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The document provides details on the water treatment system for Vinh Tan 4 Thermal Power Plant. It describes the various subsystems including pretreatment, desalination, demineralization and potable water. The pretreatment system involves clarification, filtration and ultrafiltration to remove solids and particles. The desalination system uses seawater reverse osmosis to produce demineralized water for use. It includes cartridge filters, high pressure pumps and energy recovery devices. Chemical dosing and cleaning systems are also included.

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100% found this document useful (1 vote)

269 views535 pages

Chemical

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POWER ENGINEERING

VIETNAM ELECTRICITY CONSULTING JSC 3

VINH TAN 4 THERMAL POWER PLANT

PROJECT (2X600MW)

TRAINING MANUAL
FOR
WATER TREATMENT SYSTEM

DMPP Consortium(Input the Team or Vendor Name)

WATER TREATMENT SYSTEM

TABLE OF CONTENTS

1. SYSTEM DESCRIPTION

1.1 PRETREATMENT SYSTEM

1.2 DESALINATION SYSTEM
1.3 DEMINERALIZATION SYSTEM
1.4 POTABLE WATER SYSTEM
1.5 CHEMICAL DOSING SYSTEM

2. CONTROL PHILOSOPHY

1.1 PRETREATMENT SYSTEM

1.2 DESALINATION SYSTEM
1.3 DEMINERALIZATION SYSTEM
1.4 POTABLE WATER SYSTEM

3. HMI GRAPHIC & OPERATION MANUAL

3.1 HMI START OPERATION

3.2 SYSTEM SECURITY
3.3 SYMBOL ILLUSTRATION
3.4 OPERATION GRAPHIC
3.5 POP-UP

1
WATER TREATMENT SYSTEM

1. SYSTEM DESCRIPTION

2
WATER TREATMENT SYSTEM

1. SYSTEM DESCRIPTION

Raw water will be supplied from circulating water pump and raw water supply pump. Raw water continues to be
pumped into high rate solid contact clarifier as lamellar type. Alkalinity shall be dosed in the inlet line of clarifier to
regulate pH value to an optimum level for coagulation – flocculation process followed by addition of suitable
coagulant. Coagulant will be added to increase the size of particles for effective settling. Flocculants shall be
added into the clarifier to interconnect and enmesh the colloidal particles into giant flocs. The sludge scraper in
operation continuously moves the precipitates settling on the floor of the clarifier, to the central sump where they
will be transferred to sludge thickener by pumps. Clarified water will be pumped to disc filter and Activated Carbon
Filter. As a safeguard and for polishing, the filtrate from disc filter and Activated Carbon Filter will be passed
through UF unit to arrest the leakage of suspended solids from the disc filter & Activated Carbon Filter. The
pretreatment filtration will produce water of a quality that satisfies the requirements as a suitable feed for the
downstream SWRO or BWRO in case of raw water. The Demineralized water system consists of filtration system,
Chemical injection system, SWRO & BWRO system, MBP system and chemical cleaning system, flushing system.
That is, impurities of raw water are removed through filtration system with chemical injection system, filtered raw
water is transferred to filtered water storage basin. After SWRO & BWRO system, raw water is converted to
desalinated water and desalinated water is transferred to Service/Fire fighting water tank. For chemical cleaning
SWRO & BWRO units, some desalinated water is stored at chemical cleaning tank and transferred to SWRO &
BWRO units through micro filter by chemical cleaning pump and for flushing SWRO& BWRO units at finished
cleaning, flushing pump shall be operated. Service water will be potabilized for potable water use. Activated
Carbon Filter removes the organic matter, COD, residual clorine. The potabilization system will consist of feeding
sodium hypochlorite to disinfection of the potable water. The chemicals are stored in tanks that provide suction
directly to their respective feed (metering) pump.

3
WATER TREATMENT SYSTEM

1.1 PRETREATMENT SYSTEM

 Clarifier

Raw water enters 2 x 50% the lamella clarifier where it is flash mixed with a polymer flocculant and then gently
agitated with a separated mixer. The water flows downward through the inlet chamber in the center of the unit and
enters the plate rack through sideentry plate slots. This cross-current entry method reduces the risk of disturbing
previously settled solids. As the liquid flows upward, the solids settle on the inclined, parallel plates and slide into
the sludge hopper at the bottom. The clarified liquid leaves the plate assembly through orifices or weirs at the top
and is distributed into collection channels leading to the clarified water outlet. Underflow is removed by the sludge
scraper and dewatered prior to disposal.

 Coagulant & Coagulant Aid Dosing System

Coagulant is be added to increase the size of particles for effective settling. Flocculants shall be added into the
clarifier to interconnect and enmesh the colloidal particles into giant flocs Coagulant & Coagulant Aid Dosing
System comprises of the following equipment :
- 1 x 100% Coagulant Injection tank
- 1 x 100% Coagulant Aid Dissolving System
- 2 x 100% Coagulant Injection pump for Clarifier.
- 3 x 50% Coagulant Aid Injection pump for Clarifier.

The stroke of the Coagulant Injection Pumps will be adjusted automatically based on the raw water flow transmitter
signal.

4
WATER TREATMENT SYSTEM

1.1 PRETREATMENT SYSTEM

 Disc Filter & A/C Filter for Pretreatment

In order to achieve the desired filtered water quality in the outlet of the filtration system, a two stage filtration
process is envisaged. It comprises of Disc Filter and Activated Carbon Filter. These stages have 3 x 50% train,
sized to give the desired flow velocities through them and to enable achieving the water quality. The filtering media
of Activated Carbon Filter consists of gravel and activated carbon as filtration media. Activated Carbon Filter is
provided with a differential pressure transmitter across it. Because it’s stable operation to check differential
pressure and backwash process whenever filtration

 A/C Filter Backwash Pump for Pretreatment

2 x 100% Backwash pumps are provided to carry out backwash operation of the filters. The backwash pump starts
and delivers water to the underside of the filter beds and washes out the trapped particles from the bed.

 UF Feed Pump

These pumps are mounted on the skid of plant area. Each pump caters to the flow requirement of one UF train.

5
WATER TREATMENT SYSTEM

1.1 PRETREATMENT SYSTEM

 UF (Ultrafiltration) Unit

3 x 50% Ultrafiltration (UF) is a separation process using membranes with pore sizes in the range of 0.02 micron.
Typically, UF membranes will remove high molecular-weight substances, colloidal materials, organic and inorganic
polymeric molecules. Low molecular-weight organics and ions such as sodium, calcium, magnesium chloride, and
sulfate are not removed by UF Membranes. Because only high-molecular weight species are removed, the osmotic
pressure differential across the UF Membrane surface is negligible. Low applied pressures is therefore sufficient to
achieve high flux rates from an Ultrafiltration membrane. Flux of a membrane is defined as the amount of permeate
produced per unit area of membrane surface per unit time.

 UF Backwash Pump

3 x 50% UF Backwash Pumps are provided to carry out backwash operation of the filters. The UF membranes are
cleaned on a regular basis by means of backwash (BW) and Chemical Enhanced Backwash (CEB). During BW the
UF membranes are cleaned outside-in with part of the permeate produced.

 UF CIP Tank & Cartridge Filter for UF CIP

UF CIP Tank (1 x 100%) is used to prepare and store the UF cleanup solution. It is equipped with an agitator to
ensure adequate mixing of the solution. A heater is also provided to elevate the temperature of the solution. An
elevated temperature is necessary for cleaning the UF membranes. UF CIP Cartridge Filter (1 x 100%) is a micron
cartridge filter rated at 5 μm nominal particle size. This is installed in the UF cleanup system to ensure that
suspended solids, if any, present in the UF cleanup solution are trapped before reaching to membrane.

6
WATER TREATMENT SYSTEM

1.2 DESALINATION SYSTEM

 SWRO Feed Pump

2 x 100% SWRO Feed Pumps are provided so as to feed the Filtered water to the SWRO Units. These pumps are
mounted on the skid of plant area. Each pump caters to the flow requirement of two SWRO trains.

 Cartridge Filter for SWRO

In order to guard the SWRO membranes from the particulate matter going into them, SWRO cartridge filters are
provided. 2 x 100% capacity cartridge filters are provided in this plant. These cartridge filters are provided with
suitable vent and drain valves that are to be manually operated. The cartridge filters are provided with a differential
pressure transmitter across it. The Cartridge Filters become due for replacement when the differential pressure
across the filters goes beyond a set point.

7
WATER TREATMENT SYSTEM

1.2 DESALINATION SYSTEM

 SWRO High Pressure Pump

Each SWRO train is fed by a dedicated SWRO high pressure pump sized adequately for the duty. 3 x 50% SWRO
high pressure pumps are provided. Each pump is provided with a Variable Frequency Drive (VFD) so that an
optimum performance and power consumption are achieved at various system operating conditions.

 Energy Recovery Device (PX Type)

The Energy Recovery Device(PX Type) recovers hydraulic energy from the highpressure reject stream from a
SWRO system and transfers it to low-pressure feed water. In a typical RO system, pressurized feed water from the
PX devices is pumped to the SWRO membranes by Circulation Pump.

 Circulation Pump

2 x 50% Circulation Pump boosts the pressure in the high pressure flow of a SWRO energy recovery system to
make up for the small pressure losses that occur through the membranes, the ERD and the associated piping.

8
WATER TREATMENT SYSTEM

1.2 DESALINATION SYSTEM

 SWRO Unit

The SWRO Membrane assembly consists of 2 x 50% trains with single stage system. The 8” x 40” SWRO
membranes are loaded in a pressure vessel of 7 elements long. The entire SWRO train is stacked in mounting
frames for easy operation and maintenance. The unit comprises of suitable feed headers, permeate header and
reject header. Reject control valve station is also provided so as to enable adjustment of the recovery of the plant
to the desired level. The reject control valve will adjust the feed and reject pressures in such a way that adequate
permeate pressure will be available for water to flow to the Service Water Tank. SWRO unit is provided with
pressure transmitters at feed and reject sides. The differential pressure between feed and reject will be computed
in PLC and will indicate when the membranes become due for cleaning. SWRO permeate line is provided with the
conductivity transmitter and analyzer. This will indicate if the individual SWRO train is working and producing
satisfactory quality water.

9
WATER TREATMENT SYSTEM

1.3 DEMINERALIZATION SYSTEM

 BWRO Feed Pump

2 x 100% BWRO Feed Pumps are provided so as to feed the desalinated water to the SWRO Units. These pumps
are mounted on the skid of plant area. Each pump caters tothe flow requirement of two BWRO trains.

 Cartridge Filter for BWRO

In order to guard the BWRO membranes from the particulate matter going into them, BWRO cartridge filters are
provided. 2 x 100% capacity cartridge filters are provided in this plant. These cartridge filters are provided with
suitable vent and drain valves that are to be manually operated. The cartridge filters are provided with a differential
pressure transmitter across it. The Cartridge Filters become due for replacement when the differential pressure
across the filters goes beyond a set point.

 BWRO High Pressure Pump

Each BWRO train is fed by a dedicated BWRO high pressure pump sized adequately for the duty. 3 x 50% BWRO
high pressure pumps are provided. Each pumps are provided with a Variable Frequency Drive (VFD) so that an
optimum performance and power consumption is achieved at various system operating conditions.

10
WATER TREATMENT SYSTEM

 MBP Feed Pump

The Degasified water from the Degasified Water Tank is pumped by means of 2 x 100% MBP feed pumps through
Mixed Bed Polisher for further reduction of dissolved solids to make it suitable for boiler feed application and then
stored in the downstream Demineralized Water Storage Tanks.

 Mixed Bed Polisher

The 2 x 100% Mixed Bed Polisher are cylindrical vertical vessels with dished ends. These hold the charge of anion
exchange and cation exchange resins in mixed condition. The feed water enters the vessel from top and passes
down through the ion exchange resin beds and the effluent from the bed is the demineralized water. The vessel
isequipped with inlet distribution system, bottom collection system and the middle collector system. The resin beds
require regeneration using the acid and caustic injection after the preset quantity of water is passed through it or
the quality of effluent is not as per the specifications. The MBP has both Strong Acid Cation resin and Strong
BaseAnion resin mixed in a single vessel. The regeneration of these resins is carried out i.e. cation by acid and
anion by caustic. This unit ensures consistent quality of demineralized water. The demineralized water is sent to
demineralized water storage tanks.

13
WATER TREATMENT SYSTEM

 Acid Dosing System

High pH of RO influent will cause scaling of reverse osmosis. Thererfore, it is recommended to dose Acid at the
upstream of SW/BW RO cartridge filters with a static mixer. Also it is used to preserve in case of emergency.

Acid Dosing System comprises of the following equipment :

- 1 x 100% Acid Storage Tank
- 2 x 100% Acid Transfer Pump
- 1 x 100% Acid Injection Tank for SW&BWRO
- 1 x 100% Acid Injection Tank for MBP
- 2 x 100% Acid Injection Pump for SWRO
- 2 x 100% Acid Injection Pump for BWRO
- 2 x 100% Acid Injection Pump for UF CEB
- 2 x 100% Acid Injection Pump for MBP

17
WATER TREATMENT SYSTEM

1.5 CHEMICAL DOSING SYSTEM

 Caustic Dosing System

Permeate from SWRO Units is combined into permeate header and it is then dosed with NaOH at 45%
concentration.

Caustic Dosing System comprises of the following equipment :

- 1 x 100% Caustic Storage Tank
- 2 x 100% Caustic Transfer Pump
- 1 x 100% Caustic Injection Tank for Clarifier
- 1 x 100% Caustic Injection Tank for SWRO
- 1 x 100% Caustic Injection Tank for MBP
- 2 x 100% Caustic Injection Pump for Clarifier
- 2 x 100% Caustic Injection Pump for SWRO
- 2 x 100% Caustic Injection Pump for MBP

The stroke of the Dosing Pumps will be adjusted automatically based on the signal of the pH transmitter installed
on the pipe header.

18
WATER TREATMENT SYSTEM

2. CONTROL PHILOSOPHY

2.1 PRETREATMENT SYSTEM

 Automatic Clarifier Operation

Step Operator Action and PLC sequence Process and Control System Reaction

Step 01 For Automatic Start Sequence, PLC. Navigate to “Pretreatment System Auto / Manual Start Station”
Operator must LOG-IN prior to operating the Plant. Only Authorized Operators shall have access to the HMI systems!
Ensure all AUTO/MANUAL selector switches are in AUTO and EXCEPTION: The Clarifiers may be in the OFF position and autom
LOCAL/REMOTE selector switch is in REMOTE. ated start of the system is allowed, However the manual clarifier byp
Select LEAD/LAG for pumps in the system. ass Stop Gate must be closed MANUALLY, and the clarifiers shoul
Note: Selecting a lead pump tells the control system which pump d be drained if off for an extended period!
shall start first. All pumps are alternated in case of failure In the Raw Water System, the lead/lag pumps are in order. If pump 1
automatically and sequenced if demand calls for additional load is selected, pump 2 shall be standby
if specified.
Raw Water Pump Fails if run feedbacks exceeds 3 to 5 seconds
(adjustable)
-Sea water mode : CWP
-Lake water mode : Raw Water Supply Pump

Step 2 If all systems are in AUTO , all tanks are at acceptable levels, the If PLC start is selected, the stop/start buttons on the PLC screen will
operator may select “PLC START” disappear. At any time, the operator may select “PLC” and obtain co
In PLC mode operator can Initiate by START button. ntrol of the plant.
In Remote mode PLC group Start signal will initiate start process. Once system is started, it will stop at HIGH level in Clear well and r
estart at LOW level unless it is STOPPED by operator.
If the any system or sub-system go into an ALARM, the control auto
matically switches to “PLC”.
Check feedback for Raw Water pump

19
WATER TREATMENT SYSTEM

2.1 PRETREATMENT SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 2a Caustic, Coagulant and Coagulant Aid injection will remain OFF
during Clarifier stop

Step 2b Clarifier in SERVICE, Start-up will be as follows:

START Chemical injection Caustic injection is proportional to pH

 Coagulant
 Coagulant Aid Check RUN feedback for “Agitator for Coagulation Basin”
 Caustic
Check RUN feedback for “Agitator for Flocculation Basin”
Time delay for 3 min (adj) then START
“Agitator for Coagulation Basin” (P0GBR17 / 18AM001) The VFD for “Agitator for Flocculation Basin” is operated manually
Time delay for 10-15 min (adj), START at the decision of the operator.
“Agitator for Flocculation Basin”
(P0GBR19/20AM001)
Step 2c START adjustable “SLUDGE DUMP CYCLE” timer for 6 to 24 Check open feedback for Sludge Dump valve P0GBD11/12AA051
Hours (adj).

Every Sludge dump cycle timer is complete, OPEN Sludge valve

(P0GBD11/12AA051) for (adj) 5 min SLUDGE DUMP DURAT Check Close feedback for Sludge Dump valve P0GBD11/12AA051
ION timer.
After completion of Sludge Dump Duration timer, close Sludge D
ump valve P0GBD11/12AA051

20
WATER TREATMENT SYSTEM

2.1 PRETREATMENT SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 03 IN-SERVICE Sludge Transfer System

The Sludge Transfer Pump in AUTO. Check Run feedback for Sludge Transfer Pump
Sludge from the Clarifiers is transport to sea water waste pond. T
he Associated Valves for each pump are interlocked and shall ope
n when a pump start command is given in AUTO or Manual.

Step 04 Clear Well Operation

The level Transmitter located in the clear well, (P0GBL11CL001) If the level of the Clear Well is low, Clarified Water Transfer Pump
Provides an analog signal scaled 0-100% to the PLC. is stop

The PLC Checks Raw Water Pump feedback, - ALARMS : if no fee

dback is detected in a set time, (Adjustable)
Step 05 Clarifier System Stop

If system is selected PLC and AUTO If the Clear Well Level is HIGH or operator STOP initiated, system
mode, then shutdown will be initiated by will be set in to Stand-By mode If shut down by FAULT, Type-II sh
Clear Well Level High (P0GBL11CL001) or Operator can press utdown the system will be DIABLED and cannot take part in autom
STOP button, or atic operation until FAULT is reset.
If system is selected in PLC control, upon
Group Stop signal Pretreatment shutdown system will be initiated
as follows.

21
WATER TREATMENT SYSTEM

2.1 PRETREATMENT SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 06 Clarifier Shutdown/Stopping

Stop lead Sludge Transfer Pump Check pump stop feedback
P0GBD14/15AP001
Stop Agitator Check Agitator & Scraper stop feedback
P0GBR17/18/19/20AM001
Stop Scraper Check valve close feedback
P0GBD16/17AM001
Upon confirmation of pump stop feedback
Close service inlet valve
P0GBR21AA051
Close Sludge Dump valve P0GBD11/12AA051

22
WATER TREATMENT SYSTEM

2.1 PRETREATMENT SYSTEM

 Automatic Disc Filter Operation

Step Operator Action and PLC sequence Process and Control System Reaction

Step 01 Clarified Water Transfer Pump - Disc filter

In AUTO, Pump Fail if start feedback exceeds 3 to 5 seconds (adjustable)
Valve OPEN : P0GBB11/12AA051,
Put All Disc filter SERVICE position as per table 4.1 Check Start/Stop feedback for Clarified Water Transfer Pump
The two Clarified Water Transfer Pumps (P0GBK11/12AP001) alternat
es based on the Lead Switch in the PT Start Station in the HMI. Check Open/Close feedback for Disc Filter inlet valve (P0GBB11/12/13AA
051)
The Clarified Water Transfer Pumps are controlled by the Buffer pond
Level (P0GBL21CL001) and Clear Well Level (P0GBL11CL001). If th
e level in the Clear Well (P0GBL11CL001) drops below “Low” level th
e lead pump will stop pumping water into the filters. The pumps are prot
ected by the level transmitter in the Clear Well.

Step 02 Disc filter

All (3) Disc filter shall run in AUTO and valve positions will be as per t The Filters shall go into automatic backwash every 24 hours. As one filter
he table 4.1. completes the backwash cycle, the next filter will follow.
The Disc filter shall operate for 24 hour period by timer or until the cont
roller detects a high Differential Pressure.

23
WATER TREATMENT SYSTEM

2.1 PRETREATMENT SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 03 Disc Filter System Stop

If system is selected PLC and AUTO If the Buffer pond Level is HIGH or operator STOP initiated, system
mode, then shutdown will be initiated by will be set in to Stand-By mode If shut down by FAULT, Type-II sh
Buffer pond Level High (P0GBL21CL001) or Operator can pres utdown the system will be DIABLED and cannot take part in automa
s STOP button, or tic operation until FAULT is reset.
If system is selected in PLC control, upon
Group Stop signal Pretreatment shutdown system will be initiated
as follows.
Step 04 Disc Filter Shutdown/Stopping

Stop lead filter feed pump Check pump stop feedback

P0GBK11/12AP001

Upon confirmation of pump stop feedback Check valve close feedback

Close service inlet valve
P0GBB11AA051
P0GBB12AA051
P0GBB13AA051

24
WATER TREATMENT SYSTEM

2.1 PRETREATMENT SYSTEM

 Automatic A/C Filter for Pretreatment Operation

Step Operator Action and PLC sequence Process and Control System Reaction

Step 01 Clarified Water Transfer Pump - A/C filter for Pretreatment

In AUTO, Pump Fail if start feedback exceeds 3 to 5 seconds (adjustable)
Valve OPEN Put All A/C Filter for
Pretreatment SERVICE position as per Check Start/Stop feedback for Clarified Water Transfer Pump
table 4.1
The two Clarified Water Transfer Pumps (P0GBK11/12AP001) Check Open/Close feedback for A/C Filter for Pretreatment inlet valve.
alternates based on the Lead Switch in the PT Start Station in the HMI.
The Clarified Water Transfer Pumps are controlled by the Buffer pond
Level (P0GBL21CL001) and Clear Well Level
(P0GBL11CL001). If the level in the Clear Well (P0GBL11CL001) drops
below “Low” level the lead pump will stop pumping water into the
filters. The pumps are protected by the level transmitter in the Clear
Well.

Step 02 A/C Filter for Pretreatment

All (3) A/C filter shall run inAUTO and valve positions will be as per th The A/C Filter for Pretreatment shall go into automatic backwash every 24
e table 4.1. The Disc filter & A/C filter shall operate for 24 hour period hours (staggered 1, 2 & 3). As one filter completes the backwash cycle, the
by timer or until the controller detects a high Differential Pressure. next filter will follow. If during one A/C filter Backwash cycle, a running A
A/C Filter A : P0GBB21CP001 /C filter reaches a HIGH Differential, that the Filter will be isolated and mo
A/C Filter B : P0GBB22CP001 ved to the next position in the BW sequence.
A/C Filter C : P0GBB23CP001

25
WATER TREATMENT SYSTEM

2.1 PRETREATMENT SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 03 A/C Filter Automatic backwash cycle.

During the normal automatic A/C Filter operation, a 24 hour
timer in the
PLC shall trigger a A/C Filter Backwash Cycle. The backwash
sequence shall be : Lead, Lag, Lag/Lag based on the
selected Lead A/C Filter , or by High Differential Pressure as
described in
Step 04. When a backwash cycle is called, See Backwash
Sequence Table.

Step 04 A/C filter Shutdown/Stopping

Stop lead filter feed pump Check pump stop feedback
P0GBK11/12AP001

Upon confirmation of pump stop feedback Check valve close feedback

Close service outlet valve
P0GBB21AA052
P0GBB22AA052
P0GBB23AA052
Close service inlet valve
P0GBB21AA051
P0GBB22AA051
P0GBB23AA051

26
WATER TREATMENT SYSTEM

2.1 PRETREATMENT SYSTEM

 Automatic UF Unit Operation

Step Operator Action and PLC sequence Process and Control System Reaction

Step 01 UF feed Pumps

In AUTO, Pump Fail if start feedback exceeds 3 to 5 seconds (adjustable)
OPEN VALVE (P0GBB31/32/33AA081),
Put All UF filter in SERVICE position as per table 4.1. Check Start/Stop feedback for UF Feed Pump & UF Backwash
The two UF feed pump (P0GBK21/22/23 AP001) alternates base Pump
d on the Lead Switch in the PT Start Station in the HMI. Check Open/Close feedback for UF Unit inlet valve.

The UF feed pump are controlled by the Filtered water basin Lev
el (P0GBL31CL001) and Buffer pond Level (P0GBL21CL001).
If the level (P0GBL21CL001) in the Buffer pond drops below “L
ow” level, the lead pump will stop pumping water into the filters.
The pumps are protected by the level transmitter in the Buffer po
nd
Step 02 UF Unit
All (3) UF filter shall run in AUTO and valve positions will be as per th The Filters shall go into automatic backwash every 24 hours
e table 4.1 (staggered 1, 2 & 3). As one filter completes the backwash cycle, the
The UF filter shall operate for a 24 hour period by an internal 24 hours t next filter will follow. If during a UF Backwash cycle, a running UF
imer
filter reaches a service time & Pressure at inlet & outlet, that tank
will be isolated and moved to the next position in the BW sequence.

27
WATER TREATMENT SYSTEM

2.1 PRETREATMENT SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 03 UF Unit Automatic Backwash Cycle

During the Normal Automatic UF Unit operation, 24 Hour Timer
in the PLC shall trigger a UF Unit Backwash Cycle. The
backwash sequence shall be: Lead, Lag, Lag/Lag based on the
selected Lead UF Unit, or by Pressure as described in Step 04.
When a backwash cycle is called, See Backwash Sequence Table.
Step 04 UF Unit Stop
If system is selected PLC and AUTO mode, then shutdown will be If the Filtered water basin Level is HIGH or operator STOP initiated,
initiated by Filtered water basin Level High (P0GBL31CL001) or system will be set in to Stand-By mode
Operator can press STOP button, or
If system is selected in PLC control, upon Group Stop signal. If shutdown by FAULT, Type-II shutdown the system will be DIABLED
UF Unit shutdown system will be initiated as follows. and cannot take part in automatic operation until FAULT is reset.

Step 05 UF Unit Shutdown/Stopping

Stop lead filter feed pump
P0GBK21/22/23AP001
Upon confirmation of pump stop feedback Check stop feedback
Close service outlet valve P0GBB31AA052 Check valve close feedback
P0GBB32AA052
P0GBB33AA052
Close service inlet valve Check valve close feedback
P0GBB31AA081
P0GBB32AA081
P0GBB33AA081

28
WATER TREATMENT SYSTEM

2.2 DESALINATION SYSTEM

 Automatic SWRO Unit Operation

Step Operator Action and PLC sequence Process and Control System Reaction
Step 01 Pre-Start-up
PLC keeps tracking of the state of RO train and displays the state on the
HMI screen and code the RO train symbol with corresponding color.

OPERATOR shall select PLC or PLC Mode for start. In PLC mode, STA PLC system displays pop-up windows to select RO Trains to
RT/STOP pushbutton will be enabled. start with (1 & 2 train). For the RO Train which is not ready
(DISABLE or OFF-LINE),
Start-up sequence will start by any of the following conditions: selection will be disabled on the pop-up window.
Once sequence is started then demineralizaed water storage t
A. Operator initiate START pushbutton in PLC mode ank level is HIGH, the system will STOP and once the LEV
B. PLC provides the GROUP START command in PLC mode EL is LOW, the system will START again

PLC verifies above permissive condition and enables the start-up If any one of above permissive condition is violated, display
sequence. alarm of the non-permissive condition(s) and abort the start-u
p.

29
WATER TREATMENT SYSTEM

2.2 DESALINATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 02 Feed Water Quality Check

Open feed water dump valve, P0GBK41AA601 The PLC shall be monitored for feedback from valve. And if the fee
Check ORP, Conductivity, Temperature, chlorine residual, pH an dback is not within preset limits, the cycle shall be aborted and an A
d SDI. Start monitoring the water quality: LARM will be set.

Cond. Analyzer: P0GBK41CQ501

ORP/Temp. Analyzer: P0GBK41CQ304
pH Analyzer: P0GBK41CQ503
SDI Analyzer: P0GBK41CQ502
Check feedback if valve is open
Start SBS injection system If water quality is not within limits after 5 minutes delay, abort start-
Start Acid injection if required up and close the feed dump valve stop all the injection pumps.
If all water quality are within the limits go to Pre-Flush. If not wi
thin 5 minutes (adjustable), and re-check water quality.

30
WATER TREATMENT SYSTEM

2.2 DESALINATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 03 Pre-Flushing
Open RO Feed Valve Change the state of RO train to “STARTING” and display the
message “RO train is starting…”Valve Feedback Open
Open Reject Valve, P0GBF21AA0553.
Valve Feedback Open

Open permeate dump valve

P0GBF11/12AA054 Valve Feedback Close. The PLC shall monitor for feedback from
valves, if the feedbacks are not within preset limits, the cycle shall
Close Feed water dump Valve, P0GBK41AA601 be aborted and an ALARM will be set.

An OPEN command is sent to the P0GBF11AA202

Start Pre-Flush timer for 3-mitues (adjustable).

After the Pre-Flush timer is completed, go to the next step.

31
WATER TREATMENT SYSTEM

2.2 DESALINATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 04 Start RO HP Pump

Check feed pressure, (Pressure = P0GBF11/12CP001) to selected If feed pressure is low, initiate alarm and abort start-up.
RO train if it is above set point.
Check if permeate valve dump valve is open (P0GBF11/12AA055. Valve Feedback Open
If it is closed, initiate OPEN command. Check the valve Feedback position.
Valve OPEN(P0GBF11/12AA054)
Start Reject Control valve under PID control FIC
(P0GBF11/12CF002)

Start RO HP Pump for selected RO Train, P0GBK51/52 / 53AP001 Check Pump Run feedback
with initial speed of 25% (to be adjustable)

Ramp up the speed of selected RO HP pump gradually to 95% of Concentrate water will increase gradually at this time and shall be
the permeate flow set point. Ramping rate can be adjusted up dumped through permeate dump valve P0GBF21/22AA054 which
to 2 minutes to reach the 95% limit during commissioning. will remain open.

PLC waits for feedback

(Pump speed)
RO HP pump will switch over to permeate flow control loop in PLC starts permeate flow control loop, and modulate VFD speed
AUTO mode based on proportional control algorithm:
PLC shall calculate the total permeate flow by adding the flow:
P0GBF11/12CF002

(Total permeate flow set-point = 200 m³/hr)

32
WATER TREATMENT SYSTEM

2.2 DESALINATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 05 Start Permeate Water Quality Checks

Enable the monitoring of permeate conductivity, Start monitoring permeate water conductivity
P0GBF11/12CQ502. If the measured conductivity value is lower Wait
than set point, go to next step.

If measured conductivity value is higher than the set point, wait Warning will be displayed to operator and go to the next step.
for additional 10 minutes Operator will decide to abort the start-up.

33
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

 Automatic BWRO Unit Operation

A. Operator initiate START pushbutton in PLC mode Once sequence is started then DEMIN storage tank level is H
B. PLC provides the GROUP START command in PLC mode IGH, the system will STOP and once the LEVEL is LOW, th
e system will START again
PLC verifies above permissive condition and enables the start-up sequenc
e. If any one of above permissive condition is violated, display
alarm of the non-permissive condition(s) and abort the start-u
p.

34
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 02 Feed Water Quality Check

Check ORP, Conductivity, Temperature and pH. Start monitorin
g the water quality:

Cond. Analyzer: P0GCK21CQ501

ORP/Temp. Analyzer: P0GCK21CQ503
pH Analyzer: P0GCK21CQ502
Temperature : P0GCK21CT001

Start SBS injection system

Start Acid injection if required
If all water quality are within the limits go to Pre-Flush. If not wi If water quality is not within limits after 5 minutes delay, abort start-
thin 5 minutes (adjustable), and re-check water quality. up and close the valve stop all the injection pumps.

35
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 03 Pre-Flushing
Open Reject Control Valve, P0GCF11/12AA059, to 100%. Change the state of RO train to “STARTING” and display the
message “RO train is starting…”Valve Feedback Open = XB01
Open permeate dump valve P0GCF11/12AA056 Valve Feedback Open

Close Feed water Valve, Valve Feedback Close. The PLC shall be monitored for feedback
An OPEN command is sent to the PLC. from valves, if the feedbacks are not within preset limits, the cycle
shall be aborted and an ALARM will be set.
Start Pre-Flush timer for 5-mitues (adjustable).

After the Pre-Flush timer is completed, go to the next step.

36
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 04 Start RO HP Pump

Check feed pressure, (Pressure = P0GCF11/12CP001) to selected If feed pressure is low, initiate alarm and abort start-up.
RO train if it is above set point.

Check if permeate valve dump valve is open (P0GCF11/12AA056, Valve Feedback Open
P0GBL31AA051). If it is closed, initiate OPEN command. Check the valve Feedback position.
Check Pump Run feedback= XB01
Start Reject Control valve under PID control FIC
(P0GBF28/38CF001) Permeate water production will increase gradually at this time and
shall be dumped through permeate dump valve P0GCF11/12AA056,
Start RO HP Pump for selected RO Train, P0GBK30/34/35AP001 P0GBL31AA051which will remain open.
with initial speed of 25% (to be adjustable)
PLC waits for feedback YQ01
Ramp up the speed of selected RO HP pump gradually to 95% of (Pump speed)
the permeate flow setpoint. Ramping rate can be adjusted up to PLC starts permeate flow control loop, and modulate VFD speed
2 minutes to reach the 95% limit during commissioning. based on proportional control algorithm:

PLC shall calculate the total permeate flow by adding the flow:
RO HP pump will switch over to permeate flow control loop in P0GCF11/12CF001
AUTO mode 1. P0GCF11CF001
2. P0GCF12CF001

(Total permeate flow set-point =

60 m³/hr)

37
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 05 Start Permeate Water Quality Checks

Enable the monitoring of permeate conductivity, Start monitoring permeate water conductivity
P0GCF11/12CQ502. If the measured conductivity value is lower Wait
than set point, go to next step.

If measured conductivity value is higher than the set point, wait Warning will be displayed to operator and go to the next step.
for additional 10 minutes Operator will decide to abort the start-up.

38
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 06 BWRO System Service

Open service effluent valve, PLC Waits for Feedback
P0GCF11/12AA055

After confirmation valve that service outlet valve is open, PLC Waits for Feedback
P0GCF11/12AA055, then close the recirculation valve,
P0GCF11/12AA056, P0GBL31AA051.

PLC status illustrates the RO System is in SERVICE, and the PLC Totalizing is utilized for calculating through-put of BWRO.
will start totalizing flow of selected BWRO.
RO system will remain In-Service until alarm is initiated. All alarms
are monitored and based on alarm conditions, the plant will go into
alarm condition as described in the next section.

39
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

 Automatic Degasifier & Degasified Water Tank Operation

Step Operator Action and PLC sequence Process and Control System Reaction

Step 01 Operator will operate RO feed pump and press START RO feed p Check that operation pump is remarked in PLC.
ump start push button.

or Degasified water tank Level is Low.

Step 02 Service
If fan is operated according to RO feed pump operation. And if degasifi PLC Waits for RUN feedback
ed water tank Level is high, MBP feed pump is operated.

40
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

 Regeneration of Mixed Bed Polisher Operation

Step Operator Action and PLC sequence Process and Control System Reaction

Step 01 Operator will select MBP unit for regeneration and press START Check that all Permissive are satisfied.
Regeneration Cycle

or
Totalized volume have reached the set point for regeneration
or
Conductivity is above high alarm set point
Step 02 Stop
Close service inlet and outlet valves, P0GCF21/22AA051 and P0 PLC waits for feedbacks
GCF21/22AA052
Step 03 Mixed Bed Polisher Shutdown/Stopping
Stop lead MBP Feed Pump Check pump stop feedback
P0GCK41/42AP001
Upon confirmation of pump stop feedback Check valve close feedback
Close service outlet valve
P0GBB21AA052 Check valve close feedback
P0GBB22AA052
Close service inlet valve
P0GCF21AA051
P0GCF22AA051

41
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 04 Backwash
Sampling Valve is closed, P0GCF21/22AA063

Open BW inlet and outlet Valves, P0GCF21/22AA053 and PLC waits for feedbacks
P0GCF21/22AA054

Upon confirmation of open feedback from BW valves , start MBP PLC waits for feedbacks
regeneration pump,
P0GCP31/32AP001

Upon confirmation of pump RUN feedback, start the BW timer PLC waits for feedbacks
and runs for the preset time (Adjustable).

After BW timer elapsed, stop the regeneration pump

Upon confirmation of pump shutdown, close BW inlet and outlet

valves,
P0GCF21/22AA053and
P0GCF21/22AA054

Upon confirmation of above valves CLOSED feedback, settling

cycle begin.

42
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 05 Rest
All valves are closed and the resin is in the process of settling.

Once the Settling cycle ends and the timer have expired, the Pre-Inject c
ycle begins.

Step 06 Caustic Injection

PLC check level switch of caustic injection tank, P0GCN41CL081 PLC waits for feedback

PLC will initiate a START Command for the metering pumps:

START Command
Caustic Injection Pump, P0GCN43 /44AP001

Upon receiving RUN feedbacks from metering pumps.

PLC waits for RUN feedback

Check the % concentration of diluted chemical solution at discharge lin

e.
PLC waits if (RUN) feedback is turned off (N.O.)

The PLC will start a chemical injection timer for 40 minutes.

When 40 minutes have elapsed since the start of the timer, the caustic in
jection pump stops.

43
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 07 Caustic displacement

In this cycle, the caustic displacement rinse begins. The caustic
injection pumps will shut down, and the demi water will injected
from the previous step for the duration of this cycle. This cycle
will continue for 25 minutes.

When the above 25 minutes timer have expired, the PLC will do The PLC turns off the OPEN command and waits to check if the
the following: RUN feedback is OFF

Stop Regeneration Water Pump, P0GBP31/32AP001

Close caustic inlet valve P0GCF43AA202. PLC waits for CLOSED feedback
Open caustic dilution water inlet valve P0GCF21/22AA057 PLC waits for OPEN feedback

Close Acid inlet valve P0GCF33AA202 PLC waits for CLOSED feedback

Open Acid dilution water inlet valve P0GCF21/22AA059 PLC waits for OPEN feedback

Open regenerate outlet valve P0GCF21/22AA058 PLC waits for OPEN feedback

44
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 08 Acid Injection

PLC check level switch of acid injection tank, P0GCN31CL081 PLC waits for feedback

PLC will initiate a START Command for the metering pumps: START Command

RUN Acid Injection Pump, P0GCN33/34 AP001 PLC waits for RUN feedback

Upon receiving RUN feedbacks from metering pumps. If Acid is not within preset limits in 5 minutes, a warning will
illuminate on the HMI, if not within limits for another 5 minutes, an
Once confirmation of % concentration is within preset-limits, the ALARM will activate and the system stops.
PLC will start a regeneration/displacement timer for 40 minutes.

When 40 minutes have elapsed since the start of the timer, the PLC waits if (RUN) feedback is turned off (N.O.)
acid injection pump stops.

45
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 09 Displacement
In this cycle, the acid displacement rinse begins. The acid
injection pumps will shut down, and the acid displacement rinse
will continue from the previous step for the duration of this cycle.
This cycle will continue for 25 minutes.

When the above 25-minutes timer have expired, the PLC will do The PLC turns off the OPEN command and waits to check if the
the following: RUN feedback is OFF

Stop Regeneration Water Pump, P0GCP31/32 AP001

Close acid inlet valve P0GCN33AA051 PLC waits for CLOSED feedback

Open diluted acid inlet valve P0GCN21/22AA059 PLC waits for OPEN feedback

Close caustic inlet valve P0GBN43AA051 PLC waits for CLOSED feedback

Open diluted Caustic id inlet valve P0GBF21/22AA057 PLC waits for OPEN feedback

Open regenerate outlet valve P0GCF21/22AA058 PLC waits for OPEN feedback

46
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 10 1st Rinse

In the 1st rinse, the water flow is injected upward and PLC send OPEN Command and waits for OPEN feedback
downward. Two water flow is drained through middle collector.
The PLC issue the following Command:

Open Regeneration pump suction valve, P0GCP31AA051 PLC waits for OPEN feedback
Open BW inlet valve, P0GCF21/22AA053 PLC waits for OPEN feedback
Open (slow) rinse valve, P0GCF21/22AA055 PLC waits for OPEN feedback
Siphon breaker open, P0GCF21/22AA060 PLC waits for OPEN feedback
Waste water outlet (Middle collector) valve open, PLC waits for OPEN feedback
P0GCF21/22AA058

Upon confirmation of OPEN feedback from the above valves, the

PLC will start a drain timer set initially for 5 minutes. This timer
in particular will have to be adjusted in the field during
commissioning.

PLC will initiate a START Command for the metering pumps: START Command

Regeneration pump start PLC waits for RUN feedback

P0GCP31/32AP001
Flow : upward 37.6m3/hr, Downward : 37.6m3/hr Check flow at site flow-meter.

Once the 1st Rinse step timer elapsed, the PLC will close the BW
inlet and (slow) rinse inlet valves.

47
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 11 Water Drain

In the drain step, the water level is drained to approximately PLC send OPEN Command and waits for OPEN feedback
150mm above the separated resin. The vessel will drain from
top and bottom.

The PLC issue the following Command:

Siphon breaker open, P0GCF21/22AA060 PLC waits for OPEN feedback

Waste water outlet (Middle collector) valve open, PLC waits for OPEN feedback
P0GCF21/22AA058

Air vent open, P0GCF21/22AA062 PLC waits for OPEN feedback

Upon confirmation of OPEN feedback from the above valves, the

PLC will start a drain timer set initially for 5 minutes. This timer
in particular will have to be adjusted in the field during
commissioning.

Once the drain timer elapsed, the PLC will close the BW outlet
and rinse valves while the air vent valve will remain open.

48
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 12 Air Mixing

In the air mix cycle, the blower is turned on to mix the resin PLC send OPEN Command and waits for OPEN feedback
while the air inlet valve remains open. The PLC will start the
following sequence of events:

Open Air Inlet Valve, P0GCF21/22AA061 PLC waits for OPEN feedback
Open Air vent Valve, P0GCF21/22AA062 PLC waits for OPEN feedback

Start Blower, P0GCF23/24AN001 PLC send a START command signal and waits for RUN feedback

Upon confirmation of blower RUN feedback, the Air-Mix cycle

timer begins (10 minutes). Once cycle is complete, the process
of Settle begins. And drain valve is open during last 15sec of this
step.

When step is finished, associated valve is all closed. PLC waits for CLOSED feedback

When step is finished, associated blower is stopped. PLC send a STOP command signal and waits for feedback

49
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 13 Rest
After the above cycle is complete and the timer has expired, the
PLC initiates the Settle cycle. During this cycle, the following
sequence of events occurs:
After a time delay, the blower shuts-down. Upon confirmation
of the blower STOP feedback, the PLC will start the next process
of filling the vessel.
At the end of this cycle, the air outlet valve on top of the vessel
will remain open and the resin is expected to be mixed.
Step 14 Water Filling
In this cycle, the vessel is filled with low rate water using the PLC send OPEN Command and waits for OPEN feedback
regeneration pump while evacuating air from the top of the
vessel. The process continues until water start coming out from
the top valve.

Open rinse inlet valve, P0GCF21/22AA055 PLC waits for OPEN feedback
Open air vent valve, PLC waits for OPEN feedback
P0GCF21/22AA062

Start Regeneration Water Pump (P0GCP31/32AP001) FILL cycle PLC send a START command signal and waits for RUN feedback
timer (5 minutes)

After Slow Fill Cycle is complete, stop regen. water pump. Once
pump shutdown feedback is confirmed, the next process of fast
rinse began.

50
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 15 Final Rinse

The above cycle will continue until all water quality parameters PLC send OPEN Command and waits for OPEN feedback
are met. The FINAL RINSE timer is set tentatively at 12 minutes.

Open Analyzer Sampling Valve P0GCF21/22AA063

PLC waits for OPEN feedback

Open MBE inlet valve

P0GCF21/22AA051
PLC waits for OPEN feedback
Open Rinse outlet valve
P0GCF21/22AA056
PLC waits for OPEN feedback

If FAST_RINSE_TIME expired, progress to next step.

51
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 16 Recycle & Conductivity Check

If FAST_RINSE_TIME expired, and if CONDUCTIVITY is NOT OK, PLC Waits for CLOSED feedback
wait for additional 5 minutes.
If COND remains HIGH, stop the step and alarm COND. HIGH.

If COND. is not met with required quality, Final rinse is carried PLC Waits for CLOSED feedback
out during additional time (more than 2 hours).
If product water is met with required water quality, step is
progressed to Service step.
But if not, Chemical injection (Caustic injection, Acid injection) is Display DISABLE mode
carried out again. Follow below.

Close MBE inlet valve, P0GCF21/22AA051

Close Rinse outlet valve

P0GCF21/22AA056

The PLC will disable the MBP and warn operators of FAULT
condition.

If all water quality are met, proceed to the next step

52
WATER TREATMENT SYSTEM

2.3 DEMINERALIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 17 Stand by
If all water quality is met, the PLC will put the MBP on standby.

Close MBP inlet valve PLC Waits for CLOSED feedback

P0GCF21/22AA051
Close Rinse outlet valve PLC Waits for CLOSED feedback
P0GCF21/22AA056
Step 18 Conductivity Check
If Service step is started, this step is carried out before service PLC send OPEN Command and waits for OPEN feedback
step.
PLC waits for OPEN feedback
Open Analyzer Sampling Valve P0GCF21/22AA063
Open MBE inlet valve PLC waits for OPEN feedback
P0GCF21/22AA051
Open Rinse outlet valve PLC waits for OPEN feedback
P0GCF21/22AA056

If This step TIME expired, progress to next step.

Step 19 Service Step
Open MBP inlet valve PLC send OPEN Command and waits for OPEN feedback
P0GCF21/22AA051
Open MBP outlet valve PLC waits for OPEN feedback
P0GCF21/22AA052

Open Analyzer Sampling Valve P0GCF21/22AA063 PLC waits for OPEN feedback

53
WATER TREATMENT SYSTEM

2.4 POTABLIZATION SYSTEM

 Operation & Backwash Step of A/C Filter for Potablization

Step Operator Action and PLC sequence Process and Control System Reaction

Step 01 Pre-Startup
Select Service for ACF’s: One ACF can be selected at a time for DUTY.
P0GHB31/32AT001

OPERATOR shall select PLC or PLC Mode for start. In PLC mode,
START/STOP pushbutton will be enabled.

Start-up sequence will start by any of the following conditions:

A. Operator initiate START pushbutton in PLC mode

B. Potable water tank level LOW from PLC

Step 02 Startup Rinse
1) Service inlet : P0GHB31/32AA051 Check valve open feedback
2) Rinse outlet : P0GHB31/32AA056 Check valve open feedback
3) Once valve open feedback received, start 3 minutes (adj.) On completion of rinse timer, go to next step
rinse timer.
4) Check Rinse outlet water by visual.

54
WATER TREATMENT SYSTEM

2.4 POTABLIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 03 Service
1) Open Service inlet : P0GHB31/32AA051 Check valve open feedback
2) Open Service outlet : P0GHB31/32AA052 Check valve close feedback
3) Once Service outlet valve open feedback received, close rinse Once Operation timer is complete, change the DUTY CYCLE of ACF.
outlet valve
4) Set OP_TIME timer

Note: If out of limits for a preset time, an ALARM shall be

indicated.
Step 04 Stopping
If there are at least one unit in service (including the unit to be
stopped), then Select STOP

or
Potable Water Storage Tank level HIGH signal from PLC PLC waits for level high feedbacks

Close Service inlet Valve Check valve CLOSED feedback

P0GHB31/32AA051

Close Service outlet Valve Check valve CLOSED feedback

P0GHB31/32AA052

OFF LINE Displayed

End

55
WATER TREATMENT SYSTEM

2.4 POTABLIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 05 Backwash
1) Open Backwash inlet valve : P0GHB31/32AA053 Check valve open feedback
2) Open Backwash outlet valve : P0GHB31/32AA054 Check valve close feedback
3) Once valve open feedback received, start backwash step timer Once Operation timer is complete, change the DUTY CYCLE of ACF
after 3 minutes (adj.). and progress to next step.

Use feed pump for backwashing.

If when 10 minutes have elapsed since the start of the timer, the
backwash step is stops.
Step 06 Settle
1) Close Backwash inlet valve : P0GHB31/32AA053 Check valve close feedback
2) Close Backwash outlet valve : P0GHB31/32AA054 Check valve close feedback

If When 5 minutes have elapsed since the start of the timer, the
settle step is stops

56
WATER TREATMENT SYSTEM

2.4 POTABLIZATION SYSTEM

Step Operator Action and PLC sequence Process and Control System Reaction

Step 07 Rinse
1) Open Service inlet valve : P0GHB31/32AA051 Check valve open feedback
2) Open Rinse outlet valve : P0GHB31/32AA052 Check valve open feedback

If When 5 minutes have elapsed since the start of the timer, the
settle step is stops.

If This step TIME expired, progress to next step.

Step 08 Stand by
If all backwash time is finished, the PLC will put the Activated
carbon filter on standby.

Close ACF inlet valve Check valve close feedback

P0GCF31/32AA051

Close Rinse outlet valve Check valve close feedback

P0GCF31/32AA054
If other train is not service, change over service step.

57
WATER TREATMENT SYSTEM

3. HMI GRAPHIC & OPERATION MANUAL

3.1 HMI START OPERATION

 Turn On the Desktop Computer

Power Button

58
WATER TREATMENT SYSTEM

3.1 HMI START OPERATION

 Enter the password to uppercase.

abb

No. PC Admin Password

1 HMI-1 PC OPCSERVWT1 abb
2 HMI-2 PC OPCSERVWT2 abb

59
WATER TREATMENT SYSTEM

3.1 HMI START OPERATION

 Run the SIMATIC WinCC Explorer On the Desktop.

60
WATER TREATMENT SYSTEM

3.1 HMI START OPERATION

 In the top menu bar

[File] → [Open] → [Open Window] → [VT4 Program File]

 If click the activate button, HMI is run

Activate

61
WATER TREATMENT SYSTEM

3.2 SYSTEM SECURITY

 Username and passwords defined

Mode ID Password Current User Name

Operator operator oper123 operator
Engineering engineering engin123 engineering

 Login

1. Touch the login button.

2. Login as an operator or engineering.

62
WATER TREATMENT SYSTEM

3.2 SYSTEM SECURITY

 Privilege Mode Defined

Each security level for the project is defined for actions with required permissions as shown in the tables

Centrifugal Pump Stopped Green (0,128,0)

Fault Amber (255,194,0)

71
WATER TREATMENT SYSTEM

3.3 SYMBOL ILLUSTRAION

 Symbol Illustration Color Color

Element Symbol Status RGB color code Remark
Name Sample

High-high,
Red (255,0,0)
Low-low

Level Switch

High,
Yellow (255,255,0)
Low

Normal Green (0,128,0)

72
WATER TREATMENT SYSTEM

3.3 SYMBOL ILLUSTRAION

 Symbol Illustration

Color Color
Element Symbol Status RGB color code Remark
Name Sample

High-high,
Red (255,0,0)
Low-low

Pressure Switch /
Flow Switch /
D.P Switch

High,
Yellow (255,255,0)
Low

73
WATER TREATMENT SYSTEM

3.3 SYMBOL ILLUSTRAION

 Symbol Illustration
Color
Element Symbol Status Color Name RGB color code Remark
Sample

High-high Red (255,0,0)

High Yellow (255,255,0)

low Yellow (255,255,0)

Transmitter

Low Low Red (255,0,0)

Normal Green (0,128,0)

Bad Quality Magenta (255,0,255)

74
WATER TREATMENT SYSTEM

3.3 SYMBOL ILLUSTRAION

 Symbol Illustration

Color Color
Element Symbol Status RGB color code Remark
Name Sample

Permissive Red (255,0,0)

Permissive /
Not-Permissive

Not-Permissive Green (0,128,0)

Duty Red (255,0,0)

Duty /
Stand-by

Stand-by Green (0,128,0)

Remote Red (255,0,0)

Remote /
Local

Local Green (0,128,0)

Auto Red (255,0,0)

Auto /
Manual

Manual Green (0,128,0)

75
WATER TREATMENT SYSTEM

3.3 SYMBOL ILLUSTRAION

 Symbol Illustration

No System R G B Color

1 Service Air 58 145 150

2 Instrument Air 58 145 150

3 Chemical 128 0 128

4 Potable water 112 154 87

5 Service Water 112 154 87

6 Demi Water 112 154 87

7 Feed Water 0 128 0

8 Sludge 153 112 0

9 Waste Water 139 69 19

No Symbol Description Color

Navigation Tag Background : White

1
(From / To) Text : Black

76
WATER TREATMENT SYSTEM

3.4 OPERATION GRAPHIC

 Main

77
WATER TREATMENT SYSTEM

3.4 OPERATION GRAPHIC

 Main

No Description No Description

1 Current User Name 8 System Control Popup

2 Login Button 9 CPU, Remote , Panel Fan Monitoring Button

3 Logout Button 10 Sea Water / Lake water Mode Select Button

4 Main Screen Button 11 Alarm Banner

Alarm Acknowledge Button /
5 Trend Button 12
All Alarm Acknowledge Button
6 Current Screen Print Button 13 Alarm History Button

7 Exit Button 14 Sequence of Event Button

78
WATER TREATMENT SYSTEM

3.4 OPERATION GRAPHIC

 Alarm Banner
1

2
3
4
5
No Object Description
Notify Alarm to user when abnormal condition has been occurred on the equipments
anywhere. Current alarm Information is shown by blinking text message on the Alarm
Banner. User can confirm the Alarm Tag and description and occurred time.

1 Alarm Banner
Alarm information can be checked which is currently with Alarm time, Acknowledged
time, Alarm Tag Name and Alarm Description.
- After the alarm is cleared, If push the ACK button, alarm message will be disappeared
from the Banner.

2 Acknowledge Button Acknowledge the recent alarm express on the alarm banner.

 DCS Interface

• All instrument symbols include current value form field.

current operation can see blow signal from HMI.

101
WATER TREATMENT SYSTEM

3.5 POP-UP

 Valve control pop-up

No. Object Color Description

1 TAG - Valve tag

2 DESCRIPTION - Valve description

OPEN Red

3 CLOSE Green Status

ABNORMAL CONDITION Amber

AUTO Red
4 Control
MANUAL Green

OPEN Red Control

5
CLOSE Green (If Manual Mode Select, the Button is activated.)

TAG SET Red Used for maintenance mode.

6 TAG RESET Green You cannot control the HMI until you click the Cancel button.

RESET - Abnormal state is released.

102
WATER TREATMENT SYSTEM

3.5 POP-UP

 Valve control pop-up

No. Object Color Description

1 TAG - Valve tag

2 DESCRIPTION - Valve description

OPEN Red

3 CLOSE Green Status

ABNORMAL CONDITION Amber

AUTO Red
4 Control
MANUAL Green

OPEN Red Control

5
CLOSE Green (If Manual Mode Select, the Button is activated.)

TAG SET Red Used for maintenance mode.

6 TAG RESET Green You cannot control the HMI until you click the Cancel button.

RESET - Abnormal state is released.

7 ON TIME Red
Valve ON/OFF Time Setting and Operating Time Monitoring.
8 OFF TIME Green

103
WATER TREATMENT SYSTEM

3.5 POP-UP

 PID control pop-up

No. Object Color Description

1 TAG - Valve tag

2 DESCRIPTION - Valve description

3 POINT VALUE - Current point value

4 PID OUTPUT - Current PID output value

AUTO Red
5 PID function AUTO / MANUAL select button.
MANUAL Green

6 SET POINT - Only Auto mode, can be set the set point value

7 PID MANUAL - Last analog output value. Only manual mode, can be set the value.

CONTROL VALUE
8 - Maximum / Minimum Control value.
MAXIMUM / MINIMUM
PROPORTIONAL -

9 INTEGRATOR - PID current value indicatior.

DERIVATIVE -

104
WATER TREATMENT SYSTEM

3.5 POP-UP

 Pump control pop-up (1 of 2)

No. Object Color Description

1 TAG - Pump tag

2 DESCRIPTION - Pump description

REMOTE Red

LOCAL Green
TEST POSITION Red

READY TO START Red

3 DUTY Red Pump current status

STAND-BY Green

RUN Red

STOP Green

FAULT Amber

TOTAL RUN TIME - Pump Total Runtime

4 RUN TIME - Pump Current Runtime

RUNNING COUNT - Pump Total Running Count

5 DUTY - Duty select

AUTO Red
6 Control
MANUAL Green

START Red Control

7
STOP Green (If Manual Mode Select, the Button is activated.)

TAG SET Red Used for maintenance mode.

8 TAG RESET Green You cannot control the HMI until you click the Cancel button.

RESET - Fault state is released.

105
WATER TREATMENT SYSTEM

3.5 POP-UP

 Pump control pop-up (2 of 2)

No. Object Color Description

1 TAG - Pump tag

2 DESCRIPTION - Pump description

REMOTE Red

LOCAL Green

TEST POSITION Red

READY TO START Red

3 DUTY Red Pump current status

STAND-BY Green

RUN Red

STOP Green

FAULT Amber

TOTAL RUN TIME - Pump Total Runtime

4 RUN TIME - Pump Current Runtime

RUNNING COUNT - Pump Total Running Count

AUTO Red
5 Control
MANUAL Green

START Red Control

6
STOP Green (If Manual Mode Select, the Button is activated.)

TAG SET Red Used for maintenance mode.

7 TAG RESET Green You cannot control the HMI until you click the Cancel button.

RESET - Fault state is released.

106
WATER TREATMENT SYSTEM

3.5 POP-UP

 Permissive pop-up

No. Object Color Description

1 TAG - Equipment tag

2 DESCRIPTION - Valve description

PERMISSIVE Red
3 Status
NOT PERMISSIVE Green
4 PERMISSIVE CONDITION Red Current permissive condition status

107
WATER TREATMENT SYSTEM

3.5 POP-UP

 Agitator control pop-up No. Object Color Description

1 TAG - Agitator tag

2 DESCRIPTION - Agitator description

REMOTE Red

LOCAL Green

TEST POSITION Red

READY TO START Red

3 DUTY Red Agitator current status

STAND-BY Green

RUN Red

STOP Green

FAULT Amber

TOTAL RUN TIME - Agitator Total Runtime

4 RUN TIME - Agitator Current Runtime

RUNNING COUNT - Agitator Total Running Count

AUTO Red
5 Control
MANUAL Green

START Red Control

6
STOP Green (If Manual Mode Select, the Button is activated.)

TAG SET Red Used for maintenance mode.

7 TAG RESET Green You cannot control the HMI until you click the Cancel button.

RESET - Fault state is released.

108
WATER TREATMENT SYSTEM

3.5 POP-UP
No. Object Color Description
 VFD control pop-up 1 TAG - VFD tag

2 DESCRIPTION - VFD description

REMOTE Red

LOCAL Green
3 RUN Red VFD current status

STOP Green

FAULT Amber

TOTAL RUN TIME - VFD Total Runtime

4 RUN TIME - VFD Current Runtime

RUNNING COUNT - VFD Total Running Count

MCCB OPEN Red

5 MCCB CLOSE Green MCCB Current Status

MCCB TRIP Amber

AUTO Red
6 Control
MANUAL Green

START Red Control

7
STOP Green (If Manual Mode Select, the Button is activated.)

TAG SET Red Used for maintenance mode.

8 TAG RESET Green You cannot control the HMI until you click the Cancel button.

RESET - Fault / MCCB Trip state is released.

RPM 1 -
9 Current RPM value indicator
RPM 2 -

CURRENT MONITORING 1 -
10 Current Monitoring value indicator.
CURRENT MONITORING 2 -

11 RPM CONTROL - Set to RPM control value

109
WATER TREATMENT SYSTEM

3.5 POP-UP

 Heater control pop-up

No. Object Color Description

1 TAG - Heater tag

2 DESCRIPTION - Heater description

RUN Red
3
STOP Green Heater current status

4 TRIP Amber

AUTO Red
5 Control
MANUAL Green

START Red Control

6
STOP Green (If Manual Mode Select, the Button is activated.)

TAG SET Red Used for maintenance mode.

7 TAG RESET Green You cannot control the HMI until you click the Cancel button.

RESET - Trip state is released.

110
WATER TREATMENT SYSTEM

3.5 POP-UP

 Transmitter control pop-up

No. Object Color Description

1 TAG - Instrument tag

9
2 DESCRIPTION - Instrument description
8
3 CURRENT VALUE - Instrument current value

4 BAD QUALITY MAGENTA Indicates any physical connection troble.

ON : Red
5 ALARM HIDE Can view the alarm
OFF : Black
HIGH-HIGH Red Alarm status

HIGH Yellow Alarm status

MIDDLE HIGH Yellow Alarm status (Only LIT)

6
LOW Yellow Alarm status

MIDDLE LOW Yellow Alarm status (Only LIT)

LOW LOW Red Alarm status

7 CURRENT VALUE - Setting / Monitoring value

8 TOTAL FLOW - Total flow value (Only FITQ)

9 FLOW RESET - Total flow value reset button (Only FITQ)

111
WATER TREATMENT SYSTEM

3.5 POP-UP

 Filter control pop-up (1 of 4)

No. Object Color Description

1 TAG - Filter tag

2 DESCRIPTION - Filter description

AUTO Red

SEMI Green

STEP ON Red
Control
HOLD ON Red
3
BY-PASS Red

NORMAL Green

1 TRAIN Blue Status

2 TRAIN Blue Status

4 STEP STATUS Filter Step Status

5 TIME CONTROL Set to control time (HH/MM/SS)

6 OPERATING TIME Current time (HH/MM/SS)

 Panel fan monitoring

118
POWER ENGINEERING
VIETNAM ELECTRICITY CONSULTING JSC 3

VINH TAN 4 THERMAL POWER PLANT

PROJECT (2X600MW)

TRAINING MANUAL
FOR
WASTE WATER TREATMENT SYSTEM

CHUNG-AM WATER TREATMENT & ENGINEERING CO., LTD.

TABLE OF CONTENTS

■ INTRODUCTION
- Water Condition 03

- Flow Chart 04

- Layout 05

- Mass Balance 06

- Major Equipment 09

■ OPERATION PROCEDURE
- Preparation for Start up 15

- Start Up 18

- Normal Operation and Routine Checks 51

- Shut Down 57

- Alarm Procedure 58

- Emergency Procedure 59

■ MAINTENANCE MANUAL
- Maintenance Management Systems 61

- Preparing Maintenance Plan 63

- Preventive Maintenance 70

1
■ INTRODUCTION

2
- WATER CONDITION

1.1 Regular Waste Water Characteristics & Effluent Criteria

Design Treatment Effluent Tank Regulation

Influent Overall
Contaminants Influent
mg/l Effluent Effluent IFC Guidelines Efficiency
mg/l Removal Removal
mg/l mg/l
125
COD 180 180 31% 125 - 125 31%

50
SS 180 180 72% 50 - 50 72%

6-9
pH 4-12 4-12 - 6-9 - 6-9 -

1.2 Oily Waste Water Characteristics & Effluent Criteria

Oil Skimmer
Design Oil Separator Effluent Tank
Influent
Contaminants Influent
mg/l Effluent Effluent Effluent
mg/l Removal Removal Removal
mg/l mg/l mg/l

COD 125 125 - 125 - 125 - 125

SS 100 100 100 50% 50 - 50

Oil 1000 1000 80% 200 99% 10 - 10

3
- FLOW CHART

4
- LAYOUT

5
- MASS BALANCE

6
- MASS BALANCE

7
- MASS BALANCE

8
- MAJOR EQUIPMENT

Regular & irregular Waste Water Pond

1.To provide adequate flow to compensate the daily fluctuation of
waste water from the sources.
2.To homogenize waste water from the sources.

pH Adjustment tank
1. To collect and buffer the waste water by means of chemical injection.
2. To control pH and regular waste water by means of agitator.

Coagulation tank
The debris and dense material is removed by means of chemical cohesion.
Commonly alum is used and the coagulation of cohesion is as following.
Al2(SO4)3 ·18 H2O + 3 Ca(HCO3)2 → 2Al(OH)3↓ + 3CaSO4 + 6CO2 + 18H2O

The formed floc in the coagulation basin overflows to flocculation basin where it
grows big and heavy by reacting with the polymer from polymer dosing
equipment.
To remove colloidal pollutions by means of chemical cohesion.

Flocculation tank
A-polymer will be dosed in the flocculation basin for aiding floc formation.
The flocs would then be settled in the downstream conventional clarifier.
To aid floc formation.

9
- MAJOR EQUIPMENT

Clarifier

The mixed liquor waste water from flocculation tank flows to clarifier by gravity.

The waste water enters the clarifier in the central well. The central well is a cylindrical part located at the center of clarifier.

The waste water flows to bottom of clarifier from central well due to hydraulics and comes out of central well.

Then waste water starts rising with very low velocity to top of clarifier.

While the waste water is rising in clarifier, the flocs of the solid particles get settled at the bottom and only clear water rises to top.

The scraper arm rotates at a low speed at the clarifier bottom. Due to the rotating movement of the scraper arm of driven unit, the sludge collected at bottom of

clarifier is moved to the central cone of clarifier.

To separate water and sludge by means of the difference of specific gravity.

10
- MAJOR EQUIPMENT

Dual Media Filter

clarified water pumps will feed clarified water to the dual media filter units.
cylindrical type dual media Filter units. Finer impurities will be removed in the
dual media filter units.

Activated Carbon Filter

Any kind or smell etc. from the waste water will be removed by the process of

adsorption in the 2x100% activated carbon filters.

11
- MAJOR EQUIPMENT

Sludge Thickener

Sludge thickener works on similar principle of clarifier.

The sludge enters the thickener at central well and flows to bottom of thickener.

The sludge comes out of central well from bottom and rises to thickener

periphery.

While sludge rises to thickener top, the solid particles settle at bottom cone and

top risen water overflows to the waste water pond.

To store and thicken the sludge.

Belt Press & Cake Hopper

Belt press is a sludge dewatering device that applies mechanical pressure.

The sludge is trapped between filter plates and is passed through a belt filter.

Due to the pressure applied, the water is squeezed out of the sludge.

Dehydrator receives slurry of about 2% feed solids and produces a final product

of 20% cake solids.

The sludge cake formed is stored in a hopper and periodically disposed by

owner using the truck or trolley.

12
- MAJOR EQUIPMENT

Oil Skimmer

The initially suspended oil is drawn by rotating high adhesive nitrite belt

equipped in oil skimmer which is located on the oily waste water pond.

Oil Separator

The oily water flows into the oil separator that consist of number of

corrugated plate mounted parallel to each other at a space.

When the raw waste water containing the oil passes between the plates

(laminar flow is mandatory for the proper functioning of the operation) in

the course of passing from EPS pack inlet to EPS pack outlet, the oil

float upwards into the top of EPS pack and rise up the incline of the

plates to the surface of the system where it can be removed by pipe oil

separator.

13
■ OPERATION PROCEDURE

14
1. PREPARATION FOR START UP

The personnel provided by the customer works on basis of the operating manual and procedure of the DOOSAN commissioning engineer.

1.1 System Status

• Mechanically Complete
• Oily & Chemical Waste Water Treatment System and services commissioned, all basins for storage, chemical unloading / delivery
areas, overhead crane, etc.

• System cleaned, checked and tested (pre-commissioned), including pumps, motor operation valves, instrumentation and gauges, piping, etc.
• All safety procedures and signs in place.
• Service air available.
• Potable Water available (eye wash and emergency showers, etc)
• All waste water & equipment ready for service in accordance with Sec. 2.0 Start up for Waste Water Treatment System.
• Firewater and fire-fighting systems tested and operational/ready.
• Plant Earthing system tested and operational
• Plant Control (DCS) and Communications operational
• LV Power available

15
1.2 Provisions for Complex Function Test

• Start of complex function tests for commissioning provides finalization of the internal function checks.
• These checks include all single processes of systems and system parts on perfect assembly, switching and function.
• It includes electrical and mechanical function tests with influent waste water or medium respectively.
• DOOSAN signalizes the final inspector when the system/system parts are ready for complex function test.

1.3 Contents of Complex Function Tests

• Effluent water quality check of complete plant.

• Filling of corresponding technological units with oil water separator, clarifier, chemicals and so on.
• Testing of chosen systems on perfect interaction of equipment incl. auxiliary medium.
• Proof of function of control, locking, signal and similar.

1.4 Provisions for Carrying-Out Test Operation

• Provisions for test operations are:

• finalization of complex function checks (documented)
• an actual operation instruments as well as operating manual of single partial equipment
• signal of readiness for taking over test operation
• manually revised documentation incl. test and permission certificates for special equipment parts
• execution of a practical training

16
1.5 Provisions for Starting Continuous Operation

• Provisions for contractual inspection are a successfully finalized test operation.

The test operation is finished, if correspondingly agreed proofs/works have been submitted.

• The permissible limits for aqueous discharges into the sea are described in the above-mentioned table.
( Refer to System Description Table 1.2.1 “Aqueous discharges” in the Section 1.2.1. )

• All faults hindering the inspection are mentioned in the records for start of complex function tests and for test operation is settled.
• A record regarding result of the test operation must be prepared.
• Complete system documentation, AS-built drawings and revision documents, document the condition at point of time of inspection must be handed over to the
final inspector at point of time of inspection.

17
2. START UP

2.1 REGULAR WASTE WATER FEED PUMPS(P0GNK06/07AP001)

Two regular waste water feed pumps(1W+1S) will be operated alternatively and controlled by level transmitter

(high/low operation by clarified water tank level transmitter).

The operator, the operating time of both pumps will be manually operated in the same.

Even if signal for regular waste water feed pond & irregular waste water feed pond is both high level , there is no problem in operation, as the capacity of

regular waste water feed pumps is enough to handle all regular waste water & irregular waste water.

HMI
Mode Pump Status Operation condition Remark
Select mode
START Level transmitter (P0GNK01CL001) level equal or more than high

Level transmitter (P0GNK01CL001) level equal or less than low or

Level transmitter (P0GNK01CL001) level less than low low or
AUTO Select HMI Level transmitter (P0GNK20CL001) level more than high high or
MODE Touch Auto Chemical tank level switch
STOP
(P0GNN10CL080, P0GNN20CL080, P0GNN01CL080, P0GNN30CL080,
P0GNN35CL080) level less than low low or
Agitator for Coagulation Tank (P0GNK08AM002), Agitator for
Flocculation Tank(P0GNK08AM003) is trip

MANUAL Select HMI START Pumps can be operated by start using the HMI.
MODE Touch Manual STOP Pumps can be operated by stop using the HMI.

18
2.2 IRREGULAR WASTE WATER FEED PUMPS(P0GNK15/16AP001)

Two irregular waste water feed pumps(1W+1S) will be operated alternatively and controlled by level transmitter

(high/low operation by clarified water tank level transmitter).

The operator, the operating time of both pumps will be manually operated in the same.

If regular waste water feed pumps have problem, irregular waste water feed pump’s water can be transported to pH adjustment tank.

HMI
Mode Pump Status Operation condition Remark
Select mode

START Level transmitter level equal or more than high

AUTO Select HMI
MODE Touch Auto Level transmitter level equal or less than low or
STOP Level transmitter (P0GNK10CL001) level less than low low or
Level transmitter (P0GNK01CL001) level more than high high or

START Pumps can be operated by start using the HMI.

MANUAL Select HMI
MODE Touch Manual
STOP Pumps can be operated by stop using the HMI.

19
2.3 AGITATOR FOR
pH ADJUSTMENT TANK(P0GNK08AM001), COAGULATION TANK(P0GNK08AM002), FLOCCULATION TANK(P0GNK08AM003)

The agitator will be interlocked with regular waste water feed pumps.

HMI Agitator
Mode Operation condition Remark
Select mode Status
START Regular waste water feed pumps are start.
AUTO Select HMI
MODE Touch Manual Regular waste water feed pumps are stopped.
STOP
(after 5 minutes)

MANUAL Select HMI START Pumps can be operated by start using the HMI.
MODE Touch Manual
STOP Pumps can be operated by stop using the HMI.

20
2.4 CLARIFIER SCRAPER(P0GNQ01AM001), SLUDGE THICKENER SCRAPER(P0GNS05AM001)

Clarifier scraper and Sludge thickener scraper will be operated manually.

Normally Clarifier scraper and Sludge thickener scraper will be operated continuously.

HMI Scraper
Mode Operation condition Remark
Select mode Status
START Waste water system is ON.
AUTO Select HMI
MODE Touch Manual
STOP Waste water system is OFF.

MANUAL Select HMI START Pumps can be operated by start using the HMI.
MODE Touch Manual
STOP Pumps can be operated by stop using the HMI.

21
2.5 CLARIFIED WATER PUMPS(P0GNK22/23AP001)

Two clarified water feed pumps(1W+1S) will be operated alternatively and controlled by level transmitter

(high/low operation by clarified water tank level transmitter).

The operator, the operating time of both pumps will be manually operated in the same.

HMI
Mode Pump Status Operation condition Remark
Select mode
START Level transmitter(P0GNK20CL001) level equal or more than high.

Level transmitter(P0GNK20CL001) level equal or less than low or

Level transmitter(P0GNK20CL001) level less than low low or
Level transmitter(P0GNK20CL001) level more than high high or
Dual Media Filter A(P0GNK24BB001)

Select HMI - service in valve(P0GNK24AA051) / service out valve(P0GNK24AA052) is open or

AUTO
Auto Manual Activated Carbon Filter A(P0GNK26BB001)
MODE
STOP
- service in valve(P0GNK26AA051) / service out valve (P0GNK26AA052) is open or
Dual Media Filter B(P0GNK25BB001)
- service in valve (P0GNK25AA051) / service out valve (P0GNK25AA052) is open or
Activated Carbon Filter B (P0GNK27BB001)
- service in valve (P0GNK27AA051) / service out valve (P0GNK27AA052) is open or
Turbidity (P0GNK26CQ001) is above about 0.5 Value.

MANAU Select HMI START Pump can be operated by start using the HMI.
L MODE Touch Manual STOP Pump can be operated by stop using the HMI.

22
2.6 DUAL MEDIA FILTER(P0GNK24/25BB001), AIR BLOWER FOR DMF(P0GNC20/21AN001), FILTER BACKWASH PUMPS(P0GNK32/33AP001)

Clarified water will enter dual media filter from the clarified water tank by clarified water pump.
Air blower for DMF is bubbling the sludge and Filter backwash pumps are remove suspended solid in Dual Media Filter.

- Backwash Mode

Drain: (30 seconds)

Vent operation when deferential pressure transmitter becomes the high point to : Open and close automatic valves, as per the following table 1.

Air bubbling: (5 minutes)

Air inlet after vent operation is finished : During air inlet period, air blower for dual media filter will be on operation.

Open and close automatic valves, as per the following table 1.

Backwash period: (15 minutes)

Backwash after air blowing : During backwash period, filter backwash pump will be on operation.

Open and close automatic valves, as per the following table 1.

Vent operation: (30 seconds)

After backwash time is finished, a signal will reverse the opening of the above valves : Open and close automatic valves, as per the following table 1.

Rinse operation: (5 minutes)

After vent time is finished, a signal will reverse the opening of the above valves : During rinse period, clarified water pump will be on operation.

Open and close automatic valves, as per the following table 1.

Stand-By:

After rinse time is finished, a signal will reverse the opening of the above valves:

Open and close automatic valves, as per the following table 1.

23
This control description covers the process control functional logic requirement for following equipment.

KKS. NO. Description Purpose

P0GNK24/25AA051 Dual Media Filter Valve #1 Service water inlet
P0GNK24/25AA052 Dual Media Filter Valve #2 Service water outlet
P0GNK24/25AA053 Dual Media Filter Valve #3 Backwash water inlet
P0GNK24/25AA054 Dual Media Filter Valve #4 Backwash water outlet
P0GNK24/25AA055 Dual Media Filter Valve #5 Vent
P0GNK24/25AA056 Dual Media Filter Valve #6 Rinse outlet
P0GNK24/25AA057 Dual Media Filter Valve #7 Air inlet

※ Command Status Table 1

Air Water
KKS. NO. Service Drain Backwash Rinse Stand-By
Bubbling Filling
P0GNK24/25AA051 ON OFF OFF OFF ON ON OFF
P0GNK24/25AA052 ON OFF OFF OFF OFF OFF OFF
P0GNK24/25AA053 OFF OFF OFF ON OFF OFF OFF
P0GNK24/25AA054 OFF OFF ON ON OFF OFF OFF
P0GNK24/25AA055 OFF ON OFF OFF ON OFF OFF
P0GNK24/25AA056 OFF ON OFF OFF OFF ON OFF
P0GNK24/25AA057 OFF OFF ON OFF OFF OFF OFF
Filter backwash pump
OFF OFF OFF ON OFF OFF OFF
(P0GNK32/33AP001)
Air blower for DMF
OFF OFF ON OFF OFF OFF OFF
(P0GNC20/21AN001)

Depending on site conditions, regeneration time and sequence can be modified

24
- Operation Description:

• Backwash Start Condition

• Dual Media Filter and Activated Carbon Filter Train’s Service Sequence will be decided using The Touch buttons on HMI.
• Backwash Sequence
1. Operation Time: Dual Media Filter and Activated Carbon Filter is sequentially regenerated after 24 operating.

2. Differential Pressure Transmitter: If the differential pressure over 1bar, Dual Media Filter and Activated Carbon Filter is sequentially regenerated.

3. When final effluent tank level is high.

• When the Dual Media Filter and Activated Carbon Filter are backwash, other Dual Media Filter and Activated Carbon Filter are service operation in the
standby state.

• After the backwash ended, Dual Media Filter and Activated Carbon Filter will be in standby mode.

25
2.7 ACTIVATED CARBON FILTER(P0GNK26/27BB001)

Filtrated water will be transferred from dual media filter to the activated carbon filter.

- Backwash period: (15 minutes)

Backwash when deferential pressure transmitter becomes the high point to:

During backwash period, filter backwash pump will be on operation.

Open and close automatic valves, as per following table 2.

- Vent Operation: (30 seconds)

After backwash time is finished, a signal will reverse the opening of the above valves:

Open and close automatic valves, as per following table 2.

- Rinse operation: (5 minutes)

After vent time is finished, a signal will reverse the opening of the above valves:

During rinse period, clarified water pump will be on operation.

Open and close automatic valves, as per following table 2.

- Normal operation:

After rinse time is finished, a signal will reverse the opening of the above valves:

Open and close automatic valves, as per following table 2.

26
This control description covers the process control functional logic requirement for following equipment.

KKS. NO. Description Purpose

P0GNK26/27AA051 Activated Carbon Filter Valve #1 Service water inlet
P0GNK26/27AA052 Activated Carbon Filter Valve #2 Service water outlet
P0GNK26/27AA053 Activated Carbon Filter Valve #3 Backwash water inlet
P0GNK26/27AA054 Activated Carbon Filter Valve #4 Backwash water outlet
P0GNK26/27AA055 Activated Carbon Filter Valve #5 Vent
P0GNK26/27AA056 Activated Carbon Filter Valve #6 Rinse outlet

※ Command Status Table 2

KKS. NO. Service Backwash Rinse Stand-By

P0GNK26/27AA051 ON OFF ON OFF
P0GNK26/27AA052 ON OFF OFF OFF
P0GNK26/27AA053 OFF ON OFF OFF
P0GNK26/27AA054 OFF ON OFF OFF
P0GNK26/27AA055 OFF OFF OFF OFF
P0GNK26/27AA056 OFF OFF ON OFF
Filter backwash pump
OFF ON OFF OFF
(P0GNK32/33AP001)

Depending on site conditions, regeneration time and sequence can be modified.

27
- Operation Description:

• Backwash Start Condition

• Dual Media Filter and Activated Carbon Filter Train’s Service Sequence will be decided using the Touch buttons on HMI.
• Regeneration Sequence
1. Operation Time: Dual Media Filter and Activated Carbon Filter is sequentially regenerated after 24 operating.

2. Differential Pressure Transmitter: If the differential pressure over 1bar, Dual Media Filter and Activated Carbon Filter is sequentially regenerated.

• When the Dual Media Filter and Activated Carbon Filter are backwash, other Dual Media Filter and Activated Carbon Filter are service operation in the
standby state.

• After the backwash ended, Dual Media Filter and Activated Carbon Filter will be in standby mode.
• DMF & ACF sequentially proceed the backwash process. After completion of the process and stand-by.

28
2.8 AGITATOR FOR FINAL PH ADJUSTMENT TANK (P0GNK30AM001)

The agitator will be interlocked with clarified water pumps.

HMI Agitator
Mode Operation condition Remark
Select mode Status
START Clarified water pump is start.
AUTO Select HMI
MODE Touch Manual Clarified water pump is stopped.
STOP
(after 5 minutes)

MANUAL Select HMI START Pumps can be operated by start using the HMI.
MODE Touch Manual
STOP Pumps can be operated by stop using the HMI.

29
2.9 SLUDGE TRANSFER PUMPS(P0GNS02/03AP001)

Two sludge transfer pumps will be operated alternatively and intermittently required.

The operator, the operating time of both pumps will be manually operated in the same.

HMI
Mode Pump Status Operation condition Remark
Select mode

MANUAL Select HMI START Pumps can be operated by start using the HMI.
MODE Touch Manual
STOP Pumps can be operated by stop using the HMI.

30
2.10 CAUSTIC DOSING PUMPS(P0GNN13/14/16/17AP001)
Two caustic dosing pumps will be operated alternatively and controlled by pH analyzer, caustic dosing tank level switch and interlocked with regular waste
water feed pumps. Another two caustic dosing pumps will be operated alternatively and controlled by final pH analyzer, caustic dosing tank level switch
which is interlocked with clarified water pumps.

- CAUSTIC DOSING PUMP A/B FOR pH ADJUSTMENT TANK

HMI
Mode Pump Status Operation condition Remark
Select mode
Regular waste water pump is start.
START
pH analyzer (P0GNK08CQ001 is lower than 11.4
AUTO Select HMI
MODE Touch Auto Regular waste water pump is stop or
STOP pH meter is indicated higher than 11.4 or
Level switch (P0GNN10CL080) level less than low low.

MANUAL Select HMI START Pump can be operated by start using the HMI.
MODE Touch Manual
STOP Pump can be operated by stop using the HMI.

- CAUSTIC DOSING PUMP A/B FOR FINAL pH ADJUSTMENT TANK

HMI
Mode Pump Status Operation condition Remark
Select mode
Clarified water pump is start.
START
pH analyzer (P0GNK30CQ001) is lower than 6.
AUTO Select HMI
MODE Touch Auto Clarified water pump is stop or
STOP pH meter is indicated higher than 6 or
Level switch (P0GNN10CL080) level less than low low.

MANUA Select HMI START Pump can be operated by start using the HMI.
L MODE Touch Manual
STOP Pump can be operated by stop using the HMI.

31
2.11 ACID DOSING PUMPS(P0GNN23/24/26/27AP001)
Two acid dosing pumps will be operated alternatively and controlled by pH analyzer, acid dosing tank level switch and interlocked with regular waste water
feed pumps. Another Two acid dosing pumps will be operated alternatively and controlled by Final pH analyzer, acid dosing tank level switch which is
interlocked with clarified water pumps.

- ACID DOSING PUMP A/B FOR pH ADJUSTMENT TANK

HMI
Mode Pump Status Operation condition Remark
Select mode
Regular waste water pump is start.
START
pH analyzer (P0GNK08CQ001) is lower than 11.6.
AUTO Select HMI Regular waste water pump is stop or
MODE Touch Auto
pH meter is indicated higher than 11.5 or
STOP
Level switch (P0GNN20CL080) level less than low low or
Level switch (P0GNN20CL080) level equal or less than low.

MANUAL Select HMI START Pump can be operated by start using the HMI.
MODE Touch Manual
STOP Pump can be operated by stop using the HMI.

- ACID DOSING PUMP A/B FOR FINAL pH ADJUSTMENT TANK

HMI
Mode Pump Status Operation condition Remark
Select mode
Clarified water pump is start.
START
pH analyzer (P0GNK30CQ001) is lower than 9.1.
AUTO Select HMI Clarified water pump is stop or
MODE Touch Auto
pH meter is indicated higher than 9 or
STOP
Level switch level less than low low or
Level switch (P0GNN20CL080) less than low.

MANUA Select HMI START Pump can be operated by start using the HMI.
L MODE Touch Manual
STOP Pump can be operated by stop using the HMI.

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2.12 COAGULANT DOSING PUMPS(P0GNN37/38AP001)

Two coagulant dosing pumps will be operated alternatively and controlled by from pH analyzer (P0GNK08CQ002), coagulant dosing tank level switch

(P0GNN35CL080) and interlocked with regular waste water feed pumps.

The operator, the operating time of both pumps will be manually operated in the same.

HMI
Mode Pump Status Operation condition Remark
Select mode
Regular waste water pump is start.
START
pH analyzer (P0GNK08CQ002) is lower than 7.5.
AUTO Select HMI Regular waste water pump is stop or
MODE Touch Auto
pH meter is indicated higher than 6.5 or
STOP
Level switch (P0GNN35CL080) level less than low low or
Level switch (P0GNN35CL080) level less than low.

MANUA Select HMI START Pump can be operated by start using the HMI.
L MODE Touch Manual
STOP Pump can be operated by stop using the HMI.

33
2.13 FLOCCULENT DOSING PUMPS(P0GNN03/04AP001)

Two flocculent dosing pumps will be operated alternatively and controlled by from HMI of flocculent auto dissolving unit, level switch (P0GNN01CL080) and

interlocked with regular waste water feed pumps.

The operator, the operating time of both pumps will be manually operated in the same.

HMI
Mode Pump Status Operation condition Remark
Select mode

START Regular waste water feed pump is start.

AUTO Select HMI
MODE Touch Auto Regular waste water feed pump is stop or
STOP
Level switch (P0GNN01CL080) level less than low low.

START Pump can be operated by start using the HMI.

MANUAL Select HMI
MODE Touch Manual
STOP Pump can be operated by stop using the HMI.

34
2.14 FLOCCULENT AUTO DISSOLVING UNIT AND POLYMER AUTO DISSOLOVING UNIT FOR DEHYDRATOR

Flocculent auto dissolving unit will be operated continuously and separately automatic operation.

Flocculent auto dissolving unit will be controlled by level switch (P0GNN01/05CL080) of hopper and dissolving tank.

HMI
Mode Status Operation condition Remark
Select mode

START Level switch (P0GNN01/05CL080) level equal or less than low.

AUTO Select HMI
MODE Touch Auto
Level switch (P0GNN01/05CL080) level equal or more than high or
STOP
Level switch (P0GNN01/05CL080) level less than low low or

START Pump can be operated by start using the HMI.

MANUAL Select HMI
MODE Touch Manual
STOP Pump can be operated by stop using the HMI.

35
2.15 AGITATOR FOR FLOCCULENT AUTO DISSOLVING UNIT AND DISSOLVING UNIT FOR DEHYDRATOR

The agitator will be controlled by level switch (P0GNN01/05CL080).

HMI Agitator
Mode Operation condition Remark
Select mode Status

START Flocculent dosing pumps are start.

AUTO Select HMI
MODE Touch Auto
Flocculent dosing pumps are stopped for a long period or
STOP
Level switch (P0GNN01/05CL080) level equal or less than low

START Pump can be operated by start using the HMI.

MANUAL Select HMI
MODE Touch Manual
STOP Pump can be operated by stop using the HMI.

36
2.16 POLYMER DOSING PUMPS FOR DEHYDRATOR(P0GNN07/08AP001)
Two polymer dosing pumps for dehydrator will be operated alternatively and controlled by polymer auto dissolving unit for dehydrator level switch and
interlocked with dehydrator.
The operator, the operating time of both pumps will be manually operated in the same.

HMI Pump
Mode Operation condition Remark
Select mode Status

START Dehydrator is start.

AUTO Select HMI
MODE Touch Auto Dehydrator is stop or
STOP
Level switch (P0GNN05CL080) level less than low low.

START Pump can be operated by start using the HMI.

MANUAL Select HMI
MODE Touch Manual
STOP Pump can be operated by stop using the HMI.

37
2.17 THICKENED SLUDGE TRANSFER PUMP(P0GNS06/07AP001)
Two thickened sludge transfer pumps will be operated alternatively and intermittently required.
The operator, the operating time of both pumps will be manually operated in the same.

HMI
Mode Pump Status Operation condition Remark
Select mode

MANUAL Select HMI START Pumps can be operated by start using the HMI.
MODE Touch Manual
STOP Pumps can be operated by stop using the HMI.

38
2.18 DEHYDRATOR(P0GNS10AP001)

This equipment is package system. Dehydrator will be operated using LCP only. It will be only monitored by MMI of PLC.

- Automatic Mode Is In The Maker Standard Package:

• AUTO START
1. After the Recycle system water line open, Press the button 'AUTO START', then [DRIVE MOTOR, WASHING MOTOR, RECYCLE SYSTEM MOTOR]
operates.

2. After 10 minutes, then [MIXING MOTOR, POLYMER MOTOR, SLUDGE MOTOR] operates.

• AUTO STOP
1. Press the bottom 'AUTO STOP', then [MIXING MOTOR, POLYMER MOTOR, SLUDGE MOTOR] stops.

2. After 20 minutes, [MIXING MOTOR, POLYMER MOTOR, SLUDGE MOTOR] stops.

3. Release the pressure turning the cushion lever of upper/lower belt in Air Panel.

39
- Manual Mode :

• Operate the cushion lever of the belt cloths in the Air Panel and then put the pressure of cushion bellows of the filter belts.
(Regulator : 5 – 6kg/cm2, Upper belt : 2.5 - 3.0kg/cm2, Lower belt : 3 - 3.5kg/cm2)

• Stop the operation and release the pressure turning the cushion lever.
• Recycle system water line open
Input the sludge and close.

• Run the drive motor at proper speed.

• * In need : Control the speed spinning the lever of gear box in the machine. (It must be controlled in operation.)
• Operate Recycle System. Supply the water in advance in operation of recycle system for a good condition of belt washing and washing pump.
• Operate Washing Pump.
• Operate Mixing Tank.
• Operate Polymer Pump. (Check input of polymer first.)
• Operate Sludge Pump.
• * Make the best floc conditions in the Mixing Tank controlling sludge, polymer and rpm of mixing tank.
• The diagonal travel of the belt is set automatically by mechanical valve. Roll size is 1100 mm, the width of belt is 1000 mm and the diagonal travel can be
20mm±.

• Check the mechanical valve of come-off direction when the belt comes off the roll.
• In case black line is found on the belt and washing is not being done properly, close the washing valve and clean the nozzle pipe with a brush.
• Disassemble the nozzle pipe and clean it if you have difficulties cleaning it with a brush.

40
2.19 OIL SKIMMERS(P0GNB01/02AT001)

- Manual Mode:

• Oil skimmer will be operated manually.

• Oil skimmer will be operated by start and stop push buttons on control panel except for the system trip.
• Operation time : 24hr

2.20 OILY WASTE WATER FEED PUMPS(P0GNB04/05AP001)

Two oily waste water feed pumps(1W+1S) will be operated alternatively and controlled by level transmitter.

The operator, the operating time of both pumps will be manually operated in the same.

HMI Pump
Mode Operation condition Remark
Select mode Status

START Level transmitter (P0GNB01CL001) level equal or more than high.

AUTO Select HMI
MODE Touch Manual Level transmitter (P0GNB01CL001) level equal or less than low or
STOP Level transmitter (P0GNB01CL001) level less than low low or
Level switch (P0GNB02CL080) level more than high high.

MANUAL Select HMI START Pumps can be operated by start using the HMI.
MODE Touch Manual
STOP Pumps can be operated by stop using the HMI.

41
2.21 SKIMMED OIL PUMP, OIL SLUDGE PUMP(P0GNB10AP001, P0GNB15AP001)

Skimmed oil pump, oil sludge pump will be operated manually according to requirements.

In purging the sludge, operator keep watching level switch to prevent overflow.

2.22 OIL SEPARATOR(P0GNB05AT001/002)

Two oil separators will be operated manually according to requirements.

Inlet water quantity is controlled by two of manual valves on the oily waste water feed pump discharge line at the constant rate.

Pipe oil skimmer is installed lower by 1mm than the water level by turning the handle of pipe skimmer.

With oily water separating tank uncovered, check that water and oil flow from pipe skimmer and then set the height of water dam regulator lower by 3.2mm

than oil dam.

It must be confirmed that the effluent fulfils the required oil content after 15minute of operation time.

If effluent water would not be fulfilled the requirement by monitoring of oil analyzer, it returns to the oily waste water pond through 3-way valve.

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2.23 POST TREATED OILY WASTE WATER FEED PUMPS(P0GNB20/21AP001)
Two post treated oily waste water feed pumps(1W+1S) will be operated alternatively and controlled by level switch (P0GNB02CL080).
The operator, the operating time of both pumps will be manually operated in the same.

HMI Pump
Mode Operation condition Remark
Select mode Status

START Level transmitter (P0GNB02CL080) level equal or more than high.

AUTO Select HMI
MODE Touch Manual Level transmitter (P0GNB02CL080) level equal or less than low or
STOP Level transmitter (P0GNB02CL080) level less than low low or
Level switch (P0GNK01CL001) level more than high high.

MANUAL Select HMI START Pumps can be operated by start using the HMI.
MODE Touch Manual
STOP Pumps can be operated by stop using the HMI.

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2.24 SUMP PUMPS(P0GNK50/51/52/53AP001)
Two sump pumps will be operated alternatively and controlled by level switch (P0GNK50CL080 / P0GNK52CL080).
The operator, the operating time of both pumps will be manually operated in the same.

HMI Pump
Mode Operation condition Remark
Select mode Status

START Level transmitter (P0GNK50CL080/P0GNK52CL080) level equal or more than high.

AUTO Select HMI
MODE Touch Manual Level transmitter (P0GNK50CL080/P0GNK52CL080) level equal or less than low or
STOP Level transmitter (P0GNK50CL080/P0GNK52CL080) level less than low low or
Level switch (P0GNK01CL001) level more than high high.

MANUAL Select HMI START Pumps can be operated by start using the HMI.
MODE Touch Manual
STOP Pumps can be operated by stop using the HMI.

44
2.25 AIR BLOWER FOR REGULAR WASTE WATER POND(P0GNC01/02AN001)
Two air blower for regular waste water pond(1W+1S) will be operated alternatively and controlled by level transmitter
(low operation by regular waste water pond level transmitter).
The operator, the operating time of both air blower will be manually operated in the same.

HMI Blower
Mode Operation condition Remark
Select mode Status

START Level transmitter (P0GNK01CL001) level equal or more than low.

AUTO Select HMI
MODE Touch Manual
STOP Level transmitter (P0GNK01CL001) level equal or less than low low.

MANUAL Select HMI START Pumps can be operated by start using the HMI.
MODE Touch Manual
STOP Pumps can be operated by stop using the HMI.

45
2.26 AIR BLOWER FOR IRREGULAR WASTE WATER POND(P0GNC10/11AN001)
Two air blower for irregular waste water pond(1W+1S) will be operated alternatively and controlled by level transmitter
(low operation by irregular waste water pond level transmitter).
The operator, the operating time of both air blower will be manually operated in the same.

HMI Blower
Mode Operation condition Remark
Select mode Status

START Level transmitter (P0GNK01CL001) level equal or more than low.

AUTO Select HMI
MODE Touch Manual
STOP Level transmitter (P0GNK01CL001) level equal or less than low low.

MANUAL Select HMI START Pumps can be operated by start using the HMI.
MODE Touch Manual
STOP Pumps can be operated by stop using the HMI.

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2.27 3-WAY PNEUMATIC VAVLE(P0GNB21AA051)- Final Effluent Disposal

- Operation Condition

①
When Final effluent pump start or pH 6-9

3 way valve
flow Regular waste water pond line MCW discharge channel line
direction
Valve Status Open Close

Not rage pH 6-9

3 way
valve flow Regular waste water pond line MCW discharge channel line
direction
Status Close open

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2.28 3-WAY PNEUMATIC VAVLE(P0GNK40AA051) - Post Treated Oily Waste Water

- Operation Condition

When Post treated oily waste water feed pump start or

Oil analyzer value is more than 10
3 way valve
flow Oily waste water pond line Regular waste water pond line
direction
Valve Status Open Close

②
When Post treated oily waste water feed pump start or
Oil analyzer value is more than 10
3 way valve
flow Oily waste water pond line Regular waste water pond line
direction
Valve Status Close Open

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2.29 FINAL EFFLUENT PUMPS(P0GNK40/41AP001)

Two post final effluent pumps(1W+1S) will be operated alternatively and controlled by level transmitter(P0GNK30CL001).

The operator, the operating time of both pumps will be manually operated in the same.

HMI Blower
Mode Operation condition Remark
Select mode Status

START Level transmitter (P0GNK30CL001) level equal or more than high.

AUTO Select HMI
MODE Touch Manual
STOP Level transmitter (P0GNK30CL001) level equal or less than low.

MANUAL Select HMI START Pumps can be operated by start using the HMI.
MODE Touch Manual
STOP Pumps can be operated by stop using the HMI.

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2.30 CHEMICAL FILLING

2.30.1 Caustic Dosing Tank (P0GNN10BB001)

Level Switch Water Pneumatic Valve Chemical Pneumatic Valve Agitator

(P0GNN10CL080) (P0GNN10AA052) (P0GNN10AA051) (P0GNN10AM001)

High Point OFF OFF ON
Chemical Point OFF ON ON
Low Point ON OFF OFF

2.30.2 Acid Dosing Tank (P0GNN20BB001)

Level Switch Water Pneumatic Valve Chemical Pneumatic Valve

(P0GNN20CL080) (P0GNN20AA052) (P0GNN20AA051)

High Point OFF OFF
Chemical Point OFF ON

Low Point ON OFF

2.30.3 Coagulant(Alum) Dosing Tank(P0GNN35BB001)

Level Switch Water Pneumatic Valve Coagulant Transfer Pump Agitator

(P0GNN35CL080) (P0GNN35AA051) (P0GNN32/33AP001) (P0GNN35AM001)

High Point OFF OFF ON
Chemical Point OFF ON ON
Low Point ON OFF OFF

Note: When the agitator has CP point, start and when high point, stop. And stop after 30 minutes.

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3. NORMAL OPERATION AND ROUTINE CHECKS

3.1 Organizational Measures

• Retain operation instructions at the system.

• Observe safety and danger notes at the system.
• Keep safety and danger notes at the plant completely and in readable condition.
• Before starting works, the operation personnel must have read and understood the operating manual and especially the chapter ”safety”.
We recommend the operator to get a written confirmation. This applies especially for personnel, operating only occasionally at the system.

Use only skilled and specialized personnel.

• Check the works of the personnel regarding safety and dangerous consciousness from time to time under consideration of the operating manual.
• In case of safety relevant alterations of the operation, rebuilding works at the system without written approval of the manufacturer.
This applies especially to the installation and adjustment of safety devices.

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3.2 Instructions regarding Normal Operation

• Plant to be operated only, if all protection devices and safety relevant installations are available and able to function.
• Observe operation and maintenance instructions.
• Stop the plant, if fault, function troubles or other troubles occur.

3.3 Maintenance Works


Important
Keep prescribed adjusting, maintenance works and dates, incl. information regarding
neutralization/oil water separator/biological of parts

Inform the operating personnel before starting maintenance and repair works.

WARNING

Risk of Injury!
If the plant is completely switched-off in case of maintenance and repairing
works, it must be protected against unexpected and unintentional restart.

If disassembly of safety devices becomes necessary, inspection has to be carried out immediately after finishing of maintenance manometric switches.

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3.3.1 System Maintenance in normal operation

WARNING

Risk of Injury!
When maintaining the wastewater treatment plant, individual operating
instructions for equipment components shall be kept.

Maintaining the waste water system includes servicing of following equipment:

 Oily & Chemical waste water system

• Maintenance of portable oil skimmer, oil water separator.
• Maintenance of sedimentation basin, rotating scraper.
• Maintenance of pumps, blowers, Agitators.
• Maintenance of safety facilities.
• Maintenance of auxiliary equipment.

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3.4 Controls during normal operation

In normal operation permanently shall be controlled:

• pH/flow/temp quantity at effluent outlet.

• pH in reaction tank.
• Calibration of pH value measuring,
• Controlled parameters shall be taken down into a protocol.
When operating the waste water treatment system the following shall be controlled:

• Outer state of pumps, blower, agitator, piping and piping connections as well as instrumentation
• Leak-proof of piping and flange connections.
• Occurrence of strange noise during operation of pumps/blower/agitator as well as sparks and fume coming out of motors
• Temperature of pump bearings (must not exceed 70 °C)
• Temperature of motor cases (must not exceed 80 °C)
• Appearance of vibrations at pumps and piping
• Packing glands (drops are admissible)
• Provision of lubricant in the bearings
• Operation of instrumentation and alarm facilities.
During operation of the waste water treatment system water parameters shall be controlled both in crude water and in treated water.

These parameters should be taken down into a protocol. Norms required for the treated water are specified in the instruction manual submitted.

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3.5 Repair Cases

3.5.1 Automatic Operation Switched-Off

The system works in automatic operation.

By switching into manual operation pumps in oily & chemical treatment system could be switched on and off by means of selector switches.

3.5.2 Failure Switching of Aggregates

In case of failure, as for instance of a pump, it will be switched over to the stand-by pump by the control system, thus, no operation failure will occur.

3.6 Chemicals

The following chemicals are used in the wastewater treatment system:

HCl, NaOH, alum and polymer for chemical cohesion of the wastewater.

Handing of above mentioned chemicals as per enclosed safety data

3.7 Use as agreed

The treatment system has exclusively to be used for desalination and power plant.

Another or further use is not as agreed. The manufacturer/supplier is not liable for damages resulted here from. The user is solely responsible for the risk.

The instructions mentioned in these operation instructions and in other regulations have strictly to be observed.

55
3.8 Personal Protection Equipment

ATTENTION
Observe safety procedures!
All clothes must be acid and lye proof. Furthermore,
we recommend safety shoes and helmet.
When handling with chemicals of any kind protection
glasses and gloves have to be worn

3.9 Dangerous Sources

DANGER
Risk of Injury!
The electrical voltage is 230/400 V, 50 Hz. Installation,
maintenance works must be carried out by specialized
electricians only.

56
4. SHUTDOWN

4.1 Shutdown of Waste Water Treatment System

Practically, the system may be put out of operation at any time. There are following possibilities to put the system down:

A) The entire system will electrically be switched off.

This would make sense of a longer shutdown is planned.

When it will be put into operation again, waste water treatment system may possibly become necessary.

In case of a longer shutdown time preservation of the system is necessary.

But there is no general conclusion at which shutdown time this may become necessary, because this mainly depends on the waste water quality.

If required, please contact the company DOOSAN.

B) Putting the system out of operation in case of emergency:

In case of emergency the plant may be put out of operation without any problems by switching off the main switch.

All automatic doors will close, since in any case control air will be available.

Special-type safety armature will open and protect the system being in shutdown condition.

57
5. Alarm Procedure
All limit valves of the quality measurement, level controls, PH and oil analyzers as well the malfunction signals of the motor controls will be tested via the DCS

and shown in the local illuminated mimic diagram.

In case of failure the indicator lights shall be shown a text information in the monitor of DCS.

The malfunction and the collective alarm are given as a volt free contact to the external DCS-system according the measurement list.

During the operation of waste water system the different alarms can be given.

The following shows what is the cause of alarm and the remedy measures to remove this alarm.

58
6. Emergency Procedure

Independent of this automatic, order ”emergency-Operation” can be given via the ”DCS { XE “Distributed Control System (DCS)” }”-system. In this case all

”sewage collection pumps” start one after the other and step by step (approx. 3 sec.).

In case of emergency switch {XE “emergency switch” } main switch (EMERGENCY-OUT) off and shut the Sewage treatment system down.

Please, contact next DOOSAN office being responsible for you and submit them detailed information about malfunction and possible reasons.

59
■ MAINTENANCE MANUAL

60
1. MANINTENANCE MANAGEMENT SYSTEMS

1. MAINTENANCE MANAGEMENT SYSTEMS

Maintenance Management is an orderly and systematic approach to planning, organizing, monitoring and evaluating maintenance activities and their costs.

A good maintenance management system coupled with knowledgeable and capable maintenance staff can prevent health and safety problems and

environmental damage; yield longer asset life with fewer breakdowns; and result in lower operating costs and a higher quality of life.

This document provides general information and guidance on establishing Maintenance Management Systems for use in First Nations communities.

It describes a system framework from the initial step of inventory gathering to preparing a community maintenance budget for asset maintenance planning

and monitoring. Depending on the application and design, Maintenance Management Systems may have various formats and procedures,

(e.g., various formats of work orders, reports and computer screens, etc.), but the basic principles of all these systems are similar to the one presented in this

document.

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1.1 TYPES OF MAINTENANCE
The word “Operation” is usually linked with “Maintenance”. To put these terms in context, Operation is the performance of work or services and the provision
of materials and energy to ensure the day-to-day proper functioning of an asset, e.g., the work activities, associated chemicals and electricity to run a waste
water treatment plant. As such, it has a direct but simple impact on the cost of operating an asset. Maintenance is the work performed on an asset such as a
road, building, utility or piece of equipment to preserve it in as near to its original condition as is practical and to realize its normal life expectancy.
This Technical Information Document, as its name implies, concentrates on maintenance management systems only.

In general, maintenance can be classified into the following categories:

• routine - ongoing maintenance activities such as cleaning washrooms, grading roads

• and mowing lawns, which are required because of continuing use of the facilities;
• preventive - periodic adjustment, lubrication and inspection of mechanical or other equipment to ensure continuing working condition;
• major projects such as floor replacement, re‐roofing, or complete re‐painting which are performed once every few years; and
• Emergency - unexpected breakdowns of assets or equipment. These are unpredictable or reactive type of maintenance and are more difficult to schedule
than the above three categories.

Repair is restoring an asset by replacing a part which is broken or damaged, or reconditioning that part to its original or acceptable working condition.

The need for repairs can result from normal wear, vandalism, misuse or improper maintenance.

62
2. PREPARING A MAINTENANCE PLAN

2. PREPARING A MAINTENANCE PLAN

Depending on the application and design of a maintenance system, the format and steps of preparing a maintenance plan can vary.

The key steps in preparing a typical maintenance plan are:

• Prepare an asset inventory - identifying the physical features (e.g., area, material, etc.) of all assets which require maintenance;
• Identify maintenance activity and tasks - defining the type of maintenance task(activity) to be performed on each asset and what work should be done
under each activity,

• Identify the frequency of the task - determining how often the activities should be performed (frequency of service); this is important particularly in
preventive type of maintenance. Emergency or reactive type of repairs are unpredictable, but with good preventive maintenance, the frequency of

emergency situations occurring may be reduced;

• Estimate the time required to complete the task - indicating how long each task should take to complete;
• Develop an annual work schedule - planning what time the maintenance work for the entire year should take place;
• Prepare and issue a work order - identifying what, when, where and by whom maintenance work is to be done; and
• Determine a Budget - determining the costs for all maintenance activities by calculating labour hours, material, equipment, and contracting costs.
A chart showing a Maintenance Management System Process is shown in Figure. More detailed discussion of the steps are covered in subsequent sections.

63
A chart showing a Maintenance Management System Process is shown in Figure.

More detailed discussion of the steps are covered in subsequent sections.

TASKS,
ASSET
FREQUENCIES &
INVENTORY
TASK TIMES

WORK SCHEDULE

Assign WORK ORDERS

Personnel

COSTS SOURCES OF
MAINTENANCE FUNDS
• Labour Rate
BUDGET • DIAND O&M
• Equipment
Funding
Rate
• User Fees
• Material Costs
• Other
• Contract
Sources

64
Inventory

The inventory is a list of physical features (area, material, etc.) of capital assets that require

maintenance. The types of data to be kept vary with the maintenance activity and the task required.

Table 1 gives examples of the types of inventory detail.

Task Statement / Frequency / Task Times

A task statement is a detailed list of the generic maintenance tasks to be performed for a particular type of asset in conducting preventive or routine

maintenance.

Frequency refers to how often the maintenance tasks are performed, for example, daily, weekly or every five years.

Task times indicate how long it will take to do such an amount of work.

Each task statement relates to a specific type of maintenance activity appropriate for an asset.

A component of an asset, such as a boiler in a building, may require maintenance checks weekly, monthly, quarterly, and/or annually.

Similarly, a road may have a single task statement, such as grading, to be repeated a number of times during the year.

To prepare a set of tasks applicable to a particular asset, one should review the physical features of an

asset and/or the manufacturer’s operation and maintenance manual to determine the maintenance tasks, task times and frequencies required.

For emergency or reactive type work orders, the maintenance tasks and estimated task times will have to be assessed based upon the problem occurring.

65
Work Schedule

The work schedule lists all maintenance work to be done for the whole year for each asset.

It can be used to identify work load peaks and valleys, i.e., where load balancing, overtime and/or part-time help is needed. It also serves as a basis for

preparing and issuing scheduled work orders and for preparing the maintenance budget.

When all work orders have been listed and the hours distributed, the sub-totals of each period for each worker are calculated.

This process is repeated for work orders to be carried out by other workers, and extended to all capital assets to obtain the annual work load profile for each

worker.

Balancing Work Load

Work load balancing may reduce the extreme demands of personnel and provide a more even work load, leading to better use of human resources, reduced

administrative paper work and improved efficiency. To balance the work load, one may:

a) Shift some of the work in the peak period(s) to other weeks, either sooner or later than originally planned.

If the demand in certain weeks is still greater than the available hours from a regular shift, the deficit could be made up by overtime;

b) Assign part‐time personnel for the peak periods; or,

c) Assign additional duties or emergency work to the worker in the period where the worker is not busy.

Decisions of this type are required to make the total work load for each worker as even as possible to facilitate staffing and to identify periods when additional

help is required.

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Work Orders

Work orders provide information on what, where, when, how long and by whom maintenance is to be carried out.

Work orders are prepared from inventory data (physical features) and task statements.

Each work order lists tasks for the same frequency of work and for the same asset.

Another work order could contain different tasks for monthly maintenance of the same asset.

The general guidelines for preparing a work order are as follows:

a) Starting with any asset on reserve, say a First Nations Day Care Centre, examine the inventory data and typical task statements to determine the tasks

appropriate for that specific asset;

b) List the asset name, maintenance activity number and work order number, etc. on a blank work order. Using the task statement or manufacturer’s operation

and maintenance manual as a reference (modify, if necessary, to suit specific situations), fill in the appropriate tasks (i.e., Work To Be Performed) on the

work order;

c) Calculate or estimate the time needed to complete the individual tasks and enter the total time for all tasks in the “planned time” block. The sum of work order

planned times for all assets in a reserve will determine the workforce requirement for planning and scheduling personnel resources. Time standards for

routine and preventative maintenance activities are based on time studies and are available from reference books. If time data for a specific task is

unavailable, it can be estimated based on similar past experience. This is particularly true for emergency or reactive type work orders. When the task has

been completed, the actual time taken should be compared to the estimated time to determine the accuracy of the estimate or measure the productivity of the

maintenance team.

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Maintenance Budget

A maintenance budget is a cost projection based on the costs of labour, equipment, material and other items (such as contracts) required to do all work

identified in the Work Schedule.

After the costs are calculated for one work order, the process is repeated for the remaining work orders to get the total cost required to maintain the asset. The

maintenance supervisor is responsible for monitoring the actual expenditures against the budget for the year. He or she is also responsible for its yearly update

using forecast labour rates, and material and service contract costs. The updated budget would be used for determining the operation and maintenance costs of

the First Nation’s physical assets. The Annual Maintenance Budget recaps total labour hours, labour cost, equipment cost and material cost for the asset.

At this point, all overhead costs, utility costs, and maintenance management supervision costs are also entered.

To determine the total maintenance budget for a First Nation, simply prepare a similar summary for each asset in the community and add up the totals of each

asset in the community.

68
Management of Maintenance

There is a lot of work required to set up a successful maintenance management system.

However, once it is in place, most of the data and calculations remain the same from year to year. Changes are required only when there is an addition or

deletion to the inventory or when cost increases and estimates need to be corrected. In these cases, the appropriate work orders and schedule must be revised

and the labour, equipment, material and contract costs updated for the new year. There are numerous computerized maintenance management systems

available in the commercial market to assist in effectively managing the maintenance of on‐reserve assets.

The maintenance supervisor or manager must also monitor the work progress daily, weekly or monthly depending on the nature of the situation and the

potential impact of a service breakdown to the community.

He or she must not wait until the year end to review the budget, as it would be too late to take any corrective action if it were necessary.

Any significant variance in labour hours, work order costs or total maintenance cost for a particular asset should be identified through exception reporting.

The supervisor should determine the cause of the variance and, where possible, develop alternative solutions or actions to reduce time and costs.

Taking these steps will help improve the efficiency and effectiveness of the maintenance program.

69
3. PREVENTIVE MAINTENANCE

3. PREVENTIVE MAINTENANCE

GENERAL

Doosan should be inspected externally every six months and any damaged paintwork on pipe work and valves renewed. An annual internal inspection of

vessels is also recommended.

In case of any visible external damage, consider possibilities of corrosion, due to underlying causes such as a damaged lining in a tank or a pipe carrying alkali.

Consequently, when removing scale on such items (e.g. chemical storage tanks, measuring and dilution tanks) exercise caution.

If there is any possibility of a break‐ through, consult the waste water treatment plant Engineer.

In addition to the items specifically mentioned in the MAINTENANCE section, rectify leaking valves and joints immediately by tightening loosened nuts and bolts

or changing sealing joints (gaskets). Replace gland packing when required DON’T LET LEAKS PERSIST. KEEP THE WASTE WATER TREATMENT PLANT

DRY AND WELL SWEPT.

If it is necessary for maintenance personnel to enter any of the treatment units, rubber or soft soled shoes must be worn and great care taken to avoid damage

to any rubber lining and internal lateral systems.

The feet should be placed on the lateral clamping bars, not on the laterals themselves and every effort taken to avoid standing on the small plastic strainers.

Entry into the vessels should be discouraged, but if unavoidable, must be carried out under the supervision of the waste water treatment plant Chemist or

Engineer.

70
On equipments where, internal stud, nuts, bolts and washers are made of high-grade stainless steel, it is essential that only the right quality replacements be

used.

The stainless steels are virtually non-magnetic and therefore the quality of a replacement can easily be confirmed with a magnet.

Any items showing magnetic properties must be rejected.

Whenever a bolt or nut butts against rubber, use the special rectangular plate washers.

When tightening down on these washers ensure that friction between the nut (or bolt head) and the washer does not cause the washer to rotate and peel-off the

rubber lining.

Valves should be inspected regularly and gland packing where used should be replaced regularly.

Valves of the plug type and some diaphragm type, which require lubrication, should be attended regularly.

Refer to the auxiliary manuals for maintenance instructions on other equipment that may be supplied such as pumps and instrumentation.

71
CHEMICAL TANKS

Every six months inspect all measuring tanks externally, including connecting paperwork and valves.

Remove any loose paintwork and scale and make good with fresh paint.

If the internal condition of the tank is suspect the tank cover must be removed under the supervision of the Water Treatment Plant Chemist and the interior

inspected and cleaned.

Whilst the cover is removed, ensure that any sludge in the bottom of the measuring tanks is removed.

On automatic plants, a possible cause of a ‘slow acid’ is sludge in the bottom of the tank forming a permanent circuit between the earth and the low-level

electrode.

When scraping out sludge in the acid measuring tanks use a wooden spatula or a piece of hard polyphone to avoid damage to any lining.

The level indicator glasses should also be cleaned periodically with clean rags and hot water.

The lining material in the acid measuring tanks is normally rubber when hydrochloric acid is used.

Tanks for concentrated alum are unlined. The caustic soda measuring tanks are normally unlined.

72
Note:

If at any time the unlined pipe‐work to and from the acid measuring tanks are flushed out with water for cleaning purposes, it is essential that the pipes are

thoroughly dried out before concentrated acid is again passed through them, otherwise the local dilution of the acid by the residual water on the walls of the pipe

will result in corrosion.

The back bone of a successful plant is the regular preventive maintenance by the operating staff.

The following are the general points to be noted for the maintenance. Besides the instructions are outlined for important operative equipments in the

manufacture’s instructions manual.

a) Oil levels are to be checked and the deficit level is to be made up by using the recommended grade of oil.

i. Reduction gears

ii. Oil lubricated pumps (if any)

The frequency of application and type of lubricants to be used, is to be followed as per the manufacturer’s instruction manual.

b) The major greasing points to be checked once in a week are listed below:

i. Plummer blocks

ii. M. S. Shutter / gates sides

iii. Hand Wheel operated spindles/ valve

iv. Motors

73
c) Check for tightness of nuts and bolts every month of all equipments and ensure that all are free from undue vibration.

d) Some hand operated shutters which are not in regular use should be operated from time to time for easy movement and preventions of failures when

required to be put into service.

e) The carbon brushes of the current collector box should be checked for abrasion and wear every three months and replaced when worn out, with brushes

suitable for use in slipring (5 rings) induction motor.

I. Study the layout of the pumping installations and valves for familiarization.

II. The layout chart should be displayed prominently in the pump house for ready reference.

III. Ensure that the specifications of the pumps, motors, valves etc. on the chart tally with those at the installation.

IV. Ensure that adequate quantities of the appropriate lubricant oil and grease are available in stock.

V. Also display the electrical wiring diagram for ready reference.

74
START – UP PREPARATION

i) Check and ensure that the pump sets, motors, valves, piping etc. are secured and in proper alignment.

ii) Remove all construction materials and tools lying in and around units.

iii) Ensure that the drainage is in working conditions.

iv) Fill up the bearings, gear boxes and the moving parts with the correct grade and quantity of lubricants.

v) Turn unit by hand to ensure free movement of pump and drive shafts.

vi) Ensure that the correct grades of chemicals are available in ready stock at least for one month consumption.

vii) Ensure that all suction valves of pumps remain open.

75
ELECTRICAL MOTOR:

The following part gives a General idea about Electrical Routine Maintenance and fault finding.

1) Motors should be dusted and cleaned periodically and if possible use compressed air to clean the grills.

2) Greasing to the boaring must be done regularly.

The grease used must be of good quality and required grade.

3) The terminal box covers must be opened periodically and on opening, examine the following :

‐ The tightness of the connections

- The insulation resistance of the leads

If the connections are loose tighten them, otherwise loose connection may cause man problems like overheating.

4) The condition of the bearings must be checked periodically. If excessive noise is observed, then replace the bearings.

5) the alignment of the coupling (Motor & Pump) must be checked regularly.

6) Check the insulation resistance of the motors.

7) Put on the heater supply to motors which are not in use by operating the switch from the respective Motor control Centre cubicle.

8) If motors get too hot check the following :

- Voltage as at low voltages the motor will draw more current.

- Alignment of the coupling

76
MOTORS TRIPPING

Motors will trip either due to overload or due to single phasing.

The overload tripping can be cleared by pressing the trip release button fitted on each MCC cubicle.

However a small interval of time has to be allowed just after the motor tripping before it can be reset and restarted.

NUISANCE TRIPPING

In some bigger motors where single phase preventing relay (SPPR) has been provided, there can be nuisance tripping i.e., the pump will trip within a minute or

two just after starting.

This can be rectified by changing the wiring of SPPR as follows :

CAUTION

Whenever leads 1 & 3 are interchanged leads 2&4 must also be interchanged without fail.

77
MOTOR CONTROL CENTRE

Proper care must be taken. Periodically the cubicles should be opened out and cleaned with service air.

Keep all the door always securely closed.

During the winter season, put on the heaters to drive out moisture.

Whenever the cubicles are removed before putting it back apply petroleum jelly on the rollers.

While putting back the cubicles ensure that the cubicle has properly entered and all the four hine screws can be tightened without difficulty.

Otherwise remove the cubicle once again, push it properly.

It is to be noted that there are spare cubicles for all the drives and in case of emergency,

remove the faulty cubicle and in its place put the spare cubicle.

No motor can be started / stopped from the MCC.

However, the indication lamps are provided on the MCC cubicles (Red for ON, Green for OFF and Amber for TRIP).

A burnt‐out fuse should always be replaced only by HRC fuse.

78
POWER ENGINEERING
VIETNAM ELECTRICITY CONSULTING JSC 3

VINH TAN 4 THERMAL POWER PLANT

PROJECT (2X600MW)

TRAINING MANUAL
FOR
CONDENSATE POLISHING PLANT

DMPP Consortium(Mechanical Engineering Team)

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CONDENSATE SYSTEM

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TABLE OF CONTENTS

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Introduction to CPP

What is Condensate?

Condensate is treated water that has gone through a steam cycle generally in a
power plant.

The quality of condensate will be depend on the quality of treated water and
operating pressure of boiler.

3
Introduction to CPP

The Condensate Cycle

4
Introduction to CPP

What is in Condensate?

What is supposed to be in the condensate ?

• High Purity Water
• Amines/Corrosion Conditioning Chemicals

What are the contaminants and where are they come from?
• Strong Acidic ions - Make-up or Condenser Leak
• Strong Basic ions - Make-up or Condenser Leak
• Weak Acidic ions - Make-up or Condenser Leak and air in leakage
• Organics – Make-up or decomposition of boiler additives
• CO2 - air in leakage
• Crud – condenser, piping, boiler components etc.

5
Introduction to CPP

What is condensate polishing?

Condensate Polishing is the act of removing impurities from steam cycle
such as metal oxides (crud), scales, trace ionic impurities, silica, fragments
of IX resin and/or filter media.

6
Introduction to CPP

Why use Condensate Polishing?

1. Save money
• Reduce start-up time after outages
• Reduce heat loss due to fouling of heat transfer surfaces by
preventing transport of iron and/or copper corrosion products
• Extend the life of the power plant
• Maximum water utilization

2. Improve, maintain the boiler and steam chemistry

3. Enable power plant to stay on line with a small to moderate
condenser leak
4. Provide time to arrange for orderly shutdown in the event of a
large condenser leak

7
Condensate Polishing Techniques

Condensate Polishing Options

• High-performance back washable filters
• for heavy metal, suspended solids removal primarily
• Powdered resin precoat style cartridge filter / demineralizers
• light ion exchange loading
• excellent heavy metal removal
• Deep bed Demineralizers
• largest bulk ion exchange capacity
• moderate iron removal capability
• external regeneration
• Multiple combinations of the above options

8
Condensate Polishing Techniques

Why are Deep Beds Externally Regenerated?

1. Prevents chance of strong acids and/or bases from accidentally getting
into the boiler

2. Polisher vessels are designed for high flow rates at low pressure loss
and are not well suited for the much lower flows encountered during
regeneration

3. By keeping a freshly regenerated “spare” charge of resin, the polisher

can be put back in service in much less time than it takes to perform a
regeneration.

4. Avoid cross contamination of resins, regenerant chemicals

9
Condensate Polishing Techniques

External Regeneration Design

Three Tank Design (For Gheco-One) Advantage
• Resin Separation Tank (RST) • Best Value Proposition
• Cation Regeneration / Resin Mix / • Lower cross contamination
Storage Tank (CRRMST) • Higher regen efficiency
• Anion Regeneration Tank (ART) Disadvantage
• Height of SPT
From Polisher • Spare charge resin storage

To Polisher

RST ART CRRMST

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3D Modeling Overview – Condensate Polishing Area

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3D Modeling Overview – Regeneration Area

13
3D Modeling Overview – Chemical Storage Area

14
Process Flow Diagram

15
GA_CPP Area

16
GA_Regeneration Area

17
POWER ENGINEERING
VIETNAM ELECTRICITY CONSULTING JSC 3

VINH TAN 4 THERMAL POWER PLANT

PROJECT (2X600MW)

TRAINING MANUAL
FOR
CHEMICAL DOSING SYSTEM

DMPP Consortium(Whasung Systech Co., Ltd.)

CHEMICAL DOSING SYSTEM

TABLE OF CONTENTS
1. INTRODUCTION

2. SYSTEM AND COMPONENTS DESCRIPTION

3. OPERATION PROCEDURE

4. MAINTENANCE / TROUBLE SHOOTING

5. Q/A

1
CHEMICAL DOSING SYSTEM

1. INTRODUCTION

2
CHEMICAL DOSING SYSTEM

Whasung Systech is..

Whasung Systech Co., Ltd is one of the leading SYSTEM INTEGRATOR and process
equipment supplier in Korea, and established by over 15 year’s experienced engineers
in the Power Plant Industries.

Our System Packages are;

► Chemical Dosing System

► Closed Cooling Water System
► Odorization System
► Ammonia Stripping & Scrubber Package
► Offshore Packages
► Skid mounted Pump Package

3
CHEMICAL DOSING SYSTEM

What is Chemical Dosing System for Power Plant ?

Chemical Dosing System is a facility for injecting various types of Chemicals

Into Water Cycling Circuit to dose exact amount Chemicals that is needed to
control the water chemistry within specified values.

Problems
 Scale with hardness
 Corrosion
Fail to water chemistry control

Result
 High operating cost
 Reduced throughput
 Increased maintenance cost

4
CHEMICAL DOSING SYSTEM

What Chemicals is used ?

Ammonia To keep a pH in optimum level

(NH3)

Oxygen To make surface passivation of

(O2) steel material

5
CHEMICAL DOSING SYSTEM

2. SYSTEM AND COMPONENTS DESCRIPTION

6
CHEMICAL DOSING SYSTEM

Typical Installation

7
CHEMICAL DOSING SYSTEM

P&ID for Ammonia Dosing System

CHEMICAL DOSING SYSTEM

P&ID for Oxygen Dosing System

CHEMICAL DOSING SYSTEM

What is Dosing (Metering) Pump ?

The dosing pump is positive displacement chemical dosing device with
the ability to vary capacity manually or automatically as process
conditions require.

NEEDS

 Low flow rate are required (ml/hr)

 High system pressure exists
SOLUTION METERING PUMP
 High accuracy feed rate is demanded
 Dosing is controlled by DCS, PLC,
or flow proportioning
 Corrosive, hazadous fluids are handed

10
CHEMICAL DOSING SYSTEM

Dosing Pump Design (I) (Milton-Roy)

11
CHEMICAL DOSING SYSTEM

Dosing Pump Design (II) -Animation

-Later-

12
CHEMICAL DOSING SYSTEM

Dosing (Metering) Pump Characteristics (I)

The pumping action is developed by a reciprocating
piston. This reciprocating motion develops a flow easily
represented by a sine wave.
Actual flow rate is determined by the following formula:

Flow rate = Displacement x Cycle per unit of time.

Unlike centrifugal pump, flow rate is not greatly affected

by changes in discharge pressure.

13
CHEMICAL DOSING SYSTEM

Dosing (Metering) Pump Characteristics (II)

The metering pump flow vs. stroke characteristic curve
is linear. However, necessary proportional in that 50%
stroke setting may not equal 50% flow. This is due to the
fact that the calibration like may not pass through 0 on
both axes simultaneously. By measuring flow at 2
stroke settings, plotting both points and drawing a
straight line through them, other flow rates vs. stroke
can be accurately predicted.

Most of metering pumps have a turndown ratio of 10:1,

which simply means that the pump is within its accuracy
rating anywhere between 10% and 100% of capacity.

14
CHEMICAL DOSING SYSTEM

3. OPERATION PROCEDURE

15
CHEMICAL DOSING SYSTEM

3.1 Start up cleaning / Strainer requirement

 All the incoming and outgoing pipe line shall be installed, connected, tested,
flushed and ready to service

 Chemical tank inside shall be cleaned and rinsed with clean Water

 Check for the cleanliness of the entire system and it must be free of any
foreign material or dirt, which may damage the equipment or impair the system
functionality

 Y-type strainer (minimum 18mesh) shall be furnished in the suction leader for
the skid and check this for the presence of trapped solids and clean as required.

16
CHEMICAL DOSING SYSTEM

3.2 Pump stroke calibration

17
CHEMICAL DOSING SYSTEM

4. MAINTENANCE / TROUBLE SHOOTING

18
CHEMICAL DOSING SYSTEM

4.1 MAINTENANCE
Routine maintenance will depend upon your service requirement:
Injection chemical being handled, environmental condition, duty cycle of pump, etc. When working on
any component of the system, i.e. pump, valves, pulsation dampener, refer to the Installation, Operation
and Maintenance manual for that particular items. Some operational and maintenance checks that need
to be performed as followings;

 Piping/ Tubing integrity: Routinely check piping, tubing, Isolation valves and connections for leaks.
Replace tubing as necessary. Recommend weekly check.

 Strainer: Y-strainer is furnished in the suction piping of each pump. Check this for the presence of
trapped solids and clean as necessary. Recommend weekly check.

 System operation: Perform flow calibration regularly to ensure that dosing chemical is being added at
the proper rate. Recommend monthly.

 PSV: Check to ensure that bolts are tight. Recommend monthly.

 Pulsation dampener: Check air pressure versus recommended set point. Recommend weekly.

 Calibration pot: If handling sticky chemicals, may require cleaning to view liquid level inside. Perform
as necessary.

 Injection Pump: Replace check valves, diaphragm and pump internal relief valve poppet. Recommend
yearly.

19
CHEMICAL DOSING SYSTEM

4.2 TROUBLE SHOOTING

Refer to Attachment

20
GENERAL TROUBLE SHOOTING GUIDE

Symptom Cause Corrective Action

Pump motor won’t • No power. • Supply correct power in

operate. accordance with motor
nameplate.

• Blown fuse. • Check for short circuit or

overload.

• Low voltage. • Check for too thin wiring.

• Low liquid level (where low • Fill tank.

level cutoff is used).

• Oil is frozen in pump. • Thaw out.

• Bad motor. • Replace motor.

Pump doesn’t deliver • Starved suction. • Replace suction piping with

rated capacity. larger size, or increase
suction head.

• Leaky suction piping. • Repair or replace defective

piping.

• Excessive suction lift. • Rearrange equipment

location to reduce suction
lift.

• Liquid too close to boiling • Lower temperature or

point. increase suction pressure.

• Air in hydraulic or reagent • Bleed system.

system.

• Air or gas trapped in oil or • Decrease capacity to 20%

pump. for 5minutes. Then increase
to 100% for 5 minutes.

• Worn or dirty valves or • Clean or replace cartridges.

seats.

• Viscosity of liquid too high. • Reduce viscosity by heating

or other means, or increase
size of suction piping, or
increase suction pressure.

• Low discharge pressure. • A minimum discharge

GENERAL TROUBLE SHOOTING GUIDE

pressure is required to insure

proper capacity control.

• Capacity adjustment set • Reposition adjustment knob

above 100% capacity mark. to 100% mark.

Pump delivers erratically • Leaky suction line. • Repair or replace piping.

• Worn or dirty valves or • Clean or replace cartridges.

seats.

• Excessive excursion of ball • Replace cartridges.

valves from seats (indicated
by ball chatter).

• Insufficient suction pressure. • Increase suction pressure by

raising tank level or
pressurizing suction tank.

• Liquid too close to boiling • Reduce temperature or raise

point. suction pressure.

• Leaky system relief valve. • Repair or replace relief

valve.

Motor overheats thermal • Supply does not match • Check power supply against
overload switches. motor characteristics. motor nameplate.

• Overload caused by • Check operating pressure

operating pump above its against pump manufacturer’s
discharge pressure. data plate max. rating and
correct the cause of the
pressure abnormality.

Noisy operating in drive • Fluid compressibility causes • Not considered detrimental.

casing (pounding noise reversal load on gears at end No action needed.
at high discharge of pressure stroke.
pressure).
• Pump internal relief valve • Lower pump or raise level of
actuating, caused by liquid.
excessive suction lift
conditions.

• Pump internal relief valve • Correct poor suction

actuating, caused by condition.
insufficient suction pressure.
GENERAL TROUBLE SHOOTING GUIDE

• Pump internal relief valve • Clean strainer.

actuating, caused by clogged
or partially blocked filter or
strainer in suction line.

• Pump internal relief valve • Clean or replace.

actuating caused by clogged
or fouled suction or discharge
check valves.

• Pump internal relief valve • Remove blockage.

actuating, caused by blocked
discharge line.

• Pump internal relief valve • Install back pressure valve

actuating, caused by or device to create back
insufficient discharge pressure at pump discharge
pressure. connection.

One or all pumps do not • Wires to motor may be • Make sure that pump’s
work, or run backwards. reversed or not firmly seated. connectors are in the correct
locations and firmly seated on
main PCB.

• Incorrect polarity. • Check trigger signal polarity

(in most cases polarity should
be “+”)

• Power off • Make sure power is on

Improper oil level in • Flexible diaphragm • Replace diaphragm

reservoir increases and punctured by foreign material. .
overflows.

Pump delivery is not • System pressure too low. • Install a back pressure valve
adjustable. in the discharge line
(preferred method), or install a
back pressure spring
(provided) into discharge
cartridge.

Pump does not develop • O-rings on control spool are • Replace O-rings.
required pressure. nicked.
GENERAL TROUBLE SHOOTING GUIDE

Agitator; • wear of the bearing

Abnormal sound of • bearing is contaminated • Replace the bearing
bearing • mechanical damage
• unbalanced load
CHEMICAL DOSING SYSTEM

5. Q/A

21
CHEMICAL DOSING SYSTEM

Thanks for your listening !

END OF DOCUMENT

Name : Gilbert, Park

Phone : 82-31-380-6988
E-mail : [email protected]

22
POWER ENGINEERING
VIETNAM ELECTRICITY CONSULTING JSC 3

VINH TAN 4 THERMAL POWER PLANT

PROJECT (2X600MW)

TRAINING MANUAL
FOR
SAMPLING SYSTEM

DMPP Consortium : WOORI SYSTEM

SAMPLING SYSTEM

TABLE OF CONTENTS

1. OBJECTIVE & INTRODUCTION

1.1 Equipment Included in Sample Conditioning Rack
1.2 Analyzer Equipment

2. ANALYZER TRAINING MANUAL

2.1 Conductivity Transmitters & Cells Conductivity Analyzer
2.2 pH Monitoring
2.3 Dissolved Oxygen Monitoring
2.4 Sodium Monitoring
2.5 Silica Monitoring

3. TROUBLE SHOOTING
1. Sample Line
2. Coolant Line
3. Analyzer Trouble Shooting

1
2

1. OBJECTIVE & INTRODUCTION

WOORI SYSTEM Co., Ltd

SAMPLING SYSTEM

1. Objective & Introduction

The primary purpose of the Sampling System is to allow efficient operation, monitoring and control of
Sampling, analyzing and chemical feed to facilitate optimum chemistry control.
Sample pressure and temperature is reduced and controlled by the sample system to provide optimum
Sample conditions for continuous analysis, chemical feed control and grab sample purposes.

1.1 Equipment included in Sampling Conditioning Rack

• Primary Sample Cooler(except Closed cooling water)

• Secondary Sample Cooler
• Pressure Reducing(Regulating) Valve
• Pressure Relief Valve
• Back pressure Regulating Valve
• Rotameter with Needle Valve
• Double Isolation Valves
• Pressure Gauge
• Temperature Indicator w/ Switch
• Automatically controlled sample inlet and drain valve
• Grab Sample valve

3
SAMPLING SYSTEM

1.2 Analyzer Equipment

a) Analyzers used in this project are listed below.

• Cation Conductivity Analyzer

• Specific Conductivity Analyzer
• Dissolved Oxygen Analyzer
• pH Analyzer
• Sodium Analyzer
• Silica Analyzer

b) There are detail information for analyzer in Table of contents No.2 Analyzer Training Manual.

4
5

2. ANALYZER TRAINING MANUAL

WOORI SYSTEM Co., Ltd

2.1 Conductivity Transmitters & Cells
6

Technical Support
Department
ABB Analytical Instrumentation
7
Conducting Aqueous Solutions

Current Current
Meter

Cathode Anode

- +
-
- + - +
Cathode
- - + Anode
- -
Reaction + Reaction
+ +
H+ + e- = H2 - + + Cl- = Cl2 + e-
- + - +
- + +
- +
- - +
- +

Cations Anions
8
Unit of Conductivity Measurement in Common Use

The unit of Conductivity (G) is based on the

unit called the Siemen (S) but we need to
define the dimensions of the Cell

The unit is now expressed as:

1cm
S/cm or S cm-1
and at low levels as: µS cm-1
1cm 1cm and is calculated from resistance:

µS cm-1 = 1 x 106
R
Conductivity Cell Constant (K)
9

l
K =
a
1cm
1cm
=
1cm2
1cm 1cm
= 1.0
Conductivity Cell Constant (K)
10

Measurement
Still Based on
1cm2 x 1cm
l
Cell K =
a
1cm 0.1cm
=
1cm2
1cm 1cm
0.1cm = 0.1
Resistance vs Conductivity for Different Cell Constants
11

Cell Resistance
K 1MΩ 500kΩ 200kΩ 100kΩ 10kΩ 1kΩ 100Ω

1.0 1.0 2.0 5.0 10 100 1,000 10,000

0.1 0.1 0.2 0.5 1.0 10 100 1,000

0.05 0.05 0.1 0.25 0.5 5.0 50 500

0.01 x x 0.05 0.1 1.0 10 100

Conductivity values in µS cm-1

G = K x 106 R = K x 106
or
R G
12
Conductivity of Common Solutions
Strong
Acids & Alkalis
CIP Detergents

Cooling Water
Boiler Water

Sea Water

Ultra Pure Water

Potable Water

0.01 0.1 1.0 10 100 1.0 10 100 1000

| µ Scm-1 | mScm-1 |
Conductivity
Conductivity of Concentrated Solutions
13

900
750 HCl
Conductivity, µS cm-1 x 103

600 HNO3
450
300 CrO3
150
0
NaOH
NaCl
H2SO4

0 10 20 30 40 50 60 70 80 90 100
% by weight
Typical Temperature Coefficients
14

Solutions Temperature Coefficient

Acids 1.0 to 2.2% per ºC

Alkalis 1.5 to 2.2% per ºC

Salts 2.0 to 3.0% per ºC

Temperature Coefficients in High Purity Water Applications (between 20 and 50ºC)
15

Solutions Temperature Coefficient

Condensate (NaCl) 2.52% per ºC

Boiler Water (NH3) 1.59% per ºC

After-cation Conductivity
(HCl) 2.16% per ºC
Construction of the AC220 Series Stainless Steel Conductivity Cell
16

PEEK Insulator

Central Electrode
Housing (IP68)

Sample
Flow

Outer Electrode
‘Frosted’ Surfaces
AC221 Stainless Steel Cell - Detachable Connector Version
17
Correct Installation of Conductivity Cells
18

Screw-in Screw-in
Cell in Cell in Flow-through Screw-in
Flow Jacket Elbow Cell Cell

Air
Space

Sample

Sample Sample Pipe or Cell Always

Flow Flow Vessel Fully Immersed
2.2 pH Monitoring
19

Technical Support
Department
ABB Analytical Instrumentation
Current Flow from Potential Developed on the pH Responsive Glass Membrane
20

Internal Filling Stem Glass

Solution

Silver/Silver Chloride
Sample Element

pH Responsive
+ ++ Glass Membrane
++ + + ++ +
+ + ++ Potential
+ + Developed on Surface
+ ++ + of the Glass
Basic pH Measuring System
21

High Impedance
mV meter
pH Glass Reference
Electrode Electrode

Internal Element Liquid Junction Tube

Internal Filling Reference Element

Solution Internal Filling
Solution
pH Sensitive Glass Stable Potential
Membrane Porous Junction
Independent of
Chemical Conditions
The Nernst Equation
22

mV = 0.1984 x (ºC + 273) x pH

Output for each 1pH change

ºC 0 25 50 75 100

mV 54.20 59.16 64.12 69.08 74.04

23
Potentials Generated by the pH Electrode Pair

mV Meter Possible
deterioration to
pH response due to
glass membrane
Stable mV value
due to constant pH
and chloride conc. of Possible mV
internal solution changes due to
problems in the
Reference
Electrode

Internal Potentials Potential Internal Potentials

of Glass Electrode due to pH of Ref. Electrode
of Solution
Standard pH Buffer Solution Values
24

ºC pH4 pH7 pH9

0 4.000 7.11 9.475
10 3.997 7.06 9.347
20 4.000 7.01 9.233
25 4.005 7.00 9.182
30 4.011 6.98 9.134
40 4.027 6.97 9.051
50 4.050 6.97 8.983
60 4.080 6.97 8.932
70 4.116 6.99 8.898
80 4.159 7.03 8.880
90 4.208 7.08 8.840
25
Causes of a Change in Check Reading

High or Low Check Reading

Contaminated internal reference filling solution
Contaminated porous reference junction

Unstable or Drifting Readings (slow response)

Contaminated internal reference filling solution
High resistance or open circuit reference junction
Loss of reference filling solution
Aged or cracked glass membrane
26
Cleaning Glass Electrodes

General sludge and loosely adhering matter:

Rinse off excess matter with a jet of water and wipe the glass
membrane with a soft cloth or tissue.
Heavy non greasy deposits, e.g. iron or lime deposits:
Dip glass membrane in concentrated HCl.
Greasy or organic deposits:
Wipe the glass membrane with a detergent or acetone based
solvent.
Protein deposits:
Digest with an enzyme such as pepsin. Soak the glass membrane
in 0.1M hydrochloric acid with the enzyme added.
27
Construction of the AP100 Electrode

Reference Electrode
Glass Electrode With Inner Junction End Cap

Reference
Cable
Junction Pt100 Temperature Connections
Compensator
KCl Slurry
2.3 Dissolved Oxygen Monitoring
28

Technical Support
Department
ABB Analytical Instrumentation
Basic Arrangement of the Amperometric Dissolved Oxygen Sensor
29

At the anode: 2Pb 2Pb2+ + 4e-

At the cathode: O2 + 2H2O + 4e- 4OH-
Overall reaction:
O2 + 2Pb + 2H20 2Pb(OH)2 (insoluble)
DO Input
Circuit
- 100R Lead (Pb)
+ Anode

Alkaline
Electrolyte

Silver (Ag)
Cathode
Oxygen-permeable
Plastic Membrane Oxygen (O2)
from Sample
30
Construction of the 9435 300 Sensor
Cathode Anode
Contact Contact

Plastic
Lead Body
Anode

Electrolyte

Membrane
Retaining
Guard Ring
Oxygen
Electrode
Permeable
Silver Cathode Membrane
Connecting the Sensor Showing Sealing Ring
31
9437 Transmitters and Sensor Flowcell
32
Flowcell Schematic Arrangements
33

Drain Drain
Tundish Tundish
Flowcell Flowcell

Sample Sample
Drain Drain

Sample Drain
Flowmeter Flowmeter
Sample connections Valve for
Inlet & Outlet 6.3mm od Insitu Calibration
9437 Calibration Sequence
34

Normal
Activity Expose to Air Recovery
operation

Valve Open Close None

Timing 3 to 5 minutes 15 minutes

Lower -1 -1
Calibrating Air D.O. µgkg D.O. µg kg
Display

Current Output and Alarm States Held

if selected in software
Calibration - Sensor Efficiency
35

Bars Sensor Output Efficiency

> 85 %

> 60 %
Pass
> 50 %

< 50 %
Low Sensor Efficiency
Routine Maintenance
36

NONE
Only an occasional check for the build up of solids
on the sensor membrane and change the sensor
after a failed calibration
2.4 Sodium Monitoring
37

Technical Support
Department
ABB Analytical Instrumentation
Current Flow from Potential Developed on the Sodium Glass Membrane
38

Internal Filling Stem Glass

Solution

Silver/Silver Chloride
Sample Element

Sodium Responsive
+ ++ Glass Membrane
++ + + ++ +
+ + ++ Potential
+ + Developed on Surface
+ ++ + of the Glass
39
Basic Sodium Ion-selective Electrode Measuring System

High Impedance
mV meter
Sodium Glass Reference
Electrode Electrode

mV = 0.1984 x (ºC + 273) x pNa

Output for each decade change

ºC 0 20 25 30 40

mV 54.20 58.17 59.16 60.15 62.14

The Effect on the Output of the Sodium Electrode at Different Sample pH Values
41

-100

-150 8pH
230µg l-1
-200
9pH
23µg l-1
mV -250
10pH
-300 2.3µg l-1
11pH
-350
0.23µg l-1
-400
0.1 1.0 10 100 1000
Sodium Concentration, µg l-1
Optimum pH required for Sodium Measurements
42

Maximum pH using
Ammonia
Diethylamine = 10.7 (0.5µg l-1 Na+)
11.0

10.0
pH Region of error due Safe pH area
to H+ concentration
9.0

8.0
0.1 1.0 10.0 100
Na+µg l-1
8037 Flow Schematic
43

Pre-amplifier Entrainment
‘T’ Piece Constant
Head Unit

Output to Standard
Transmitter Solution
Container

Ammonia Reference
Solution Electrode Sample
Inlet
Flowcell Sample/Calibrate
Sodium Solenoid Valve
Electrode
Temperature Contaminated Clean
Compensator Drain Drain
Principle of Entrainment
44

Acrylic
Bev-A-Line Tube Sample
Entrainment
(Ethyl Vinyl Acetate“T”
outer
Drop in pressure
Piece inner)
Polyethylene
draws in vapour
1mm Bore

Breather
Hole
Stainless Steel
Entrainment Tube
Vapour

Segmented water
droplets falling down
Entrainment Tube
Ammonia or
Diethylamine
Solution
Sensor Panel and Transmitter
45
Entrainment ‘T’ Piece and Bottom of Entrainment Tube
46
Two Point Calibration Sequence
47

Introduce Introduce Normal

Activity Recovery
STD1 STD2 Operation

Valve Open Open Closed

Timing 15 Minutes 15 Minutes 30 Minutes

Relays Concentration Alarms frozen

Single Point Calibration optional

Calibration - Sensor Efficiency
48
Calibration - Sensor Efficiency
49

Bars Sensor Output Efficiency

> 110% High Slope

> 93 %

> 86 % Slope

> 79 %

< 79 % Low Slope

Routine Maintenance
50

Weekly: - Carry out single point calibration (optional)

4 weekly:- Replace reagent

- Check level reference electrode
- Etch / reactivate sodium electrode (immerse for 1 minute)
- Carry out two point calibration

Twelve monthly: - Replace plumbing tubing

Reagent Solution:
35% (s.g. 0.880) ammonia solution
or 50% diethylamine solution
750ml up to 28 days

Etch / reactivation solution:

50g l-1 sodium fluoride + 20g l-1 acetic acid

Standard Solutions:
Two solutions normally 100 and 1000 or 50 and 500µg kg-1
1 litre per calibration
2.5 Silica Monitoring
51

Technical Support
Department
ABB Analytical Instrumentation
52
Basic Colorimetry for Silica & Phosphate Measurement

Overall Transmission
Light Output from LED Transmission of Solution

Sample +
λ λ λ Reacted
Reagents
Sample Resulting
in Drop in
Transmission

Electrical
Output
Blue
Solution
LED Measuring
Measuring Photocell
Cell
(Cuvette)
NAVIGATOR 600 Silica Analyser –Chemical Schematic
53

Reacted sample
to optical unit
Production of blue
molybdosilicic acid 45 OC
complex
1 min

0.8 to 1.0pH providing Ascorbic Acid

reducing conditions to stop
formation of yellow complex
2 min

Second Acid
1.4 to 1.8 pH providing
conditions for the production 2 min
of yellow β-molybdosilicic acid
Molybdate

Sample First Acid

NAVIGATOR 600 Silica Analyser – Chemical Schematic during Auto Zero
54

Reacted sample
to optical unit
Production of blue
molybdosilicic acid
complex

0.8 to 1.0pH providing Ascorbic Acid

reducing conditions to stop
formation of yellow complex

Second Acid
1.4 to 1.8 pH providing
conditions for the production
of yellow β-molybdosilicic acid
Molybdate
Small quantity
of SiO2 in
Sample First Acid reagents
Compensation Applied During a Zero Calibration
55

Reacted Silica in Cuvette

Monitor Range
Silica in 0 to 5000µg l-1 Displayed
Sample Value
= 0µg l-1

Silica in Silica in
Reagents Reagents
Silica Reaction During a Auto Zero
56

Silica in the sample is not be reacted because the pH is too low

(<1.0pH)
This provides a clear solution (known as a blank) to establish a
zero calibration

Silica in the first two reagents (when mixed together) will be reacted
to form a yellow silica complex, that is converted to blue.
This is simply offset by the software.

This provides us with a baseline calibration

Flow Schematic
57
Secondary Debubbler

Cuvette

15ml min-1
225ml min-1

95ml min-1 Zero

Solenoid
Valve
Reaction Block

Primary Debubbler

Calibration Solenoid Valve

Cleaning Solenoid Valve

Multi-stream Unit(s)
Level
Sensors
Filter & Filters

Cleaning Calibration Reduction Acid Ammonium Acid

Sample(s) Solution Solution Ascorbic Sulphuric Molybdate Sulphuric
& Citric
Compensation Applied During a Calibration
58

100%

Theoretical response
Cal. Factor 1.0
Displayed reading

Instrument Response
Cal. Factor 0.9

Baseline zero

Silica in Reacted Silica in Cuvette (µg l-1 )

Reagents
Compensation Applied During a Calibration
59

100%

Theoretical response
Cal. Factor 1.0
Displayed reading

Zero Offset = 2µg l-1

Cal. Factor = 0.9
Instrument Response
Cal. Factor 0.9
Baseline zero
Routine zero
0%

Silica in Zero Offset Reacted Silica in Cuvette (µg l-1 )

Reagents 2µg l-1
Zero Calibrations
60

Baseline Zero Calibrations

Only selected manually in software scrolls
Always carried out after the reagents are replaced
A secondary calibration always follows
Resets the Zero Offset parameter to 0.0µg l-1

Routine Zero Calibrations

Instigated automatically on regular timed intervals or is
selected manually in software scrolls
Optional secondary calibrations
Calculates the Zero Offset since the last Baseline Zero
Calibration Parameters
61

Acceptable Limits
Zero Offset: < ±100µg l-1
Calibration Factor < ± 0.2 (80 to 120% of the theoretical)

Causes of Abnormal Calibration Factors

High Cal. Factor: This is ALWAYS the Standard Solution (as long
as the liquid handling is OK and the Auto Zero
was stable)
Low Cal. Factor: Possible Std or Reagent Solutions
Zero Cal. Factor: No chemical reaction taking place - liquid
handling or Reagents or Standard Solutions
Loss of Sample – Automatic Shutdown
62

Automatic Shutdown starts 15min after loss of sample.

Reagent pump stops.

Secondary Calibration solution valve energised.
Sample pump speed increased for 5 mins
Reagent pump reverses for 1 minute
Both pumps stop and secondary cal valve de-energised.

This purges reaction block and cuvette of reacted sample, (Clean),

enabling trouble free restart.
Power Loss – Automatic Startup
63

Analyzer Status Period of Loss of Power

< 24 hours > 24 hours
Between Calibration & Sample & Reagent Purge Sample & Reagent Purge
Clean Sequence Sequence Sequence
Recovery Sequence Clean Sequence inc Zero
Cal.

During Calibrations or Sample & Reagent Purge Sample & Reagent Purge
Clean Sequences Sequence Sequence
Recovery Sequence Clean Sequence (inc Zero
Restart calibration or Cal)
clean sequence Secondary Cal (if part of
original Calibration)
Reagent Solutions/ Rinse and Standard Solutions
64

Reagent Solutions: (quantities for 2.5l)

1. 0.4M (54.5ml) conc. sulphuric acid

2. 50g ammonium molybdate

7.5ml conc. ammonia solution

3. 1.25M (170ml) conc. sulphuric acid

63g citric acid (375g for phosphate suppression)
250ml Propan-2-ol

4. 43g ascorbic acid

0.18g di-sodium EDTA
4ml formic acid solution
Rinse Solution:
50g l-1 sodium hydroxide
5g di-sodium EDTA

Secondary Standard Solutions:

One solution between 15 and 5000mg kg-1
65
Routine Maintenance

Yearly: - - Replace pump tube assemblies

- Replace pump capstans

Very Simple ! < 5 minutes

Problems With Calibration
66

Making a 15µgkg-1 SiO2 Calibration Solution

1. Take 3.133g (±0.001g) of sodium fluorosilicate:
Problems With Calibration
67

Making a 15µg kg-1 SiO2 Calibration Solution

1. Take 3.133g (±0.001g) of sodium fluorosilicate:
make up to 1l with high purity water
= 1,000,000mg kg-1
2. Take 10ml of 1,000,000µg kg-1 solution:
make up to 1l with high purity water = 10,000µg kg-1
3. Take 10ml of 10,000µg kg-1 solution:
make up to 1l with high purity water = 100µg kg-1
4. Take 150ml of 100µg kg-1 solution:
make up to 1l with high purity water = 15µg kg-1

Note: expected accuracy not less than 5%, good high purity water containing 1mg kg-1
will give an error of 6.6%
68

3. TROUBLE SHOOTING

WOORI SYSTEM Co., Ltd

SAMPLING SYSTEM
69

3. TROUBLE SHOOTING
1. SAMPLE LINE

a) Low total flow or low reduced pressure.

1) Improperly adjusted pressure reducer - check that pressure reducer is properly adjusted according to instructions under Manual.

2) Clogged sample line - shut down the sample line purge the sample line for 30 to 60 seconds and then re-start the sample line

3) Clogged sample filter - shut down the sample line remove the filter element, clean or replace, reinstall the filter element and then re-start
the sample line.

b) High total flow or high-reduced pressure.

Pressure reducer failure - high pressure reduction devices wear with use. The valves used for pressure reduction in this system are no different. As
they are used, both the plug and the seat wear, eventually allowing more flow to pass than is acceptable. Remove and replace the Pressure Reducer.

c) within specifications, check the chiller for proper operation.

If this direction does not bring temperature to an acceptable High temperature

Total flow may be too high. (For high flow conditions. Refer to No. 2 above.) If flow is temperature, consult WOORI SYSTEM Co., Ltd.

2. COOLANT LINE

a) Cavitation can be caused by three (3) factors: The coolant flow rate is too low;

The coolant pressure is too low(Display on the Chiller) the sample flow is too high. Check to see that all parameters are within design
specifications.

b) Excessive coolant velocity can cause a condition similar to “water hammer”.

Reduce coolant flow by adjusting coolant valve (CW).

3. ANALYZER TROUBLE SHOOTING

a) There are detail information. so refer to each analyzer manual in O&M manual.

69
70

Thank you for your Attention.

POWER ENGINEERING
VIETNAM ELECTRICITY CONSULTING JSC 3

VINH TAN 4 THERMAL POWER PLANT

PROJECT (2X600MW)

TRAINING MANUAL
FOR
LABORATORY EQUIPMENT

DMPP Consortium : NAMDO ENGINEERING

Laboratory Equipment

TABLE OF CONTENTS
1. OBJECTIVE & INTRODUCTION

1.1 Laboratory Equipment

1.2 Laboratory Glass Ware

1.3 Laboratory Chemical Reagent

1.4 Laboratory Chemical Reagent Test Kit

1.5 Laboratory Safety First Aid Kit

1.6 Laboratory Miscellaneous Item

2. ANALYZER TRAINING MANUAL

Laboratory Equipment

1. OBJECTIVE & INTRODUCTION

Laboratory Equipment

1. Objective & Introduction

Laboratory equipment is for QMC(Quality Management Control) of coal, water, and oil often used in a coal fired power plant.

1.1 Laboratory Equipment

a) Analyzers used in this project are listed below

aa) Analytical Equipment

- High Pressure Liquid Chromatograph
- Atomic Absorption Spectrophotometer
- UV Spectrophotometer
- Bomb Calorimeter
- Ash Fusibility Determinator
- Automatic Sulfur Determinator
- Proximate Analyzer for Coal
- Elemental Analyzer

bb) General Equipment

- Dry Oven
- Handheld Multi-Parameter for pH, Conductivity and Dissolved Oxygen
- Dispenser
- Jar Test Apparatus
- Ultrasonic Bath
- Thermo reactor 150°C for COD Analysis
- Hot Plate
- Desecrator Cabinet
- Top Weight Balance
- Multi Gas Detector
- Single Gas Detector
- Freezer
- Muffle Furnace
- Platinum Crucible
- Sieves Shaker with Sieve
- Cole Pulverizer
Laboratory Equipment

High Pressure Liquid Chromatograph

An apparatus for analysis of organic matter in the waste water generated from a
power plant (e.g. Phenol, Benzene, etc.)

Atomic Absorption Spectrophotometer

An apparatus for testing the ingredients of a sample including heavy metals and
microanalysis (e.g. Na, Pb, Zn, etc.)

UV Spectrophotometer
An apparatus for water quality analysis of a power plant (e.g. Copper, Silica, COD,
Chlorine, etc.)

Bomb Calorimeter
An apparatus for calorimetry of coals

Ash Fusibility Determinator

An apparatus for finding out the melting point of coals, determining the quality and
price of ingredients and researching into the composition of raw materials.
Laboratory Equipment

Automatic Sulfur Determinator

A device for measuring the content of sulfur in both organic and inorganic
substances of coals. It is also used for research into the composition of materials
and the development of them.
Proximate Analyzer for Coal
An apparatus for measuring the content of volatile matters, ash, fixed carbon in
inorganic or organic substances of coals.

Elemental Analyzer
An apparatus for measuring the content of carbo, oxygen, and nitrogen in organic
substances of coal and oil.

Dry Oven
A device used for drying out glassware and samples

Handheld Multi-Parameter for pH,Conductivity and Dissolved Oxygen

A portable device for measuring PH, Cond, and DO on the spot. A multi meter
capable of measuring three things simultaneously.
Laboratory Equipment

Dispenser
A laboratory aid

Jar Test Apparatus

An apparatus for determining the amount of a coagulant for water aggregation test

Ultrasonic Bath
A laboratory aid capable of cleaning glassware using ultrasonic waves

Thermoreactor 150°C for COD Analysis

An aid of the spectrometer increasing the heat of a sample when measuring COD

Hot Plate
A laboratory device for heating
Laboratory Equipment

Desecrator Cabinet
A device for drying out glassware, crucible, dishes, etc.

Top Weight Balance

An apparatus for weighing a sample

Multi Gas Detector

An apparatus for measuring toxic gases generated on the spot

Single Gas Detector

An apparatus for measuring toxic gases generated on the spot

Freezer
A device for the storage of chemical reagents and samples needed to be under
refrigeration
Laboratory Equipment

Muffle Furnace
An apparatus for the sintering of a sample and pretreatment at high temperature

Platinum Crucible
An apparatus for weighing a sample burned in the furnace

Sieves Shaker with Sieve

An apparatus for sorting out a sample according to particle sizes using sieve. It is
also used for the pretreatment for HGI or other coal analyzers.

Cole Pulverizer
A device for making a mass like coals into very small particles (60mesh)
JW1
Laboratory Equipment

1.2 Laboratory Glass Ware

Glassware and plastic ware (Beaker, Flask, Cylinder, Sample Bottle, etc.) necessary for laboratory operation.

1.3 Laboratory Chemical Reagent

Basic chemical reagents needed in the laboratory and chemical reagents necessary for wet analysis (Titration, Extraction, etc.)

1.4 Laboratory Chemical Reagent Test Kit

HACH Test reagent kits (Copper, Silica, COD, Chlorine, etc.) necessary for water quality analysis

1.5 Laboratory Safety First Aid Kit

Safety kits (Burns, Tourniquet, Fracture, etc.) for first aid helpful for laboratory emergency situations

1.6 Laboratory Miscellaneous Item

Basic laboratory consumable parts besides glassware

슬라이드 10

JW1 Jin-wook Won, 2016-09-07 (수)

Laboratory Equipment

2. ANALYZER SPECIFICATION
Item No. : 1.1/High Pressure Liquid Chromatograph

Maker : Thermo Dionex

Model : ULTIMATE 3000

Description Q'ty

1 set

Specification
‐ The LC system provides ultrafast and Analytical Separation.
‐ Liquid Chromatograph for quantitative and qualitative analysis of wide range of organic UHPLC compounds
Ultra High performance modular HPLC system is ideal for a wide range of both and conventional analytical
chromatography applications.
‐ Unique SmartFlow® technology automatically compensates for changing eluent compressibility and auto
corrects compression‐related flow anomalies for maximum detection sensitivity without pulsation‐related noise.
‐ Isocratic and various gradient pumps are equipped with an active rear‐seal wash system to eliminate abrasive wear
from buffer crystallization.
‐ Various optional gradient pumps can be selected not only binary(from 2‐4 solvents) or quaternary, but also,
dual ternary(6) for applications such as parallel LC, online SPE‐LC, or Multi‐Dimensional LC, for each conventional,
or bio‐compatibility and analytical, microbore, capillary, or nano scale flow.
‐ Floating piston design allows self‐alignment during operation for increased life time of piston seals.
‐ Autosampler is fully automated micro autosampler of the in‐line split‐loop injection principle,
using the needle and sample loop as integral parts of the high‐pressure fluidic path.
‐ Front‐panel display and software for easy monitoring of detector status to maximize uptime Lamps and flow cells
equipped with ID chips for identification.
‐ Chromeleon software options can do full control for over 200 different instruments from more than 20 manufacturers.
Item No. : 1.2/Atomic Absorption Spectrophotometer

Maker : Thermo Scientific

Model : iCE 3500Z

Description Q'ty

1 set

Consist of
‐ High Precision Double Beam optics
‐ Echelle Monochromator
‐ 6 lamps coded, Dedicated power supply, auto‐aligning
‐ Accepts GFS35 or GFS35Z Graphite Furnace and Autosampler
‐ GFTV as standard
‐ Background correction : Guarantted Quadline
‐ Gas management : Automatic binary control
‐ Wavelength : 180 ‐ 900 nm
‐ Solaar software, Enhanced software as standard
Item No.    : 1.3/UV Spectrophotometer

Maker : Hach

Model : DR6000

Description Q'ty

1 set

Specification
Operation Mode : Transmittance (%), absorbance and concentration (wavelength, time)
Source Lamp : Tungsten (visible range), deuterium (UV range)
Wavelength Range : 190 ‐ 1100 nm
Wavelength Accuracy : ± 1 nm
Wavelength Reproducibility : < 0.1 nm nm
Wavelength Resolution : 0.1 nm
Wavelength Selection : Automatic, based on method selection
Spectral Bandwidth : 2 nm
Scanning Speed : 900 nm/min (in 1 nm steps)
Photometric Measuring Ra
: ± 3 Abs
nge
Photometric Accuracy : 5 mAbs at 0.0‐0.5 Abs <1% at 0.5‐2.0 Abs at 546 nm
Photometric Linearity : 0.005 ‐ 2 Abs ≤ 0.01 at > 2 Abs with neutral glass at 546 nm
Stray Light : KI‐solution at 220 nm
Disply : TFT 7 inch WVGA color touch
Data Logger : 5000 data points (result, date, time, sample‐ID, user‐ID)
Preprogrammed Methods : > 250
User Programs : 200
Sample Cell Compatibility : Rectangular: 10, 20, 30, 50 mm, 1 inch; round: 13 mm, 16 mm, 1 inch
Optional 100 mm rectangular cell with additional adapter
Dimensions : 8.5 in x 19.7 in x 18.1 in
Item No. : 1.4/Bomb Calorimeter

Maker : Parr

Model : 6400EF

Description Q'ty

1 set

Configuration
Calorimeter module with a built‐in controller and built in water bucket, water jacket,
Cylinder & Water Recirculation system with Thermoletric water cooler
Pressure regulator for O2
Pressure regulator for N2
Rinse tank assembly
Accessories for installation

Specification
Method : Isoperibol
Data communication : Ethernet TCP/IP
Test per hour :8
Sample size : o.4~1.6g
Standard Deviation(RSD) : less than 0.1%
Water jacket Temp. stability : ±0.1 degree
Balance connect : Direct & Samart link
Calibration : Automatic
Bo,b type : Removable head & fixed Cylinder
Bucket filling : Automatic
Oxygen charging : Automatic
Bomb washing : Wash by water, automatic
Display : Touch screen display
Item No. : 1.5/Dry Oven

Maker : Daihan

Model : ThermoStable OF‐105

Description Q'ty

1 set

Specifications
Capacity : 105 Lit
Dimention Internal : 480 x 485 x 535 mm (W x D x H)
External : 653 x 711 x 879 mm (W x D x H)
Heating Power : 1.4 kW
Temp. Range : Ambient temperature +5 °C to 250 °C
±0.3 °C at 100 °C, ±0.5 °C at 150 °
Fluctuation :
C
Variation : ±1 °C at 100 °C, ±1.8 °C at 150 °C
Sensor : PT 100
Control Resolution : ±0.1 °C
Heat‐up Time : 25 min. to 100 °C, 45 min. to 150 °C
Recovery Time(Door open 3
: 6 min. to 100 °C, 6 min. to 150 °C
0sec)
Controller : Digital fuzzy control by advanced microprocessor jog‐dial with push button
RS232 Port : Available to connect with PC
Display : Digital LCD with back light
Timer : 99 hr 59 min (delay / continuous function)
Item No. : 1.6/Handheld Multi‐Parameter for pH, Conductivity and Dissolved Oxygen

Maker : Hach

Model : HQ40D

Description Q'ty

1 set

Specification
HQ40d Portable pH, Conductivity, Dissolved Oxygen, ORP, and ISE Multi‐Parameter Meter
Parameter: pH, mV, ISE, ORP/Redox, Dissolved Oxygen, Conductivity, TDS, Salinity, Resistivity, Temperature

pH Accuracy : 0.002

Range 0 ~ 14 Ph

Conductivity Accuracy : ± 0.5 in (1µS/cm ‐200mS/cm)

Range 0.01 µS/cm to 200.0 mS/cm

DO Resolution : 0.01 mg/L

Range 0.01 to 20 mg/L (0 to 200%)
Item No. : 1.8/Jar Test Apparatus

Maker : Daihan

Model : JT‐M6C

Description Q'ty

1 set

Feature
Deciding on Coagulant Chemistries
Ideal for Flocculation Testing in Water Treatment Laboratories
6 Independent Light Source for each Stirring Point
Digital Feedback Control using Microprocessor
Geared DC Motor and Specially Designed Timing Belt used
Stable and Accurate Stirring Speed by Feedback Control
Digital Display for RPM, Power Bar‐Graph and Status
Digital LCD with Back‐Light Function
Programmable Operation : 10 Step, 6 Programs
Overload Protection and Over‐Heat Protection Functions for Motor
Storage Function for Set Values : RPM and Timer

Specification
6×Paddler : Ø8 × L400mm
(Stainless steel Shaft) : Straight Blade w75 × h25mm
Stirring Capacity : 6 × 1 Liter Beaker
Motor : Geared DC Motor (10:1 ratio), 40W
Speed : 20~300 rpm
Speed Accuracy : ±5 rpm
Timer : 99hr 59min 59sec (Programmable)
Display : Digital LCD with Back‐Light Function
Controller : Programmable Digital Feedback Controller
with Jog‐Shuttle Switch (Turn + Push)
Item No. : 1.14/Multi Gas Detector

Maker : Industrial Scientific

Model : MX6

Description Q'ty

1 set

Specification
Case : Lexan/ABS/Stainless Steel w/protective rubber overmol
Measuring items : LEL /CH4 /O2/CO /H2S /CL2 /NO2,SO2 /H2,NO /HCN,HCL /
NH3 /CLO2 /PH3 /CO2 /VOCs (Optional)
Measures Max. 6 items simultaneously
Sensor
Combustible gas/Me
: Catalytic Diffusion/Infrared
thane
Oxygen and Toxic ga
: Electrochemical
ses
CO2 : Infrared
VOCs : 10.6 eV PhotoIonization
Measuring range
H2 : 0 to 1000ppm with 1ppm increments
NH3 : 0 to 100ppm with 1ppm increments
Display/Readout : STN Color Graphic LCD
Operating Temperature R
: 20ºC to 55ºC (‐4ºF to 131ºF) typical
ange
Operating Humidity Rang
: 15% to 95% non‐condensing (continuous) typical
e
Certification : IECEx/ATEX, UL, CSA, MSHA, GOST‐R
Item No. : 1.15/Single Gas Detector

Maker : Industrial Scientific

Model : GASBADGE®PRO

Description Q'ty

1 set

Specification
Alarms : User selectable low and high alarms
Ultra‐bright LEDs, loud audible alarm (95 dB) and vibrating alarm
Sensor (Options)
Gas Range Resolution
Carbon Monoxide 0‐1,500 1 ppm
Hydrogen Sulfide 0‐500 ppm 0.1 ppm
Oxygen 0‐30% of volume 0.01%
Nitrogen Dioxide 0‐150 ppm 0.1 ppm
Sulfur Dioxide 0‐150 ppm 0.1 ppm
Ammonia 0‐500 ppm 1 ppm
Chlorine 0‐100 ppm 0.1 ppm
Chlorine Dioxide 0‐1 ppm 0.01 ppm
Phosphine 0‐10 ppm 0.01 ppm
Hydrogen Cyanide 0‐30 ppm 0.1 ppm
Hydrogen 0‐2,000 ppm 1 ppm
CO/H2 Null 0‐1,000 ppm 1 ppm
Item No. : 1.19/Ash Fusibility Determinator

Maker : Leco

Model : AF700SC

Description Q'ty

1 set

Features
‐ This Ash fusibility determinator is automatically monitors ash cone deformation to accurately determine
deformation temperatures that define the fusibility of coal and coke ash.
‐ After conventional sample preparation, up to 6 ash cones are mounted on a cone tray and placed in the furnace.
Atmosphere is selected and a touch of the start key initiates a typical cycle :
1) The furnace heats at the selected rate.
2) The selected atmosphere, oxydizing or reducing, is introduced.
3) At 1800℉/980℃ the cone monitoring system activates and the tray rotates so that each cone is presented
to the measurement approximately once every 6 seconds by CCD camera.

Ash Fusibility Determination : Auto or Manual(IT, ST, HT, FT)
Accuracy : Meet or exceeds ASTM, DIN, ISO, BSI...
Deformation Temperature precision : Less than 30℃
Repeatability : 50℉(30℃) or better
Item No. : 1.20/Automatic Sulfur Determinator

Maker : Leco

Model : S‐632C

Description Q'ty

Specifications 1 set
Sulfur Analyzer
Instrument Range @ 350mg : 10ppm or 0.001% to 28% Sulfur
Precision : 5ppm or 1% RSD
Nominal Sample Size : 350mg for coal
Analysis Time : 60 to 120seconds(Typical)
Detection Method : Infrared Absorption
Furnace : 600 to 1500℃ ±1% of set point and controlled through
software ; Concentric, Ceramic with open end and lance
tube ; Horizontal Type
Gas required : Oxygen, 0 to 125psi ; CGA 540
Heating Element : Six, 5/8" Silicone Carbide
Dimensions(LxWxH) : 66 x 33 x 79cm
Data System : Windows based Software Supports compliance to 21 CFR
part 11 Regulations manated by the EPA and LIMS
(Dual Core or higher, HDD 200GB, RAM 2GB, Windows7 Prof. & 20" LCD)
Item No. : 1.21/Proximate Analyzer for Coal

Maker : Leco

Model : TGA701S4C

Description Q'ty

1 set

Features
‐ This Analyzer determines moisture, volatiles, ash or fixed carbon as well as weight‐loss on ignition in a variety of materials.
‐ This Analyzer saves the user time by analyzing 19 samples in the time it would normally take to do one.
‐ Selection of the desired method from the PC begins the analysis.
‐ This instrument could perform a moisture determination and then proceed to perform loss‐on‐ignition (LOI)
determination on the same set of samples.
Specifications
Proximate Analyzer with furnace
Sample Size: up to 5 grams
Number of Samples : 1 to 19(+1 for reference, total 20 positions)
Materials
Crucibles : Robust ceramics (for do not warp under temp. stress)
Carrousel : Ceramics (non‐metal)
Weight Loss/Gain Range : 0 ‐100%
Precision : 0.02% RSD (1sigma, 1g inert sample)
Item No. : 1.22/Elemental Analyzer

Maker : Leco

Model : CHN628C

Description Q'ty

1 set

Specifications
Carbon, Nitrogen Determinator
Instrument Range
Carbon : 0.02 to 175mg
Hydrogen : 0.1 to 12mg
Nitrogen : 0.04 to 50mg
Precision Range; C : 0.01mg or 0.5% RSD
H : 0.05mg or 1.0% RSD
N : 0.02mg or 0.5% RSD
Readability : 0.0001
Item No. : 1.23/Sieves Shaker with Sieve

Maker : W.S Tyler

Model : RX‐29‐16 LabKit

Description Q'ty

1 set

Specification
Sieve Diameter : 8"(20cm)
Includes one sieve shaker, sound enclosure, test stand and two test sieve cleaning brushes.
Hold 6 sieves with full‐height pan or 13 sieves with half‐height pan for particle testing, 2"(5cm) down through 635 mesh.
Come with integral cover but without sieves or receiver.
Sound enclosure : Reduces operating noise levels up to 60dB.
Built‐in 99‐minute digital timer/clock accurate to 0.1 second.
Motor : Vertically mounted 1/4hp mortor
Testing Application : 2" down through 635 mesh (20 micron)
Oscillations per Minute : 278 ±10
Oscillations Displacement : 1" x 0.75"
Taps per Minute : 150 ±10

Accessories
Brass Test Sieve 8" Dia. 2" Depth (Fisher 04‐881A/K/P 2ea per Each, 04‐881BB 1ea)
Brass Sieve Receiver for 12" Dia. Sieve (Fisher 04‐886B 1ea)
Item No. : 1.24/Cole Pulverizer

Maker : Preiser Scientific

Model : 91‐7120‐01

No. Description Q'ty

1 set

Specification
Auger speed : about 130 rpm with TEFC gear motor
Rotor speed : 10,000 rpm
Capacity : 400g/min using a dia. 0.024" Screen
Recommended : ‐ 4mesh to – 60mesh
pulverizing range
Each motor has a Nema‐1 motor starter for overloaded protection
Power off to both motors when the door is open
60 cubic inch capacity feed hopper has a vinyl shap‐on cover
Pulverizing chamber is completely machined and sealed.
Optional Screens : 0.020, 0.024, 0.033, 0.040, 0.0625 or 0.010×17/32 slots
POWER ENGINEERING
VIETNAM ELECTRICITY CONSULTING JSC 3

VINH TAN 4 THERMAL POWER PLANT

PROJECT (2X600MW)

TRAINING MANUAL
FOR
GAS CHLORINATION SYSTEM

DMPP Consortium (Grundfos Pumps Korea Ltd.)

GAS CHLORINATION SYSTEM

TABLE OF CONTENTS
1. Objective & Introduction

2. Performance data

3. Safety Information
3.1 Reasonably foreseeable misuse
3.2 Retrofitting or changing the machine
3.3 Spare and wear parts as well as supplies
3.4 Risks associated with the chlorination system
3.5 Responsibilities of the operator
3.6 Personnel qualification
3.7 Personal safety equipment
3.8 Avoidance of Danger
3.9 Safety and protective devices
3.10 Operating personnel work places
3.11 Fire protection

4. Construction and Function

4.1 Chlorine gas basics
4.2 Chemical Reactions of Chlorine in Water
4.3 Equipment Description
4.4 Function and Design of Chlorine Storage and Change-Over-System
4.5 Function and Design of Evaporator
4.6 Function and Design of Vacuum Regulators
4.7 Function and Design of Gas Dosing Systems
4.8 Function and Design of Booster Pumps and Injectors
4.9 Function and Design of Chlorine measurement system
4.10 Functional Description of Safety Installations
4.11 Function and Design of Gas Neutralization System

1
GAS CHLORINATION SYSTEM

TABLE OF CONTENTS
5. Calculation Sheet for Gas Chlorination System
5.1 General method for doing the calculation
5.2 Specific calculation for Vinh Tan 4 and Vinh Tan 4 extension project
5.3 Designing of the size of the equipment to match the peak consumption
5.4 Changing interval

6. Operation and Handling of the Unit

6.1 General
6.2 Assembly and Installation
6.3 Commissioning
6.4 Filling of chemicals
6.5 Dosing chemicals
6.6 Start-Up / Subsequent Start-Up of booster pump
6.7 Setting the chlorine gas sensors
6.8 Calibration of the gas dosing system
6.9 Operating of the gas dosing system
6.10 Maintenance of booster pumps
6.11 Start-up of the Gas Chlorination System
6.12 Stop of the Gas Chlorination System
6.13 Emptying of injection package

7. Spare parts

8. Possible system malfunction

9. Shutdown

2
GAS CHLORINATION SYSTEM

1. Objective & Introduction

• Manufacturer : Grundfos Water Treatment GmbH

• Product : Gas Chlorination System
• Type : Continous 266 kg/h / Shock 797 kg/h
• Year of manufacture : 2016
• Site / Location : Vinh Tan 4 Thermal Power Plant Project (600MW x 2 units)

The system is sized to comply with the maximum chlorine demand per hour which results from the shock dosing operation
mode :
3 x 177.419 kg/h = 532.257 kg/h

Since the biggest flow to be handled by a single element in the chlorination line is 200kg/h, the smallest possible configuration
3 x 200kg/h is chosen.

The following elements are included 3 times with a maximum capacity of 200kg/h each :
• Evaporator, liquid chlorine trap, pressure reducing valves, vacuum regulators, dosing regulators, injectors

The storage area elements are able to handle a capacity of 600kg/h of liquid chlorine each.
The following elements are included with a capacity of 600kg/h each :
- Header lines (1 duty + 1 stand-by), change over device (1 unit)

The continuous dosing rate only requires one 200kg/h chlorination line to be in operation at the same time.

3
GAS CHLORINATION SYSTEM

2. Performance data

The performance of chlorine equipment is mainly defined by the flow of chlorine.

• Header lines x 2 Sets : Capacity (liquid Cl2) : max. 600 kg/h

• Change over device x 1 Set : Capacity (liquid Cl2) : max. 600 kg/h

• Evaoprator x 5 Sets : Capacity (gaseous Cl2) : max. 200 kg/h

• Liquid chlorine trap x 5 Sets : Capacity (gaseous Cl2) : max. 200 kg/h

• Pressure reducing valves x 5 Sets : Capacity (gaseous Cl2) : max. 200 kg/h

• Vacuum regulators x 5 Sets : Capacity (gaseous Cl2) : max. 200 kg/h

• Gas dosing regulators x 5 Sets : Capacity (gaseous Cl2) : max. 200 kg/h

• Gas Chlorinator x 5 Sets : Capacity (gaseous Cl2) : max. 200 kg/h

• Injectors x 5 Sets : Capacity (gaseous Cl2) : max. 200 kg/h

• Motive Water Pump x 5 Sets : Capacity (Seawater) : 110 m3/h, Head: 60m

• Neutralization unit x 1Set : Capacity (Raw gas): 1,000 kg/h

4
GAS CHLORINATION SYSTEM

3. Safety Information

3.1 Reasonably foreseeable misuse

Any use other than the one specified under or going beyond "intended use" is deemed unintended!
Where damage is caused by improper use
• are the sole responsibility of the operator,
• the manufacturer assumes no liability.

3.2 Retrofitting or changing the machine

Unauthorized retrofitting or modifications of the chlorination system void any liability and warranty by the manufacturer!
Regard regulations concerning accident prevention and other generally accepted regulations concerning health and safety.
The electromagnetic behavior of the machine can be impaired through any additions or modifications.
For this reason, do not make any modifications of or additions to the chlorination system without consultation and written
approval of the manufacturer. This manual contains all information or links to the sub documents for integration of chlorine
dosing package in electrical / automation system.
It describes to necessary function of installed equipment on skids for function of the units.

3.3 Spare and wear parts as well as supplies

The use of spare and wear parts from third-party manufacturers can cause risks. Use only original parts or parts released by
the manufacturer.
The manufacturer assumes no liability for damages resulting from the use of spare and wear parts or supplies no released by
the manufacturer.

5
GAS CHLORINATION SYSTEM

3.4 Risks associated with the chlorination system

The use of the chlorination system can result in risks and interferences
• to life and limb of the operator or third persons,
• to the chlorination system itself,
• to other tangible assets.

The knowledge of this instruction is the basic for a save use of the machine.

Important
Always keep the operating instructions in the vicinity of the chlorination system!
The operating instructions must be accessible to the operator and maintenance personnel.

Also regard the following:

• General and local regulations concerning accident prevention and environmental protection.
• General and local regulations concerning storage of chlorine gas

3.5 Responsibilities of the operator

The operator is responsible for allowing only those employees to work with the chlorination system who
• are familiar with the basic regulations about work safety and accident prevention
• have received instructions in working with the machinery and chlorine,
• have read and understood these operating instructions.
• keep the operating places clean and dry. Remove leakages at earliest convenience. Chlorine gas is highly corrosive
against most metal parts!

The Gas Chlorination System hast to be protected against operation by unauthorized persons.

6
GAS CHLORINATION SYSTEM

3.6 Personnel qualification

Personnel Task Specially trained personnel Trained operating personnel Trained personnel with
subject specific education
(mechanical/electronic)
Transport X -- --
Assembly -- -- X
Commissioning -- -- X
Change of tools -- -- X
Use -- X --
Maintenance -- -- X
Troubleshooting and repair X -- X
Disposal/recycling X -- --
Legend: X..allowed / --..not allowed

3.7 Personal safety equipment

The operator must provide the following personal protection equipment.

• Breathing apparatus
• Protective suit
• Safety glasses
• Protective gloves

7
GAS CHLORINATION SYSTEM

3.8 Avoidance of Danger

WARNING
Regard the safety information for the chemicals used!
Work on the system must only be carried out at standstill and with the master switch switched off!
Do not open the device components! Cleaning, maintenance and repairs must only be carried by authorized
person.
Operate the chlorination system only if all safety and protective equipment are completely present and
functional!

8
GAS CHLORINATION SYSTEM

3.9 Safety and protective devices

1) Location of safety and monitoring devices

Provides an overview of the most safety and

monitoring devices and shows their location at the
chlorination system:

[0] Doors and escape ways

[1] Chlorine gas sensors
[2] Emergency shower
[3] Alarm horn and light
[4] Chlorine Gas Neutralization System

2) Faulty safety and protective devices

Faulty safety and protective devices can lead to

dangerous situations.

For this reason

• switch off the chlorination system immediately
• secure it against restarting
• if necessary, isolate it from electrical current
supply.
• flush Gas Chlorination System Location of safety
and monitoring devices

9
GAS CHLORINATION SYSTEM

3.10 Operating personnel work places

1) Work places inside drum storage room

[1] Replacement of gas sensors

[2] Drum handling, weight control, drum
replacement
Replacement of gaskets and flexible
copper lines
[3] Check for leakages and corrosion.
[4] Cleaning and maintenance of all functional
parts in contact with chlorine gas (filters,
valves)
[5] Regular functional check of safety systems.

10
GAS CHLORINATION SYSTEM

2) Work places at booster pump skid

[1] Replacement of cleaning of inlet filter screen

[2] Maintenance at booster pump hydraulic

3) Work Places at chlorine measuring system

[1] Recalibrate measuring device
Maintain and replace measuring cell and Clean filter

11
GAS CHLORINATION SYSTEM

3.11 Fire protection

Regard general requirements concerning fire protection. Electrical installations must be set-up according to effective
regulations that include fire prevention measures. Do not store inflammable materials near the chlorine dosing station. In case
of fire do not switch on the ventilation system or extraction fans.

WARNING
Do not use the chlorination system for dosing of flammable liquids.

12
GAS CHLORINATION SYSTEM

4. Construction and Function

4.1 Chlorine gas basics

Atomic weight 35.457

Molecular weight Cl2 70.941
Density (liquid) 1.57 g/cm³ at -34.05 °C
Density (gaseous) 3.214 g/l at 0 °C, 1 bar
1 l liquid chlorine at 0 °C corresponds to 457 l (0.457 m³) gaseous chlorine
1 kg liquid chlorine at 0 °C corresponds to 311 l (0.311 m³) gaseous chlorine
Specific gravity 2.486 (specific gravity of air: 1)
Boiling point -34.05 °C (at 1 bar)
Melting point -100.98 °C
Evaporation heat 269 kJ/kg (at 0 °C)
Degree of purity 99.5 %

4.2 Chemical Reactions of Chlorine in Water

Chlorine gas mixed into water decomposes and reacts with it to form disinfectant substances (HOCl, OCl- and dissolved Cl2).
Most effective reaction product is HOCl due to its similar structure compared to HOH (H2O).
These substances interfere with live bacteria in the treatment-requiring water.
HOCl can penetrate through cell membranes and react with cell fluids and thus can manipulate some vital enzymes.
Most notably is the enzyme “Triose-Phosphate-Dehydrogenase” that has the function to break down sugar molecules.
In general enzymes are catalysts that strongly accelerate very specific chemical reactions. When an enzyme gets slightly
manipulated (by reacting with chlorine) it completely loses its chemical function.
As a result the metabolism of bacteria cells is stopped. Because of its oxidizing properties chlorine also reacts with virus and
spores.
When a reduction of germ number by factor 100.000 is reached we can call the water to be disinfected.

13
GAS CHLORINATION SYSTEM

4.3 Equipment Description

The complete chlorination closing system is described according to a basic system schematic and the flow sheet.

The Chlorination System is fully automatic with control from 10 to 100% output. The Gas-chlorination plant is designed for, in
addition to local controls, remote operation. The control of the system can be controlled remotely from the central control
room. Manual operation is only possible at the local control boxes and instruments.

Motor of booster pumps are provided with local start/stop facility. The alarm signal is also sent to CCR.

The chlorination system will be interlocked with the operation of the Main Cooling water pumps for Cl2 injection as well as to
prevent Cl2 injection when the pump is shutdown.
14
GAS CHLORINATION SYSTEM

4.4 Function and Design of Chlorine Storage and Change-Over-System

Gaseous chlorine is supplied by drums of 840 liter of volume. For liquid chlorine extraction use lower drum valve.

Eight drums are connected in parallel using a chlorine manifold (collecting-line or connection-line or header line). Each drum is
connect to Chlorine manifold using a flexible connector line. Also the Nitrogen flushing device is connected via a flexible
connector line.

15
GAS CHLORINATION SYSTEM

Two chlorine manifolds are connected via a change-over-

system.

The chlorination system is supplied out of one chlorine

manifold until all eight chlorine drums run empty and the
pressure drops below 3-2 bar.

Then the change-over-system automatically switches to the

other chlorine manifold with full chlorine drums connected
to it.

This change-over-system consists of two motor driven 2-way

ball valves. The motors are connected to a control device
that gets a signal from a manometer connected with the
chlorine manifolds.

Now the empty drums can be disconnected and replaced

by full ones.

Beware that the pressure of the drum does not inform about
the filling level of the liquid chlorine inside. The content of
chlorine can be read from the drum balance.

Drums are moved using a crane system and a lifting beam. The chlorination system is fully operational during this time. After
replacement of the drums the chlorine manifold should be flushed out using dry air or nitrogen. This work step removes any
humidity out of the pipe that would otherwise lead to corrosion inside the pipe.

 NOTE
Never flush chlorine manifolds and metal type pipeline of the chlorination system with water.

16
GAS CHLORINATION SYSTEM

4.5 Function and Design of Evaporator

The Automatic liquid gas evaporator heats the liquid chlorine supplied from the
storage containers, transforming it into a gaseous state.

The unit is specifically designed for use in large-scale dosing plants in chemical
water treatment facilities.

It basically consists of the evaporator component with electrical heating

elements, regulation, control and safety units, and the control panels which are
divided into a load unit and a separate control unit. All of the assemblies, with the
exception of the control panel, are compactly combined in a glass-fiber
reinforced plastic housing.

The evaporator consists of a vertical multi-tube heat exchanger. The heating

elements, which are controlled by thermostats, generate a constant temperature
in the heat transfer medium circuit. An additional contact thermometer triggers
an alarm if the temperature falls below 50 °C or in the event of cable breakage
and a supplied appropriate pressure reducing valve is closed, if the temperature
exceeds 75 °C, the heating is switched off. The liquid gas to be vaporised is fed
at pressure into the bottom of the heat exchanger and leaves it at the top as a
dry saturated gas flow.

17
GAS CHLORINATION SYSTEM

With regard to the gas outlet temperature, the outlet is designed to prevent the
dosed gas recondensing as it passes through the installation downstream
towards the pressure reducing valve.

The equalizing tank contains a float switch, which switches off the evaporator in
case of lack of liquid, in order to protect the heating elements against damage.
A second monitoring of the heating circuit is run by a pressure switch mounted
at the equalizing tank. If the pressure in the heating circuit increases
inadmissibly, e.g. by overheating of the heat transfer medium, or by penetration
of chlorine because of a leakage in the heat exchanger, the evaporator is
switched off.

A bursting disk connected to an expansion tank provides a check against the

maximum admissible operating pressure being exceeded. This is dimensioned
in such a way that it can significantly release excess pressure by rupturing the
bursting disk. A pressure switch reports when the bursting disk has been burst
and the heating is switched off. The same message occurs in the event of cable
breakage excessively high or low gas pressure is reported by a contact
pressure gauge with two adjustable limit contacts. If the pressure falls below 3
bar a supplied appropriate pressure reducing valve is closed, if the pressure
exceeds 12 bar, the heating is switched off.

18
GAS CHLORINATION SYSTEM

4.6 Function and Design of Vacuum Regulators

The gaseous chlorine is pushed out of the drums, through the liquid filter and
pressure reducers into vacuum regulators. In case of maintenance service at a
vacuum regulator the chlorination system can be operated by any other vacuum
regulator.

The vacuum regulator is the main part for fundamental system safety. It
operates using a membrane with different surface areas at pressure and
vacuum side. Chlorine gas can only flow though the regulator if a minimum
vacuum level is available.

After this component the system pressure of chlorine gas will be lower than
environmental pressure. During system operation chlorine leakages are not
possible after the vacuum regulator.

19
GAS CHLORINATION SYSTEM

4.7 Function and Design of Gas Dosing Systems

Best available technology for chorine dosing is based on vacuum gas dosing systems.

Basically a chlorinator consists of variable cavity between a cone and a cone seat that creates
pressure drop for the chlorine gas flow. The chlorine amount flowing to through the dosing
system is regulated by adjusting this cavity. Here a stepper motor adjusts the spindle position to
set the cavity range.

Gas flow is indicated locally at a flowmeter (rota-meter). Different volume flow through the dosing
system cause different pressure drops. This effect causes erroneous dosing accuracy and is
therefore compensated by a differential pressure regulator. This device is placed at the outlet of
the dosing regulator and keeps the differential pressure around the dosing system at constant
level.

It operates similar to the vacuum regulator by using a membrane. In case of variable water quality,
manual dosing rate adjustment is based on concentration of residual chlorine value at discharge
channel (P1HTQ03CQ003). Residual chlorine in the discharge seawater form Power Plant is
measured by an on-line measuring device (P1HTQ03CQ003) at discharge channel. The residual
chlorine value can be monitored at the local control panel of gas chlorination system.

The operator in local control room controls the dosing rate of gas chlorine by manual adjusting of
spindle position on touch screen at the local control panel.
The chlorinated solution will be dosed at each dosing point with the constant flow rate regardless
of the chlorine concentrations. The gas chlorination system is designed to be able to dose 1 mg/l
continuous dosing rate and 3 mg/l shock dosing rate at the maximum chlorine concentration.

When chlorine concentration is lowered by operator to keep the residual chlorine at the seawater
discharge within the locally regulated value (0.2 mg/l), the continuous dosing rate and shock
dosing rate will be reduced in proportion to the concentrations of the chlorine solution.

20
GAS CHLORINATION SYSTEM

4.8 Function and Design of Booster Pumps and Injectors

Driving force of a vacuum gas chlorination system is the

booster pump that powers the injectors. Booster pumps are
designed as efficient standard centrifugal pumps producing
enough pressure and volume flow for the injector. Driving fluid
must be clean water free from particles and chlorine. As pump
fluid is clean water a single mechanical seal is applicable as
dynamic seal barrier. At suction side we recommend to install
a particle filter for protection of pump and higher system
availability.

Pump failure and dry run are monitored using a pressure side
manometer with min/max contacts. Injectors operate according
to the venture-effect are also known as water jet ejectors.

Apart from generating a vacuum for the dosing system the

ejector ensures mixing and dissolving of chlorine gas and
water. Injectors are equipped with an internal check valve to
prevent back flow of water into vacuum gas system.

At pressure side there is another manometer. Differential

pressure around the ejector is an indicator for good operation
status. Leaving the injector the high concentrated chlorine
solution is injected into the pipeline via a seeding point.

21
GAS CHLORINATION SYSTEM

4.9 Function and Design of Chlorine measurement system

The chlorine measurement system operates according to potentiostatic principle and

measures free chlorine content of water flow inside the pipeline after the seeding
point. For good system control it is recommended to install the sample point so that
contact time of chlorine is about 10 minutes. Higher contact times result in higher
dead times of the control systems measuring loop. It is also possible to measure the
residual chlorine content after 30 minutes of contact time but in this case it is not
possible to control the dosing regulators because the dead time is too high.

A sample pump will deliver the sample water to the measuring cell. For details about
the sample system, please refer to the documentation “Data Sheets Measuring
System”. Free chlorine content is defined as content of one of three chlorine
containing molecules (HCIO, CIO-, and C12). Oxidizing these molecules at the
cathode by means of adding electrons to the molecules takes up two electrons for
each of the molecule. By measuring electric current to the cathode and keeping
electric potential at the same level it is possible to read free chlorine content inside
the water flow.

22
GAS CHLORINATION SYSTEM

4.10 Functional Description of Safety Installations

Safety system reduces probability of chlorine leakages. In case of release of chlorine this malfunction will be detected and an
alarm will be triggered.

Additionally personal safety equipment is supplied. This must always be worn when operating or maintaining chlorine
containing machinery.

Some plant components required for system safety are described together with the chlorination system.

There are additional safety installations that are triggered by chlorine gas sensors. These sensors measure contents of
chlorine in the air of the chlorination building. There are two set points; a lower limit will switch on the ventilation fans to remove
low chlorine content out of the building. A second high sensor level will usually trigger a neutralization plant.

23
GAS CHLORINATION SYSTEM

4.11 Function and Design of Gas Neutralization System

The scrubbing system is exclusively intended for neutralization of chlorine gas within the context of the possible applications
described in this manual. The system is designed for operation during emergency situations only.

Neutralization system, pre-installed with following components

 Circulation pump (2x)
• Flow adjustment valve
• Flow meter with min. contact
 Blower (2x)
• Flaps installed in suction side air duct system
 Tower (2x)*
• Filled with packing material
• Spray nozzle
• Man holes
 Storage tank*
• Min. level contact
• Man hole
 Terminal box
• Circulation pump
• Blower
• Minimum flow contact
• Minimum liquid level contact
* Basic material of contruction is PEHD

24
GAS CHLORINATION SYSTEM

The chlorine gas neutralization system is designed for operation during emergence case only. Apart from that the system
should be turned on verification of functionality once a year. Further maintenance is described in the detailed description of the
scrubbing unit.

In case of an emergency the gas detector starts the neutralization unit automatically as follows:
The alarm of the gas detector starts the circulation pump.
The caustic soda is delivered up to the spray nozzles inside the
tower where it gets spayed uniformly over the tower packing.
The alarm also starts the blower to exhaust the contaminated
air through the neutralization column.

After the caustic soda has been started to circulate, the blower
blows the contaminated air upwards the tower, so the caustics
and the contaminated air will flow in opposite direction.

The fan as well as the circulation pump is made of polypropylene

and therefore is long-term resistant against liquid chemicals and
gas mixtures. To obtain the required surface for neutralization,
the tower is filled with rings. It ensures that a maximized surface
comes to minimized volume to guarantee the right
neutralization of the contaminated air.

A mist collector on top of the tower column ensures that no

droplets of chemical solution can leave the system. The heat
produced by the chemical reaction of caustics and chlorine
gas is absorbed by the washing liquid.

25
GAS CHLORINATION SYSTEM

Functional Description of Ventilation fans

Chlorine continually diffuses through PVC pipes, membranes and gaskets.

Dust from mechanical work and vapors from building materials and installations need to be transported to the outside. The fans
are required to maintain clean air for operators and personnel.
Also minor chlorine leakages can increase chlorine concentration in the air inside the building.

Chlorine concentration should be kept below 5ppm in order to protect personnel health and in order to prevent installations
from corrosion.
The ventilation fans will be triggered by chlorine gas detectors at a chlorine concentration of 1.5 ppm. The positions of air inlet
into the rooms should be designed for air exchange. In normal operation the chlorine content should drop below 1.5ppm by air
exchange.
In case of larger leakages the ventilation fans will be switched off automatically
at chlorine gas concentration of 5 ppm.
The plant operator must refer to local regulations concerning environmental
contamination by chlorine gas.

26
GAS CHLORINATION SYSTEM

Functional description control cabinet

Function is described in electrical plans that are included in the project documentation. Special modifications were applied for
this particular project concerning the automatic flaps installed at the air ducts. There are 2 flaps installed in the suction line.

Concept of control

Volume flow needs to be adjusted using the manual ball valve at

pressure side of the circulation pump.
The floater inside the flow meter should float close under the
maximum mark. Too high volume flow can reduce live time of
the circulation pump.

27
GAS CHLORINATION SYSTEM

5. Calculation Sheet for Gas Chlorination System

5.1 General method for doing the calculation

Chlorine consumption = Water flow rate * Concentration

5.2 Specific calculation for Vinh Tan 4 and Vinh Tan 4 extension project

Water flow rate: 265,620 m3/h

Continuous dosing rate: 1 ppm = 1 mg/l
Shock dosing rate: 3 ppm = 3 mg/l
Shock dosing duration / interval: 20 minutes per every 8 hr = 1 hr per day
Continuous dosing: 265,620,000 l/h * 1 mg/l = 265,620 g/h = 265.620 kg/h
Shock dosing: 265,620,000 l/h * 3 mg/l = 796,860 g/h = 796.860 kg/h

5.3 Designing of the size of the equipment to match the peak consumption

Biggest single line components available: 200 kg/h

 4 lines of 200 kg/h in duty & 1 line of 200kg/h stand-by are necessary to fulfil the peak consumption

28
GAS CHLORINATION SYSTEM

5.4 Changing interval

5.4.1 General method for changing interval of chlorine drum bank

Changing interval = Amount of chlorine available / Chlorine consumption.

5.4.2 Specific calculation for Vinh Tan 4 and Vinh Tan 4 extension project

Amount of chlorine available: 8 * 1,000 kg = 8,000 kg

Chlorine consumption daily: 23 h * 265.620 kg/h + 1 h * 796.860 kg/h

= 6,109.260 kg + 796.860 kg = 6,906.120 kg

Changing interval: 8,000 kg / 6,906.120 kg / day = 1.16 days

 8 drums need to be changed every day assuming the indicated dosing rates.

Total consumption period of entire storage

= 58 * 1,000 kg / 6,906.120 kg / day = 8.4 days

 58 drums can serve max. 8.4 days of whole chlorination plant consumption.

29
GAS CHLORINATION SYSTEM

6. Operation and Handling of the Unit

6.1 General

Interaction of Gas Chlorination System and operation in respect to other functional processes inside the water works must be
prepared by the client and handed over to the owner before commissioning.

6.2 Assembly and Installation

6.2.1 Product Identification

Parts in scope of delivery are marked using the SAP material numbers. The numbers are attached as stickers. The numbers
are also referenced in the delivery documents (delivery note and packing list).
Additionally main plant components are marked with tag labels. The Tag numbers are referenced in the parts list and P&ID.

Tag labels:
- TAG number Grundfos part number
- Bar code

6.2.2 Documents

Basic documents for assembly of the plan is the flow sheet and the arrangement drawing and electrical control plan. Document
number are indicated in this documents. These documents are included in the project documentation file.
Each part of the chlorination plant is shown in the arrangement drawings and is referred by tag number and index number.
Using the index number that parts list shows detailed information about each part. For complete information refer to the
documentation catalog.
The arrangement drawing also includes detail drawings of the fixation materials.
It is recommended to read the documentation of each equipment before beginning the assembly.

30
GAS CHLORINATION SYSTEM

6.2.3 Lifting devices and tools

• A crane is required for installation of the neutralization system. Suitable lifting height of 7m should be considered.
• For installation of air ducts it is recommended to use a suitable scaffold (movable, working height of 6 m)
• For heavy weight-equipment a fork lift devices is recommended.
• Standard instruments like screw wrenches, pipe tong, level, measuring tape, cutter, wire cutter e.g.
• Drilling machine (concrete, metal)
• extension cables for drilling machines as required
• Torque wrench (see attached the manual of torque)
• Iron saw or grinder for the PVC pipe work
• Welding instruments for carbon steel piping

6.2.4 Installation routine

This order of installation is a recommendation only. Based on local situation other sequences may be preferred.

• Installation of crane system

• Installation of drum storages, drum header line and connecting steel pipes
• Installation of Change-Over-Skids
• Installation of Evaporator Skids
• Installation of Chlorinators
• Installation of Motive Water Pump Skids
• Installation of Ejector Skids
• Installation of Neutralization System
• Installation of connecting PVC pipes, connecting steel pipes and water supply lines
• Installation of pressure air supply and solenoid valves
• Installation of electrical control panel
• Installation of measuring and safety systems
• Installation of electrical wiring

31
GAS CHLORINATION SYSTEM

6.2.4 Installation routine

This order of installation is a recommendation only. Based on local situation other sequences may be preferred.

• Installation of crane system

• Installation of drum storages
• Installation of drum header line
• Installation of connecting steel pipes
• Installation of Change-Over-Skids
• Installation of Evaporator Skids
• Installation of Chlorinators
• Installation of Motive Water Pump Skids
• Installation of Ejector Skids
• Installation of Neutralization System
• Installation of connecting PVC pipes
• Installation of connecting steel pipes
• Installation of water supply lines
• Installation of pressure air supply and solenoid valves
• Installation of electrical control panel
• Installation of measuring and safety systems
• Installation of electrical wiring

32
GAS CHLORINATION SYSTEM

6.2.5 Electrical Installations

Steps of installation

Installation of cable trays between control panels and equipment acc. drawings. The cable trays for signal and power cables
should be separated.

Fix installation pipes from cable trays to electrical consumers actuators acc. drawings.

Before starting cable pulling check that all equipment is installed and marked with correct Tag numbers. This must be
confirmed by using the overview drawings and PID diagram to avoid mixing up something. Start pulling power cables to each
equipment by following attached cable list. Meanwhile always sort and fix cables by using cable ties.

Pulling signal cables to each equipment by following attached cable list. Meanwhile always sort and fix cables by using cable
ties.

Each cable should be marked with cable number in beginning and end of route to avoid mistakes during connection.

For proper installation take care for cable routing and location of terminal rows in control panels. In General the power cables
are located left hand side and signal cables are right hand side.

Terminal row numbers (always check terminal plan of wiring diagram):

- X1 used for single and 3 phase power supplies (eg.: motors; fans)
- X2 used for control voltage single phase supplies (e.g.: motorized valves, analyzers)
- X3 used for digital signals (e.g.: level switch, limit switch)
- X4 used for analogue signals (e.g.: level measurement, flow rate)
- X5 used for potential free signals to Scada
- X5x used for signal exchange between main control panel and local control panels (e.g.: neutralization, evaporator)

33
GAS CHLORINATION SYSTEM

A) After cable pulling start preparing the cables for connection:

Remove carefully insulation. Take care not to damage inner insulation of cores.
B) Using cable sleeves only at screwed terminals. Spring-cage connection terminals don´t require cable sleeves!
C) Connect the cores by following the wiring diagram or using the terminal diagram.

After finishing connections start with insulation tests for power cables

Turn on fuses step by step following the pages in the wiring diagram. Confirm once again that the correct device is energized
and measure the correct voltage.

Adjust current for motor circuit breakers accordingly given name plates data’s

Check signal wiring and current loops by operating or simulation of the equipment. Where not applicable you can check digital
signals with temporarily link, analogue signals with signal generator. For further information please refer to user manuals of
equipment in delivered documentation.

Caution: Make sure cables connected accordingly wiring diagram, otherwise risk of damages at sensors, actuators and PLC.

34
GAS CHLORINATION SYSTEM

6.3 Commissioning

For setting the chlorine gas sensors read the separate documentation (VT4-DN05-P0PUS-120001 Commissioning Manual for
Gas Chlorination System).

6.4 Filling of chemicals

• Before handling chemicals always read safety instructions and use personal safety equipment.
• Storage, transportation, changing as well as complete handling of the dosing chemicals are in the responsibility of the owner.
• Chlorine drums must be filled by a chemical supplier. Therefore the drums must be transported to the chemical supplier.

WARNING

Regard the safety information for the chemicals used!

6.5 Dosing chemicals

Storage, transportation, changing as well as complete handling of the dosing chemicals are in the responsibility of the owner.

6.6 Start-Up / Subsequent Start-Up of booster pump

For Start up the pumps please read the separate pump documentation (VT4-CQ02-P0PUS-120001 O&M Manual 17.2.1
Motive water pump).
Never let the pump run dry.
Ensure inlet pressure min. 0,5 bar and differential pressure according to the pump curve.

6.7 Setting the chlorine gas sensors

For setting the chlorine gas sensors read the separate documentation (VT4-CQ02-P0PUS-120001 O&M Manual 13.2.13 Gas
Warning Device).

35
GAS CHLORINATION SYSTEM

6.8 Calibration of the gas dosing system

For calibration of the gas dosing system please read separate documentation file (VT4-CQ02-P0PUS-120001 O&M Manual
16.2.1 Vacuum gas metering system).

6.9 Operating of the gas dosing system

For operation of the gas dosing system please read separate documentation file (VT4-CQ02-P0PUS-120001 O&M Manual
16.2.1 Vacuum gas metering system).

6.10 Maintenance of booster pumps

For maintenance of the pump please read the separate pump documentation (17.2.1 Motive water pump).

6.11 Start-up of the Gas Chlorination System

• Check that chlorine drums are connected to the chlorine manifolds. Use the lower drum valve for gas extraction.
• Make sure there are no chlorine leakages. Even small leakages can cause wide range damage.
• Leakage test must be performed at every connection inside the high pressure piping.
• Check that chlorine measuring systems are installed
• Check that vacuum system is correctly installed
• Ensure that booster pressure is sufficient
• Check ball valves and make sure that water supply is available.
• De-aerate and fill the pumps with water and start the pumps against nearly closed pressure side ball valve.
• Open pressure side ball valve. Check pressure side manometers for suitable booster pressure.
• Start the evaporator in operation, close valves of evaporator in stand-by
• Open vacuum side ball valves and check gas chlorine gas flow at the gas dosing systems.
• At the control panel adjust required gas flow and read the chlorine concentration at the continuous chlorine measuring
systems.

36
GAS CHLORINATION SYSTEM

6.12 Stop of the Gas Chlorination System

• Usually it is possible to just switch of the booster pumps. It must be guaranteed that there isn’t any flow through the
injectors. In case of high inlet pressure of booster pumps additional measures could be necessary to stop dosing of
chlorine.
• In case it is required to empty all pipelines from most of the chlorine it is recommended to close drum valves first.
• For longer downtime it is recommended to close ball valves at chlorine and water supply.
• Flush the chlorine lines using Nitrogen

6.13 Emptying of injection package

WARNING

Regard the safety information for the chemicals used!

Regard local safety regulations!

Work on the system must only be carried out at standstill and with the master switch switched off!

Do not open the device components! Cleaning, maintenance and repairs must only be carried by authorized
person.

37
GAS CHLORINATION SYSTEM

7. Spare parts

Spare parts can be requested at Grundfos, please use therefore the order numbers which are listed in the part list or use the
spare part numbers out of technical documentation.
Use only original spare parts.

38
GAS CHLORINATION SYSTEM

8. Possible system malfunction

For possible errors of the Gas Chlorination System please read the documentation of plant component.
Please refer the list of common failures before start-up of the plant.

39
GAS CHLORINATION SYSTEM

9. Shutdown

9.1 Temporary shutdown

Switch of the dosing unit and all attached assemblies see general manual of the owner. Consider recommendations under 8.12
Stop of the Gas Chlorination System. For maintenance of the system read separate documentation files of system components.

9.2 Storage conditions

Short-term to medium-term storage (up to 2 years) without special measures is possible at the ambient conditions specified in
the technical data. For longer storage, measures for corrosion protection must be performed.

9.3 Disassembly, final decommissioning

• Switch of the dosing unit and all attached assemblies, see general manual of the owner.
• Clean the chlorination system (see chapters here before).
• Disconnect the power at the control cabinet and unplug the connector.
• Empty the operating supplies.
• Disassemble the machine in reverse order of the assembly or according to separate disassembly instructions.

9.4 Disposal/recycling

Before the removal, shut down and disassemble the machine.

For the transport, regard the notes in chapter 5!
Separate parts and electronic components homogeneously and dispose of them according to good professional practice.

NOTE

FOR QUESTIONS CONCERNING DISPOSAL/RECYCLING, PLEASE REGARD THE LOCAL REGULATIONS.

40
GAS CHLORINATION SYSTEM

Thank you

41
POWER ENGINEERING
VIETNAM ELECTRICITY CONSULTING JSC 3

VINH TAN 4 THERMAL POWER PLANT

PROJECT (2X600MW)

TRAINING MANUAL
FOR
H2 GENERATION PLANT

TELEDYNE
Hydrogen Plant Operation,
Troubleshooting, and Maintenance
Training

Titan HMXT‐200

2
"THESE COMMODITIES, TECHNOLOGY OR SOFTWARE
WERE EXPORTED FROM THE UNITED STATES IN
ACCORDANCE WITH THE EXPORT ADMINISTRATION
REGULATIONS. DIVERSION CONTRARY TO U.S. LAW
IS PROHIBITED.
UNITED STATES LAW PROHIBITS DISPOSITION OF
THESE COMMODITIES, TECHNOLOGY OR SOFTWARE
TO ANY END-USER FOR ANY END-USE RELATED TO
THE DESIGN, DEVELOPMENT, PRODUCTION,
STOCKPILING, OR USE OF CHEMICAL, BIOLOGICAL
OR NUCLEAR WEAPONS OR MISSILES, WITHOUT THE
PRIOR APPROVAL OF THE UNITED STATES
GOVERNMENT."

3
H2 Plant Training

1. Introduction
2. Hydrogen Plant Overview, Layout & Description
3. Safety Precautions
4. H2 Plant Training
1. HMXT Generator
2. Compressor
3. Gas Panel
4. Instruments
5. Annunciator Panel
6. KOH Mixing Cart

5. Troubleshooting & Maintenance

4
INTRODUCTIONS

5
TELEDYNE ENERGY SYSTEMS, INC.

CUSTOMER SERVICE ENGINEER

A Division Of
TELEDYNE TECHNOLOGIES

Teledyne (NYSE:TDY): A technology company

with a 45 year history of innovation and
excellence serving global markets

Corporate Headquarters:
Thousand Oaks, California USA

President, CEO & Board Chairman:

Dr. Robert Mehrabian

Annual Sales: ~$2 billion USD

Employees: 8,000
TELEDYNE TECHNOLOGIES SEGMENTS
TELEDYNE ENERGY SYSTEMS DIVISION

Headquarters:
Hunt Valley, Maryland USA

— 122,000 ft2 in two facilities

— Manufacturing, Engineering,
Design, Sales & Service / Support
— State-of-the-art thermoelectric,
hydrogen & fuel cell production
— 150 Employees
SAFETY PRECAUTIONS

10
Caustic Liquid
Potassium Hydroxide is a caustic liquid that can be:
 Neutralize with 3‐5% solution of Boric Acid
 10 liter container of 5% Boric Acid solution
should be in the area at all times.
 Mix 480 ml (2 cups) of boric acid powder
to 10‐15 liters of water.
 If a KOH spill or leak is present, clean the area
thoroughly.
 First with Boric ACID solutions,

 Flush with DI water.

 Dispose of any cloth material used in the
clean up. KOH residue may still be in the
cloth.

11
Safety Warnings

 Caustic Liquid
 KOH is often seen around leaks as a white crystal
powder.
 Do not handle the powder unless you are wearing proper
protection and boric acid is available to clean the KOH.

Solid KOH
12
Safety Warnings

 Flammable Gas
 Hydrogen Flammable Gas
 GAS : Clear, Odorless, Lighter than Air.
 Burns Clear
 The only time you “see” a hydrogen fire, is when other components are being burned.
 Look for heat distortion in the air if a fire is suspected.

 Once Hydrogen is easily ignited, burn rate is extremely fast
 Low ignition energy
 Dust in windy conditions,
 Stainless steel on stainless steel (static charge)

 Hydrogen in Oxygen or Air is explosive
 4% of Hydrogen Gas in Oxygen or Air is termed as the Lower Explosion limit.
 Combustible Gas Sensors are used in buildings to check for Hydrogen leaks.

13
Safety Warnings

 Flammable Gas

Conduct Periodic Leak Checks
1. Look for Leaks
2. Listen for Leaks
3. Bubble Check for Leaks with soapy water or Snoop
Note: Keep liquids away from Module ends and tie rods.
4. Immediately report a leak, and Shutdown equipment

14
Safety Warnings

 HMXT Completes Purge Cycles with Nitrogen!
 Why: To eliminate any possible mixture of Hydrogen
with Oxygen or Air when the equipment is started and
shutdown.
 At start‐up and shutdown
 If in doubt, repeat process!
 Ensure Buildings have adequate Ventilation.
 Ensure that Vent Lines are open and clearances from
Buildings are adequate.
 Use Heat tape in areas where vent lines can freeze.

15
Safety Warnings

 Generator also produces Oxygen

 Oxygen is needed in any environment to support combustion.
 A pure Oxygen environment will result in EXTREMELY RAPID
COMBUSTION
 Generator Vents Oxygen at 50% of the Hydrogen Production rate.
 BEFORE STARTING THE GENERATOR, MAKE SURE:
 THE VENT LINES ARE CLEAR
 THE VENT LINES ARE OPEN
 THAT NO IGNITION SOURCES ARE PRESENT.

16
Safety Warnings

Positive
Endplate,
Never Touch
 Electrical when
 AC Generator is
 Facility 3‐Phase Power: 380 TO 480VAC. operating
 Dryer Heater Voltage (120 VAC)
 Control Voltage (120 VAC)
 DC
 Electrolysis Module Voltage
(Up to 180 VDC WITH 450 AMPS)
 THESE VOLTAGES
ARE LETHAL:

17
Safety Warnings

 Electrical
 Keep all covers and protections in place

 Utilize Standard
Electrical Safety
Precautions

Cover must be installed

correctly, and all screws must
be plastic

18
Safety Warnings

 Compressed Gas
 Generator operates at pressure: 130psi to 160psi and can
reach pressure up to 180 psi.
 Compressors and Gas Storage may have pressures up to
150 BAR.
 Inert gas is usually in high pressure cylinders.
 Use care when handling pressurized gas.
 Depressurize System when maintenance is required
and when fixing leaks.

19
Safety Warnings

 High Temperature

 KOH loop operates between 600C and 700C.
 Dryers can reach 200oC during Regeneration Cycle.
 De‐Ox Tanks will also have High Temperature when
Generator is in operation.

 Temperature warnings are located on Generator.

20
HYDROGEN PLANT
TRAINING

21
Hydrogen Plant

H2 Plant Overview

Equipment:
• Hydrogen Generators  Qty. 2
Each HMXT‐200 is capable of up to 11.2 n‐
m3/hr. of H2
• Feedwater Tanks  Qty. 1
• Buffer Tank: Qty 1
• Compressors  Qty 2
11.2 nm3/hr. H2 compression to 150 bar

22
Hydrogen Plant

H2 Plant Overview

Equipment:
• GAS Panel
Distribution of H2 to and from:
Generators/Buffer Tank ( low pressure)
High Pressure Storage
Compressors
• High Pressure Storage
Non Portable Storage

23
Hydrogen Plant

H2 Plant Overview

Equipment:
• Instruments
• Hygrometers Qty 2 (check moisture in H2)
• Trace O2 Analyzer (TOA) Qty 2
• Thermal Conductivity Analyzer (TCA) Qty 1
• Combustible Gas Analyzer Qty 1

• Annunciator Panel

24
Hydrogen Plant

H2 Plant Overview
Operation:

• GAS PANEL
• Controls H2 GAS Flow
• FROM:
• Low Pressure ( Buffer Tank/Generators)
• Compressors
• High Pressure Storage (portable/non portable)
• TO
• Process Header (6 bar)

25
HMXT Operator Training

Operation

Review of HMXT Generator Processes

26
Supporting Systems

27
Operation

Pre‐Start Check:
Checklist for Starting
 Is Generator ready and safe to start?
 All connections are complete ( water, power, piping, etc.)
 Generator has KOH in it.
 Nitrogen is on. Pressure set at 80 to 100psi at the Generator.
 Feed water is available and valve is on.
 E‐Stops are pulled out in Generator and Power Supply.
 Blue light on the Power Supply is on.

28
Operation

 Checklist for Starting

Power Supply and UPS are turned ON.

Press this button to

turn on the UPS

29
Operation

Checklist for Starting

 Cooling Water valves are open, Chiller is ON and cooling water is
available.
 Delivery is set to Vent.
 Feedwater pump is primed.
 Open Drain valve: Make sure water flows
 Feedwater Resistivity less than 5 us.
 If the Feedwater level is below 7” add feedwater by pushing the prime button on
the feedwater screen and bring the level up to 8.0” inches with KOH Pump
running.

30
Operation

Feedwater Screen

31
Operation

Checklist for Starting

 Vent Valves if any are open.
 System at zero pressure and at “Ready” status of Generator or “Clear
Alarm Press Start” status when in alarm.
 System pressure is at near zero.

32
Operation

Starting the Generator
 Press the Start Gas Generation Button

Push
this
button
to start

33
Operation

Starting the Generator
 KOH Pumps are turned on
 Flow switches should turn Green.
 Pre‐pressurization note displayed at bottom
 Solenoid Valve SV6 cycles to provide nitrogen purge
 System pressure rises to 10 psi
 SV6 closes and SV2 begins cycling to vent
 When system pressure falls to 5 psi
 System pressure rises to 10 psi
 System pressure falls to 5 psi
 System pressure rises to 10 psi

34
Operation

Generation Screen

Pressure will
Increase to10

This box will

Go to
Pre-Pressurization

35
Operation

Starting the Generator

 Operator should remain at Generator.
 Time for Pressurization 5‐ 15 minutes depending on
the incoming pressure of Nitrogen.
 Restart Delay
 Once pre‐pressurization is completed
 Condenser Cooling valve SV3 opens

36
Operation

Generator Operation

 Generator Operating
 Once restart delay is complete
 Current is applied to the module
 Current builds slowly over time: Takes 6 minutes.
 Starts at minimum current and holds it for 3 minutes
 Next 3 minutes the current ramps to full production rate.
o
 Full 100% is not available until KOH temperature reaches 55 C

37
Operation

Generator Operation

 Generator Operating

 System pressure increases until it reaches BPR1 set point (approx.
130 psi)

 Operator should confirm that the dryers start to fill with
pressure between 125 and 132 psi.
 If not this should be corrected by the appropriate personnel.

38
Operation

Generator Operation

 Generator Operating
 BPR1 opens and the online dryer fills.
 Dryer pressure increases, when pressure reaches 80psi the On Line
dryer cycle will begin. The dryer cycle timing starts now.
 The dryer will begin where it left off on last run, unless it is less
than 30 minutes. The timer will restart at 30 minutes.
 Dryer and System pressure increase until BPR2 set point (approx.
140 psi).

39
Operation

Supporting Systems
H2 Pressure vs. Time

200

180

160

140
Pressure (PSIG)

120

100

H2 Pressure
60
BPR1
40 BPR2
BPR3
20
Dryer
0
0 5 10 15 20 25 30 35 40

Time (min)

40
Operation

Generator Operation
 Generator Operating
 BPR2 opens and Hydrogen delivery begins with gas being sent to
vent.
 Operator should confirm the following information:
 Pressure is at 140 to 160 psi.
 Delta P is at ‐1.0 to ‐0.5 inches
 KOH temperature has reached set point 60C
 Cooling water valve (MV1) is opening. The valve rotates back and
forth to control KOH temperature
 H2 in O2 Temperature is responding and flow rate set correctly.
Adjust if needed to 100 scc of air.
 Let Generator run on Vent for 15 minutes

41
Operation

Generator Operation
 Generator Operating
 Switch Generator Production from Vent to Delivery
 Close the Vent Valve.  SLOWLY
 Open the Delivery Valve.  SLOWLY
 Slowly to prevent Generator from Alarming for Delta P.
 Pressure on the Generator will begin to rise from the  140
psi condition depending on the demand of the gas.
 Example:  Buffer tank and Compressor System
Buffer Tank pressure increases and once it approaches 150psi
(set point) the production rate on the generator will begin to
decrease.

42
Operation

Generator Operation

 Once internal pressure reaches 150 psi the current is regulated to
provide the required gas flow.
 BPR2 protects the system from over demand of Hydrogen (140 psi).
 BPR3 protects the system from under demand: When the system
increases to 160 psi, the generator should be running at minimum
current 125 to 150 amps.
 If the demand is lowered, then the pressure will go up and current
will go down.

43
Operation

Generator Operation
 Dryer Sequence
 Begins when the Online dryer is pressurized
 Online dryer delivers for 6 hours
 Offline dryer heater comes on for 90 minutes
 Offline dryer then cools for 4 hours
 During heating and cooling a small amount of dry gas is vented through the offline dryer
 Offline dryer pressurizes 30 minutes prior to switch
 Dryer Sequence status can be seen on the Dryer Screen
 Feedwater
 Feedwater pump will come ON when the feedwater level reaches the start fill setpoint
typically 8 inches.
 Feedwater pump will shut off when the level reaches 8.5 inches.

44
Operation

Normal Operation
 Data Taking
 Data is collected by the PLC automatically and
stored in the Touchscreen.

 Data collection by the operator should start as
soon as the generator is in stable condition and
product gas is being sent to delivery.

 Recommend taking data a minimum of 2 times every
8 hours.

45
Operation

Normal Operation
 Data Taking
 Why do Operators need to take data?
 PLC’s are not human. They perform the functions that they are
given (by a human)
Humans can see (leaks)

Humans can hear (leaks, motors running, etc.)

Humans can touch ( dryers, etc.)

Humans can smell

46
Operation

47
Operation

Normal Operation
 Data Taking
What Data is Important and Why
 H2 in O2 Probe
 This monitors the performance of the module by looking at the amount of H2 in O2.

 The flow rate must always be controlled to the same value 100 scc of air

 Operator must make sure data is collected and record the flow rate. He must
also adjust the flow rate to the set point.
 IF the temperature is always at or below Ambient temperature, then it’s possible the
probe is no longer functioning.
 The probe can be tested simply by increasing the flow rate and the temperature should
increase.
 If it does not respond, the probe should be tested and possibly replaced.

 DO not run the generator if this probe is not functioning since the protection for the
system is not active.

48
Operation

Check and
set Flow
Rate

Use this to
adjust
Flow rate

49
Operation

Normal Operation
 Data Taking
What Data is Important and Why
 DE‐OX Tank Temperature
 This monitors the performance of the module by looking at the amount of
O2 in H2.
 IF the temperature is always at or below Ambient temperature, then it’s
possible the catalyst inside the tank is no longer functioning.
 The canister must be checked to see if the catalyst inside has been
contaminated.
 DO not run the generator if this probe is not functioning since the
protection for the system is not active.

50
Operation

Normal Operation
 Data Taking
What Data is Important and Why
 Power Supply Data
 The DC volts and DC amps are indicators that the power supply is functioning correctly

 Typical readings for an HMXT 200 generator running at 100 is 420 amps and around 160
Volts.
 IF the Volts reach 180 then the power supply is now running at its maximum output.

 There are several things that can cause this condition

 Low KOH concentration

 Something wrong in the power supply (loss of the SCR’s)

 Check that the ACE is Open

 If the current the power supply is providing is not the same as that requested there are
several things
 Loss of SCR’s

 Running the Power supply in Manual

51
Operation

52
Operation

Normal Operation

 Trace Oxygen Analyzer/Hygrometer

 Flow Rate on Trace on Analyzer and Hygrometer needs to be
confirmed. Change in flow rate will impact the measurement.

53
Operation

Flow
rate
should
always
be the
same

54
Operation

Only
small
amount
of flow
needed

55
Operation

Normal Operation

 Alarms

 Operators should also record any alarms (the PLC also keeps
this information) and any other information as to what was
going on at the time of the alarm

56
Operation

Touch Screens

 We have looked at the main screen of the generator already.

 Now we will review the remaining screens.

 Not all screens will be needed but are being shown for reference
purposes.

57
Operation

Dryer Screen

58
Operation

Feedwater Screen

59
Operation

Cooling System Screen

60
Operation

Power Supply Screen

61
Operation

Alarm Screen

62
Operation

Gas Control Screen

63
Operation

System Info Screen

64
Operation

Instruments Screen

65
Operation

Hygrometer Screen

66
Operation

Trace Oxygen Screen

67
Operation

Combustible Detector Screen

68
Operation

Data Logging Screen

69
Operation

Graph Screen

70
Operation

Shutdown and Purge
 Shutting down the system
 Method 1
 Push the Shutdown button on the touch screen
 Yes or No Screen

71
Operation

72
Operation

73
Operation

Shutdown and Purge
 Shutting down the system
 Method 1
 THE FOLLOWING WILL OCCUR AUTOMATICALLY
 Electrolysis will stop, system in 30 second hold
 Goes into Purge
 The vent valve will bleed the pressure down to 35 psi
 The Inert Gas will come on and pressurize to 40 psi
 The cycle repeats 2 times
 Goes into Pressure Release
 The vent valves vent down to atmospheric pressure
 Note: you cannot restart the generator until it says Pressure
Release

74
Operation

75
Operation

Shutdown and Purge
 Shutting down the system
 Method 2
 Push E Stop at Generator or Power Supply

76
Operation

Shutdown and Purge
 Shutting down the system
 Method 2
 Push E Stop at Generator or Power Supply
 Undervolt or E‐Stop Alarm in 5 seconds
 Purge cycle as described above.

 Not Acceptable
 NEVER USE the UPS to turn off the Generator

 NEVER, NEVER, NEVER EVER!!!

77
Operation

Compressors:
Start‐up and Priming:
‐ Starting the Compressor will require priming if
compressor has been idle for longer than 2 days or
after any troubleshooting, repair, or maintenance
allowing for oil loss.
‐ Priming sequence must be repeated prior to
placing a process load on the Compressors by
opening the 1st and 2nd stage Relief by‐pass valves.
Press and hold the JOG button, when no bubbles
are seen close valves. Then start the Compressor.

78
Operation

Compressors:
Start‐up and Priming:
‐ Re‐starting the Compressor not requiring priming
is allowed from short time of shutdown <2days.

Note: Before Priming and starting re‐establish the
cooling water flow and process gas.

79
Operation

Compressors:
Purging:
‐ Purging is required after maintenance. Nitrogen
gas supply is piped to the Compressor with
isolation valve.

Note: Before Priming and starting re‐establish the
cooling water flow and process gas.

80
Operation

Compressors:
Normal Operation (Automatic):
‐ Once the Compressors are running, it will continue
to operate until it will go to standby.
‐ Standby occurs at 2400 psi (when storage is filled),
the compressor will stop and will automatically
restart when the pressure drops to 2200 psi.

81
Operation

Compressors:
Shutting Down The Compressors:
‐ Close the H2 Inlet valve at the compressor, open
Vent valve at cylinder manifold (close full tanks).
Compressor will restart and shut down for low
suction pressure. Turn off compressor.
‐ Cooling water should be run through the
compressor for 15 minutes after the compressor is
shut down. Close the cooling water valves at the
compressor. This eliminates potential condensate
occurring in the compressor.
82
Operation

Compressors:
Safety Precautions:
Before and during any maintenance work being
performed on the compressor or any of its
support equipment, be absolutely sure the following
precautions and safety rules are observed:

• Properly shut down the compressor. Allow hot
components to cool prior to proceeding with
maintenance.

83
Operation

Compressors:
Safety Precautions:
‐ Isolate the compressor from all main service
connections such as electrical, process, cooling
water, instrument air, etc. Lock‐out/tag‐out
procedures should be used to prevent the
services from being accidentally restored.
‐ Vent residual pressure from all piping, compressor
heads, etc.

84
Operation

Compressors:
Safety Precautions:
‐ Always use the proper tools and other equipment to
perform maintenance.
‐ Never place your hand or arm inside the crankcase
without realizing the crankshaft can rotate
unless it has been mechanically secured.
‐ After any maintenance, carefully observe the
compressor for a period of time necessary to assure
the compressor is operating normally.

85
Operation

Gas Panel:

86
Operation

Gas Panel

Piping and Instrumentation

87
Operation

Gas Panel:
Gas Panel Operation:
‐ Operating the Gas Panel to supply the process by
turning ON one of the valve HV‐101, HV‐102, or HV‐
103.
HV‐101 is the supply from High Pressure Storage and
HV‐102 is from the Compressors and both
interconnected.
‐ HV‐103 is the supply from Low Pressure which is the
Buffer Tank.

88
Operation

Gas Panel:
Gas Panel Operation:
‐ All the three gas source are being regulated with
Forward Pressure Regulators (PCV‐101, PCV‐102,
and PCV‐103). Setting of all regulators is depending
from the requirement of the Plant.
‐ The Gas Panel process is also equipped with Check
Valves to prevent pressure feedback on each gas
supply (CV‐101, CV‐102, and CV‐103).

89
Operation

Other Instruments:
Thermo Conductivity Analyzer (TCA):

90
Operation

Other Instruments:
Thermo Conductivity Analyzer (TCA):
‐ This instrument is designed to measure the purity
of process in percentage unit.
‐ Before operation verification of the availability of
sample gas, REF/ZERO, and CAL Gas is a routine
operation.
‐ TCA Power and Reference gas should be always ON
unless performing maintenance.

91
Operation

Other Instruments:
TCA Operation:
‐ Verify if constant flow (40 cc/min) is available from
the REF Gas, the REF Gas should be always ON
during normal operation.
‐ Turn ON the sample gas valve and regulate not
more than 10 psi (0.7 bar).
‐ Regulate the flow from TCA instrument below 75
cc/min.

92
Operation

Other Instruments:
TCA Routine Calibration:
‐ Routine Calibration of TCA is recommended to
determine the accuracy of the instrument.
‐ The availability of calibration gas should always be
check as part of the routine check everyday.

93
Operation

Other Instruments:
TCA Routine Calibration Procedure:
1. Close sample gas.
2. Open Zero Gas valve below the instrument. Regulate the flow below 40
cc/min.
3. From the front panel press .

4. Press for auto calibration.

94
Operation

Other Instruments:
Trace Oxygen Analyzer (TOA) Operation:
‐ TOA is an instrument to measure the oxygen
content from hydrogen gas. Typically pure
hydrogen gas will have below 2 ppm of oxygen
content.
‐ Nitrogen supply is included to the instrument to be
used for more than 24 hours shutdown and during
purging.

95
Operation

Other Instruments:
TCA Routine Calibration Procedure:

5. The instrument will go analyze mode when auto
zero calibration is finished.
6. Close Zero gas valve. Do not turn OFF the REF
gas.

Zero gas valve

96
Operation

Other Instruments:
TCA Routine Calibration Procedure:
7. Open the CAL Gas and regulate flow to 75 cc/min.
8. Press

9. Press then press up and down arrow
to select the span gas value.

97
Operation

Other Instruments:
TCA Routine Calibration Procedure:
10. Press again to begin spanning.
11. The instrument display will proceed to analyze
when span CAL is finished.

98
Operation

Other Instruments:
Trace Oxygen Analyzer (TOA) Operating Procedure:
‐ From long term shutdown turn OFF the nitrogen gas
supply valve.
‐ Open the flow meter valve 100%.
‐ Open the vent toggle valve.
‐ Open needle valve.
‐ Open inlet toggle valve.
‐ Turn ON sample gas and regulate to 2‐3 sccf from the
flow meter.

99
Operation

Vent Toggle Valve

Needle Valve

Flow Meter Valve

Inlet Toggle Valve

100
Operation

Annunciator Panel:
Panel Screen Navigation And Operation:

Main Screen

101
Operation

Annunciator Panel:
Panel Screen Navigation:

Generator Screen

102
Operation

Annunciator Panel:
Panel Screen Navigation:

Compressor Screen

103
Operation

Annunciator Panel:
Panel Screen Navigation:

Feedwater Tank Screen

104
Operation

Annunciator Panel:
Panel Screen Navigation:

Feedwater Tank Screen

105
Operation

Annunciator Panel:
Panel Screen Navigation:

Instruments Screen

106
Operation

Annunciator Panel:
Panel Screen Navigation:

Alarm Screen

107
Operation

Annunciator Panel:
Panel Screen Navigation:

Combustible Gas Sensor Screen

108
Operation

Annunciator Panel:
Panel Screen Navigation:

Trace Oxygen Analyzer Screen

109
Operation

Annunciator Panel:
Panel Screen Navigation:

Thermo Conductivity Analyzer Screen

110
Operation

Annunciator Panel:
Panel Screen Navigation:

Pressure Transducer Screen

111
Operation

Annunciator Panel:
Panel Screen Navigation:

Logging Screen

112
Operation

Annunciator Panel:
Panel Screen Navigation:

Logging Screen

113
Operation

Annunciator Panel:
Panel Screen Navigation:

Logging Screen

114
Operation

Annunciator Panel:
Panel Screen Navigation:

Logging Screen

115
Operation

KOH Mixing Cart:

116
Operation

KOH Mixing Cart:
Operation and Mixing:
‐ Before operation a SAE 10 Oil (non‐detergent oil)
needed to lubricate the Air instrument system if N2
Gas will be use in the process. If using an Air the oil
is not needed.
‐ Allowable pressure to be used in the Mixing Cart
must not exceed 40 psi.

117
Operation

KOH Mixing Cart:
Operation and Mixing:

118
Operation

KOH Mixing Cart:
Operation and Mixing:
Mixing KOH:
‐ Before mixing KOH close the valve in
between the Tank and the Y‐strainer as shown below.

119
Operation

KOH Mixing Cart:
Operation and Mixing:
Mixing KOH:
‐ Fill with Demineralized Water for a total of
approximately 62 liters followed by 34 kg of 85%
KOH Pellets supplied. The mixture is enough for two
Generators (HMXT‐200).
‐ Manually mixed until the pellets are
dissolved. Sit for about 4 hours.

120
Operation

KOH Mixing Cart:
Operation and Mixing:
Mixing KOH:
‐ Temperature of the mixture might reach up
to 55C. Wait until the temperature will drop to 40C
and start circulating KOH. The main valve should be
open now at this time and the dispensing valve
should be facing the Tank as shown.

121
Operation

KOH Mixing Cart:
Operation and Mixing:
Mixing KOH:

Main Valve

122
Operation

KOH Mixing Cart:
Operation and Mixing:
Mixing KOH:
‐ Circulate for about 1 to 2 hours by connecting
N2 gas to the air inlet and should be regulated not
exceeding 40 psi. Measure the specific gravity using
Hydrometer. Measure the KOH temperature and
determine the percentage of KOH from chart located
from the HMXT Manual.

123
Operation

KOH Mixing Cart:
Operation and Mixing:
Mixing KOH:

Specific Gravity of KOH Solution at Various Temperatures
Wt % 10 C 20 C 30 C 40 C 50 C 60 C
23 1.221 1.216 1.211 1.201 1.196 1.19
24 1.231 1.226 1.221 1.211 1.206 1.2
25 1.241 1.236 1.231 1.221 1.216 1.21
26 1.251 1.247 1.242 1.231 1.226 1.22
27 1.262 1.257 1.252 1.241 1.236 1.23
28 1.272 1.267 1.262 1.252 1.246 1.24
29 1.283 1.278 1.272 1.262 1.256 1.25
30 1.293 1.288 1.283 1.272 1.267 1.261
31 1.304 1.299 1.293 1.283 1.277 1.271
32 1.314 1.309 1.304 1.293 1.287 1.281
33 1.325 1.32 1.314 1.304 1.298 1.292
34 1.336 1.331 1.325 1.314 1.308 1.302
35 1.347 1.341 1.336 1.325 1.319 1.313

124
Operation

KOH Mixing Cart:
Operation and Mixing:
Mixing KOH:
‐ Adjust concentration if the percentage is not
in range as recommended by Teledyne.

Recommended Concentration: 29% to 31%

125
Hydrogen Plant

Troubleshooting &
Maintenance

126
Troubleshooting

Hydrogen Generator

127
Troubleshooting

Hydrogen Generator

128
Troubleshooting

Hydrogen Generator

129
Troubleshooting

Hydrogen Generator

130
Troubleshooting

Hydrogen Generator

131
Troubleshooting

Hydrogen Generator

132
Troubleshooting

Hydrogen Generator

133
Troubleshooting

Hydrogen Generator

134
Troubleshooting

Hydrogen Generator

135
Preventive Maintenance

Hydrogen Generator

136
Troubleshooting

Hydrogen Generator Power Supply

137
Troubleshooting

Hydrogen Generator Power Supply

138
Preventive Maintenance

Power Supply

 The environmental condition vary with various places affecting the
performance of Power Supply. We recommend that the appropriate
personnel for maintenance will decide on the frequency of
maintenance. However we recommend visual inspection and cleaning
inside the Power Supply every two months.
1. Carefully clean the semi‐conductors, heat sinks, and terminal board
transformer connections using an air blower or a vacuum cleaner.
2. Inspect and check any sign of failure in every contacts of all relays.
Use a burnishing tool to clean the contacts.
3. Tighten any loose connections.
4. Check all SCR’s (see section 9.2 in Power Supply Manual for checking
SCR’s).
Troubleshooting

Compressor

140
Troubleshooting

Compressor

141
Preventive Maintenance

Compressor

142
Troubleshooting

Thermal Conductivity Analyzer (TCA)

For any issues in Thermal Conductivity Analyzer (TCA)
contact
[email protected]
(+1410‐771‐8600) for Customer Support.

143
Preventive Maintenance

Thermal Conductivity Analyzer (TCA)

Routine Maintenance:
1. Cleaning.
2. Checking for leaks at the gas connections.
3. Replacing fuses (limited).
4. Recalibrations (see calibration procedure).
5. Replacing Cell. See Manual.

144
Troubleshooting

Trace Oxygen Analyzers (TOA)

Analyzer is reporting erratic readings of Oxygen concentration.

Possible Causes are:
1. Inaccurate calibration.
2. Leakage in the System.
3. Atmospheric Oxygen may be diffusing in through the vent.
4. Unstable pressure
5. Defective Micro Fuel Cell.

145
Troubleshooting

Trace Oxygen Analyzers (TOA)

Solutions:
1. Cycle the power and proceed calibrating the analyzer using
zero gas, typically pure hydrogen gas.
2. Check the Sample and Calibration gas for leaks and make sure
that all fittings are tight.
3. Increase flow rate or increase the length of vent pipe to
minimize the diffusion of oxygen from the vent back to the
sensor.
4. Make sure that gas measurement pressure is stable.
5. If the steps makes no solution then it’s time to replace the
sensor.

146
Troubleshooting

Trace Oxygen Analyzers (TOA)

Note:
If there’s a reason to clean the cell block, use cloth to clean
properly and carefully. Make sure the golden spring contacts
inside the block won’t break (see manual for more
information).

147
Preventive Maintenance

Trace Oxygen Analyzers (TOA)

If Analyzer will be out of service for more than 12 hours make
sure that the measurement cell is closed to prevent oxygen
entering from outside. This will help extending the life of the
analyzer.
When back in service rinse the sampling system with
nitrogen and restart with calibration (See manual for
calibration procedure).

148
Troubleshooting

Combustible Gas Sensor (CGS)

For any issues in Thermal Conductivity Analyzer (TCA)
contact
[email protected]
(+1410‐771‐8600) for Customer Support.

149
Preventive Maintenance

Combustible Gas Sensor (CGS)

1. Routine Calibration.
2. Sensor replacement if needed.
3. Transmitter replacement if needed.

150
Troubleshooting

Hygrometer

For any issues in Thermal Conductivity Analyzer (TCA)
contact
[email protected]
(+1410‐771‐8600) for Customer Support.

151
Preventive Maintenance

Hygrometer

1. Routine Calibration (send back unit for calibration).
2. Probe replacement if needed.
3. Check for any leakage.

152

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