Project NEBULA

BASIC ENGINEERING

CONCEPT NOTES FOR

WTP PLANT

Document Number
P90-UL73-01-001

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1.0 INTRODUCTION
Aim:

 To design water network for overall plant.

 Install DM Plant, Softener Plant, Polishing Softener facility of capacity 5 m3/h, 3m3/h and
5m3/h respectively.

Sources:

DM Water:

Quantity/ Frequency per

Tag
Product Operation Batch (L) day
Five times a
Alkylation (step-4) water washing 1339 week
EHT 96R4.G
Five times a
Alkylation (step-4) water washing 1339 week
Reaction of RB-700
95R3.G Amidification reaction 1st washing 1367 Once in a week
95R4.G MDC Layer second wash 586 Once in a week

Sunbeat Recovery of MDC and filtration of RB700

SSR (4 KL) Washing of RB-700 566 Once in a week
Once in a
SSR (3.5 KL)
RB-900 Reaction (filtration) 1788 month
Once in a
GLR (4 KL)
Sunbeat reaction 1212 month
91R1.G Sodium bicarbonate solution for washing 800 Twice a week
CCTG
91R2.G Sodium bicarbonate solution for washing 456 Twice a week
Once in 15
95R1.G Behnyl chloride reaction 361 days
Galhushield Once in 15
95R4.G Synthesis of Galhueshield days
1407
KCP 93R2.G Potassium Cetyl Phosphate Process 4460 Twice a day
Reactor Reactors washing Reactors washing 9000 Once in a day
Dryer Drying unit washing Drying unit washing 2000 Once in a day
Filtration unit
Filtration washing Filtration unit washing 4000 Once in a day

Peak load: - 2.2 m3/hr.

Considering regeneration, future load we need 4 m3/h capacity of DM plant but for auto
regeneration may have 3m3/h and 5m3/h model hence we are going for higher size while selection
of DM plant 5 m3/h.

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Soft water:

Quantity Frequency
Product Tag Operation
(Lit/day) per day
Boiler 71B1.G Feed water for steam generation 48,000 Once a day

Peak load: - 2.1 m3/hr.

Note: Considering 40% condensate recovery we need to add 60% fresh water and future load we
have selected 3 m3/h softener plant.

2.0 PHILOSOPHY

Raw water:
 MIDC water is collected in UG storage tank and then passed through sand filter (20 m3/h)
and transferred in overhead terrace RCC (20 KL) storage tank.
 This raw water is further treated in WTP to generate Soft Water and DM water
User Points:
• Fire Hydrant and Sprinkler
• Safety Shower
• Eye washer
• Wash Basin

RO Water
 RO water is collected in 100 KL UG RCC storage tank in ETP area from this will be
transferred in 20 KL overhead RCC tank at plant building.
 Specific user points are connected from this RO tank
 Pump will be installed at underground RCC RO permeate tank which will work on the level
of 20 KL RCC overhead storage tank
User points:
 Cooling Tower
 Boiler
 HCL Scrubber
 Chiller
 ETP
 Toilets
 Floor Washing
 Gardening

Soft water:
 Boiler

DM water:
 Process
 Reactor washing

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Process:
DM Water:
 Raw water from overhead tank will be used in DM plant.
 Treated water from DM plant is passed through UV cell before transferring to process water
storage tank.
 Ozone dosing will be there for storage tank in continuous circulation loop.
 UV will be in line for circulation loop which is optional for ozone dosing.
 Also UV installed at individual section in plant area near user point.
 Process water will be stored in SS316L storage tank with circulation pump.
 Process water network for plant is connected in closed continuous loop with transfer pump.
 Chloride content and hardness for process water at battery limit of system will be nil.
 Regeneration of Cation will be done after 70m3 and for Auto swift model at 25 m3/hr
respectively water treatment with respective chemical (i.e. HCL, Caustic and Formalin).
 Effluent generated after regeneration will be sent to effluent treatment plant through
blowdown pit.
 Regeneration solution will be prepared in FRP tank.

Feed Water Quality Outlet water Quality

Ph 6.5-7.5 5 to7
Free chlorine 1-1.5 PPM Nil PPM
TDS 200 PPM - PPM
Conductivity 100-150 µS <1 µS
Turbidity <5 NTU <1 NTU
Hardness <50 PPM Nil PPM
Capacity 4 m3/h
Operating Pressure 3.5 bar g
Operating temp 30-40 Deg. C

Soft Water:
 Soft water produced by treatment of raw water through softener plant.
 Treated water from softener is transferred to boiler feed water tank.
 Total hardness for soft water at battery limit of system will be less than 5 PPM.
 MGF and ACF will be backwashed once in day.
 Regeneration of softener will be done after 80m3 water treatment with NaCl solution.
 Effluent generated after regeneration will be sent to effluent treatment plant.
 NaCl solution will be prepared in 225 litres P.V.C. tank for regeneration.
 Condensate polishing softener will be installed for polishing of condensate return from
plant.
 Condensate from plant will be stored in SS304 tank then passed through MS softener for
polishing before adding to boiler feed water tank

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Process Flow:

DM Water:
Refer attached P&ID.

Soft water:

Mechanical:

Construction:
Multigrade sand filter:
 FRP Vessel with Multi grade sand Filtering Media and internal Distribution System.
 This is considered for removal of suspended solids and turbidity in the water. This is to
safeguard the downstream equipment’s such as micron filters, other polishing systems
and UV. Chlorinated water helps sand filter less prone for microbial growth. Sand filter
will remove macro level particles.

Activated Carbon Filter:

 FRP Vessel with charge of activated carbon Media and internal Distribution System.
 designed with carbon media in a Down flow bed design. The impurities like colour, odour
& organics along with slipped suspended particles are removed from the raw water thus
ensuring and preventing any undesirable substances to flow into the DM Plant.

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Strong acid cation:
 FRP Vessel Charge of INDION 225 H resin Filtering Media and internal Distribution
System.
 The water from activated carbon filter shall be passed through a strong acid cation
column for de-cationising the water (i.e. removing Ca, Mg and Na) by replacing the
cations with H + IONS available in the resin. The column shall be regenerated in the
CCR (Continuous catalytic regeneration) mode of regeneration i.e. the service is in the
down flow direction and the regeneration is up flow. The CCR Mode ensures that
consistently low sodium residual treated water is obtained throughout the cycle.

Degasser Tower:
 FRP tower with HDPE tank and blower.
 Feed water from Cation column to Degasser tower to remove the Carbon Dioxide. Water
containing Bicarbonates when passed through the Cation Exchanger is converted to
Carbonic Acid. The Carbonic Acid easily breaks into Water and Carbon Dioxide.

HCO3 = H2O + CO2

 Degasser helps remove the Carbon Dioxide from the water which otherwise gets into the
Anion exchanger and loads the exchanger. The Carbon Dioxide is considerable and the
quantity of the resins increases and hence the capital cost and also the recurring cost of
the Alkali for regeneration.

Strong Base Anion:

 Anion exchange bed will be consisting of FRP pressure vessel, internals and necessary
pipe work. With first charge of resin.
 The de-cationised water from strong acid cation shall be passed through a strong base
anion unit for removal of anionic impurities by exchanging the anions (i.e. Cl, SO4, SiO2,
NO3, CO3) and alkalinity with HO -ions available in the resin.
 WBA resins do not remove silica, C02or have the ability to neutralize weak acids and
has a lower than neutral pH when used in a dual separate bed system.
 SBA resins remove all anions in the above table, including C02, and has a higher
than neutral pH when used in a dual separate bed system due to sodium leakage.

Mix Bed:
 Polisher unit bed, FRP vessel, internals, and pipe work.
 Mixed bed resins use SAC and SBA resins combined together
 Mix bed unit, which polishes the water further for obtaining water of desired quality and
for pH correction. The treated water is collected in a DM water tank.

Softener bed:
 FRP Vessel Charge of INDION 225 Na resin Filtering Media and internal Distribution
System.

Polishing Softener:
 Raw Water has Salts of Calcium (Ca++) and Magnesium (Mg++). It imparts hardness to
water eventually leads to formation of scales. These compounds forms deposit and scale
on applied area and reduces process efficiency at great extent. Softener converts
Hardness imparting salts into Sodium salts and removes raw water hardness thus
improves water potential and its usability. The softener comprises of strongly acidic
cation exchanger resin in Sodium form (Na+). It exchanges the sodium ions for the

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hardness cations. Water passes through resin bed and exchanges its Calcium and
Magnesium ions with sodium ions. It forms respective sodium compounds in water and
thus softens the feed water. After completion of each designed service cycle, exchanger
has to be regenerated with Sodium Chloride solutions i.e. Common salt (NaCl).

Piping:

DM Water:
 All interconnecting piping of DM unit is of PVC piping.
 Pump suction and discharge pipes and pipe fittings will be SS316 for process water from
storage tank to plant.
 Pipe sizes will be sized from detail engineering.
 Feed water piping is of SS304 for DM plant from overhead raw water RCC storage tank.

Soft water:
 Two Y strainer CS body with 40 mesh, SS304 filtering element will be used in the suction
of the feed pumps to filter any contaminants. One filter will be in line while the other will
be a standby filter.
 Set of UPVC frontal Pipe work with side mounted Multi-port valves
 All interconnecting piping of UPVC.
 All piping apart from softener plant will be of MS.

Valve:
DM Water:
 DM unit is operated by hydro pneumatic valves made of engineering thermoplastics
along with PVC piping.
 Manually operated Ball valves with SS316 body and neoprene seat will be used for
process water.
 The above valves are either DOPC (Diaphragm operated pressure to close) or DOPO
(Diaphragm operated pressure to open) depending on the stages of operation and
application.
 Three-way solenoid valves are used for operating the pipe line valves in the sequence
required during the regeneration cycle.

Soft water:
 All valves of MGF, ACF and softener will be of multiport UPVC.
 CS Ball valve will be used after softener plant and feed water line.

Gaskets:
 All gaskets used in process water plant line will be PTFE.
 All gasket used in DM plant interconnecting piping will be of rubber.
 All gasket should be of rubber for all interconnecting piping and for treated water is of
non-asbestos (Champion) for soft water.

Utility:
 MIDC water for DM & Softener Plant and steam condensate for polishing softener.
 RO permeate water for polishing softener

Civil:
 It will be discussed in separate concept notes
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Electrical:
 The system will be considered under non-flameproof area.
 The motors used will be of IE3 class for all the running equipment.
 It will have proper lighting arrangement for proper illumination in night.
 All running equipment’s will have local emergency stop button with protection.
 All the equipment and structure will have double earthing.
 Further more details will be included in concept notes of electrical.

Instrumentation:
DM Water:
 Overhead RCC tank will have level switches interlocked with Auto DM feed pump.
 Conductivity sensor will be installed at the outlet of the anion unit.
 Programmable Logic Controller is designed to operate a bank of solenoid valves in the
regeneration sequence, which in turn operates the piping valves
 Pressure transmitter installed at outlet of DM Plant having interlock with feed water
pump.
 Additionally, the instrument panel has Resistivity meter, which can be set to the desired
valves. Flow meter/totalizer, Push button for manual initiation
 unit is provided with a Flow meter / Flow totalizer at outlet of DM plant.
 Interlocks are provided in the panel of level switch of various tanks viz. feed water tank,
DM tank, Acid/ Alkali tanks.
 Pressure gauge will be installed at discharge of pump and inlet piping of each column
 Pressure gauge will be installed at candle filter (5 micron).
 Level transmitter will be installed at storage tank having interlock with feed water pump

Soft Water:
 Pressure gauge will be installed at discharge of pump and inlet piping of each column
 Level transmitter will be installed at boiler feed water tank having interlock with feed
water pump
 Pressure gauge to monitor the pressure drop across each column.
Polishing softener:
 Pressure gauge will be installed at discharge of pump and inlet piping of column
 Level switch (Normal float type) will be installed at condensate collection tank having
interlock with polishing softener feed water pump

Warehouse and Storage:

 Caustic, HCL and NaCl will be stored at warehouse.

Safety:
DM Water:
System will have following safety interlock
 Feed tank will have level switches interlocked with Auto DM feed pump.
 Pressure transmitter installed at outlet of DM Plant having interlock with feed water
pump.
 Audible alarm with panel reading low level for Low level in feed tank, DM tank, Acid /
Alkali tanks.
 audible alarm and also display NO AIR SUPPLY in case pneumatic air supplies to the
auto valves are not adequate or air supply has stopped

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 In case half way during regeneration there is power shut down, the unit will remember the
step at which it halted and will resume with the regeneration of unit from the point at
which it halted when the power resumes.

Soft Water:
 The feed tank will have level switches interlocked with feed water pump.

3.0 SIZING

DM Plant:

Sr. No. Equipment Tag No. Capacity Unit

1 Multigrade Filter 73F3.G 5 m3/hr.
2 Activated Carbon Filter 73F4.G 5 m3/hr.
3 Strong acid cation 73C3.G 5 m3/hr.
4 Degasser 73DG1.G -
5 Cation 73C4.G 5 m3/hr.
6 Strong Base Anion 73C5.G 5 m3/hr.
7 Polisher bed 73C6.G 5 m3/hr.
8 Feed Pump 73P2A/B.G 5 m3/hr.
9 Process water Storage tank 73T3.G 13 KL
10 Acid measuring tank 73T4.G 0.225 KL
11 Caustic dilution tank 73T5.G 0.225 KL
12 Process water tank circulation pump 73P3.G 4 m3/hr.
13 Process water plant circulation pump 73P5.G 15 m3/hr.

Softener Plant:

Sr. No. Equipment Tag No. Capacity Unit

1 Multigrade Filter 73F1.G 3 m3/hr.
2 Activated Carbon Filter 73F2.G 3 m3/hr.
3 Softener 73C1.G 3 m3/hr.
4 Feed Pump 73P1A/B.G 3 m3/hr.
5 Salt preparation tank 73T2.G 0.225 KL
6 m3/hr.
Raw water transfer pump 73P4.G 20

Polishing Softener Plant:

Sr. No. Equipment Tag No. Capacity Unit

1 Polishing Softener 73C7.G 5 m3/hr.
2 Feed Pump 73P8.G 5 m3/hr.
3 Condensate collection tank 73T3.G 2.25 KL

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4.0 LAYOUT

DM plant: -

Softener plant: -

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5.0 ANNEXURE

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