24.

OPERATION & MAINTENANCE MANUAL

 BLOCK NO. CLASS NO.
SAMWON-SERA ENGINEERING Co.,LTD. - -

DWG.NO. 161-EZ610-012 0
NO. DATE REVISIONS & DESCRIPTION Drawn Checked Reviewed Approved

0 2012.08.07 FOR CONSTRUCTION M.S.KIM S.H.JANG J.K.PARK

FOR CONSTRUCTION

OPERATION & MAINTENANCE MANUAL

UNIT TOTAL PERUNIT TOTAL

NO. DESCRIPTION MAT'(KS) REMARK'S
QUANTITY WEIGHT(KG)

SCALE NONE PROJECTION NONE

SIZE A4 DIMENSION NONE

INDONESIA ISM CHEMICAL INJECTION

REF. DWG. NO.

EQUIPMENT
POWER PLANT SYSTEM
TITLE
CHEMICAL
OPERATION & MAINTENANCE MANUAL MAKER
INJECTION SYSTEM DWG. NO.

DRAWN CHECKED REVIEWED APPROVED DRAWN CHECKED REVIEWED APPROVED

PROJECT
161-EZ610-012
(SUPPLIER)
POSCO E&C

DWG. NO.
SIGNA
M.S.KIM S.H.JANG J.K.PARK
TURE KRAKATAU
POSCO POWER
DATE 12/08/07 12/08/07 12/08/07 DWG. NO.
 POSCO
OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
Revision : 0
Chemical Injection System Date : Aug.07.12
Page: 1of 16

1.0 GENERAL

1.1 GENERAL

1.1.1 Chemical Injection System.

 CORROSION
 DEPOSITIONS (SCALING) CAUSED BY EXCESSIVE HARDNESS
- Ammonia dosing unit and Hydrazine dosing unit for the condensate/feedwater systems and the
Closed cooling water system
- Phosphate dosing unit for the HRSG system

1.2 Function and composition

1.2.1 FUNCTION
HYDRAZINE DOSING UNIT
1) The final oxygen removal of the feedwater should be done by the injection of hydrazine
2) The amount of Hydrazine injection shall be determined by the water flow and by the residual
Hydrazine actually measured at economizer inlet.
AMMONIA DOSING UNIT
1) Ammonia will be dosed into the condensate system to avoid corrosion problems and for pH-
value adjustment
2) The amount of ammonia injection shall be determined by the condensate flow and by the pH-
value actually measured.
PHOSPHATE DOSING UNIT
1) Phosphate (Na3PO4/NA2HPO4) shall be added to avoid deposits of hardness in the boiler
tube system
2) The amount of phosphate injection shall be determined from the hardness actually measured
at bolier blow-down.

1.2.2 COMPOSITION

Dosing system is structured with chemical tank, chemical injection pump and measuring cylinder.
Chemical injecton pump is type of diaphragm metering pump due to necessary of injecting small
amount of chemical in very accurate base. Injection is controlled manually according to PID.
 POSCO
OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
Revision : 0
Chemical Injection System Date : Aug.07.12
Page: 2of 16

Measuring and dissolution process is simple that first constent density of chemical is masured by
measuring cylinder and scale and sent to thank for dissolution dilution. However, Operator must
be cautious to leakage of any kind of Ammonia.

1.3 Main Scheme by System

1) The purpose of injection by chemical

Chemcial Purpose of Injection Injection Point Remark

- BFP SUCTION
- CCW PUMP SUCTION
Hydrazine Eliminate “DO” inside system - BOILER FILLING
WATER PIPE
- D/A STORAGE TANK

Preservation of “pH” level to

Ammonia moderate inside system - COP DISCHARGE

Sodium Inhibite scaling inside bolier

- STEAM DRUM.
Phophospate drum.

2) In order to adjust density of chemical, diluted water need to connect to outlet of pure transfer
pump. The level of chemcial density inside chemical solution tank is set to mix with 5% from
hydrzine tank, 5% from ammonia tank and 2 % from acid phophospate tank.

3) In than, there are (HIGH LEVEL) and (LOW LEVEL) swich also site level gauge is available.
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OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
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Chemical Injection System Date : Aug.07.12
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4) Preservatory quality of water condition by chemical injection

PART
DESIGN REQUIREMENT REMARK
FEED WATER
pH(25℃) 8.5 ~ 9.6

경도(mg/l CaCO3) 0
유지류(mg/l) 0

Dissolved Oxygen(mg/l) < 0.007

N2H4(mg/l) > 0.01
Fe(mg/l) < 0.03

Cu(mg/l) Max.0.01
전기 전도도(㎲/cm,25℃) < 0.5 -

PART
DESIGN REQUIREMENT RAMARK
BOILER WATER
pH(25℃) 8.5 ~9.8

전증발잔유물(mg/l) -
전기 전도도(㎲/cm,25℃) Max.60
염화물 이온 (mg cl-/l) <2
인산이온 (mg PO4^3-/l) 0.1~3
실리카 (mg SiO2/l) Max.0.3

5) Dilution rate by chemical

- 2% Phosphopate (Sodium Phosphopate)
- 5% Hydrazine
- 5% Ammonia

3.0 Operation and Maintenance

- General –

A. Handling Chemcial
 POSCO
OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
Revision : 0
Chemical Injection System Date : Aug.07.12
Page: 4of 16

This section is to provide basic and proper method to handle, storage to toxic chemical. Pre-acknowlege

of cautious informations of handling dangerous chemical is must. Followings are actual chemical must

handle with cautions; Hydrazine, Ammonia, and Phosphate.

A.1. Safety Education.

Only skilled and knowledged personnel who know about the characteristics, physical character of each
chemical must handle mentioned chemical after wearing proper protection gears in order to avoid direct
or indirect contact from chemical.
Therefore, before handling chemical either directly or indirectly, solid education must take place to field
personnel for actual handling chemical

A.2. Character and Caution when handling Hydrazine, Ammonia and Phosphate

- HYDRAZINE -

- Character : dyed color, flamable, alkali, liquid used for oxygen scavenger and name
and chemical symbol is Hydrazine(N2H4 ,H2O). Hydrazine can be dissolved by mixing with water
- Cautions : It can create severe damage to skin when director contact occurs. Inhaling of
dydrazine steam is very dangerous to human internal organs. Be cautious flame or any
kind of oxidizer to avoid explosion. Safety gear must be worn before handling.

- AMMONIA -

- Character : dyed coler and strong alkali liquid used to adjust level of Ph.
- Cautions : any chemical contains ammonia and ammonia itself categorized as toxic chemical
(less than 10% is exception). Ammonia can be combusted by heating or direct contact to fire.
Inhaling of ammonia gas can cause severe damage to human internal organs. Especially direct
contact to eye and skin may cause blindness. In case direct contact happen, wash out more than
15 minutes with water. Saftey gear must be worn before handling.
-
- SODIUM PHOSPHATE-

- Character : dyed coler or white powder and melting point is at 75 ℃. This chemical is used as
eliminating boiler scale.
 POSCO
OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
Revision : 0
Chemical Injection System Date : Aug.07.12
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- Cautions : Heating will make this chemical melt endlessly mixture with water will have strong alkali
character. It is also insolubility and hygroscopic to ethyl alcohol. It absorbs carbon dioxide. This
chemical need to be stored with sealed back in dry-cool area. pH level of 1% mixture with water is
11.5~12.1. Saftey gear must be worn before handling.
-
A.3. Storage

When storage, be carefull of placing closely of two different chemicals that may cause chemical
combustion. Also the chemicals better stored at inside where air circulation is good. Every chemical
must be isolated from oil, gasoline, paint, waste and any other hazardous materials that may cause
explosion. No smoking or any sparkling never allowed aroud chemical stored area.
When maintenance, first, clean tank and pipe line with water then clean rest of whole system with
carbon dioxide or an inert gas/air. Do not use torch if cutting requires on tank or pipe.

A.4 Emmergency Action

If direct contact of chemical to body occurs, instantly clean more than 15 minutes with flow water until
no chemical remains on skins and undresse clothes which is stained under shower. Also, when
chemical contact occurs to your eye, go same step above and be aware your eye must be wide open
when cleaning with water. Make sure to go see doctor right away as soon as instant procedure of water
cleaning.

A.5 Summary

- Use proper storge tank or vessel to store chemical.

- Never allows smoking or sparkling around chmical stored area and make sure to place warning sign
near by.
- Prepare proper safety procedure and educate field personnel by responsible supervisor
- Provide safey gear to field personnel who actually handles hazardous chemical..
- Cautions
a) Do not let eye and skins directly contact to the chemcial
b) When handling hazardous chemical, always wear protection eyeglasses, gloves, clothes.
c) Wash out with water instantly when chemical spread out and do not use flamable materials to wipe
out.
 POSCO
OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
Revision : 0
Chemical Injection System Date : Aug.07.12
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d) When skins are direct contacted to chemical, clean it out with succificient water and call to see a
doctor.

3.1 System Operation

3.1.1 Ready for Operation

A ) Check standard feed and other condition for readiness.

B ) Supply currency to local control panel

a) Put “Local / Remote Switch” to “LOCAL” on local control panel.

b) Check P.B Button is at "STOP" on local control panel..
c) Put “ON” position to each pump of M.C.C.B
d) Now currency is ready for operation. Take same procedure to “OFF” by taking step backward.

C ) Chemical Preparation.
a) Ammonia (NH4OH)
Prepare Ammonia in accordance to dissolution procedure.
- 5% NH4OH : 1000 Liter

b) Hydrazine (N2H4)
Prepare Hydrazine in accordance to dissolution procedure.
- 5% N2H4 : 1000 Liter

c) Phosphate (Na3PO4)
Prepare Phosphate in accordance to dissolution procedure.
- 2% Na3PO4 : 1000 Liter

d) Ready for Chemical Dosing Pump

- Open manual valve to each suction and each discharge
e) Check Manual Valve
- Check if required manual valves for operation are open and unrequried manual valves are closed.
f) Alarm Setting.
- Set alarm (Eocr) of each instrument. If alarm is already set, double check the setting.
g) Check each dilution tank if proper dilluted chemical is sufficiently filled that does not show level low.
 POSCO
OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
Revision : 0
Chemical Injection System Date : Aug.07.12
Page: 7of 16

3.1.2 Dilution of Chemical

A ) Dilution procedure of Chemical
a) Close all drain valves of System
b) Close valve between scale cylinder dilution tank.
c) “Open” chemcil inlet MOV in order to supply checmical from Drum Tank to Measruing Tank.
. (Control the power through local control panel)
d) Fill up the Mesuring Tank to proper level.
e) Close Drum tank inlet MOV once chemical is properly filled up in Mesuring Tank
f) Open water supply MOV of Solution Tank and fill-up 1/4 of water. Open measuring tank outlet
MOV to fill-up chemical.
g) When level of measuring tank hit “LOW” by chemical flow in from Mesuring Tank to Solution
Tank, close measuring tank outlet MOV.
h) In order to meet proper density of chemical, take the above steps to fill-up solution tank with
chemical and fill-up the water until level gauge of solution tank become proper level.
i) For the Sodium Phosphate, fill-up the solution tank with 1/4 volume of water first then add
proper amount of sodium phosphate after scaling by using dissolving basket.
j) For best mixture of chemical with water, operate agitator approximately 60 minutes.
( Level of solution tank must be at “HIGH” in order to activate agitator)

4.0 System Operation, Maintenance, and Trouble Shooting.

4.1 Operation and Maintenance

Initial operation and maintenance of “CHEMICAL INJECTION SYSTEM” is very important. Keep it
clean for measuring tank, solution tank, pipe line, MOV and Etc. Dissolve chemical in dissolving tank
and store properly diluted chemical liquid. Make stanby condition of system to set pipe line and valves
of MOV for injection condition using chemical dosing pump.
Do not set stroke of Chemical dosing pump at “0” but slowly increase desired stroke. Maintenance
during operation is to re-fill chemical to solution tank and also proper operation condition can be
checked by looking at actual pressure on pipe line and valves. Furthermore normal operation
condition can be checked by looking at length of stroke is liner of pump to inject chemical that make
constent efficient capacity.
 POSCO
OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
Revision : 0
Chemical Injection System Date : Aug.07.12
Page: 8of 16

Normal maintenance procedure is as followed.

( CHEMICAL DOSING PUMP normal maintenacne)

Catagory Terms Check List Remarks

Normal - Flow inside Gear Box - Permit range of Sight glass
- Over leakage case, stop operation and replace the
Normal - Leakage inside Gear Box
parts.
-Chemical Leakage on - Tighten the bolt. If volume is large, replace
Normal
CHEMICAL connecting point packing.
DOSING Normal - Abnormal vibration and noise - Shut down the system and check (contact A/S)
PUMP Normal - Abnormal heating - Shut donn the system and check (contact A/S)
Operation Normal - Discharge Pressure - Compare with daily pressure rate
Condition - Can’t check during operation but look at the level
Normal - Discharge Volume
gauge.
- Replace any defect or consumable parts which
Regular - Disassemble may have worn out. Check discharge volume and
performance.
- Inspect left volume
Check Chemical
Normal - Check operation condition of - Visual Check
Level
agitator
Leakage on - Sealing part of valve, pipe line
each part of Normal and instrument. - Tighten the bolt
equipment
System /
Normal - Adjust operation condition
Pressure gauge
Alarm Regular - Operation Test

4.2 Trouble Shooting

Among one of common trouble which related to chemical on chemical injection system is changes in
density of diluted chemical resulting change of water quality and this change can be found out early by
water quality detector. For solution, investigate operaton record and check the density of chemical,
injected volume and etc to proper diagnosis.
 POSCO
OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
Revision : 0
Chemical Injection System Date : Aug.07.12
Page: 9of 16

For mechanical troubles, replace defected or worn out consumable parts as well as cleaning the
strainer.

( CHEMICAL INJECTION PUMP Trouble Shooting Table )

Status Quo Reason Action

- worn out of connecting point or
- replace the parts and cleaing
Shortage on contaminated by impurities
discharge - check receiving point of suction line
- Abration of internal parts.
volume or - Clean pipe strainer clog
inconsistency. - Tighten bolt or replace.
- Leakage on packing part
Malfunction * be carefull of over tightening
of pump Abnormal
- Replace parts
vibration and - Abration of internal parts
- Adjust Seam
noise
- Improper flow - Adjust stroke control
- Over tightening of packing - loosen packing where heats occurs
Abnormal
- Check clogging on connected points.
Heating
- Over Load - Abnormal heat after dissemble is due to fault
adjustment. Re-adjust.
- Performe dissolution over again..
Improper chemical - Fault in dissolution
-Calibrate over all control system and go over
density -Fault on control system.
loop test

( AGITATOR )

1. Installation & Disassemble

 POSCO
OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
Revision : 0
Chemical Injection System Date : Aug.07.12
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① Set the impeller to mixing shaft and put it in the tank and take further step to ②

② Put the mixer (Agitator) to top of tank and make coupling between mixing shaft
and drive shaft by using spener.
.
③ Slowly lower the mixer (Agitator) to right sport and when it reaches the spot fix it
firmly

④ After fixing the mixer operate shaft manually and check if there is any abnormal
vibration and rotating condition. .

⑤ Take step backward in order to disassemble.

(Note : Check rotating direction of mixing shaft through reducer before installation)

Cautions

1. When setting the impeller, watch out the weight loaded by gravity to shaft. It may
result in banding shaft.
 POSCO
OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
Revision : 0
Chemical Injection System Date : Aug.07.12
Page: 11of 16

2. The most important part of mixer is mixing shaft. Handle with cares, do not let it get
impact with other materials or do not lift it up with wire to avoid putting weight on it.

2. Operation

Check and aware below step before operation..

1) Check if setting belt of each part is firmly tightened.

2) Check fixing condition of tank. If there is abnormal vibration of tank, it may cause
resonant to resulting banding shaft

3) Check connection voltage to motor is correct and look over to see if there is any
miss connection.

4) Check rotating direction.

Direction of impeller is marked with arrow symbol but its’ direction is to right from
motor to impeller.

If direction check is needed when thank is empty, turn on the motor swith no more
than 1~2 seconds.

※ Note : Naver operate when tank is empty after connecting mixing shaft.

Loswest surface level of liquid must be 100mm higher than location of impeller.

If operation starts without satisfying above mentioned condition, it may cause

bending of shaft, damage of bearing, motor and gear.

Always check and confirm condtion mentioned above before operation.

 POSCO
OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
Revision : 0
Chemical Injection System Date : Aug.07.12
Page: 12of 16

Any damage due to negligence in operation procedure other than proper steps
mentioned above will not be fall under manufacturer’s liability in terms of guarantee.

2-1 Cautions during Operation

1) Install the ammeter near Switch.

2) Make procedure to system stop when circuit break over over flow of currency.

3) When abnormal noise occurs, stop operation and go over proper diagnosis

Common troubles caused by;

A) Shaking of mixier body or slightly moving to left and right?
B) Flow of liquid is irregular?
C) Due to flow of liquid if mixing shaft is shaking? Or irregularly moving back and
forth?

4) If adding liquid or solid matter during operation, add little by little and slowly.

In order to avoid impact or over load to Impeller, be carefull when adding contents
especially big chunk of powder or solid matter. Make sure put protector or screen
to protect shaft and impeller.

Ignoring cautions mentioned in 4) may cause bend of shaft result in operation

malfunction.
The protector inside tank must be installed in order to protect level controller or
over flow.

3. Maintenance

1. BEARING
 POSCO
OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
Revision : 0
Chemical Injection System Date : Aug.07.12
Page: 13of 16

Bearing is ball type bearing and it need to be maintenance once every 1~1.5
periodically.

2. Lubricating GEAR

For lubricating gear, perform maintenance once to 750 hours use for first 2 times.
After fisrt 2 time maintenance, every 1,500 hours or every six months refill the
lubricating oil. Lubricating oil need be fully chaged every 3,000 hours.
(Recommended Lubricating Oil : SHELL.OMALLA #150-#220)

3. Mixing Shaft
Check if mixing shaft is not bended and used.
If shaft is bended, it must be replaced before further uses. Otherwise, shaft will keep
on bending and may cause server damage to other equipments. .

4. If constent noise or irregular noise occurs from bearing, there is great chance that
debris or foreign substance has get into it. Replace with new bearing.

5. Check if mixer body is not shaking?

Even thought there seems no shaking of mixer body on initial stage, other reasons
for example of impact of impeller or bendness in shaft can casue shaking of mixer
body.

※ Note : Check holizontal level between installed spot and installed fringe.

1. Installing Spot : Mixer’s Proper setting on correct spot is crucial to it’s best
performance
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OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
Revision : 0
Chemical Injection System Date : Aug.07.12
Page: 14of 16

Installing spot must be set with consideration of mixer type, purpose, outfit, type of
liquid. Therefore, take enough time to discuss internally and select best position to
install..

For your reference, normal impeller mixer’s installing sopt should be correct center
of tank if there is no baffle.

4. Problems and Toruble Shootings

1. In case of shaft is shaking is big.

Result in : It will cause mixer’s main body and effect to every rotating components.

Solution : Change of mixing shaft or if shaft is not bended, tighten the setting bolt
of mounting flange and coupling bolt.

2. Abnormal noise from bearing.

Result in : Abrasion to bearing and it can casue strong shake in shaft eventually
damage to shaft itself and impeller.

Reasons : a. Life time is over.

b. Debries or foreign substances, or acid is into bearing

c. Sudden impact is forced to it.

d. If weight balance is too much.

Solution : Change bearing.

3. See below steps for re-fill or replace the oil.

a) Unlock the air plug completely.

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OPERATION & MAINTENANCE MANUAL POWER
INDONESIA ISM Samwon-Sera
POWER PLANT
Revision : 0
Chemical Injection System Date : Aug.07.12
Page: 15of 16

b) Make sure there is no debries or any kind of foreign substances before filling the
oil

c) Open Oil Cap (Air Hole) and start filling oil while looking at the “Oil Level Gauge”

d) When oil reaches proper level, stop puring and lock air plug with cap.

5. Repair

If pump is damaged by any kind of incident or accident and it can not be easly
reapaired at site, contact to A/S..

See below for contacting A/S procedure.

1. See contents written on NamePlate (Model Number, Manufacturing Date)

2. Purchase root.

3. Name of Parts

4. Reference to mixer
 ITEM DESCRIPTION
CHEMICAL INJECTION SYSTEM

Q'ty Weight(ton) Power

No Equipment No Description Type Spec. Dimension(m) Maker
Op St (Emp / Opr) (kW/대)
1 01/02LFN01AM101 PHOSPHATE SOLUTION TANK 2 0 Geared , Propeller 200 RPM - - 0.4 TAEWOO
MIXER

2 01/02LFN02AM101 HYDRAZINE SOLUTION TANK 2 0 Geared , Propeller 200 RPM - - 0.4 TAEWOO
MIXER

3 01/02LFN03AM101 AMMONIA SOLUTION TANK 2 0 Geared , Propeller 200 RPM - - 0.4 TAEWOO
MIXER

4 01LFN01AP201/202 PHOSPHATE SOLUTION 2 2 Diaphragm 12 L/Hr , 170 Bar.g - - 0.75 Milton Roy
02LFN01AP201/202 HP METERING PUMP

6 01LFN02AP101/102/103 HYDRAZINE SOLUTION 3 3 Diaphragm 6 L/Hr , 26 Bar.g - - 0.43 Milton Roy

02LFN02AP101/102/103 METERING PUMP

7 01LFN03AP101/102/103 AMMONIA SOLUTION 2 2 Diaphragm 15 L/Hr , 26 Bar.g - - 0.43 Milton Roy

02LFN03AP101/102/103 METERING PUMP

8 01/02LFN02AA103/108 MOV 6 0 Motorizing 110V , ON/OFF - - - Nippon

01/02LFN03AA103/108
01/02LFN00AA204/208

9 01/02LFN01/02CL201 Level Switch 7 0 Electrode SUS304+PE COATING - - - Seojin

01/02LFN02CL202/203
01/02LFN03CL201/202
01/02LFN03CL203

10 01/02LFN02AP401 HYDRZINE & AMMONIA 2 2 Electric 75 L/Min - - - FTI

01/02LFN03AP201 DRUM PUMP

QAP-0406-01 (1995.8.31) (주) 포스코엔지니어링

 ITEM DESCRIPTION
CHEMICAL INJECTION SYSTEM

Q'ty Weight(ton) Power

No Equipment No Description Type Spec. Dimension(m) Maker
Op St (Emp / Opr) (kW/대)
11 NONE Local Control Panel 1 0 Self Standing (Indoor) NEMA 4 - - - Samwon-Sera

* NOTE : SAME AS UNIT 2

QAP-0406-01 (1995.8.31) (주) 포스코엔지니어링