VEMAGIRI POWER GENERATION LTD. SECTION: D1.

12
TITLE SHEET 1 OF 9
MECHANICAL SYSTEMS - 4
SPEC. NO.TCE.3837A-H-
500-01
WATER SYSTEMS

WATER TREATMENT PLANT

12.1 The water treatment plant shall provide make up water of the
specified quality (demineralised) and quantity to meet the feed
cycle make up requirement of the HRSG. The treatment is covered
in two stages - filtration and demineralisation. The filtered water
serves as influent to the demineralisation plant and the filtered
water is also utilised as plant potable water.

The DM plant capacity shall be designed based on 3% of HRSG

MCR as make up and DM water required for ACW system make
up. Clarified (and chlorinated) water to the DM plant shall be
supplied by water treatment plant supply pumps located in the
clarified water pumphouse.

The operating hours of the plant shall be considered as 18 hours in

a day between regenerations for main ion exchange units (cation
and anion) and the regeneration shall be carried-out once a week
for the mixed bed unit.

12.1.1 Alum dosing system with tanks and pumps shall be provided
upstream of filter to limit the turbidity levels. Clarified water shall be
subjected to chlorination to destroy organic matter and algae at
suction of water treatment plant supply pumps.

12.1.2 DM plant shall consist of 2 trains, of 50% capacity each. Each train
shall consist of the following units in the following sequence:

- Pressure sand filters

- Activated carbon filters
- Strong acid cation
- Degasser system
- Strong base anion
- Mixed bed

12.1.3 Operation of the plant shall be semi-automatic, PLC based and

each sequence of operation initiated manually. Cation units shall
be taken out of service after treatment of a preset quantity of water.
It's operation shall be further monitored by a conductivity
comparator. Anion units shall be taken out of service when its
effluent conductivity exceeds a preset value or a preset flow has
occurred through the anion exchanger whichever occurs earlier.
Mixed bed units shall be taken out óf operation when either
conductivity or silica levels of its effluent exceeds the acceptable
limits.
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CONSULTANT : TCE CONSULTING ENGINEERS LIMITED

 VEMAGIRI POWER GENERATION LTD. SECTION: D1.12
TITLE SHEET 2 OF 9
MECHANICAL SYSTEMS - 4
SPEC. NO.TCE.3837A-H-
500-01
WATER SYSTEMS

12.1.4 Waste water from the DM plant and filters shall be led to a common
neutralising pit. The neutralising pit shall be in two compartments
and the active volume of each pit shall be atleast 120% of the total
waste arising from regeneration of one complete DM plant train and
filter back wash water. Plant shall be designed in such a way that
the regenerant effluent from cation, anion and mixed bed units shall
neutralise each other.

Facilities for addition of acid / alkali to neutralise the effluent shall

also be provided. The neutralised effluent shall be finally disposed
to the guard pond by the neutralising.

12.1.5 Suitable bulk acid / alkali tanks and measuring tanks required for
regeneration of ion exchange units shall be provided. 30% HCL
and 48% NaOH shall be used as regenerants. DM water shall be
used for regeneration and suitable capacity DM regeneration tank
with associated pumps shall be provided.

12.1.6 The back wash water for the filters shall be led from the filtered
water over head tank which shall have adequate capacity for
washing all the filters and also cater to about two (2) hours potable
water requirement of the plant. Filtered water overhead tank shall
be filled through a line from the outlet of filters.

12.1.7 The water treatment plant equipment shall be housed in the WT

plant building. A MCC shall be provided for the water treatment
plant from where power supply to motors forming part of the water
treatment plant shall be derived. The plant potable water pumps
(described later under this section) shall also be located in the
water treatment plant building and shall derive power from the
same MCC. The MCC shall be housed in a separate room, forming
part of the WT plant building. The filtered water overhead tank shall
be located atop the WT plant building.

12.1.8 Control and Instrumentation for the Water Treatment Plant

a) Type of plant control Semi-automatic, micro processor

based PLC system: operation will be
carried out from the control
panel; Taking the equipment into
service and initiation of backwash
of filters and regeneration of ion-
exchange units shall be initiated
manually from the control panel and
balance operation shall be carried
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 VEMAGIRI POWER GENERATION LTD. SECTION: D1.12
TITLE SHEET 3 OF 9
MECHANICAL SYSTEMS - 4
SPEC. NO.TCE.3837A-H-
500-01
WATER SYSTEMS

out sequently by the PLC. Manual

overide facility for all operations shall
also be available. Local push button
stations for emergency operation
located near the equipment. Details
of instrumentation item requirements
are covered in relevant section.

b) Plant Instrumentation

i) Inlet and outlet pressure indicators for vessels and

discharge pressure indicators for various pumps.

ii) Inlet (rate of) flow indicators and outlet flow totalizers.

iii) Flow switches at filter outlet.

iv) Conductivity comparator at cation outlet.

v) Individual outlet pH recorder-indicators, conductivity

recorder-indicators for anion & MB units.

vi) Outlet silica analyser cum recorder common for both

streams and common for both anion and MB units with
multipoint recorder.

vii) Density indicators for regenerant chemical solutions.

viii) Tanks including filtered water storage tank, degassed

water storage tank and DM water storage tank - level
indicators and level switches with protection interlocks for
associated pumps.

ix) Instrumentation & control cables and erection hardware.

c) Annunciations

Annunciations for abnormal conditions like conductivity, pH

and silica levels, high flow through filters and ion exchange
units, levels (high & low) in chemical tanks, filtered water tank,
degassed water tanks, DM water storage tanks and
neutralisation pit shall be annunciated in the control panel.

d) Microprocessor based programmable logic control system

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 VEMAGIRI POWER GENERATION LTD. SECTION: D1.12
TITLE SHEET 4 OF 9
MECHANICAL SYSTEMS - 4
SPEC. NO.TCE.3837A-H-
500-01
WATER SYSTEMS

The microprocessor based PLC shall be configured with hot

back-up redundancy. The system shall provide for
sequencing of automatic start-up shutdown bringing standby
equipment into operation on failure of main equipment and
manual intervention facility for all the equipment. The PLC
shall be provided with a PC based programmer station for
performing software changes. The input modules of the PLC
shall be configured in non-redundant mode and the output
modules shall be configured in redundant mode for critical
drives. The PLC shall be provided with a CRT / Keyboard
Operator interface equipment.

A central processing unit for man-machine interface unit

(CRT/Key board) with bulk memory and floppy disc drive shall
also be provided. The CRT/Key board shall support a printer.

e) PLC Based Control System

PLC based control system shall consist of measurement

system, interlock, protection and sequential control system,
annunciation system and data bus system for control and
communication with the process. The operator interface
includes one no. 19" colour CRT with keyboard, one no.
medium speed printer, PC based programmer unit and other
peripherals as indicated in previous clause.

12.2 Service and Potable Water Systems

12.2.1 Service water system

This system shall meet the service water requirements of the plant
including makeup to the air-conditioning and ventilation system and
other miscellaneous services. Water from the clarified water
storage tank shall be drawn by two (2) Nos. (1 operating + 1
standby) service water pumps and led to the service water
overhead tank of 8 hours storage capacity. The tank shall be
located at a suitable elevation so as to ensure distribution of water
to all the consumption points by gravity. The service water pumps
shall be housed in the clarified water pump house.

12.2.2 Potable water system

(a) This system shall supply potable water (of filtered water
quality) to the plant. Potable water shall be drawn from the
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 VEMAGIRI POWER GENERATION LTD. SECTION: D1.12
TITLE SHEET 5 OF 9
MECHANICAL SYSTEMS - 4
SPEC. NO.TCE.3837A-H-
500-01
WATER SYSTEMS

filtered water storage tank (located above the water treatment

plant building) by plant potable water supply pumps and
conveyed to potable water storage tanks located on suitable
elevated structures (such as over the station building and the
administration building so as to ensure gravity flow to
consumption points). From these tanks, water should be
distributed to toilets and drinking water points. Drinking water
connections, shall be provided on each floor of all buildings
such that a person does not have to move more than 30 m to
reach any drinking water connection. At each drinking water
connection, a treatment unit such as aqua guard (or
equivalent) and a water cooler shall also be provided. The
potable water pumps shall be located in the water treatment
plant building.

(c) Control panels required for the service water pumps shall be
located in the clarified water pumphouse and the control
panels for the potable water pumps shall be located in the
water treatment plant building.

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CONSULTANT : TCE CONSULTING ENGINEERS LIMITED

 VEMAGIRI POWER GENERATION LTD. SECTION : D1.12
SPEC.NO.TCE.3837A-H- DATA SHEET - A1.12.1
500-01
WATER TREATMENT PLANT SHEET 6 OF 9

SL. NO. UNITS VALUES

A. DM PLANT

Design Code for tanks and pressure IS : 2825/ ASME Sec VIII
vessels

1.0 Pressure Sand Filters

a) Total Numbers Two (2)

b) Number normally operating Two (2)

c) Type Vertical

d) Capacity cu.m/hr Bidder to decide

e) Design Surface Flow Rate cu.m/hr/ 10.00 ( max)

sq.m
f) Air Blowers 2 x 100% capacity

g) Pressure Drop (Clogged condition) 1 kg/sq.cm. (max. including valves

and fittings connected with the
units)

h) Material of Construction (Shell & IS 2062 Gr. A / SA 515 Gr. 60 /

Dished Ends) SA 515 Gr. 70 / SA 285 Gr.C/ FRP

2.0
Activated Carbon Filters
a) Total Numbers Two (2) x 50% capacity

b) Number normally operating Two (2)

c) Type Vertical

d) Capacity cu.m/hr By Bidder

e) Design Surface Flow Rate cu.m/hr/ By Bidder

sq.m
f) Air Blowers 2 x 100% capacity

g) Pressure Drop (Clogged condition) 1 kg/sq.cm. (max. including valves

and fittings connected with the
units)
h) Material of Construction (Shell & IS 2062 Gr. A / SA 515 Gr. 60 /
Dished Ends) SA 515 Gr. 70 / SA 285 Gr.C / FRP

REV. NO. Ro PPD. BY : JOB NO. CLIENT: VEMAGIRI POWER GEN. LTD.
DATE Nov 2001 CKD. BY : TCE. PROJECT : CCPP at Vemagiri
REV. BY DATE : 3837A
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED TCE FORM 330 R1
 VEMAGIRI POWER GENERATION LTD. SECTION : D1.12
SPEC.NO.TCE.3837A-H- DATA SHEET - A1.12.1
500-01
WATER TREATMENT PLANT SHEET 7 OF 9

3.0 Ion Exchange Units

a) Number of streams Two (2) x 50% capacity

b) Number of units/stream One (1)

c) Flow rate/stream cu.m/hr Refer Water balance diagram.

d) Output between regeneration

For SAC and WBA / SBA units cu.m By Bidder

For MB units Cu.m By Bidder

e) Surface Flow rates

i) Strong acid Cation exchanger cu.m/hr/ > 10 and < 40

sq.m

ii) Strong base Anion Exchanger/Weak cu.m/hr/ > 10 and < 40

Base Anion Exchanger sq.m

iii) Mixed Bed > 10 and < 60 cu.m/hr/sq.m

f) Material of Construction (Shell & IS 2062 Gr. A / SA 515 Gr. 60 /

Dished Ends) SA 515 Gr. 70 with 4.5mm thk
rubber lining / FRP

g) Bidder to note that the design for

each stream shall be in such a way
that in the event of one of the
streams not working / out for
maintenance, the other stream shall
be capable of catering to twice
the load with 2 regenerations per
day.

4.0 Degasser system

i) Type Forced draught

ii) No. required One common for both the streams

iii) Capacity m3/hr By Bidder

iv) Degassed water tank

a) Quantity One common for both the streams

REV. NO. Ro PPD. BY : JOB NO. CLIENT: VEMAGIRI POWER GEN. LTD.
DATE Nov 2001 CKD. BY : TCE. PROJECT : CCPP at Vemagiri
REV. BY DATE : 3837A
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED TCE FORM 330 R1
 VEMAGIRI POWER GENERATION LTD. SECTION : D1.12
SPEC.NO.TCE.3837A-H- DATA SHEET - A1.12.1
500-01
WATER TREATMENT PLANT SHEET 8 OF 9

b) Capacity By Bidder (To hold 1.5 degassed

water required for one stream
regeneration)

c) Material of construction MSRL / FRP

v) Degassed Blowers

a) Quantity 2 x 100%

b) Capacity By Bidder

5.0 Regeneration Equipment

a) Regenerant Chemicals 30% HCl and 48% NaOH

b) Bulk Chemical Storage Tank 2 tanks each for storing 30% HCl
capacity and 48% NaOH. Each tank shall
be of 15 tons storage capacity.

c) Acid & Caustic Dilution Stations Dilution tanks adequate for one
regeneration, with 20% margin on
capacity, online mixing tees with
block & bleed, and ejectors.

d) Materials of construction of chemical FRP/MSRL

tanks

e) Acid unloading pumps 2 x 100% each of capacity 15

cu.m/h and 10 mLC, 3000 rpm
speed

f) Alkali unloading pumps 2 x 100% each of capacity 15

cu.m/h and 10 mLC, 3000 rpm
speed
g) Material of construction of acid / Poly propylene
alkali unloading pumps

6.0 DM water storage tank (details also

covered in Section D 1.8)
2
i) Quantity
M3 150 (each)
ii) Capacity
MS epoxy painted
iii) Material of Construction

7.0 Neutralising Pumps 2 x 100% capacity sump pumps.

REV. NO. Ro PPD. BY : JOB NO. CLIENT: VEMAGIRI POWER GEN. LTD.
DATE Nov 2001 CKD. BY : TCE. PROJECT : CCPP at Vemagiri
REV. BY DATE : 3837A
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED TCE FORM 330 R1
 VEMAGIRI POWER GENERATION LTD. SECTION : D1.12
SPEC.NO.TCE.3837A-H- DATA SHEET - A1.12.1
500-01
WATER TREATMENT PLANT SHEET 9 OF 9

8.0 Sodium Hypo Chlorite ( NaOCl) Dosing 2 x 100% capacity NaOCl dosing
System pumps, 2 Nos.dosing tank each of
capacity to store one shifts
requirement of chlorine.

9.0 Alum dosing system 2 x 100% capacity dosing pumps

with SS 316 wetted parts,
reciprocating type, 2 nos, tanks
each of capacity to store one shift
requirement.
10.0 Piping and valves

a) Pipe materials

i) Corrosive Service Stainless steel ; MSRL for acid

service only

ii) Normal service Steel to ASTM A53, Gr-B or

IS 1239 Heavy class

11.0 Eye wash fountain, safety shower To be provided

12.0 Effluent quality (min) to be guaranteed

from various units:
12.1 Pressure sand filter Turbidity = not greater than 2 ppm on
the silica scale at max flow rate

12.2 Strong acid cation unit Sodium at the outlet = not greater
than 1 ppm as Ca CO3 (av. leakage)

12.3 Degasser unit Carbon-di-oxide at the outlet = not

greater than 5 ppm as CO2 at max.
flow rate

12.4 Strong base anion unit i. Silica at the outlet = 0.1 ppm as
SiO2
ii.CO2 at outlet = Nil
iii.Conductivity = not greater than 6
micro mho/cm

12.5 Mixed bed unit Total solids at the outlet = not greater
0.15 ppm in which silica shall not
exceed 0.02 ppm
Conductivity at the outlet = not greater
than 0.1 micro-mho/ cm @ 25 deg. C

REV. NO. Ro PPD. BY : JOB NO. CLIENT: VEMAGIRI POWER GEN. LTD.
DATE Nov 2001 CKD. BY : TCE. PROJECT : CCPP at Vemagiri
REV. BY DATE : 3837A
CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED TCE FORM 330 R1