3 ./hr

4% H2S04 flow rate . 4.5 m3 ./hr

Time 35 minutes

Acid Displacement/Caustic Displacement

Acid Displacement flow rate 4.4 m3 ./hr

Caustic Displacement flow rate 4.3 m3 ./hr

Time 30 minutes

Acid Rinse/Caustic Rinse

Acid Rinse flow rate 13.6 m3 ./hr

Caustic Rinse flow rate 13.6 m3 ./hr.,

Time 20 minutes

Drain down
Rate 9. I m3 ./hr

Time 15 minutes

Air Mix
Rate 340 m3 ./hr ( 0.5 kg/ cm2.)

Time 20 minutes

Resin Slam Down

Rate 65 m3 ./hr

Time I Minute

Fast Fill
Rate 65 m3 ./hr

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Time 2 minutes

Final Rinse
Rate 65 m3 ./hr

Time 10 minutes

Pre service Rinse

Rate 65 m3 ./hr

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PREDICTING OPERATING RESULT

WELL WATER FEED

IDENTIFICATION

A Design Analysis Well Water Feed

B After Lime Softener, pH adjustment and Filtration

C After Reverse Osmosis System

D After Hydrogen Cycle Cation Units

E After Decarbonating Tower

F After Strong Base Anion Units

G After Mixed Bed Demineralizers

ANALYSIS

CONSTITUENT in MG/L AS A B C D E F G

A Calcium 111 35 1 0 0 0 0

T Magnesium 289 65 2 0 0 0 0

I Sodium 850 1052 47 .5 .5 .5 .03

O Hydrogen 0 0 0 33.5 33.5 0 0

N Potassium 90 90 4 0 0 0
0

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A Bicarbonate 345 140 20 0 0 0 0

N Carbonate 0 0 0 0 0 0 0

I Hydroxide 0 0 0 0 0 0.4 0

O Sulphate 759 866 20 20 20 0 0

N Chloride 236 236 14 14 14 .1 .03

Methyl Orange Alkalinity 345 140 20 0 0 0.4 0

Carbon Dioxide, Free 6.4 41 41 64 5 0 0

Silica 28.2 10 .5 .5 .5 .05 .01

Turbidity NTU 1 0 0 0 0 0 0

pH 8.0 6.8 6.0 3.2 3.2 8.0 7.0

Conductivity 150 5.0 .1

PREDICTING OPERATING RESULT

CANAL WATER FEED

IDENTIFICATION

A Design Analysis Well Water Feed

B After Lime Softener, pH adjustment and Filtration

C After Hydrogen Cycle Cation Units

D After Decarbonating Tower

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E After Strong Base Anion Units

F After Mixed Bed Demineralizers

ANALYSIS

CONSTITUENT in MG/L AS A B C D E F

A Calcium 83 35 1 0 0 0

T Magnesium 36 33 0 0 0 0

I Sodium 40 50 .5 .5 .5 .04

O Hydrogen 0 0 68.5 68.5 0 0

N Potassium 6 6 0 0 0 0

A Bicarbonate 96 45 0 0 0 0

N Carbonate 0 0 0 0 0 0

I Hydroxide 0 0 0 0 0.4 0

O Sulphate 43 65 55 55 0 0

N Chloride 14 14 14 14 .1 .04

Methyl Orange Alkalinity 96 45 0 0 .4 0

Carbon Dioxide, Free 1.8 1.3 40.9 5 0 0

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Silica 13.6 13 13 13 .05 .01

Turbidity NTU 482 .5 .5 .5 .5 .5

pH 8.0 7.8 2.9 2.9 8.0 7.0

Conductivity 5 .1

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 BOP Training Report

CHAPTER # 03

COOLING TOWERS

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COOLING TOWERS
Cooling towers are a very important part of many chemical plants. The primary task of a cooling
tower is to reject heat into the atmosphere. They represent a relatively inexpensive and
dependable means of removing low-grade heat from cooling water. The make-up water source is
used to replenish water lost to evaporation. Hot water from heat exchangers is sent to the cooling
tower. The water exits the cooling tower and is sent back to the exchangers or to other units for
further cooling

Cooling towers fall into two main categories: Natural draft and Mechanical draft.

NATURAL DRAFT
Natural draft towers use very large concrete chimneys to introduce air through the media. Due to
3
the large size of these towers, they are generally used for water flow rates above 45,000 m /hr.
These types of towers are used only by utility power stations.

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MECHANICAL DRAFT

Mechanical draft towers utilize large fans to force or suck air through circulated water. The water
falls downward over fill surfaces, which help increase the contact time between the water and the
air - this helps maximize heat transfer between the two. Cooling rates of Mechanical draft towers
depend upon their fan diameter and speed of operation. Since, the mechanical draft cooling
towers are much more widely used

MECHANICAL DRAFT TOWERS

Mechanical draft towers are available in the following airflow arrangements:
1) Counter flows induced draft.
2) Counter flow forced draft.
3) Cross flow induced draft.

In the counter flow induced draft design, hot water enters at the top, while the air is introduced at
the bottom and exits at the top. Both forced and induced draft fans are used.
In cross flow induced draft towers, the water enters at the top and passes over the fill. The air,
however, is introduced at the side either on one side (single-flow tower) or opposite sides
(double-flow tower). An induced draft fan draws the air across the wetted fill and expels it
through the top of the structure.
The Figure 7.2 illustrates various cooling tower types. Mechanical draft towers are available in a
3
large range of capacities. Normal capacities range from approximately 10 tons, 2.5 m /hr flows
3
to several thousand tons and m /hr. Towers can be factory built or field erected – for example
concrete towers are only field erected. Many towers are constructed so that they can be grouped
together to achieve the desired capacity. Thus, many cooling towers are assemblies of two or
more individual cooling towers or “cells.” The number of cells they have, e.g., a eight-cell tower,
often refers to such towers. Multiple-cell towers can be lineal, square, or round depending upon
the shape of the individual cells and whether the air inlets are located on the sides or bottoms of
the cells.

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COMPONENTS OF COOLING TOWER

The basic components of an evaporative tower are: Frame and casing, fill, cold water basin, drift
eliminators, air inlet, louvers, nozzles and fans.

FRAME AND CASING:

Most towers have structural frames that support the exterior enclosures (casings), motors, fans,
and other components. With some smaller designs, such as some glass fiber units, the casing may
essentially be the frame.

FILL:
Most towers employ fills (made of plastic or wood) to facilitate heat transfer by maximizing
water and air contact. Fill can either be splash or film type.
With splash fill, water falls over successive layers of horizontal splash bars, continuously
breaking into smaller droplets, while also wetting the fill surface. Plastic splash fill promotes
better heat transfer than the wood splash fill.
Film fill consists of thin, closely spaced plastic surfaces over which the water spreads, forming a
thin film in contact with the air. These surfaces may be flat, corrugated, honeycombed, or other
patterns. The film type of fill is the more efficient and provides same heat transfer in a smaller
volume than the splash fill.

COLD WATER BASIN:

The cold water basin, located at or near the bottom of the tower, receives the cooled water that
flows down through the tower and fill. The basin usually has a sump or low point for the cold
water discharge connection. In many tower designs, the cold water basin is beneath the entire fill.

Some forced draft counter flow design, however, the water at the bottom of the fill is In
channeled to a perimeter trough that functions as the cold water basin. Propeller fans are
mounted beneath the fill to blow the air up through the tower. With this design, the tower is
mounted on legs, providing easy access to the fans and their motors.

DRIFT ELIMINATORS:
These capture water droplets entrapped in the air stream that otherwise would be lost to the
atmosphere.

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AIR INLET:
This is the point of entry for the air entering a tower. The inlet may take up an entire side of a
tower—cross flow design— or be located low on the side or the bottom of counter flow designs.

LOUVERS:
Generally, cross-flow towers have inlet louvers. The purpose of louvers is to equalize air flow
into the fill and retain the water within the tower. Many counter flow tower designs do not
require louvers.

NOZZLES:
These provide the water sprays to wet the fill. Uniform water distribution at the top of the fill is
essential to achieve proper wetting of the entire fill surface. Nozzles can either be fixed in place
and have either round or square spray patterns or can be part of a rotating assembly as found in
some circular cross-section towers.

FANS:
Both axial (propeller type) and centrifugal fans are used in towers. Generally, propeller fans are
used in induced draft towers and both propeller and centrifugal fans are found in forced draft
towers. Depending upon their size, propeller fans can either be fixed or variable pitch. A fan
having non-automatic adjustable pitch blades permits the same fan to be used over a wide range
of kW with the fan adjusted to deliver the desired air flow at the lowest power consumption.
Automatic variable pitch blades can vary air flow in response to changing load conditions.

COOLING TOWER PERFORMANCE

The important parameters, from the point of determining the performance of cooling towers, are:

i) “Range” is the difference between the cooling tower water inlet and outlet temperature.

ii) “Approach” is the difference between the cooling tower outlet cold water temperature and
ambient wet bulb temperature. Although, both range and approach should be monitored, the
`Approach’ is a better indicator of cooling tower performance.
iii) Cooling tower effectiveness (in percentage) is the ratio of range, to the ideal range, i.e.,
difference between cooling water inlet temperature and ambient wet bulb temperature, or in other
words it is = Range / (Range + Approach).

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iv) Cooling capacity is the heat rejected in kCal/hr or TR, given as product of mass flow
rate of water, specific heat and temperature difference.

v) Evaporation loss is the water quantity evaporated for cooling duty and, theoretically, for
3
every 10, 00,000 kCal heat rejected, evaporation quantity works out to 1.8 m . An empirical
relation used often is:

3 3
Evaporation Loss (m /hr) = 0.00085 x 1.8 x circulation rate (m /hr) x (T -T )
1 2

T -T = Temp. difference between inlet and outlet water.

1 2

vi) Cycles of concentration (C.O.C) is the ratio of dissolved solids in circulating water to
the dissolved solids in make up water.

vii) Blow down losses depend upon cycles of concentration and the evaporation losses and is
given by relation:

Blow Down = Evaporation Loss / (C.O.C. – 1)

viii) Liquid/Gas (L/G) ratio, of a cooling tower is the ratio between the water and the air
mass flow rates. Against design values, seasonal variations require adjustment and tuning of
water and air flow rates to get the best cooling tower effectiveness through measures like water
box loading changes, blade angle adjustments.
Thermodynamics also dictate that the heat removed from the water must be equal to the heat
absorbed by the surrounding air:

where: L/G = liquid to gas mass flow ratio (kg/kg)

FACTORS AFFECTING COOLING TOWER PERFORMANCE

CAPACITY
3
Heat dissipation (in kCal/hour) and circulated flow rate (m /hr) are not sufficient to understand
cooling tower performance. Other factors, which we will see, must be stated along with flow rate
3 3 o
m /hr. For example, a cooling tower sized to cool 4540 m /hr through a 13.9 C range might be
3 o
larger than a cooling tower to cool 4540 m /hr through 19.5 C range.

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RANGE
Range is determined not by the cooling tower, but by the process it is serving. The range at the
exchanger is determined entirely by the heat load and the water circulation rate through the
exchanger and on to the cooling water.
o
Range C = Heat Load in kcals/hour / Water Circulation Rate in LPH

Thus, Range is a function of the heat load and the flow circulated through the system.

WET BULB TEMPERATURE

Wet bulb temperature is an important factor in performance of evaporative water cooling
equipment. It is a controlling factor from the aspect of minimum cold water temperature to which
water can be cooled by the evaporative method. Thus, the wet bulb temperature of the air
entering the cooling tower determines operating temperature levels throughout the plant, process,
or system. Theoretically, a cooling tower will cool water to the entering wet bulb temperature,
when operating without a heat load. However, a thermal potential is required to reject heat, so it
is not possible to cool water to the entering air wet bulb temperature, when a heat load is applied.
The approach obtained is a function of thermal conditions and tower capability.

Initial selection of towers with respect to design wet bulb temperature must be made on the basis
of conditions existing at the tower site. The temperature selected is generally close to the average
maximum wet bulb for the summer months. An important aspect of wet bulb selection is,
whether it is specified as ambient or inlet. The ambient wet bulb is the temperature, which exists
generally in the cooling tower area, whereas inlet wet bulb is the wet bulb temperature of the air
entering the tower. The later can be, and often is, affected by discharge vapours being
recirculated into the tower. Recirculation raises the effective wet bulb temperature of the air
entering the tower with corresponding increase in the cold water temperature. Since there is no
initial knowledge or control over the recirculation factor, the ambient wet bulb should be
specified. The cooling tower supplier is required to furnish a tower of sufficient capability to
absorb the effects of the increased wet bulb temperature peculiar to his own equipment.

RANGE, FLOW AND HEAT LOAD

Range is a direct function of the quantity of water circulated and the heat load. Increasing the
range as a result of added heat load does require an increase in the tower size. If the cold water
temperature is not changed and the range is increased with higher hot water temperature, the
driving force between the wet bulb temperature of the air entering the tower and the hot water
temperature is increased, the higher level heat is economical to dissipate.

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If the hot water temperature is left constant and the range is increased by specifying a lower cold
water temperature, the tower size would have to be increased considerably.

CHEMICAL TREATMENT OF
COOLING WATER

Chemicals are injected in CW system to stop microbiological growth and corrosion formation.

NALCO 23212

Nalco 23212 is used as a scale inhibitor in the Cooling Tower. It is commonly known as
phosphate treatment. As the ph of the circulating water is kept low so there are less chances of
corrosion formation in the system. The value of phosphate in circulating water is maintained at
1.5-2.2 ppm

SULPHURIC ACID
Sulphuric acid is added to reduce the ph of the circulating water & to reduce M.Alkalinity. The
ph of the Cooling Tower is maintained at about 8.2.

DISPERSANT
The scale formed tends to stay suspended long enough to be removed by either the blow down or
a filtration system. Dispersant is added to remove the scale from the Cooling Tower Basin. It
does not allow the scale to settle down to the bottom of the cooling Tower.

Two approaches can be taken to ensure adequate control

I. Increase blow down to remove solids and prevent their concentrations from going too
high. Unfortunately this approach also increases the quantities of water and treatment
products used and tends not to be cost effective.
II. Utilize heavier dosages of treatment products to prevent deposition possibly with the
Incorporation of an acid-feed system to keep the carbonate equilibrium system in the
more Soluble bicarbonate form. This approach can be very costly and is counter to
good environmental practice.

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CHLORINE
The tendency for biological activity and fouling can be effectively controlled. Chlorine is usually
added as a shock dose, usually at night. It can be added as Cl2 or as hypochlorite depending upon
the size of the system. The hypochlorite should be sodium as opposed to calcium (HTH) as the
calcium would add to the system's scaling potential. Bromination, is also becoming an accepted
procedure when the pH run >8. Alternatively a number of proprietary biocides can be used.
These include iso-thiazalones, carbonates and quaternary products. Unlike chlorine, which
oxidizes cell walls, the use of the proprietary products can lead to the development of an
organism that adapts to the biocide. It is common to alternate biocides to kill off any bacteria that
may have adapted.
Chlorine was dozed as a Biocide in Cooling Tower. At Lalpir Chlorine Dozing has been replaced
by Sodium Hypo Chloride due to safety priority. At PakGen Chlorine is still being used & is to
be replaced till December 2009.
Chlorine is maintained in the Circulating water system on residual basis. The amount of chlorine
present in Circulating water is maintained at maximum of 0.5 ppm.

OPERATING PROCEDURES

PRE-CHECKS & STARTING PROCEDURE FOR CIRC WATER

PUMP
Main breaker should be in close position and metering module showing 11 KV.
Pump discharge MOV breaker should be in close position.
Pump discharge MOV should be close with green LED lit up.
Discharge line vent valve should be open.
MOV selector switch should be on remote.
Bearing cooling water flow should be normal 30~40m3/h and differential pressure across
the strainers of cooling pumps should be below than 0.2 bar.
Cooling tower level should be greater than 400mm and maximum when starting after
outage.
Bearing lube oil should be normal.
Space heaters breaker should be open.

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STARTING OF CIRC WATER PUMP

BCW pumps for cooling of circ. Water pumps start.
If the lube water flow is 15m3/h than the circ. Water pump will start
Discharge valve will start open up to 40 % with in first 40 second.
Discharge valve will open from 40% to 100%.

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CHAPTER # 04
HYDROGEN GENERATION SYSTEM
&
WASTE WATER DISPOSAL

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HYDROGEN GENERATION SYSTEM:-

Hydrogen generation s ystem is designed to produce 5 normal cubic meters

of h ydrogen (when measured at o degree centigrade and 760 mm of Hg). It can
compress and purify 5 normal cubic meters of hydrogen to a pressure of 175
kg/cm 2 .
Hydrogen Gas Generating S ystem consists of Air Cooled Silicon Rectifier,
Transformer, and Six Stuart Electrol ytic Cells connected in Series
RECTIFIER SPECIFICATIONS
Rated Power 30 KW

Rated AC Voltage 380 +/- 10 Volts

Rated AC Current 58 Amps

Rated Frequency 50 +/- 5% Hz

Number of Phases 3

Rated DC Voltage 15 Volts

Rated DC Current 0 – 2000 A

Percent Ripple 5 %

Percent Regulation 1 %

Ambient Temperature 50 0 C

AC power at 380 volts, 3 phase, 50 hertz is supplied from the power feeder
panel through circuit breaker to rectifier and transformer. Circuit breaker is
provided for short circuit protection. In rectifier, voltage is reduced by a
rectifier transformer and converted to a Direct Current at Voltage up to 14 volts.
DC power from Rectifier is supplied to electrol ytic cells through copper bus bar
ELECTROLYTIC CELLS:-
The Stuart electrol ytic cells are of the uni polar tank t ype. The cell is known as
a 3-plate cell, having one nickel-plated iron anode plates and two iron cathode
plate. The anodes are surrounded by cloth diaphragms which prevent mixing of

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the h ydrogen and ox ygen gases formed in the cell. The electrol yte is a 25%
solution of potassium h ydroxide. (Also referred to as ‘caustic potash” or
“KOH”) in water.)

ELECTROLYTE:-
The optimum concentration is 25% by weight KON (Specific Gravit y of 1.24
when measured at 15.5° C).

DC current from the positive terminal of the rectifier enters the first cell in the
bank at the terminals of the anodes. The current flows down the anodes into the
cell, through the electrol yte to the cathodes, up the cathodes to the cathode
terminals (two per cathode), and then on to the anode terminals of the next cell
in the bank. From the last cell in the bank the current flows back to the negative
terminal of the rectifier.
Passage of direct current through the cell causes the water in the cell to be
converted into h ydrogen and ox ygen gases. Hydrogen forms on the cathode
plates:
Ox ygen forms on the anode plates. This process is known as “electrol ysis” and
the cell is called an “electrol ytic cell”. The diaphragms surrounding the anodes
are very effective at keeping bubbles of ox ygen separated from bubbles of
h ydrogen. However, they are less efficient at keeping the actual gases separated.

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For this reason the cell is normall y operated so that the diaphragms are
submerged in the electrol yte.
If for some reason the electrol yte level should drop to the point where the
diaphragms were no longer submerged, hydrogen could pass through the
diaphragms into the ox ygen, and vice-versa. Before this could happen however,
the end of the vent pipe would be exposed, allowing the gases to escape into the
cell room.
This reduces the risk of compressing impure gases. The amount of hydrogen
vented into the room is not a hazard provided the room is adequatel y ventilated.
The amounts of h ydrogen and oxygen formed are directl y proportional to the
amount of DC current flow through the cell. At 2000 amperes (maximum cell
current each cell will produce 0.7 cubic meters of hydrogen and 0.35 cubic
meters of oxygen per hour. (When measured dry, at 0°C, 760 mm of mercury).
The ox ygen gas formed on the anodes bubbles up through the electrol yte, inside
the diaphragms which surrounds the anodes, and flows into the ox ygen
compartment above the electrol yte level.
Similarl y, the h ydrogen formed on the cathodes bubbles up through the
electrol yte, outside the diaphragms, and flows into the hydrogen compartment
above the electrol yte level.

CELL TEMPERATURE
- Voltage tends to decrease as temperature increases.
The recommended cell temperature between 65° C and 700 C. Above this
Temperature the rate of corrosion of cell components increases significantl y.
ELECTROLYTE STRENGTH
- The recommended electrol yte concentration is 25% by weight. Concentrations
above or below this tend to increase cell voltage.
Concentrations above 25% also tend to increase the rate of cell corrosion. As
current flows through the cell to produce hydrogen and ox ygen, some heat is
also evolved.
The gases leaving the cell are cooled in water-cooled gas coolers. Cooling water
enters from the water header flows through the hydrogen and ox ygen gas coolers
for each cell in series and then flows to waste.

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HYDROGEN MIST ELIMINATOR

The h ydrogen gas leaving the cells carries off some of the Potassium Hydroxide
electrol yte in the form of an entrained mist. Most of this entrainment is removed
in the cell gas cooler and is returned to the cells. Some is removed at water seal.
The remainder is removed in the mist eliminator.
The mist eliminator element consists of a hollow cylindrical fiber packed unit
with a mounting flange at the top end. Mist laden gas flows through the walls of
the hollow cylinder. Clean gas leaves at the centre at the top. The entrained mist
collects in the fibers of the element and flows downward to the closed bottom
end of the element and rains throughput the dip pipe to the bottom of the tank.
Entrained mist then flows out through the overflow pipe to waste.
HYDROGEN GAS HOLDER
The hydrogen gasholder is a wet-seal t ype gasholder with a nominal volume of
30m 3 . The operating pressure will be approximatel y 125mm water column. The
gasholder is fitted with four level switches for control of the hydrogen
compressors.
HYDROGEN PURIFICATION SYSTEM
The h ydrogen at the discharge of the oil lubricated compressors contain the
following impurities
Ox ygen gas, approx 0.2 percent by volume
Water vapor, 100 percent relative humidity at operating conditions.
Oil Vapor and oil droplets picked up in the oil lubricated compressors.
Moisture condensed out of the hydrogen gas as a result of the increase in
pressure
The moisture, oil droplets and oil vapor are removed in a series of filter . Two
banks of these filters are supplied so that one bank can be in service while the
other bank is being standb y
Catal ytic purifier for removal of ox ygen impurit y in the hydrogen gas . The
purifier is fitted with inlet and outlet temperature gauges, as well as high and
coalescing high high temperature switches.
Water cooled heat exchanger for cooling the hot hydrogen leaving the catal ytic
purifier. The heat exchanger is fitted with outlet temperature gauge. Condensed
water is collected in filter.

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The h ydrogen then flows to the hydrogen dryer, where it is dried to a dew point
of –50 0 C. The h ydrogen dryer is a molecular sieve, dual column, heatless,
pressure swing t ype.
The h ydrogen then flows through the dust filter where an y dist particles carried
over from the dryer are filtered out.
From the dust filter the hydrogen flows through back pressure maintaining
valve, this valve serves to impose a minimum back pressure on the hydrogen
dryer of approximately 175 kg/cm 2 regardless of the pressure in the downstream
cylinder storage, thereby ensuring that the dryer operates at its maximum
efficiency.
CATALYTIC PURIFIER
The catal ytic purifier is used to remove oxygen impurit y from the hydrogen gas
b y causing the oxygen to catal yticall y combine with hydrogen to form water
vapor. When operating properl y the purifier should remove oxygen to a residual
impurit y of less than ten parts per million

A special “wettable” t ype catal yst is used, which does not require the use of
preheaters, temperature controllers, etc.
When ox ygen is catalyticall y combined with hydrogen, heat is given off and the
temperature of the gas increases. A temperature rise of 16 o C can be expected fro
each tenth of one percent ox ygen reacted. If too much ox ygen is present (more
than 4 %) the gas mixture could explode. For this reason extreme caution must
be taken to exclude excessive ox ygen from the Hydrogen in the catal ytic
purifier.
AFTER COOLER
The after cooler is supplied to cool the hot hydrogen leaving the catal ytic
purifier, before it enters the desiccant dryer. If the hydrogen is not sufficientl y
cooled the desiccant dryer could be overloaded, with harmful effects on the exit
dew point.
The After cooler is a shell and tube t ype heat exchanger, with hydrogen flowing
on the tube side and cooling water flowing on the shell side. Temperature Gauge
at the After cooler outlet indicates hydrogen temperature.
From after cooler the hydrogen gas goes to Hydrogen storage bottles through
coalescing filters.

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OPERATING PROCEDURE OF HYDROGEN PLANT

PRE-START CHECKS FOR GAS PRODUCTION

Check that the cells are read y for operation. Check the level (90 mm
from top of cell cover plate) and concentration (1.226 at 40 o C) of
electrol yte.
Check the vent valve at the water seal Hydrogen vent valve, ox ygen
vent valve should remain open. Hydrogen valve to gas holder should be
closed.
Check the level of water in the water seal. It should be 25mm of water
column.
Open the cooling water root valve (V-119) to cell coolers.
Check all the valve line-up of demin water to electrol ytic cell. Demin
tank makeup and discharge valve, electrolyzer root and individual cell
valves all should be open.
Check the level of water seal in gas holder. Open its filling valve and
observe from overflow pipe.
Check the drain valves of gas holder. Close the gas inlet and gas
holder drain valve.
Turn on the main power to control panel. All the annunciator lights
should turn ‘ON’.
Check that the Ampere level control potentiometer is turned full y
counter clockwise to the zero current position.
Check the rectifier cooler fan. Fan breaker should be ‘closed’. It has
interlocking with rectifier.
Push the ‘RESET’ push button. All the rectifier related annunciator
lights should extinguish.

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OPERATION OF RECTIFIER
Press the ‘RECTIFIE R START’ pushbutton. The rectifier is now
ON. The RECTIFIER ON indicating light LR should now light up.
Turn the Ampere level control slowl y clockwise in 300 ampere
increments.
After five minutes of operation, check the hydrogen gas purity. When
its purit y reaches above 99.5%, turn hydrogen gas into the gas holder.
Operate at 600 amperes for one and half hour. During this time,
measure cell voltage balance.
Check A-T (anode to tank) voltage. (0.5 to 1.4 volts)
Check C-T (cathode to tank) voltage (1.4 to 0.5 volts)
Operate at 1200 amperes for twent y four hours and then proceed to
2000 amperes in 300 amperes increment every half hour.
Open the gas holder valve slightl y and then close the hydrogen vent
valve completel y.
Adjust the water seal overflow pipe to maintain 25mm (differential)
of water column pressure as observed in manometer on front panel.

PRE-START CHECKS FOR GAS STORAGE

Select a DUTY compressor. Select ‘A’ or ‘B’ compressor.
Check oil level gauge of compressor. It should be filled 2/3 to gauge
glass.
Close the disconnect switch for the DUTY compressor motor.
Check the cooling water inlet and outlet manual valve. Inlet and
outlet valve should be open.
Gas holder level should be above minimum level.
Check the valve line-up of gas purification s ystem.

o Inlet and outlet valve should be open.

o Dryer and purifier bypass valve should be closed.

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Check storage bottle valves.

All bottles inlet and outlet valves should be open.

WASTE WATER SYSTEM

Calcium is used as a parameter to control blow down of Cooling Tower. Condenser pipes are
of Copper metal & Circ Water lines are of CS. The main cause of deterioration in this system is
bicarbonates & carbonates precipitation which is thus calculated by Calcium present in the
system.

WASTE WATER ENVIRONMENTAL STANDARDS

PARAMETERS UNITS NEQS WORLD BANK

EFFLUENT

pH 6~9 6~9

TDS mg/l 3500 -

TSS mg/l 200 60

Oil & Grease mg/l 10 20

BOD mg/l 80 (BOD5) 50 ( BOD3)

Metals mg/l 2.0(Toxic 10 (Total Heavy Metals)

Metals)

Temperature oC Influent Temp. Influent Temp. + Max. 5

+ Max. 3 and if influent temp.
Is>28 then influent temp.
+ Max. 3

Sulphate mg/l 600 -

Chloride mg/l 1000 -

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Iron mg/l 8.0 -

Copper mg/l 1.0 -

Zinc mg/l 5.0 -

Chromium mg/l 1.0 -

NORMAL CONDITIONS
After testing all parameters of blow down basin sample in lab, if found with in the limit
start dumping.
If the results are not with in the limit please act as mentioned in the above chart.

BLOW DOWN BASIN TREATMENT

During outages after Air Heater Basket washing extreme abnormal conditions are observed,
following procedure deals with such conditions;

 The blow down basin should be full Approx. High-High level.

 The blow down basin should be on recirculation before starting the chemical dosing.
 Air scouring must be in progress.

BLOW DOWN BASIN DUMPING PROCEDURE

Parameters Max. Allowable Corrective Action for abnormal

Limit & Unit results

pH 6~9.0 Adjust with acid /caustic dosing

TSS 200 ppm Wait for settlement of suspended

matter.

TDS 3500 ppm Adjust with cooling tower blow

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down

Oil & Grease 10 ppm Remove with oil skimmer from

surface.

Copper 1.0 ppm Adjust with cooling tower blow

down

Iron 8.0 ppm Adjust with cooling tower blow

down

Zinc 5.0 ppm Adjust with cooling tower blow

down

Total Heavy 10.0 ppm Adjust with cooling tower blow

Metal down

Temperature Influent temp + 3

~5o C

Sulphate 600ppm Adjust with cooling tower blow

down

Chloride 1000ppm Adjust with cooling tower blow

down

CHEMICAL DOSING:

Before starting chemical dosing maintain the pH of the blow down basin
approximately 10.00 by using caustic soda (NaOH).
Then add lime (50ppm), wait for 30 minute.
Put polymer (10ppm) in it, wait for 30 minute.
After 30 minutes stop the recirculation pump and close air scoring valve.
Wait for 2 hours to allow all impurities and suspended solids to settle down.
Now take the sample without putting the pump on recirculation.

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Perform the sample testing with digestion method of the blow down basin. If its results meet
the environmental standards, you can put it on dumping.

Note:

In the process of chemical dosing you have to maintain the pH of the blow down basin up to
10. The basic reason of this is to achieve the proper results of chemical dosing and their
actions. The pH can maintained up to 10 by using Caustic NaOH.

Before dumping if pH is above 8 then bring it to 8 by adding Sulfuric acid again put on
recirculation and again allow it to settle down for 1/2 hrs.

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APPENDIX

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TECHNICAL SPECIFICATIONS OF EQUIPMENTS

CANAL INTAKE SYSTEM

Canal Water Pump Capacity 1200m 3 /hr (110 kW)

Canal water pump Lube water pump 1.5 kW

Canal water pump Lube water Tank 2 m3

Well Water Pump Capacity 240 m3/hr (30 kW)

Bar Screen 1500mm*1000 mm(1200 m 3 /hr)

Travelling bar screen 1200mm*3500(1200 m 3 /hr)

Travelling screen wash pump 10 m3/hr (3.7 kW)

Settling Basi n 1000 m3

Settling basin wash pump 50 m 3 /hr (30 kW)

Settling basin sludg e pump 50 m 3 /hr (3.7 kW)

Clarifier supply pump 1100m 3 /hr (90 kW)

Inlet dis tribution b ox 3048 × 1828 mm ( 1023 m 3 /hr)

Clarifier 2400 m 3

Clarifier Underflow pumps 23 m 3 /hr

Clear well 165 m 3

Clear well 6.3mD 6.45m H

Coagulant Tank 15 m 3

Polymer Tank 10m 3

DMF Pumps 567 m 3 /hr (56 kW)

DMF Blowers 1360 m 3 /hr (30 kW)

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MULTIMEDIA FILTERS

Technical Data

Type Vertical

Number of Units Two

Diameter 2438 mm

Straight Side 1575mm

Design Pressure 6.9 kg/cm2

Test Pressure 10.5 kg/cm2

Design Flow/Unit 97 m3/hr/

Design Flow/Unit 20.9 m3/hr/m2

Filter Media Sand/Anthracite/Garnet

Filter Media Depth - total 838 mm

Freeboard 590 mm

Lining Plasite 7133

Maximum Operating Temperature 38°C

MULTIMEDIA CLEANING

Backwash Rate 170 m3/hr

Time 10 minutes

Rinse Rate 95 m3/hr

Time 5 minutes

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5 micron Filters

Quantity/unit 2

Diameter 406 mm

Height 2108 mm

Material 316 stainless steel

Design pressure 10.5 kg/cm2

CATION UNIT

Quantity 2

Diameter 1829 mm

Straight side 3988 mm

Design Pressure 6.9 kg/cm2

Test Pressure 10.35 kg/cm2

Capacity /Unit 1300 m3

Design Basis 124 mg/l

Capacity / m3.Resin 30 kgm/m3

Design flow rate/Unit 65 m3/hr.

Hours Run/Unit –at design flow 20

Resin/Unit 5.375 m3

Resin Bed Depth 2048 mm (app.)

Resin Freeboard 1940 mm (app.)

Maximum Operating Temperature 40oC

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ANION UNIT

Quantity 2

Diameter 1829 mm

Straight side 2794 mm

Design Pressure 6.9 kg/cm2

Test Pressure 10.35 kg/cm2

Capacity /Unit 1300 m3

Design Basis 110 mg/l

Capacity / m3.Resin 38.9 kgm/m3

Design flowrate/Unit 65 m3/hr.

Hours Run/Unit –at design flow 20

Resin/Unit 3.68 m3

Resin Bed Depth 1402 mm (app.)

Resin Freeboard 1392 mm (app.)

Maximum Operating Temperature 40oC

MIXED BED UNIT

Quantity 2

Diameter 1524 mm

Straight side 2489 mm

Design Pressure 6.9 kg/cm2

Test Pressure 10.35 kg/cm2

Capacity /Unit 12,900 m3

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Capacity /Unit -Cation 25.8 kgm

Capacity /Unit –Anion 25.8 kgm

Design Basis 2 mg/l

Capacity / m3.Cation Resin 22.9 kgm/m3

Capacity /m3.Anion Resin 22.9 kgm/m3

Design flowrate/Unit 65 m3/hr.

Cation Resin/Unit 1.13 m3

Anion Resin/Unit 1.13 m3

Cation Resin Bed Depth 610 mm (app.)

Anion Resin Bed Depth 610 mm (app.)

Resin Freeboard 269 mm (app.)

Maximum Operating Temperature 40oC

COOLING TOWER

Type Mechanical Induced Draft counter

flow

Circ Water Flow 35,000 m³/hr for two pumps

Hot (Inlet) water Temp 41.0 °C

Cold (Outlet) Water Temp 30.0 °C

Drift Loss % of Circ water 0.10% max.

flow

Number of Cells 8 cells per unit

Total no. of fans 8 sets per unit

Nominal cell dimension L x 15.8m x 19.2m

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Fan stack height 3.8m

Overall tower height 14.8m

COOLING TOWER FAN

Type & Model Axial Flow Propeller Fan (Pitch

adjustable)

Manufacturer Hudson Products Corporation

Diameter 9.76m

Number of Blades 10 Blades/fan

Fan Speed RPM 114 RPM

Tip speed 58.2 m/sec

Air Delivery/fan 754.0 m³/Sec

Fan static Efficiency 64%

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