PT PLN (PERSERO) CILEGON COMBINED CYCLE POWER PLANT (740MW) CONTRACT NO.:0136.PJ/060/DIR/2004 e OPERATION MANUAL (ST HRSG BOP PART) e MECHANICAL VOLUME-7 NJ-05036.R-1 CONTRACTOR : MITSUBISHI CORPORATION MITSUBISHI HEAVY INDUSTRIES, LTD. MITSUBISHI ELECTRIC CORPORATIONRECORD OF CHANGES. DOCUMENT NUMBER: NJ-05036 MHRSG/BOP -Part including the responses to Customer's comments. Revision Date Title and Brief Description Remarks | Entered No, by — | 2006/02/14 | Issued Design Manual, Operation Manual & Maintenance Manual for Steam Turbine/HRSG/BOP Part. 4 2006/08/11 | Fully revised Steam TurbineOo IMPORTANT INFORMATION These documents are intended for the use by operating and maintenance personnel and must be accessible to them at all times. Do not perform any operation or maintenance on this system until you read and understand all instructions in these documenis. ‘You must comply with all applicable laws, codes and local regulation. ‘Only qualified personnel must work on or around this system after becoming thoroughly familiar with all warnings, safety notices, operating procedures, and maintenance procedures contained herein. Employers must implement all training and safety requirements mandated by national standards and local governing agencies Mitsubishi Heavy Industries, Ltd. (herein after referred to as MHI) cannot anticipate every possible circumstance that might involve a potential hazard, The warnings in these documents and on the equipment are therefore not all inclusive. Improper operation or maintenance of this system can be dangerous and could result in injury or death. If a procedure, work method or operating technique not specified in this manual is used, you must satisfy yourself that itis safe for you and others. You should also ensure that the system will not be damaged or made unsafe by the method of operation or maintenance procedure you choose. Itis assumed that this system will be operated and serviced by English speaking personnel. If this is not the case, the customer should add safety, caution, and operating signs in the native language of the operating and maintenance personnel. ‘Should particular problems arise which are not covered sufficiently for the intended purposes in these documents, you Should refer to following: Mitsubishi Heavy Industries, Ltd. ‘Takasago Machinery Works 4-1,Arai-cho, Shinhama 2-chome, Takasago City, Hyogo, Japan 676-8686 ‘These documents are placed at your disposal for your own use only and may not be copied, nor reproduced in hard copy or any electric medium. The copyright remains with MHI. ‘MHI Propriotary Information ioo MITSUBISHI LIMITED WARRANTY ‘The warranty contained in the Contract between the parties is the sole warranty of MHI. Any statements contained herein do not create new warranties or modify the existing warranty. MH! DOES NOT WARRANT AND IS NOT RESPONSIBLE FOR: DAMAGE CAUSED BY FAILURE TO PROVIDE A SUITABLE OPERATING ENVIRONMENT FOR THE SYSTEM; © DAMAGE CAUSED BY FOREIGN OBJECTS, DROPPING, FALL, SPILLED LIQUIDS, OR IMMERSION IN LIQUIDS OR GASES; © DAMAGE CAUSED BY A POWER SURGE OR IMPROPER SUPPLIED UTILITY; © DAMAGE CAUSED BY ATTACHMENTS, ALTERATIONS, OR MODIFICATIONS WITHOUT MHI'S WRITTEN APPROVAL; © DAMAGE FROM IMPROPER OPERATION OR MAINTENANCE; © DAMAGE CAUSED BY ANY ABUSE, MISUSE, MISHANDLING, OR MISAPPLICATIONS; O PRODUCTS OR SERVICES OF COMPANY OTHER THAN MHI OR MHI AUTHORIZED ‘COMPANY. © DAMAGE CAUSED BY UNSPECIFIED UTILITY CONDITIONS SUCH AS TEMPERATURE, PRESSURE, FLOW RATE, CONCENTRATION AND QUALITY; © DAMAGE CAUSED BY ANY BUGS IN THE MEMORY CHIPS OR OPERATING SOFTWARE OTHER THAN MHI'S SOFTWARE; (Mtl Proprietary Information iiA Le SAFETY INSTRUCTION General Safety Rules © This system contains hazardous voltage, rotating parts, high pressure, high temperature, chemical and noise. © During operation and maintenance, extreme caution must be exercised for personnel to be in proximity of potentially dangerous mechanical and electricat devices. © Never operate any equipment unless all guards and safety devices are in place and in proper operating conditions. O Keep the area well maintained at all times. © Most accidents involving system operation and maintenance are caused by failure to observe basic safety rules or precautions. © Wear appropriate work clothes, gloves, shoes or boots, hard hats and eye protectors in accordance with customer's Personal Protective Equipment Program. © In case of an accident while running, shut down the system immediately if required. O MSDS (Material Safety Data Sheets) should be filed for easy access, and safety & handling instruction should be followed. © Operate the system in accordance with customer's Health and Safety programs. °° Make reports for any improper operation, misoperation of system, especially safety devices and repair records. Return tools to their proper places after use. Warn others of an intended action that may endanger them. Do not remove safety devices. Do not start the system unless you are sure there is no danger to you and others. oo 0 0 0 Do not leave unattended equipment in an unsafe condition. (ME Proprietary Infomation ide METSURIS HH © General Safety Rules (Cont.) of Signal Words In these documents and on the product, leai DANGER indicates immediate danger and that special precautions are necessary. CAUTION indicates warning against potential hazards or caution against unsafe practices. ‘MHI Proprietary Information ivINDONESIA PLN CILEGON C/C OPERATION MANUAL {R-1) ST HRSG BOP PART IMPORTANT INFORMATION LIMITED WARRANTY SAFETY INSTRUCTIONS SECTION 1 SECTION 2 SECTION 3 SECTION 4 GENERAL POWER PLANT MECHANICAL ELECTRICAL Short ContentsContents VOLUME SECTION DESCRIPTION PAGES 1 41 GENERAL 14 GENERAL INFORMATION ON OPERATION 14-4 2 2 POWER PLANT 24 OPERATING PROCEDURE 24-1 22 PRINCIPAL OPERATING LIMITS 22-1 23 REQUIRED ACTION AT EMERGENCY 23.1 GENERAL 23-4 2.3.2 STEAM TURBINE 2.3-3 2.3.3 BOTTOMING CYCLE 23-47 24 CONTROL SETTING {INCLUDING ALARM & TRIP SET POINTS) 241 STEAM TURBINE RELATED EQUIPMENT 24-1 24.2 BOTTOMING CYCLE 24-3 25 HRSG OPERATION 25.1 FUNCTIONAL DESCRIPTION OF CONTROL 25-1 25.2 OPERATION GUIDELINES 2.5.2.1 GUIDELINES FOR HRSG START-UP OPERATION 25-35, 25.2.2 PREDICTED START-UP AND SHUT-DOWN, 25-37 PERFORMANCE 2.5.2.3 GUIDELINES OF HRSG CONTROL 25-42 2.5.2.4 HRSG PREDICTED PERFORMANCE 25-43 26.2.5 GENERAL PRECAUTION 25-44 2.5.2.6 PRECAUTION DURING OPERATION 25-46 2.5.2.7 BLOW-OFF PROCEDURE 25-49 2.5.2.8 PRESERVATION PROCEDURE 2.5-50 25.3 CONTROL SETTING 25-51 (INCLUDING ALARM & TRIP SET POINTS)Contents VOLUME SECTION DESCRIPTION PAGES 3 3 MECHANICAL 34 OlL SYSTEM 3.1.1 CONTROL AND LUBE OIL SYSTEM. 3.1-41 32 CONDENSATE WATER SYSTEM 3.2.1 CONDENSATE PUMP: 3.2-1 32.2 CONDENSER VACUUM PUMP 3.2- 39 3.2.3 MAKE UP WATER PUMP 3.2-101 3.3 FEED WATER SYSTEM 3.3.1 HP/IP FEED WATER PUMP. 3.3-1 3.3.2 LP FEED WATER PUMP: 3.3-331 4 3.4 CIRCULATING WATER SYSTEM 344 CIRCULATING WATER PUMP: 34-1 34.2 CWP LUBE WATER PUMP 3.4-169 343 SEA WATER BOOSTER PUMP 3.4-221 344 CONDENSER TUBE CLEANING SYSTEM 3.4-289 345 CONDENSER DEBRIS FILTER 3.4-323 34.6 ‘CW PRIMING PUMP: 3.4-547 3.5 ST CLOSED COOLING WATER SYSTEM 3.5.1 ST CLOSED COOLING WATER PUMP. 3.561 5 36 MAIN CYCLE CHEMICAL INJECTION SYSTEM 3.61 37 SAMPLING SYSTEM & CONDENSER TUBE LEAK 37-1 DETECTOR 6 38 FUEL GAS TREATMENT PLANT 3.8-1 3.9 HSD FUEL-OIL UNLOADING STATION 39-1 3.10 DESALINATION PLANT 310-1 7 3.11 DEMINERALIZED WATER SYSTEM 3.11.1 DEMINERALIZED WATER SYSTEM 314-1 3.11.2 DEMINERALIZED WATER TRANSFER PUMP, 3.41-2 3.12 SERVICE WATER SYSTEM 3.12.4 SERVICE WATER PUMP 312-1 3.13 INSTRUMENT AND SERVICE AIR SYSTEM 3.13.4 INSTRUMENT AND SERVICE AIR COMPRESSOR: 3.13-1 3.13.2 INSTRUMENT AIR DRYER. 3.13-185 8 3.14 FIRE FIGHTING SYSTEM 3.14-4 9 3.15 NITROGEN STORAGE AND DISTRIBUTION SYSTEM = 3.15- 1 3.18 HYDROGEN PLANT 3.16-1 3.17 STANDBY DIESEL ENGINE GENERATOR 3.17-1 3.18 HVAC SYSTEM 18-1Contents VOLUME SECTION DESCRIPTION PAGES (Cont) 3.19 WASTE WATER TREATMENT SYSTEM 3.19-1 10,11 3.20 AUXILIARY BOILER 3.20-1 12 3.21 SCREEN SYSTEM 3.21.1 STOP LOG & STORAGE 3.21-1 3.21.2 BAR SCREEN & TRAVELING TRASH RAKE 3.21-27 3.21.3 TRAVELING BAND SCREEN & WASH WATER DEVICE = 3.21-105) 3.22 CHLORINATION SYSTEM 3.22-1 3.23 CATHODIC PROTECTION SYSTEM 3.23.1. CATHODIC PROTECTION SYSTEM FOR FIELD PIPING 3.23-1 3.23.2 CATHODIC PROTECTION SYSTEM FOR CIRCULATING 3.23-15 WATER SYSTEM 3.24 POTABLE WATER CHEMICAL INJECTION SYSTEM 324-4 13,14 3.25 HSD FUEL OIL TREATMENT SYSTEM 3.25- 1 14 3.26 ‘SUMP PUMP 3.26-41 15 4 ELECTRICAL 44 GENERATOR 44-1 4.44 GENERATOR AND GENERATOR AUXILIARY (STG) 44-3 42 PT & SA CUBICLE 42-4 43 CONTROL PANEL 43-1 431 SYSTEM DESCRIPTION 43-3 4.3.2 EXCITATION CONTROL PANEL (EXC, AVR) 43-39 43.3 GENERATOR CONTROL PANEL 43-137 434 GENERATOR PROTECTION RELAY PANEL 4.3-385 16 43.5 TRANSFORMER PROTECTION RELAY PANEL 4,3-937 43.6 SEAL OIL CONTROL PANEL 4.3-1397 4A TRANSFORMER 44-1 441 ST GENERATOR TRANSFORMER, 44-3 4.4.2 LV TRANSFORMER 44-9 45 ISOLATED PHASE BUSDUCT 45-1 46 NIA 17 47 6.3KV MV SWITCHGEAR, 47-1 47.41 MC SET-INSTRUCTIONS FOR USE, 47-3 472 LF DRAW-OUT CIRCUIT BREAKERS-INSTRUCTIONS = 4.7-51 FOR USEContents VOLUME SECTION DESCRIPTION PAGES 17(cont) 4.7.3 MC SET METAL CLAD SWITCHGEAR-CATALOGUE 47-91 2003 ATA SEPAM-PROTETION RELAY FOR MC SET METAL 47-147 CLAD SWITCH GEAR 475 HIGH SPEED BUS TRANSFER RELAY-BECKWITH 4.7-239 MODEL M-0272-0236B RELAY 48 380V LV SWITCHGEAR 48-1 48.1 BLOKSET-INSTRUCTION MANUAL. 48-3 48.2 LV POWER CIRCUIT BREAKERS-MASTERPACT NT 48-75, AND NW-CATALOGUE 2003 49 380V MCC 4.9-1 4.9.4 BLOCSET-INSTRUCTION MANUAL 49.3 4.9.2 LV POWER CIRCUIT BREAKERS-COMPACT NS 4.9-75 CATALOGUE 2002 4.10 AC DISTRIBUTION PANEL 410-1 18 4d DC SYSTEM 411-1 412 UPS SYSTEM 412-1 413 AUXILIARY MOTORS, 4.13-4 4.44 COMMUNICATION SYSTEM 414-1 4.15 CLOCK SYSTEM 4.15-1 19 4.16 LIGHTING SYSTEM 4.16-1 4.17 CLOSED CIRCUIT TV SYSTEM 417-1 4.18 ST DC STARTER PANEL 4.18-1 20,21,22 4.19 450 KV SUBSTATION 4.19-1de MITSUBISHI 3 MECHANICAL ‘MHI Proprietary Informationoe AETSUBIS HL 3.11 DEMINERALIZED WATER SYSTEM ‘MHI Proprietary informationfe MUTSUBIE 3.11.1 DEMINERALIZED WATER SYSTEM KKS NUMBER : 10GCB01SS101 ‘MHI Proprietary Informationje AUTSURISH- 3.11.1 Demineralized Water System Drawing No. Title ~ Demineralized Water System SALCON LIMITED. Operation Manual MHI Proprietary information 3.444fe MUTSBRISHE- Intentionally Blank |Mt Proprietary informetion 3.44-2PT PLN (PERSERO) CILEGON COMBINED CYCLE POWER PLANT (740MW) DEMINERALIZED WATER SYSTEM INSTRUCTION MANUAL PART 2 OPERATION MANUAL SALCON LIMITED > 3.143Intentionally Blank 311-4TABLE OF CONTENT PART 2 - OPERATION MANUAL CHAPTER 1 seo EQUIPMENT LIST CHAPTER 2 swene CONTROL PHILOSOPHY CHAPTER 3 tne OPERATION TIME CHART CHAPTER 4 soe SETPOINT LIST CHAPTERS (esse START UP PROCEDURE CHAPTER6 esau SHUT DOWN PROCEDURE CHAPTER7 . NORMAL OPERATION CHAPTER 8 SAFETY PRECAUTION CHAPTER 9 ENGINEERING INFORMATION CHAPTER 10 TROUBLESHOOTING CHAPTER 11 wee P&ID APPENDIX 1 “sun LOGSHEET p> 341-5Intentionally Blank 311-6oxanterens ___ CHAPTER 1.0 EQUIPMENT LIST 344-7311-8T Sms TARTS] i aap anes wou ¢ ‘pa ! usar wom pre Ruong : adi! 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WHISAS ALVA GEZTIVANIWC GATWORD LoarOud 4409 NODA (OXESATA) NTd Ld e e GULUIATINOSTVS 3.41-13Intentionally Blank 341-14canneimanes CHAPTER 2.0 CONTROL PHILOSOPHY 341-15Intentionally Blank 3.11-16SALCON LIMITED PI PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM. (O&M/161784/263 PART 2- OPERATION MANUAL. CONTROL PHILOSOPHY 1 Water Treatment Supply Pump (LOGAFILAP001; 10GAFI2AP001) Function: To supply feed water from Raw Water Tank to Demineralization Plant, Operation : LCP Automatic Operation 1. Set the selector switch to “Local” position, Whichever pump switched to “Local” first shall be duty pump. 2. Duty Water Treatment Supply Pump will start when i Raw Water Tank level above LL Mixed Bed Polisher in “Automatic” service step ili. Make Up Water Tank level below H 3. Standby Water Treatment Supply Pump will start when i, Mixed Bed Polisher in “Automatic” regeneration step (by sequence control). To refer to timing chart. 4, Duty Water Treatment Supply Pump will stop when i, Raw Water Tank level below LL ii, Mixed Bed Polisher not in “Automatic” service step . Make Up Water Tank level above HH. iv. End of Polisher’s service cycle. 5. In case “Remote” option is selected in DCS, and “Local” selection in selected on MCC, the local switch shall be governing, Manual 1. Set the selector switch to “Manual” position. Start and stop by push button on MCC, DCS Operation 1. Set the selector switch to “Automatic” position. 2, Control shall follow that under LCP Automatic Control, 3. In addition, start and stop command to the pumps by soft switches on DCS is possible, Chap 2-1 314-47SALCON LIMITED PTPLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM (0&M/161784/263 PART 2 - OPERATION MANUAL, Alarms 1. In case of high differential pressure alarm across suction strainer, switch pump to “Off”, Remove strainer and clean, 2. In case of low discharge pressure alarm, switch both pumps to “OM”, Check the whole line to ensure that valves are properly ‘opened, and that pumps are operating properly. Warning : Before the operator start the pump running in Manual mode, he should check that the mixed bed polisher is in service or regeneration. Level interlock is disabled in Manual mode. 2 Pre-Filter (LOGCB11AT001; 10GCB12ATO01) Function; ‘To remove suspended solids from distillate, Operation : 1. The pre-filter is a mechanical equipment. Operator only has to ensure that the isolation valves are opened before the system is in operation, 2. The filter cattridges are to be changed at regular interval, or when differential pressure across the filter is high. Alarm 1. High differential pressure alarm across pre-filter indicates that the filter cartridges are choked up, and-change is necessary. Chap 2-2 3.44-18SALCON LIMITED PI'PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM (O&M/161784/263 PART 2- OPERATION MANUAL 3 Mixed Bed Polisher (10GCF10BB001; 10GCF20BB001) Function. Operation i To remove ions present in the water to produce demineralized water. : Automatic Service 1, Set the selector switch to “Automatic” and “Service” position. Whichever Polisher switched to “Automatic” and “Service” first shalt be duty train. The second Polisher shail be standby train. y Polisher runs when i, Raw Water Tank level above LL ii, Make Up Water Tank level below H 3. Polisher stops when i, Raw Water Tank level below LL fi, Make Up Water ‘Tank level above HH. iii, Polisher flow below L. 4, Once switched to service, the Polisher shall first undergo 2 quality rinse step. Service inlet valve (AA100) and rinse outlet valve (AA108) open, . 5. When conductivity rinses below H, the service outlet valve (AA101) opens and rinse outlet valve (A108) clases. 6, Any time during service if the conductivity reaches H, the Polisher shall go into quality rinse. Go back to step 4 and 5, In case the conductivity is still H after rinse time, Polisher is considered “Exhausted”. 6. Polisher is considered to be exhausted upon the following conditions: i Total throughput H Conductivity H (after quality siuse) . Silica H 7. When duty Polisher is exhausted, it shall be put to stop. Buzzer and lamp indication shall be on to alert operator of exhausted condition. Operator shall then switch the exhausted polisher to regeneration. ‘The standby Polisher shall only go into service when the conditions in Point 2 are met. Chap 2-3 314-18SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT. DEMINERALIZED WATER SYSTEM ‘O&M/161784/263 PART 2— OPERATION MANUAL Manual Service 1 Set the selector switch to “Manual” and “Service” position. Service inlet (AA100) and outlet valves (A101) open. 2. Operator to manually select Water Treatment Supply Pump to run 3. in manual mode, No interlock to stop service when Polisher is exhausted. Automatic Regeneration 1 Set the selector switch to “Automatic” and “Regeneration” position. Press “Start/Advance” push button to start. Once initiated, the sequence proceeds automatically by PLC control. . Regeneration proceeds when the following conditions are satisfied: i. HC! Day Tank level H ii, NaOH Day Tank level H iii, Regeneration Neutralization Pit Sump Pump level L iv. Another Polisher is not in regeneration Backwash step Standby Water ‘Treatment Supply Pump runs and the backwash inlet (A102) and outlet (A103) valves open, Settle step Standby Water Treatment Supply Pump is stopped and the ‘backwash valves (AA102 and AA103) closed. Chap 2-4. 3.11-20SALCON LIMITED PTPLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM. O&M/161784/263 PART2~ OPERATION MANUAL $. Chemical injection step “The following valves are closed: = Acid bleed valve (10GCRA0AA203) = Caustic bleed valve (10GCN404A203) Note that these 2 valves are always open and close only during chemical injection step. The following valves are opened: Caustic in (AA104) + Acid in (A105) + Regeneration out (A106) = Acid injection and block valves (1OGCE40AA201 and AA202) ~ Caustic injection and block valves (LOGCN40AA201. and A202) \ = - Acid dilution water valve (LOGCB40AA204) = Caustic dilution water valve (10GCB30AA204) - Steam in valve (LOGCX10AA100) ‘The following pumps are started: = Standby Water Treatment Supply Pump = Duty HCI Metering Pump = Duty NaOH Metering Pump 6. Slow rinse step HCl and NaOH Metering Pumps are stopped. Caustic (LOGCN40AA203) and acid (LOGCE40AA203) bleed valves are opened. Caustic injection and block valves (L0GCN40AA201 and AA202) are closed. ‘Acid injection and block valves (L0GCE40AA201 and 202) are e@ closed, 7. Drain step Standby Water Treatment Supply Pump is stopped. Caustic in, acid in and regeneration (A104, A105 and AA106) valves are closed. Caustic (10GCB30AA204) and acid (LOGCB40AA204) dilution water valves are closed” Steam in (10GCK10AA100) valve is closed. Backwash outlet (AA103) and air vent (AA109) valves are opened. Rinse outlet (AA108) valve is opened. The water is drained to about 100mm above the resin level. Chap 2-5 3.4121SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM (O&M/161784/263 PART2- OPERATION MANUAL 8. Air mix step Close the rinse out valve (A108) and open air in valve (A107). Rinse out valve is opened at the last mimute of air mix. 9. Slow refill Close air in (A107) and rinse out (44108) valves. Open caustic ditution valve (10GCN40AA204). Start standby Water Treatment Supply Pump to fill up the vessel with some water, By using a slow refill flow, the resin is prevented from splashing around in the vessel. 10. Fast refill Close caustic dilution valve (10GCN40AA204), Opon service inlet valve (4A100). 11, Fast Ringe Open rinse outlet valve (AA108) and close backwash outlet valve (A103). Delay close air vent valve (A109) fo ensure that air in vessel can be displaced out. Final rinse proceeds until conductivity drops below H. In case conductivity remains high after fast rinse time, the Polisher is taken to be “Exhausted”. Operator is then to check whether this is due to ‘malfunction of regeneration. 12. Upon completion of Regeneration, buzzer and indication lamp shall be on to alert the operator. Operator is then to switch the Polisher back to “Automatic” and “Service”. In case the other Polisher is in regeneration, this Polisher shall be switched to standby automatically, ready to take over service. Manual Regeneration 1. Set the selector switch to “Manual” and “Regeneration” position. Press “Start/Advance” push button to start. 2. The regeneration follows the steps listed under “Automatic” regeneration. The only difference is that the sequence will not automatically proceed to the next step, 3. Only by pressing the Start/Advance push button at cach step, the sequence will proceed. In this mode, operator has to monitor the duration of each step himself,SALCON LIMITED PLPLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM. (O8M/161784/263 PART 2~ OPERATION MANUAL Alarm 1. 2. 3. 4, Conductivity high alarm to identify Polisher is exhausted. Total throughput reached to identify Polisher is exhausted, Silica high to identify Polisher is exhausted. High differential pressure actoss resin trap indicates the strainer is choked up. Isolate and clean. ‘Treated water high and low pH] alarm for monitoring purpose. Diluted NaOH concentration H and L alarm. In this case, chemical or water flow may not be sufficient, Diluted HCI concentration H and L alam. In this case, chemical or water flow may not be sufficient, Low concentrated NaOH flow alarm. Operator may have to check if dosing pump is working properly, and if valves on that line are full open. Low concentrated HCI flow alarm. Operator may have to check if dosing pump is working properly, and if valves on that line are full open, 10. Low NaOH dilution water flow alarm. Operator to check if Water ‘Treatment Supply Pump is working properly, and if valves on that line are full open, 11. Low HC dilution water flow alarm. Operator to check if Water ‘Treatment Supply Pump is working properly, and if valves on that Tine are full open. 12, Polisher low flow to stop Polisher operation, Chap 2-7 3.11-23SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM O&M/161784/263 PART 2- OPERATION MANUAL 4 NaOH Storage Tank (L(0GCN20BB001) Function: To store concentrated NaOH used for the regeneration of Polishers, ‘The capacity is sufficient for 2 months usage based on 2 trains operation, Operation : 1. The storage tank is equipped with level transmitier. On low level, an alarm will be initiated and operator has to order and fill up chemical by using NaOH Transfer Pump. Chap 2-8 311-24SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT ‘DEMINERALIZED WATER SYSTEM. O&M/161784/263 PART 2- OPERATION MANUAL 5 NaOH Transfer Pump (10GCN20AP001) Function: i, Filling up of NaOH Storage Tank. ii, To transfer NaOH from Storage Tank to NaOH Day Tank, Operation : 1, Filling of NaOH Storage Tank i. Select the pump operation to “Local”. i, Cotmnect the pump suction to truck, and check that all valves on the filling line are opened. sii, Start the pump from local panel and allow to fill until level is, high (by observing level gauge). iv. Stop the pump and close chemical filling valve, y. Close pump suction valve and open drain valve to drain off remaining chemical in the pipeline before disconnecting the piping from truck, 2. ‘Transfer of NaOH to NaOH Day Tank i, Set the selector switch at “Automatic” position, ii, After regeneration, NaOH Day Tank filling valve 1OGCN20AA200 shall open and NaOH ‘Transfer Pump shall start. “iii, Upon NaOH Day Tank level high, the pump shall stop and valve shall close. Manual 1. Set the selector switch to “Manual” position. Start and stop by push ‘button on MCC. Field Operation 1. Set the selector switch to “Local” position, Start and stop by push button at field. Warning : Under Manual mode, operator has to manually check and ensure that all valves for the service intended is opened before the pump is put to start. Chap 2-9 311-25SALCON LIMITED PI-PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM. O&M/161784/263, PART 2~ OPERATION MANUAL 6 NaOH Day Tank (10GCN30BB001) Function Operation : To hold NaOH used for the regeneration of Polishers. 2 1. The day tank is equipped with level transmitter. On low level, the ‘NaOH Metering Pumps will be interlocked to stop. When level is below H after completion of regeneration, NaOH shall , be automatically refilled to high level. 2. The day tank can also be refilled manually by holding the regeneration start push button for 5 seconds to initiate the tank filling. Alarms 1. Incase of HH alarm, operator is to immediately put NaOH Transfer Pump to stop. Possible cause is due to pump running in manual mode, or filling valve leaking. Operator is to check and rectify. 2. In case of LL alam, operator is 10 immediately put the NaOH Metering Pumps to stop. Possible cause is due to pump running in manual mode, or faulty level transmitter. Chap 2-10 311-26SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM. (O&M/161784/263 PART 2—- OPERATION MANUAL 7 NaOH Metering Pumps (10GCN36AP001; 10GCN37AP001) Function Operation : To inject NaOH from NaOH Day Tank to the Polisher during chemical injection step of the regeneration. : Automatic: 1, Set the selector switch at “Automatic” position, The pump that is selected to “Automatic” first shall be the duty pump. 2. Pump starts automatically during chemical injection step of Polisher, or dosing step of Neutralization if pH is below L. 3. Pump stops when chemical injection timer counts up, when chemical injection step is Advanced, when pH of regeneration neutralization waste water is above L or by NaOH Day Tank low level signal, Manual 1. Set the selector switch to “Manual” position, Start and stop by push ‘button on MCC. ati 1. Set the selector switch to “Local” position. Start and stop by push button at field. Warning : Under Manual mode, operator has to manually check and ensure that all valves for the service intended is opened before the _pump is put to start. Level interlock is disabled in Manual mode, Chap 2-11 3.11-27SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM (O&M/161784/263 PAR 2- OPERATION MANUAL, 8 Heat Exchanger (10GCNS0AC001) Function : To heat up dilute NaOH to improve regeneration efficiency of anion resins. Operation : 1, Heat exchanger by itself is just a flow through equipment. Alt isolation valves for the Heat Exchanger must be ensured to be open for operation. 2. Temperature of dilute caustic is adjusted by controlling the amount of steam through the Heat Exchanger. This is achieved by the steam control valve (10GCX10AA101), During chemical injection and slow rinse step of regeneration, the steam in valve (10GCX10AA100) opens to supply steam to the Heat Exchanger. Otherwise, the steam in valve shall be closed. Chap 2-12 311-28SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM 08M/61784/203 PART 2~ OPERATION MANUAL. 9 ‘HCI Storage Tank (10GCE20BB001) Function: ‘To store concentrated HC! used for the regeneration of Polishers. The capacity is sufficient for 2 months usage based on 2 trains operation, Operation : 1, The storage tank is equipped with level transmitter. On low level, an alarm will be initiated and operator ns to order and fill up chemical by using HCl Transfer Pump. Chap 2-13 311-20SALCON LIMITED PT PLN (PERSERO) CHLEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM O8M/161784/263 PART 2~ OPERATION MANUAL 10 HCI Transfer Pump (10GCE20AP001) Fonction: i, Filling up of HCI Storage Tank. ii, ‘To transfer HCI from Storage Tank to HCI Day Tank. Operation : 1, Filling of HCI Storage Tank Select the pump operation to “Local”, i, Connect the pump suction to truck, and check that all valves on the filling line are opened. iii, Start the pump from local panel and allow to fill until level is high (by observing levet gauge). iv. Stop the pump and close chemical filling valve, v. Close pump suction valve and open drain valve to drain off remaining chemical in the pipeline before disconnecting the piping from truck, 2, ‘Transfer of HCl to HCI Day Fank i. Set the selector switch at “Automatic” position, ii, After regeneration, HCl Day Tank filling valve 10GCE20AA200 shall open and HICI Transfer Pump shall start. iii, Upon HCI Day ‘Tank level high, the pump shall stop and valve shall close. Manual 1. Set the selector switch to “Manual” position. Start and stop by push button on MCC, Field Operat 1, Set the selector switch to “Local” position. Start and stop by push button at field. Warning : Under Manual mode, operator has to manually check and ensure ihat all valves for the service intended is opened before the pump is put to start. Chap 2-14 3.11-30SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT. DEMINERALIZED WATER SYSTEM ‘O&M/161784/263 PART 2~ OPERATION MANUAL i HCI Day Tank Q0GCE30BB001) Fanction ; To hold HCl used for the regeneration of Polishers. Operation: 1, ‘The day tank is equipped with level transmitter, On low level, the HCI Metering Pumps will be interlocked to stop. When level is below H after completion of regeneration, HCI shall be automatically refilled to high level. 2 The day tank can also be refilled manually by holding the regeneration start push button for 5 seconds to initiate the tank filling. Alarms 1. In case of HH alarm, operator is to immediately put HCI Transfer Pump to stop. Possible cause is due to pump running in manual mode, or filling valve leaking, Operator is to check and rectify. 2. In case of LL alarm, operator is to immediately put the HCI Metering Pumps to stop. Possible cause is due to pump running in ‘manual mode, or faulty level transmitter, (Chap 2-15 314-34SALCON LIMITED PTPLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM. O&M/161784/263 PART 2- OPERATION MANUAL 12 HCI Metering Pump (LOGCE36AP001; 10GCE37AP001) Function Operation : To inject HCI from HCI Day Tank to the Polisher during chemical injection step of the regeneration. : Automatic 1. Set the selector switch at “Automatic” position, The pump that is selected to “Automatic” first shail be the duty pump. 2, Pump starts automatically during chemical injection step of Polisher, or dosing step of Neutralization if the pH is above H. 3. Pump stops when chemical injection timer counts up, when chemical injection step is Advanced, when pH of the regeneration neutralization waste water is below H or by HCI Day Tank low Jevel signal. Manual 1, Set the selector switch to “Manual” position. Start and stop by push button on MCC, ield Operation 1. Set the selector switch to “Local” position. Start and stop by push button at field. Warning : Under Manual mode, operator has to manually check and ensure that all valves for the service intended is opened before the pump is put to start, Level interlock is disabled in Manual mode. Chap 2-16 3.11-32SALCON LIMITED PTPLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM. ‘O&M/161784/263, PART 2~ OPERATION MANUAL. 13 Regeneration Neutralization Pit (OGCR70BB001) ‘Regeneration Neutralization Pit Sump Pump (10GCR70AP001) Function; To neutralize regeneration waste water before discharge to WWTP. Operation : Automatic Start Neutralization 1. Set the selector switch to “Automatic” position. Select also Regeneration Neutralization Pit Sump Pump to “Automatic” position. 2. Neutralization starts on the following condition: ‘Completion of Polisher regeneration fi, Regeneration Neutralization Pit level H 3, Mixing Ait mixing valve (10GCP20AA100) and recycle valve (10GCR7LAA100) opens. Regeneration Neutralization Pit Sump Pump starts. Proceed to next step upon timer counts up. 4, pH Confirmation i. If pH is within range, proceed to Step 6 (Discharge) after timer ‘counts up. si, If pH is out of range, proceed to Step 5 (Dosing Step). 5. Dosing i, If pH is below L, NaOH metering pump nm and caustic dosing valve 10GCN60AA100 opens. fi, IEpHis above H, HC] metering pump run and acid dosing valve 10GCE60AA100 opens, iii, After dosing time counts up, go back to mixing step. 6. Discharge Discharge valve (1OGCR72AA101) opens and recycle valve (L0GCR71AA100) closes. Proceeds until Regeneration Neutralization Pil level is low. Regeneration Neutralization Pit Sump Pump stops, and air mixing valve (LOGCP20AA100) and discharge valve (10GCR72AA101) close, Chap 2-17 3.11-33SALCON LIMITED PT PLN (PERSERO) CHLEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM. ‘ORM/161784/263 PART 2~ OPERATION MANUAL Manual Start Neutralization 1. Set the selector switch to “Manual” position, Select Regeneration Neutralization Pit Sump Pump to “Automatic” position, 2. Press “Start” push button to start neutralization process. Steps 3 to 6 of “Automatic Start Neutralization” follows. Ma eration Neutralization Pit Sump Pur 1, Set the selector switch to “Manual” position. Start and stop by push button on MCC. Field Operation of Regeneration Neutralization Pit Sump Pump 1. Set the selector switch to “Local” position. Start and stop by push button at field. Warning : Under Manual mode, operator has to manually check and ensure that all valves for the service intended is opened before the ‘pump is put to start, Level interlock is disabled in Manual mode. Chap 2-18 3.14634omnis CHAPTER 3.0 OPERATION TIME CHART 311-35Intentionally Blank 3.11-36“HR WOPEEO ‘davon omnes a9 NOOETD OSESEED TL] ansrroganccxam| eauvarnoows penISis MELvA eEZTTVONTE brn ava Nottvana0 - Checklist for Mechanical Equipment e 2 ee Checklist for Electrical and Control Items 3 <= Switches on Control Panel 4 ~~ Equipment and Instrument Check e 3.11-47Intentionally Blank 3.11-48SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM O&M/161784/263 PART 2~ OPERATION MANUAL 1 Checklist for Mechanical Equipment 1) Water Treatment Supply Pump. 2) Check the pump is primed 10GAFI1 APOO1 OGAF12 APOOt 2) The suction isolating valve is open 10GAC11 AOL 10GACI2. AADOL 3) The discharge isolating valve is open 10GAC11 AA003 10GACI2 A003 4) Check minimum flow return valve 10GAC13 A001 is open 10GAC13 AA003 2) Pre:Filter 1) Check that the cartridges are 10GCB11 ATOO1 installed 10GCB12 ATOOL 2) Check that the filter is filled with 10GCB11 ATOOL water 10GCB12 ATO01 3) The inlet isolating valve is open 10GCB11 AA001 10GCB12 AA001 4) The outiet isolating valve is open 10GCB11 AAGO2 10GCB12.AA002 3) Mixed Bed Polisher 1) Check that the polisher is filled 10GCF10 BR001 with water 10GCF20 BBOO1 2) The inlet isolating valve is open 10GCF11 AA0O1 10GCF21 AA001 CHAP S-1 3.11-49SALCON LIMITED PT-PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM. 0&M/161784/263 PART 2~ OPERATION MANUAL. 3) The outlet isolating valve is open 10GCK10.AA00L 10GCK20 A001 4) The resin trap outlet isolating 10GCK10 AA002 valve is open 1OGCK20 AA002, 5) The level control valve up stream/ — 10GCK30 AA002 downstream isolating valve is open 10GCK30 AA003 6) The manual drain valve is closed 1O0GCF13 AAO01 10GCF23 AA00L 7) The manual air vent valve is closed 10GCR10 AAOOL. 10GCR20 A001 8) The service air supply valve is open 10GCP10 AA001 4) NaOH Transfer Pump 1) Check that pump has been primed 10GCN20 APOOL 2) The suction isolating valve from 10GCN20 AAOO1 ‘NaOH Storage Tank is open 3) The suction isolating valve from 10GCN21 AA001 truck is closed 4) The pump suction valve is open 10GCN20 AA002 5) The discharge isolating valve to 10GCN20 AA004 NaOH Day Tank is open 6) The discharge isolating valve to 10GCN20 AA00S NaOH Storage Tank is closed 7) Air supply isolation valves are open 10GCP50AA001 10GCPS0AA003 CHAP 5-2 3.11-50SALCON LIMITED PT'PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM ‘O8M/161784/263 PART 2- OPERATION MANUAL 5) NaOH Storage Tank 1) Check the tank is filled with the 10GCN20 BBO01 Correct chemical (45% wt NaOH) 2) Check that the drain valve is shut WOGCR31 AAOOL tight ©) NaOH Metering Pump 1) Check that the pump is primed 10GCN36 APOOL 10GCN37 APOOL 2) The suction isolating valve is open 10GCN36 AAODL 10GCN37 AAOO1 3) The discharge isolating valve is open 10GCN36 A002 10GCN37 AA002 4) The dampener is charged with air 10GCN40 A300 up to 6 bar range 5) The dosing flowrate is already set 10GCN36 APOOL 10GCN37 APOOL 1) NaOH Day Tank 1) Check the tank is filled with NaOH 10 GCN30 BBOOL 2) Check that the drain valve is shut 20GCR41 AAO01 tight 3} The tank outlet valve is open 1OGCN35 AA001 CHAP 5-3 3.4151SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM. ORMILGL784263 PART 2~ OPERATION MANUAL 8) NaOH Dilution Station 1) _ Dilution water isolation valve is open 10GCB30 AAQO1 2) Regenerant sampling valve is closed 10GCN10 AA002 3) NaOH line isolating valve is open 10GCN40 AA002 4) NaOH line isolating valve to Regeneration Neutralization Pit 10GCN60 AA001 is open 9) Heat Exchanger 1) Steam isolating valve is open OGCX10 AA001 2) Cold dilute NaOH inlet valve isopen . 10GCNS0 AAQ01 3) Hot dilute NaOH outlet valve is open 10GCN10 AA001 10) HCI Transfer Pump 1) Check that pump has been primed 10GCE20 APOO1 2) The suction isolating valve from 10GCE20 AAOOL HCI Storage Tank is opened 3) The suction isolating valve from 10GCE21 AAGOL truck is closed 4) The pump suction valve is opened 10GCE20 A002 5) The discharge isolating valve to HCl 10GCE20 AAQO4 Day Tank is opened 6) The discharge isolating valve toHCl © 10GCE20 AA00S: Storage Tank is closed 7) Air supply isolation valves are open 10GCPS0AA002 CHAP 5-4 3.11-52SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT. DEMINERALIZED WATER SYSTEM O&M/161784/263 PART 2~ OPERATION MANUAL 11) HC1Storage Tank 1) — Check the tank is filled with the 10GCE20 BBOO1 correct chemical (35% wt HC!) 2) Check that the drain valve is shut 10GCRS1 AAOOL Tight 3) Check that overtlow pipe is sealed 10GCR82 A001 with water 12) HCl Metering Pump 1) Check that the pump is primed 10GCE36 APOO1 10GCE37 APO? 2} The suction isolating valve is open 10GCE36 AA001 . 10GCE37 AA00L 3) The discharge isolation valve is open 10GCE36 A002 10GCE37 AA002 4) The dampener is charged with air 10GCE40 AA300 up to 6 bar 5) The dosing flowrate is already set 10GCE36 APOOL 10GCE37 APOOL 13) HCLDay Tank 1) Check the tank is filled with HCL 10GCE30 BBOOL 2} Check that the drain valve is shut 10GCR61 AAQOL tight 3) The tank outlet isolating valve is open 10GCE35 AA001 4) Check that overflow pipe is sealed: 10GCR82 AAO02 with water CHAP 5-5 311-53SALCON LIMITED PTPLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED ‘WATER SYSTEM (O&M/161784/263 PART 2 - OPERATION MANUAL 14) HCl Dilution Station 1) Dilution water isolation valve is open 10GCB40 AAOOL 2) Regenerant sampling valve is closed 10GCE10 A001 3) HCl Line isolating valve is open 10GCE40 AAGO2 4) HCI line isolating valve to 10GCE60 A001 Regeneration Neutralization Pit is open 15) HCI Gas Seal Tank 1) Fill the seal tank with water by 10GCR55 BBOOL opening water in valve (10GCBS1AA001). Close when water starts to overtlow out. 2) Check the water inlet valve is closed 10GCBS1 AAOOL 3) Check the seal tank drain valve is 10GCRS8 AAO0L closed 16) Neutralization System 1) The Regeneration Neutralization 10GCR70 BB001 Pit is empty 2) Check that pump discharge 10GCR70 AA002 isolating valve is open 17) Utilities 1) Check that the air supply is available 2) Check that the steam supply is available 3) Check that the electrical power supply is available CHAP 5-6 3.1184SALCON LIMITED PT PLN (PERSERO) CHLEGON CCPP POWER PLANT DI )EMINERALIZED WATER SYSTEM O&M/161784/263 PART 2 - OPERATION MANUAL 2 Checklist for Electrical and Control Items 1) — Water Treatment Supply Pump 1) Check that pump discharge pressure 10GAC11 AA304 gauge isolating valve is open 1OGACI2 A304 2) Check that pump suction pressure 10GACL1 AA303 gauge isolating valve is open J0GAC12.AA303 3) Check that pump suction strainer 10GAC11 A301 differential pressure switch isolating 10GACI11 A302 valves are open 1OGACI2 AA301 10GACI2 A302 4) Check that pump discharge pressure 10GAC14 AA301 switch isolating valve is open 5) Check that the lub oil level is full 1OGAFL1 APOOL 10GAF12 APOOL 2) Pre-Filter 1) Check that the differential pressure 10GCB11 AA301 switch inlet isolating valve is open 10GCB12 A301 2) Check that the differential pressure 10GCBI1 AA302 switch outlet isolating valve is open 10GCB12 AA302 3) Check that the differential pressure 109GCB11 CP010 switch is set to 1.0 bar difference 10GCB12.CP010 3) Mixed Bed Polisher 1) Check that inlet pressure gauge 10GCF12 A301 isolating valve is open 10GCF22 AA30L 2) Check that the outlet pressure. 10GCFI3 AA301 ‘gauge isolating valve is open 10GCF23 AA301 CHAP 5-7 3.11-55SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM O&M/161784/263 PART 2 OPERATION MANUAL 3) The conductivity meter set point 10GCF13 CQ010 iat 1.0 microSiemens/em 10GCF23 CQ010 4) Check that resin trap differential 10GCK10 AA301 pressure inlet isolating valve is open 10GCK20 AA301 5) Check that resin trap differential 10GCK10 A302, pressure outlet isolating valve is open 10GCK20 AA302 6) The silica analyzer chemical is 10GCK30 CQO10 available 7) The silica anslyzer set point is at 10GCK30 CO010 0.05 ppm 8) Check that silica analyzer isolating: 10GCK30 AA3OL valve is open 9) Check that pH meter isolating valve 10GCK30 A302 Is open 10) Check that service air pressure gauge 10GCP10 A301 isolating valve is open 4) NaH Transfer Pump 1) Check that pump discharge pressure 10GCN20 A301 gauge isolating valve is open 5) NaOH Storage Tank J) Check that the level gauge isolating 10GCN20 AA301 valve is open 10GCN20 A302 CHAPS -8 3.11-56SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED ‘WATER SYSTEM oaMi61784263 PART 2 - OPERATION MANUAL 6) Metering Pum 3) Check the level of the Iub oil in the ~ 10GCN36 APOOL pump casing 10GCN37 APOOL 2) Check that the dampener pressure 10GCN40.AA300 gauge is showing 6 bar 3) Check that pump discharge pressure 10GCN36 AA301 gauge isolating valve is open 10GCN37 AA301 7) NaQH Day Tank 1) Check that the level gauge isolating 10GCN30 AA301 valve is open 40GCN30 A302 8) NaOH Dilution Station 1) Check thet the flow switch is secured — 10GCB30 CF011 to the flow indicator 9) HC1Transfer Pump 1) Check that pump discharge pressure 10GCE20 AA301 ‘gauge isolating valve is open 10) HC! Storage Tank J) Check that the level gauge isolating 10GCE20 AA301 valve is open 410GCE20 AA302 CHAPS-9 3.11-57SALCON LIMITED PY PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM O&M/161784/263 PART 2- OPERATION MANUAL. 11) HCI Metering Pump 1) Check the level of the Iub oil inthe 10GCE36.APOOL pump casing 10GCE37 APOO1 2) Check that the dampener pressure 20GCE40 AA300 gauge is showing 6 bar 3) Check that pump discharge pressure 1GGCE36 A301 ‘gauge isolating valve is open 10GCE37 A301 12) HCl Day Tank 1) Check that the level gauge isolating 10GCE30 AA301. valve is open 10GCE30 A302 13) HCt Dilution Station 1) Check that the flow switch is secured 10GCB40 CFO11 to the flow indicator 14) Neutralization System 1) Check that the lub oil is filled in 10GCR70 APOOL the Regeneration Neutralization Pit Sump Pump 2) Check that pump discharge pressure 10GCR70 A301 gauge isolating valve is open 3) Check that pH meter isolating valve 10GCR70 A302 is open CHAPS -10 3.11-58SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM O&MI161784/263 PART 2~ OPERATION MANUAL 15) Control Panel, 1) Check that all the indicating lights are functioning 2) Check that all the alarm lights are functioning 3) Check that all the three phase voltage Red are similar (380v) Yellow Blue 4) Check the recorders have chart paper is in it, And then pens are in working condition 5) _Alll the indicators are switched on. ‘And in working condition. Conductivity Meter 1 10GCF13 CO010 Conductivity Meter 2 1OGCF23 CQ010 Flow ‘Totaliser 1 10GCF11 CROLL Flow Totaliser 2 10GCF21.CFO11 Raw Water Tank 1 Level Indicator: 10GADOICL301 ‘Tank: 10GADOLBB101_ Make-Up Water Tank Level Ind 10GCKO1BB101 ‘Tank: 10GCKO1BB101 Silica Indicator 10GCK30 CQ011 ©) Check that instrument air supply 10GCP30 A301 pressure gauge isolating valve is open CHAP S-11 3.11-59SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM PART 2- OPERATION MANUAL 3 Switches on Control Panel Xv 2) 3) 4) Before the Main Circuit Breaker is switched on, make sure i) All isolator breaker for the motors are at ‘O’ position ii) Ail selector switch for the motors arc at ‘Off’ position iii) The two mixed bed operation selector switches are at ‘Of? position iv) ‘The regeneration key switch is at ‘Of position ‘Switch on the Main Circuit breaker at “I” Position. Put all motor isolating breakers to “I” position Pur all the motor selector switch to “Auto” position Put the selector switch for both mixed bed At “Service” position. The first mixed bed put to service will be running while the other mixed bed is in standby CHAP 5-12 “3.1160 08&M/161784/263,SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM ‘O&M/161784/263 PART 2~ OPERATION MANUAL 4 Equipment and Instrument Check 1) Water Treatment Supply Pump is running 10GAF11 APOO1 10GAF12 APOO1 2) The pump discharge pressure is 5.8 bar 1OGACI1 CPO30 10GAC12 CPO30 3) Open the pre-filter vent valve until the TOGCB11 A003 ‘water comes out from the vent 10GCB12. AA003 then close the vent valve 4) _ Open the mixed bed vent valve until water 10GCR10 AADO1 comes out from the vent, Then close the 10GCR20 A001 veut valve 5) Record all instrument readings CHAP 5-13 311-61Intentionally Blank 3.11-62ommenene CHAPTER 6.0 SHUT- DOWN PROCEDURE 1 -—- Switches on Control Panei 2 <-~ Equipment and Instrument Check 3.11-63Intentionally Blank 3.11-64SALCON LIMITED ‘PT PLN (PERSERO) CILEGON CCPP POWER PLANT ‘DEMINERALIZED WATER SYSTEM. (O&M/161784/263 PART 2~- OPERATION MANUAL SHUT-DOWN PROCEDURE 1 Switches on Control Panel 1) Put the two mixed bed selector switch at “Of?” position. All the interlocked equipment will stop 2) Putall the motor selector switch to “Off” position 3). Put all motor isolating breakers to ‘O” Position 4) Switch on the Main Citcuit Breaker to ‘O” position CHAP 6-1. 3.11-65SALCON LIMITED PI PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM O&M/161784/263 PART 2- OPERATION MANUAL 2 Equipment and Instrument Check J) Water Treatment Supply Pump has stop 10GAF11 APOO1 running 1OGAF12 APOOL 2) There is no differential pressure across 10GCB11 CPO10 the pte-filter. Otherwise, open vent 10GCBI12.CPOLO valve to vent off accumulated pressure 3) Check that there is no water flowing into 10GCF11 CF010 the mixed bed that is in service 1OGCF12 CFD10 4) Check that all mixed bed on/off valve is closed 5) Drain the water from the HCl Gas Seal LOGCRS8 AA001 ‘Tank (open the drain valve) 6) Check all pressure gauge to ensure that ‘there is nor pressure build up along pipe Yine, Open drain or vent valve to relieve pressure CHAP 6-2 3.11-66oannaimania CHAPTER 7.0 NORMAL OPERATION 1 ~~ Regeneration e 2 ~~ Checklist During the Regeneration 3 ——- Daily Checklist 3.11-67311-68SALCON LIMITED PTPLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM PART 2 - OPERATION MANUAL, IRMAL OPERATION 1 Regeneration 1) When the mixed bed is exhausted, an alarm will sound “The operator has to press the “Alarm Acknowledge” button to stop the buzzer 2) Pat the “System Control” switch to “Auto” position 3) Using the key, turn the “Regeneration” Sequence to “On” 4) Push the “Regeneration Start-Advance” button to start the regeneration CHAPT-1 3.11-69 0RM/161784/263,SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM (O&M/161784/263 PART2- OPERATION MANUAL 2 Checklist During the Regeneration 1) Make sure that the there is dilution water 10GCB30.CFO10 low 10GCB40 CFO10 2) Make sure that the NaOH Metering Pump 10GCN36 AP001 is at “Auto” position 10GCN37 APOOL 3) Make sure'that the HCI Metering Pump is 10GCE36 APOO1 at “Auto” position 10GCE37 APO01 4) Check the flowrate of NaOH Metering ---10GCN36 APOO1 Pump by reading from 10GCN40CFO10. 10GCN37 APOOL Confirm against Operation Time Chart 5) Check the flowrate of HCI Metering Pump 10GCE36 APO01 by reading from 10GCE40CFO10 10GCE37 APOOL Confirm against Operation Time Chart . 6) Check the valve sequence and time for: 10GCF10 BBOO1 each regeneration step as per Operation: 10GCF20 BBOOt Time Chart 7) Check dilute NaOH concentration 10GCN10 CQ010 8) Check dilute NaOH temperature 10GCN10 Cro10 9) — Check-dilute HCI concentration 10GCE10 C010 Keep a proper regeneration record in the Log Sheets in Appendix 1. CHAP T-2 3.41-70SALCON LIMITED PL PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM O&M/161784/263 PART 2 - OPERATION MANUAL 3 Daily Checklist To ensure. proper operation of the plant, it is necessary for the operators fo follow a daily operation schedule. It is recommended that the operators for each shift walk round the plant for routine checking and data recording once they report for work A daily report of instrument data or trending should be checked to ensure that there is no unusual reading / trend. Keep a record of all instrument readings in the Log Sheets in Appendix 1, 1) Water-Treatment Supply Pump 1) Check that the pump is running 10GAF11 APOOt 1OGAFI2 APOO 2) Check the pump discharge 10GAC11 CP030 pressure 10GACI2 CPO30 3) Check the pump suction 10GAC11 CP020 pressure 10GAC12 CP020 4) Check that the noise level is within. 10GAF11 APOO1 85 dB level 0GAFI2 APO 5) Check the motor temperature rise. 10GAF11 APO01 to be less than 80 deg C 10GAP12 APOOL 6) Check the lub oil level for the 10GAF11 APOOL pump. Top up if necessary 1OGAFI2 APOO1 7) © Check differential pressure across. 10GAC11 CPO10 pump suction strainers 1OGACI2 CPO10 Te differential pressure is high, switch over duty pump and clean or replace strainer. CHAP7-3 341-74SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM ‘O&M/161784/263 PART 2- OPERATION MANUAL 2) Pre-Filter 1) Check the differential pressure across. 10GCB11 CP010 the pre-filter 10GCB12 CPOL0 2) When the differential pressure set. 10GCB1.1 ATOO1 point is reached, put the standby 10GCB12 ATOO1 filter into service by opening isolating valves, Close the dirty filter’s isolating valves, Change the filter cartridges 3) Mix Polisher 4) Check inlet pressure 10GCF12 CP010 10GCF22 CP010 2) Check outlet pressure 10GCF13 CPO10 1OGCF23 CPO10 3) Check the flow totalized value for. © L0GCF11. CFO10 each mixed bed 10GCF21 CFO10 4) Check the conductivity for each 10GCF13 CO010 mixed bed 10GCF23 CO010 5), Check the silica level for demin 10GCK30 CQ010 water 6) Check the pH level for demin water 10GCK30 CQ020 7) Check the differential pressure across 10GCK10 CP010 resin trap, Clean or replace element — 10GCK20 CP010 ifnecessary CHAP T-4 311-72SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT ‘DEMINERALIZED WATER SYSTEM. 0&M161784/263 PART 2 - OPERATION MANUAL 4) Tank Level 1} Check the water level in the Raw 10GADO01CL301 Water Tank (Tank: 10GAD01BB101) 2) Check the water level in the Make-Up 10GCK01CL301 Water Tank (Tank: 10GCKOIEBIO1) 3) Check the liquid fevel in the NaOH = 10GCN20 CLO10 Storage Tank 4) Check the liquid level in the HCI 10GCE20 CLO10 Storage Tank 5) Check the liquid level in the NaOH = 10GCN30 CLO10 Day Tank 6) Check the liquid level in the HCI 140GCE30 CLO10 Day Tank 5) Metering Pump 1) Check the lub oil level of the NAOH = 10GCN36 APOOL Metering Pump. Top up if necessary 10GCN37 APOOL 2) Check the lub oil level of the HCL 10GCE36 APOO1 Metering Pump. Top up ifnecessary 10GCE37 APOO1 3) Check the noise level of the NAOH =: 10GCN36 APOO1 Metering Pump during regeneration 10GCN37 APOO1 4) Check the noise level of the HCL 10GCE36 APOO1 Metering Pump during regeneration 10GCE37 APOO1 5) Check the temperature rise of the 10GCN36 APOOL NaOH Metering Pump during 10GCN37 APOO1 regeneration 6) Check the temperature rise of the 10GCE36 APOOL HCI Metering Pump during 10GCE37 APOOL regeneration CHAP 7-5 341-73SALCON LIMITED PTPLN (PERSERO) CILEGON CCPP POWER PLANT ‘DEMINERALIZED WATER SYSTEM. O&M/161784/263, PART 2- OPERATION MANUAL. 7) Check the pressure inside the 40GCN40 AA300 dampener is not less than 5 bar. 40GCE40 AA300 Fill up with air again if necessary 6) Jostrument 1) Check the clarity of the rotameter. If itis dirty, dismantle and clean Cone HCL 10GCE40 CF010 Dilution Water for HCL 10GCB40 CFOLO ‘Conc NaOH 10GCN40 CFO10 Dilution Water for NaOH 10GCB40 CFO1O 2) Check the level of reagents inthe 10GCK30CQ010 [| silica analyzer. Replace if necessary CHAP T-6 3.41-74cena CHAPTER 8.0 SAFETY PRECAUTION Section] ——- _ Cheimical Characteristics Section2 ~~ Contact with Chemical 341-75Intentionally Blank 3.11-76SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWERPLANT DEMINERALIZED WATER SYSTEM 0&M/161784/263 PART 2 — OPERATION MANUAL SECTION 1 - CHEMICAL CHARACTERISTICS 1 SODIUM HYDROXIDE (CAUSTIC SODA) Coloutiess sticks, flakes, powder or pellets, soluble in water. Causes severe burns, Prevent contact with eye and skin. ‘Toxic effects + The solid and its strong solutions cause severe burns of the eyes and skin, If taken by mouth there would be severe internal irritation and damage, Solutions as weak as 2.6 M can damage eyes severely. Hazardous : Very exothermic with limited amount of water; reacts vigorously with chloroform/methanol. Explosion results when it is heated with zirconium as accidental contamination of metal scoop with flake NaOH, prior to its use with zinc dust, causes the latter to ignite. First aid 2 Alluciad eyes : Standard treatment Skin contact : Standard treatment Iswallowed ; Standard treatment Spillage + Wear face-shield or goggles and gloves, Empty into enamel or polythene bucket and add a little at a tine, with stirring, to a large volume of water. After solution is complete, run this to waste, diluting greatly with running water, then thoroughly wash down site of spillage with water. * Standard treatment : Rinse with plenty of water immediately and seck medical attention. Chap 8-2 314-77SALCON LIMITED PL PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM 0&M/161784/263 PART 2 - OPERATION MANUAL 1.2 HYDROCHLORIC ACID Colourless, fuming liquid with pungent smeil, commonly available in concentrations of 32% to 36% HCI; miscible with water. Causes burns and isritation to respiratory system. Avoid breathing vapour. Prevent contact with eyes and skin. ‘Toxic effects : ‘The vapour innitates alll parts of the respiratory system, The vapour iitates and the liquid bums the eyes severely, The vapour and liquid may irritate and burn the skin, If taken intemally, there would be severe irritation and damage. Spillage disposal 2 Instruct others to keep at a safe distance. Wear breathing apparatus and gloves. Spread soda ash liberally over the spillage and mop up cautiously with water — run this to waste diluting greatly with running water, Chap 8-2 311-78SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM (O&M/161784/263 PART 2 - OPERATION MANUAL SECTION 2 - CONTACT WITH CHEMICAL 21 2.2 CONTACT WITH SKIN a Flood the splashed surface thoroughly with large quantities of running water and continue for at least 10 minutes, or until satisfied that no chemical remains in contact with the skin. Removal of agents insoluble in water will be facilitated by cleaning the contaminated skin area with soap. b) Remove all contaminated clothing, taking care not to contaminate yourself in the process. c) If the situation warrants it, arrange for transport to hospital or refer to medical advice of the nearest doctor. Provide information on the chemical responsible to accompany the casualty with brief details of the first aid treatment given. SPLASHES OF THE EYE 8) Flood the eye thoroughly with large quantities of gently running water either from a tap or from one of the eyewash-bottles provided and continue for at least for 10 minutes, b) Ensure the water bathes the eyeball gently prising open the eyelids and keeping them apart unti! the treatment is completed. ©) All eye injuries from chemical require medical advice. While giving treatment arrange transport to hospital and supply information on the chemical responsibie with brief details of the treatment already given. Chap 83 3.11-79SALCON LIMITED PT PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM (O&M/161784/263. PART 2 - OPERATION MANUAL 23 INHALATION OF GASES 9 Remove the casualty out of the danger area after first ensuring your own safety. ) Loosen clothing, ©) If the casualty is unconscious, place in a face-dowa position and watch to see if breathing stops. 4) If breathing has stopped, apply artificial respiration by the mouth-to-mouth method.- If the gas responsible is hydrogen cyanide only use the Silvester method. ©) If the emergency warrants it, remove the patient to hospital and provide information on the gas responsible with brief details of the first aid treatment given, §) Administer oxygen if available and if the casvalty's condition is scrious. 24 INGESTION OF POISONOUS CHEMICAL a) If the.chemical has been confined to the mouth, give large quantities of water asa mouth wash. Ensure the mouth wash is not swallowed. b) Ifthe chemical has been swallowed, give about 250 ml of water to dilute it in the stomach. ©) Arrange for transport to hospital. Provide information to accompany the casualty on the Chemical swallowed with brief details of the treatment given and if possible an estimate of the quantity and concentration of the chemical consumed and the time elapsed since the emergency occurred. Chap 8-4 3.11-80camuerneass CHAPTER 9.0 ENGINEERING INFORMATION 3.41-81Intentionaliy Blank 3.11-82SALCON LIMITED PI PLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM (0&M/161784/263 PART 2 ~ OPERATION MANUAL, Conductivity of Wotor as Function of the Temperature Conductviy (pSiem) ar a ee a a ) Tomperature °C) “The conductviy of water, fee of any Impuritios, will vary with temperature as presentad in tho graph above, in accordance wit its changing degree of ‘utodissodation Ito HP and OFF, and fhe dfleont mobiles of theco ions at ‘foront temperatures. Chap 9-1 3.11-83SALCON LIMITED PT PLN (PERSERO) CILEGON CCRP POWER PLANT DEMINERALIZED WATER SYSTEM O&M/161784/263 PART 2 - OPERATION MANUAL pH of Pure Water as a Function of Temperature 78 70 pH Value 65 60 ‘ The pH of pure waters 7.0 at 25°C. Deviations at otter temperatures aro ‘due tothe changing degree of autodlesocistion of water, PH measurements in water of high purty become very dificult. pH values registered with normal pH metres in weter with conduetivies below 0.2 ‘om should thoroforo bo considered vnretable. ‘5H metres wil olen have an intemal temperature com pensation; values feared tr tmeraures wl aay be corecod fo tho valun a Chap 9-2 311-84SALCON LIMITED PTPLN (PERSERO) CILEGON CCPP POWER PLANT DEMINERALIZED WATER SYSTEM ORM/LGLTBA2D PART 2 - OPERATION MANUAL Information on Regenerant Chamicias Properties, Impuritis and regenerant concentrators and flow _Hytrechorsaci solutions are most Concentrations. rales can affoct tho aficienay of tre ltd to 4 fo § percent for fhe ‘operation. regeneration of strongly ac ion: sxchangers, and from 1 to 5 pacent General Recommendatons onthe quafty of fer weakly sede reins in water Sufficient precautions shoud be regeneration chemicals ae given in taken when Rening, teneporing ore flaeng socons. Tha recor cieposing of acl o basic re [lites shoul prove (teen Eton afr den o sac bra nrg ren ir operationl concerrations orn spp¥cations, and under crtain the was fi’ regeneralon suff condtions lesser quails can bo dont acl or base.can be prosont to. used cluding everiuaty waste cauccorecgonog;tormina) Poni enperaziers yor al parts of Figures for impr leels are on tho tetoa therefore be pros basi of a 100% regeneration eneveruniog ene chemical ronal anh arteto’s Giles rhein tesogo, 1. Sétoclrs Ale: Hel ‘cls shouldbe carci foLawed, (muri acid) Both as @ gos and in soluton FC “The specifications onthe purty of very corresve and can cause {he regonorat chemicals have ty severe bums on contact. Mucous ‘eure. ouble‘ree operation of temanes ofthe ayes and of ho thelon exchange resin ater re. _Upper respiratory trata especiaky ‘generation, The chemicals have. suscaple to high amnaphatio thorofoo tobe free of suspended concentations, Avoid inhalaton of, ‘malas, or other materials hat the fumes and provide adequate tay be procipiated on or absorbed ventilation when handing the acid. bythe ri. They should azo be The aids commerce offered ws fee offone species cher than Ug colourless to ight yelowigreen ‘lve regeneration agents, as ‘liquid in concentrations of about 28 {His wil decrease the regenoraton 1036 weigh to weigh percent Ci. ‘ciency andlor ntease the Feakage ofthis spaces during the ‘operationat cycle. For example, sou hydroxide containing 2% [NaCl wil reduce tno offcency by 5 ‘10% and cause a highar Ci- Jeska rom te storoy base anton exchange resin. nemmarnmesen ces |Srse coset arate ‘contain minimal levo's of impurities, ius oferta aes logies and iforent requirements 28 — jydrochirc acid fom Ja of ‘othe quali af th bested olfuent Chornated organic meters rot ul hetfore mpose diferent | sulanl ford os repenorrt Ald ‘esticions onthe mpurlylevelsin fmt ont acy pecans by tho regeraraton chemicals andthe the lorie process ts dubon water. In he sameway, sath Chap 9-3 311-85 SALCON LIMITED. engneae’ on Nowtecned rerseanabe | Tce ES i case coume eS omy ° ‘i fe] ome aor | _ra sror_[eer0 aon ee oa ors) aan | ~trcreins | —oneravena [uo ocoreush _ CAPACI = co sone — od Treo | a Ore co ce. aif Role eves | amet “| amen | oasemen | ambxsat Le MENGES GACH HORS 7 z 3 7 = 3 7 @ = 70 7 12 5 4 15 6 3.44-102Seruaroat N ERE pee aoc mau ew emer TT ToT TTT 3 ae LORS ge teu but reo So i 9 {Geo sn | vrais oe [Tove i [us aemn_[ este wom [ vero er [ene ww | voi io [ vss wnt [omer men] tne nove tte it inane ra Kania ETAT [OETA] rETECMREE | MOEN | WIRE we | OTRMRRR | vODTOR | Mnrenoaei | waueTenerap=] SMCS et (eectscrs) “gum na ease SaSpewer m= i “0 tm - = - en rs “en, = att a's we = = eee ea eee | dE TEE env [ear > : i Gara _|_aaney "TARASACO MACHINERY WORKS s 4 ee 7 se a is i+ 15 6 Ee SH cea OT TTR le |alale)eia|a PT PLN (PERSERO) ‘tenon conanen cts Pome PLAT Na | asco SKY TANBAS GEN LE 2 H67N PIN PRED, PETS ome. 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MITSUBISHI HEAVY INDUSTRIES, LTD. TAKASAGO MACHINERY WORKS CUSTOMER PT PLN. (PERSERO) CILEGON COMBINED CYCLE POWER PLANT (740 MW) OPERATING INSTRUCTIONS PRODUCT Ns SoU Wateanarennaa [amma [eronsioe TORISHIMA PUMP MFG. CO., LTD. adlasIntentionally Biank 3.11-116| SAFETY PRECAUTIONS © Atter reading through this paper, be sure to keep il in the place exposed to view at all times for operators. Concerning the safely precautions, this paper describes the contents of WARNING by the use of the following symbols and sign. Indicating the contents where @ possiblity of leading to serious results such as a danger of injuries which persons may undorgo in causes of mishandling due to neglect of this display is 1, General 1) Never allow any persons other than service engineers to engage In disassembly, repair oF remodeling work, 2). Naver work alone and be eure fo put on helmet, safety gougles ear plugs, safety shoes, efc, in conformity with the Labor Safety and Health Law, etc, 3) Prior fo carrying out any sparking work such as welding, etc., make sure that where are no dangers of fire and explosion hazards. 4) Check the place where emission of toxic gas and deficiency of oxygen are concelvable, such as pit, ‘manhole, etc. before starting on work and make sure of safety. '5) When carrying out the work for centering check, disassembly, etc., be sure to turn OFF the motor sswltch and affix a tag indicating ‘NO POWER ON" or the lke to the switch so that the switch will not be turned ON by mistake, Before starting on work, be sure to conduct checking of sliding outfits such as crane, wire rope, tc, untailingly. Install safety fence around the working atea and.secure an emergency passageway, Since any spilt oil on the floor, passageway, etc. may lead to a cause of slippage etc., wipe it off forthwith, Shaft seal parts will not function to stop the pumpecttiquid completely. When handling such a liquid which may cause serious troubles to the human body, therefore, do not touch the splashing liquid from shaft sea! parts, Keep away from the casing of @ pump thet is handling a hot liquid as may lead to a danger of ssatds if coming in contact with the body. 14) Do not gain access to rotating parts recklessly since there is a possibilty of scattering caused by breakage of rotating parts. 42) Take precautions against the possible breakage and scattering which may be caused if leaning against or stepping on the guard, 12) Do not open the terminal cover of electrical devices including motors as there is a danger of electrification while they are energized PL_ENJTD ; 344-1172. Handling Where both pump and motor are assembled on a common bed, never hang a wire rope on the sysbolt of the motor, Furthermore, do not gain access to the underside of the suspended pump. 8. Direct-coupling For the type of coupling applied with satety cover (coupting guard), fix the safety cover securely to. the predetermined position with clamping bolts. 4, Maintenance When carrying out the work for replacement of gland packing or a mechanical seal, be sure to turn OFF the motor swlich and affix a tag Indicating 'NO POWER ON or the like to the switch so that the switch will not be furn ON by mistake. 5, Disassembly and Reassembly 1) Before carrying out disassembly work, be sure to turn OFF the motor switch and affix a tag indicating "NO POWER ON’ or the like to the switch so that the switch wll not be turned ON by mistake. ‘Close the valves on the suction side and discharge side fully and, in the case of hot liquid, discharge the pump interior liquid from drain valve at the point when the casing temperature has. ‘core down fo the room temparature or so. Where the pumped liquid is a chemical solution, it may lead to a danger or causing Injuries such ‘as inflammation and the like if adhering to the body. To prevent this, make sure that the casing interior liquid has been discharged thoroughly. ‘When removing parts and parlly-assembled components, hang wire ropes to the positions as shown in the instruction manual and use a chain block, etc, When handling hot components such as bell bearing, Coupling, ete., be sure to wear on protective gloves. PL_EN.JTD v 311-118CONTENTS PAGE 1 2 2 AGENERAL =) ‘1=1,PRECAUTION PRIOR TO USE 1-2.PERFORMANCE TEST =~ 4-3.NAMEPLATE =~ 2DESCRIPTION —==-->--~ 2-1,APPLICATION 2-R.CONSTRUCTION — - A.VOLUTE CASING (1020) 2IMPELLER (2900) SSTUFANG-BOK 2-8.SHAFT SEAL ~ 2-4.BEARINGS (3210.1/9210.2) 3-1.INSTALLATION OF 3-2.DIRECT-COUPLING 3-3.PIPING 4.OPERATION ~ 4-1. STARTING-UP 4-2.SHUTTING OFF 4-3,CONTROL OF OPERATION AND MAINTENANCE {GENERAL REQUIREMENTS =~ 2.SHAFT SEAL S.MEASURING INSTRUMENTS. 8 4.LUBRICATION 8 —EGEAREOUPINE— - 20 a 4-4. TROUBLE SHOOTING AND REASSEMBLY 5-~1,GENERAL Nt 5-2,DISASSEMBLY S-3.REASSEMBLING = --~ 3 -ERICHYPE BEARING HOUSINE-18800)— MECHANICAL SEAL INSTRUCTION —~ oa note; The number in the parenthesis means part number. CPC1aX.jtd . 3.11-119Iintentionalty Blank 3.11-1204. GENERAL OPCIAX.ité 174, PRECAUTION PRIOR TO USE Any CPC pumps, which incorporating the mast excellent aump technology ensures entirely, satisfactory and trouble-free service throughout a period of iong time, provided that they are installed and operated correctly as instructed in this manual. Bafore the use, operating and maintenance personnels are requested to raed carefully all the Instructions contained in this manual to always operate and maintain the pumps in satisfactory condition. Moreover, this manual should be preferably stored and controlled at an easily accessible place to ‘enable to operating or maintenance personnel to refer to it promptly at any time, All pump components manufactured under strict process and quality coniro! specific performance, provided they are in perfect condition and in conformance to purchasers order specification, fulfill securely their This manual, therefore, gives in detail the operating instructions. Bo noted that our guarantee shall be ineffective for any trouble possibly caused by non— conformance to the instructions in this manual or resulting from; 1) application to pumping fluids (of different density and temperature) different from those indicated In purchaser's order specification, or operation of the pumps beyond the specified performance characteristic range, and 2) any damage or deficiency caused by fallure in observing the instructions contained in this, ‘manual, |. Improper handling and operation, of Incorrect installation, or use of unsuitable operating material (i.e. lubricant) , of faulty or imperfect piping. For rapalr of the pumps, It is recommended thal pumps with major trouble should be repaired by one of our skilled fitters, or be sent back to our works for repair, 344-1211-2, PERFORMANCE TEST Performance test is conducted with the guaranteed for all CPC pumps to verify thelr conformity with the guaranteed design performance, before dispatch, and only accepted pumps ave released for delivery. 1-8. NAMEPLATE (Fig.1) All pumps are provided with nameplate on their bracket (3440). Furthermore, the product number is, stamped on its flange part. When ordering spare parts, let us have the following information without feil. 1) Pump type & size, Product number, Kem number. 2) Part designation, quantity and material, ® @TORISHIMA PUMP ° (TYPICAL) Rowe @ TORISHIMA PUMP MFG.CO.LTD. [OSAKA JAPAN Fig.t cpciax.jtd 3.11-1222. DESCRIPTION 2-1. APPLICATION ‘Type CPC is much suitable for the following application. (1) Handling a corrosive (2) Pumping tiguid to be kept clean (3) Pumping liquid to be processed at high temperatures (4) Pumping liquid of high density (5) Requirement of special shaft sea! Note thet the materials of the pump need to be selected appropriately depending on the working conditions even for the above application. 2-2, CONSTRUCTION ‘Type CPC pumps are horizontal shaft, single stage, single entry centrifugal process pump with vartical split type volute casing (1020) with integraty casted axial suction nozzle and top discharge nozzle, Moreover, the volute casing (1020) is complete with support foot, which are bolted to the baseplate, {Some of pump executions have double volute cesing.) By using a spacer coupling, the complete pump rotor can be dismantled for periodic maintenance and inspection without disconnecting the plping from volute casing (1020) and moving the driver. 1. VOLUTE CASING (1020) ‘The casing cover (1610) and the bracket (3440) are jointed together to the volute casing (1020) with stud bolts (9020) which ere studded in the volute casing (1020). Gaskets (4000.3,4000.4) are fitted in the sealing faces between the volute casing (1020) and casing cover (1610) and between the casing cover (1610) and bracket (3440), for tight~ seal of pumping fluid, cPCIaX.jtd -3- 3.114232. IMPELLER (2300) ‘The most axial thrust load is counter balanced with the back vane provided on the back of the impeller (2300). “The outside diameter of the back vane is adjusted at the design stage according to the magnitude of the suction pressure and total head. ‘To prevent the pumping fluid on the discharge side from returning to the suction side as much as possible, casing wearing ring (5020) is installed in the volute casing (1020) and the clearance between the casing wearing ring (6020) and the impeller (2300) Is minimized. The clearance is determined according to the materials, According to our standard design, casing wearing ring (6020) is not used when the volute casing (1020) 1s stainless steel, ‘The impetier (2300) and the packing sleeve (5240) or seal sleeve (6241) are slipped onto the shait (2100). and fastened with the Impeller nut (9220) or hard lock nut (9288). "Otting (4120.4) Is installed the packing sleeve (5240) or seal sleeve (5241) inside, so that its prevent the leakage of the purnping fluid from the gap of between the shaft (2100) and sleave. A tock heli~sert is instatied in the tapped hole of the impeller nut (9220), for the positive fastening to the shaft (2100), (Refer to Fig.2 and 3.) IMPELLER NUT LOCK- HELI. SERT LOCK-HELI- SERT Fig.2 Fig3 cPcraxitd 3.14-124Lf 40,260 50 10 nt 2 ‘The casing cover (1610) which constitute the shatt seal is ailached to the volute casing (1 ‘together with bracket (3440) . ‘Where the temperature of the pumping fluid exceeds 108 °C , cooling to the shat seal In this case the casing cover (1610) ts applied the cooting Jacket type. The cooling/water inlet and outlet ports of the Jacket are provided both side of the etutfing box. ‘The cooling water flow rate varies with the type of the pump and the tempesd{ure of the pumping fluid, Determine the adequate flow rate of the cocling water according to Table 1 Cooling water tlow raip/Clit. min.) SIZE Upto y Up to 260 C_| Over 260°C 32-13, 60-13 32-16, 40-16, 50-16 3 4 8 32-20, 40-20, 60-20 65-16, 80-16 {65~20, 80-20,100-20 32-26, 40-26, 50-26, 65-26, 40-82, 60-32 100-26,125-26,150-26, CPCIAX itd 3.11-1252-8, SHAFT SEAL ‘The shaft seals are applied two types, gland packing type and mechanical seal type. As to the pumps with mechanical seal, refer to the separate INSTRUCTION MANUAL OF MECHANICAL SEAL? for the construction, handling and maintenance of the mechanical seal, Fhe-reease-of-the-casing-cover (4610) cf tha stuffing box le-cosigned-to-house-clther-shrgland- packings 14610) or four gland-packinge-and.one-lantorning (4580) FFhe-glanc-bushing_H4s46) 2 eptiteble-tn-twepatis-ancthe gland 1600) 16 a-rower-sids-opes-type— forthe-case-oLcoplacing the gland packings (aba) “This type le suitable for the pumping fluid of sotid~-free, good lubricating property and agecivate temperature, For this type, the pump needs to be operated by forcing liquid in and Ji€*pressure at the stung box is higher than the atmosphere resulting inthe leekage of the pupagifa fluld from the casing cover (1610) to the atmosphore side. Fig cPcraxitd 3.11-126(4580) (Refer to Fig.6) ‘This type Is suitable for the following. 2. Pumping at suction pressure lower than atmosphere. b. Cooling the gland packings (4610). c. Preventing abnormal wear of the gland packings and the ps the pumping fluid. d, Pumping toxic or odorous fiuid which leakage is ct allowable, 'e. Preventing the ‘eakage of fluid that vaporizgsinder one atmosphere. 4. Pumping fluid of poor tubricating propg ng sleeve (5240) due to solids in ‘Sealing liquid is supplied tothe Jantern ring from either the pump discharge side or an extemal source, Circuit (Sealing liquid from pump discharge side) liquid is, led to the lantern ring (4580) through the path provided in the casing cover fo} —-Openrciranit {Seating ttquieHtremrentemnatscuree% The incopendent supply is used where the external liquid can be mins Part of the sealing liquid Is fed into the volute casin atmospheric side through the clear Piimped fluid. id other part flows out to the Gland bushing (4540). fe of sealing liquid should conform to the specification shown in the outtine drawing ATMOSPHERE Figs cPctax.jta -T- 314-1272-4, BEARINGS The shaft (2100) of the pump is supported by two bail bearings (3210.1/82102, C3 clearance) . The ball bearings (3210.1/3210.2) ere shrink—fitted on the shaft (2100) and housed in the bearing housing (3300). The bearings are lubricated by the oil bath system. ‘The lubricant in the bearing housing (8300) Is sealed by labyrinth . (Note) Where operating conditions are heavy duty, for instance, high suction pressure, the larger ball bearings may be employed. Tha combinatfon of the bearings on such an occasion is: Refer to the “SECTIONAL DRAWING" of each pump for the combination of bearings. The outside dimensions of the pump are not affected by the variation of the bearing combination. CPC1AX. itd -8- 3.11-128‘a: INSTALLATION 1, INSTALLATION OF BASEPLATE ‘The top face of each packer should be leveled horizontal by measuring with a level gauge. ‘The height of the packers need no Be leveled uniformly because the height of the packers are adjusted by shims when the baseplate installed. 8) After the concrete bonding the packer Is cu mounted) on the packers temporarily. Check fongitudinal and lateral level of the pump with sh surface of the pump. , place the beseplate (with the pump and driver height of the pump axis end adjust the 3s by applying a level on the cischarge flange 4) After the position and level of the pump are determined, with the alignment fools (Refer to Par. 8.2 for the details.) Record the values of the temporery allgnment and they will be alignment. porarily align the purnp and the driver for the tater check of the 5) On completion of the torhporary alignment, place concrete in the anchdk bolt holes. 6) After the concrete placed in the anchor bolt holes is cured thoroughly, tighten the nuts of the anchor bolts firmly. 7) On completion of the Inspection of the coupling, place mortar in the baseplate to con leaving cavities. 8) On completion of the above, connect the suction and discharge pipes. cpctax.itd 3.11-129‘9-2, DIRECT-COUPLING 2 3) 4) 5) 1996 of this pump, can be exploited 100 9%. the pump axis and the driver axis must be aligned exactly. Align the pump and the driver in applying a straight—edge to the peripheries of the both couplings and a wedge Illustrated In Fig.6, or with the aligning tools as Illustrated in Fig.7> Check the angular and parallel alignments at four points equally spaced, je, 90° , on the periphery of the couplings\gnd the errors shall not exceed 0.05 mm, Do not fail to check the rotati pump and the driver. “The rotatlonal direction is shown by)gn arrow on the bearing housing (3300) and is clockwise (CW) viewing from the dri direction of the driver before connecting the couplings of the Aiter ensuring the cotational direction, confgct the couplings of the pump and the driver, Where the temperature of the pumping fluid Is again alter the pump is stabilized at the specifi temperature is expected during run, the shafts may coupling of larger flexibility. the ambient temperature, check the alignment perature, Where the variation of fluid divallgnod more or less, requiring the Fig.6-1 CPCtX.ite = 10 3.11-4302 es na gs > yi ys ae 1 Pump side coupling 63 Nut 2 Driver side coupling 6.4 Washor 8 Spacer 6.5 Washer 4 Set bolt 66 Spring washer 8 Set bolt 7 Reamer bolt sat 6 Coupling bolt set 7A Bolt 64 Bott 7.2 Nut 6.2 Coupling rubber 7.3 Spring washer ePCraxitd ne 3.11-1343-8, PIPING cout piping by paying attention to the following points, v the suction and discharge pipes so that the forces due to the pipes will not work on the pum ‘Where the pump is subjected to force due to pit 2) Install the sdgtion pipes s0 as to minimize the energy loss of the pumping fluid due to the resistance of the suction pipe by avoiding abrupt veriation of cross sectional areas and sharp bonding. Determine the pipe size eo that the velocity of the pumping fiquid will not exceed 8 mvsec. 3) Where the suction pide size and the pump suction port are different, connect them by inserting an ‘eccentric reducer between them so as to eliminate air pockets. (Refer to Fig.&) 4) Where a valve Is Installed on nozzle as possible. To provide a check valve, locate it discharge side, locate the vaive as close to the pump discharge nthe purnp discharge nozzle and the discharga valve, 5) Where the piping line is not flushed, a Mrainer should be installed before the pump Inlet port the early stage of operation, Employ the strainer having the filtration aredof 8 fo 4 times as large as the cross sectional area of the suction pipe. If indication on the suction sige pressure gauge changes during operation, the strainer is clogged. Remove the strainer and cledg the strainer. Whore there are sufficient reasons {0 beliave that the foreign matters in the piping aré\horoughly cleared out, remove the strainer, 6) As the auxiliary pipes for cooling water, sealing water akd circulating water are designed and manufactured sultable for their application and shape, they can be Installed easily. Install them so that they will not apply undesired force on the pump, same as the main pipes. Before installation, be sure that foreign matters will not remaih inside of the pipes. If remain, thoroughly clean the inside of the pipes before installation. 7) Whore the temperature of pumping fluid is higher or varies, the pipedvare expanded or contracted by the varlation of temperature. Provide flexible pipes and other appropiate devices on the pipe line so that forces due to expansion or contraction of the pipes will not wock on the pump. '8). On completion of piping, again check the alignment of the pump and the drivéx in order to make ‘sure that the alignment is not disturbed by excess forces due to piping. a Fig CPC14X.jtd == 3.11-132.4, OPERATION oa 1 ay @ (3) @ @) (6) a” () @ 10) ‘STARTING-UP “To start up the pump for the frst time after the pump is installed, check the following points and be sure that there are no irreguiarities before starting up. Correct irregularities, it any, according to this instruction manual. Be sure that the rotational direction of the driver is correct. (The rotational direction of the pump is clociwise viewing from the driver.) Checking the direction, coupling bolts shall be removed. Be sure that the alignment between the pump and the driver is satisfied, Also be sure thet the ‘coupling bolts are installed. Be sure that excess forces due to piping do not work on the pump, Be sure that all the auxiliary pipes are installed correctly. a strainer be installed on the suction pipe, be sure that the strainer Is not clogged. Be sure that the bearing housing is filled with lubricating oi! to specification, ‘Supply oil if nsuificient, (Refer to Table 3 and 4.) Be sure that cooling water will circulate. Bo sure that the suction valve is fully opened and the discharge valve fully closed. Fill the suction pipe and the pump (the volute casing) with fluid, and be sure there are no Jeakage and other Irregularities. Be sure that the gland Is tightened evenly and is not tightened excessively, As to the ‘mechanical seal, be sure that the mechanical seal is not feaking. Where the gear coupling is used, be sure that TSfilled with the specified type and ‘quantity of lubricating oil, it, supply oil. Tantity of lubricating oi are specified in the instruction manual of the gear (43) ‘Tum the coupling by hand and be sure the shafts rotate smoothly without irregularities. epcrax.jid -18- 3.11-133,CPCI4K.jtd If the above items be checked and no irregularities be found, switch on the driver for a moment and switch off Immediately. During the time, be sure that the pump rotates smoothly and ‘comes to a halt sofily. It no irregularities exist, agaln switch on the driver, gradually open the discharge valve untll the fiow rate reaches the specified level. If run be continued with the discharge valve closed, the ‘temporature of fluid inside the pump rises and the pump may become faulty. ‘On such an occasion, do not continue operation and shut off the pump. ‘Adjust so that the pressure and flow rate of the sealing water and cooling water reach the respective specified values. To resume the operation of the pump after a long operation, be sura thal the pump is not Irregular by checking the above items, before starting up the pump. ~ 14> 3.11-1344-2, SHUTTING OFF To shut off the pump, comply with the following steps. 1. Fully close the discharge valve. This is not necassary where the check valve is provided. 2, Switch off the driver, Then check if the rotational speeds of the pump reduce smoothly and the pump come to a half softly. $$ Shot otttheseatingranchsupptytiqeic-terthe shalt seat — 4. Shut off the cooling liquid, (Where the cooling liquid can not be turned off because of operation, continue feeding.) 5, Where there is a possibility of freezing, drain all the liquld in the volute casing (1020) and the cooling chamber. 4-8. CONTROL OF OPERATION AND MAINTENANCE 4, GENERAL REQUIREMENTS. During the run of the pump, pay attention to the following. I any inegularty be detected, shut off the pump Immediately and inspect the irregularity. (4) . Be sure that pump runs smeothly without vibration. (2) Be sure that no cavitation occurs. (Check indication on the suction pressure gauge.) (3) Be eure that the specified discharge pressure is attained. (4) Be eure that the driver is not overloaded (6) Be careful so that the pump will not be run without filling the casing with liquid or with the discharge valve closed. (6 Check:the bearing temperature and the lubricating oil ai the regular intervals. (7) On the gland packing type pump, be careful so that the gland will be tightened evenly and will not be overtightened, and run the pump in the state where liquid leaks a litle, ‘The adequate leakage from the gland section is generally 10 to 18 ce per minute (8) Ba sure that cooling water and sealing water are fed positively. ePCiaxjtd ~~ 3.14-4352. SHAFT SEAL Tho slulfing bonol the-gland-packing-typo-pump-letnelaltod-the-glané pact He ring (4880) and gland bushing (4540). The surface of the packing sleeve (5240) must be ‘smooth all the time, Cuts in the surface of the packing sleeve (5240) and the uneven tightening and overtightening ‘of the gland (4820) may cause the overheat of the shaft seal or the erly wear of the gfand packings (4610). ‘To replace the gland packings (4610), select the material resistive to the pumping tluid. Before reassembling, clean the lantern ring (4580), gland bushing (4540) and gland 4520). Cut the gland packings (4610) by a cutting tool with a sherp edge, using the tool spwn in Fig, Install the gland packings In the casing cover (1610) with the cuts of thefackings apart 90° from each other. (Refer to Fig. 10.) Engage the gland bushing (4540) partly with the casing cover (16194. Tighten the gland packings (4610) lightly at first and retighten atter operating sornedime so that the laakage of ‘luld from the gland section will be generally 1010 18 ce per one/inute, ‘The dimensions of the stuffing box and the gland packings (9610) are shown in Fig.t1 and Table 2 cur or cay pacneitcr0) (san susan Fig Fig 10 cpoixjtd = 16-Table 2 No. oF Gland packing dimensions gland [Pre—formed _[Foning rom continuous cot pth SIZE packing _|dixdaxsize |size | unit [Total engiy& | of [Lantern ring ength | Lanyeftring |stuffing |32-20ff0- 200-20 [Yes _[NO. NO_[box: 1 [32— 13,50—13 '32— (6,40 16,50-16 416 |s6xbtx8 aia | 540 | eto} 53 65-16,80-16 |65~20,80-20,100-20 4 | 6 /abxa 10 | 173 | 692 |1038 | 64 |32-26,40~26, 60-26,65- 26,80-26 |49-32,50-32 100- 28,125-26,180-26 (65~32, 80 32,100~32, 125-32 .80- 40,100— 40ffa5— 4d 4 | 8 |sexr6x10 10 | 204 | B16 [224 | Gt 200-26 180~32,200~ 82,250—3 100.50,126-5efg0—6a)200- 50 4 | 6 |roxsx125 | 42 | 269 [1036 [1554 | 79 pH 50 41 6 [soxiosxi25 | 12 | 290 [1160 |iza0 | 79 Preforably user preformed gland packings ‘One of the major advantages of the mechanical seal is that the maintenance Is not almost required, resulting in the elimination of time—spending gland packing replacement. But the sliding faces of the seat and the washer may be wom by operation over @ long period “The degree of wear varies with various factors such as operating conditions, lubricating property cof pumping liquid, and impurities in pumping liquid. Therefore, it is not possible to recommend the general operating hours requiring the replacement of wear parts (seat and washer), but we recommend to maintain the operation record of the pump to facilitate the later operation and maintenance. Examine the mechanical seal after about 4,000 operation hours and the replaced mechanical seal after further operation, and the operation hours requiring the next inspection can be determined from the status of the mechanical seal examined at the first time, Replace the worn mechanical seal with a new one before It starts to leak. It is advised to keep ‘some complete sets of the mechanical seal as a spare part and replace the faulty mechanical ‘seal in the complete set. At least, a faulty sot of seal ring (seat and washer) . Do not run the mechanical seat in a dry state and prime the seel before starting up the pump and operate the pump always with the stutting box filled with liquid. ‘Tha mechanical seat may leck a litte for a while after starting up, until the seal is stabilized. To modify the mechanical seal type pump to the gland packing type pump, the machining of the casing cover (1610) is not required but the seal cover needs to substituted by the gland (4520) and the gland bushing (4840), and the lantern ring (4520) sto be added if necessary. Further the seat sieeve (6241) _of the balanced mechanical seal or the seat holder (4751) of the double mechanical seal must be substituted by a suttable part. cPCtax.jta <= 3.14-1378. MEASURING INSTRUMENTS. It Is recommended to install a compound gauge on the suction pipe and a prassure gauge on ‘the discharge pipe sear to the pump easing or on the pump casing for the control of operation. Select the scale of the gauge so as to cover the pressures exceeding the maximum ‘operating pressure by 80 %. Also, provide the gauge cocks. Employ the gauge cocks of corrosion resistant materials strainer whore the piping fluld includes: suspensions or solids. ‘To extend the service life of the pressure gauges, operate the gauges only when the ‘operating pressure is checked, and close the cocks normally. 4, LUBRICATION ‘The maintenance of the pump bearings is very important. Check the bearing temperature and the lubricating oil level at the rogular intervals, The maximurn permissible bearing temperature is 80 othe room temperature plus 40 °C. ‘Check the lubrication oll level before starting up the pump. Where the pump is not operated for a e long petlod, clesn the bearings and the bearing housing (3800) with cleaning oll or thinner, before starting up the pump again. Dust can be washed off well by wa jing white turning the shaft (2100) by hand, ‘mounting port of the oller. Then fill the oiler with lubricating oll and i (Roter to Fig.t2 and 13.) Change the entire oll after 300 operating hours from the installation of new bearings, and every 3,000 operating hours afterward, The type and the required quantity of oil are shown in Table 3 and 4, CPCIAX,jtd - B= 311-138Tabled LUBRICANT LIST. ‘SIZE 1850-73 32 1B 1650-16 32—2040~ asq~ 20 Quantity City NORMAL | Stype [VAX type ef 65—18,80~ 16 65 20,80-20,100-20 [22-26,40~26, 60~26,65— 26, 40-~92,50~32 '100= 26,125—26,160-26 65-92, 80-82,100-82,125-92 180-40,200-40.280-40 100-50,125 £0,460 50,200— 60.260—50 os 08 Table 3 “TYPE OF LUBRICANT ex SHELL Turbo oil T48 SSO ‘Teresso 46 MOBIL:DTE ofl medium [Turbine olf 150 V632 BO ‘SHELL‘Turbo off T32. ESSO :Teresso 32 MOBIL:DTE ofl light g-302444 CPCI4 itd ~~ 3.11-139 he