DOCUMENT SUBMISSION STATUS: AP

D 5.18.2012 fourth Issue

Yao J un Zhang Fei J iang Bao Cai
C 3.20.2012 third Issue
Yao J un Zhang Fei J iang Bao Cai
B 2.20.2012 Second Issue
Yao J un Zhang Fei J iang Bao Cai
A 7.14.2011 Initial Issue
Yao J un Zhang Fei J iang Bao Cai
REV DATE DESCRIPTION DRWN CHKD APPN
OWNER






OWNERS CONSULTANT



EPC CONTRACTOR







EPC CONTRACTORS CONSULTANT



PROJECT TITLE
VUNG ANG 1 THERMAL POWER PLANT 2 x 600MW
M_LOT1D-BOP OF TURBINE
CONTRACT No. 290110/LILAMA-DEC

DRAWING TITLE
THE DESCRIPTION OF CONDENSATE POLISHING
SYSTEM AND REGENERATION SYSTEM
SUB-CONTRACTOR


FUNCTION NAME SIGN DATE
DRWN Yao J un

5.18.2012
CHKD Zhang Fei

5.18.2012
APPD J iang BaoCai

5.18.2012
DOCUMENT No. VA1-DEC-00100-M-M1D-PHL-8202
SCALE REV D
VIETNAM OIL AND GAS GROUP (PVN)
POYRY ENERGY LTD
VIETNAM MACHINERY
INSTALLATIONCORPPORATION (LILAMA)
FICHTNER GmbH & Co. KG
1













THE DESCRIPTION OF
CONDENSATE POLISHING SYSTEM
AND REGENERATION SYSTEM

The drawing number: VA1-DEC-00100-M-M1D-PID-8301
VA1-DEC-00100-M-M1D-PID-8501
VA1-DEC-00100-M-M1D-PID-8701
VA1-DEC-00100-M-M1D-LST-8203
VA1-DEC-00100-M-M1D-CAL-8012
2








Approved by: J iang Bao Cai

Examined by: Zhang Fei

Checked by: Zhang Fei

Compiled by: Yao J un
3

Table of content
1. Summary ...................................................................................................................... 4
2. Technical parameters .................................................................................................... 4
3. Overview of Condensate Polishing System ............................................................... 11
4. Equipment structure and principle ............................................................................. 12
5. Design description ...................................................................................................... 21
6. Instrument & Control requirements ........................................................................... 31
7. Running and operating procedures for the system ..................................................... 34
8. Installation and commissioning of the process system .............................................. 36
9. Instructions of installation .......................................................................................... 40
10. Others ......................................................................................................................... 41

4


1. Summary
Vietnam Vung Ang Power Plant includes two 600MW units. In order to improve the
quality of the condensate water, the safety of the unit and shorten the starting duration of
the unit, a Condensate polishing system is equipped. The process flows of the system
installed in this project is:
Condensate water from the main Condensate water pump the prefilter high speed
mixed bed resin trap low pressure heating system
The Condensate polishing system includes the prefilter system, desalting system (the
mixed bed system), external regeneration system, related pipelines among systems,
instrumentations and control systems.
Each unit is equipped with three prefilters, each output is 50% Condensate water flow.
Two prefilter s are running and the other one is standby. When starting the unit, the
prefilter will filter the foreign contamination over 10m. When the units are running
normally, the prefilter will filter the foreign contamination over 1m.
Each unit will be equipped with three sets of mixed bed exchangers, each output is 50%
Condensate water flow. Two mixed beds are running and the other one is standby. One
set of water recirculating pump and three resin traps will be provided. The designed flow
rate of the mixed bed exchanger is normally 100m/h and 120m/h at the maximum. After
the exhausted resin is delivered out off the external regeneration system, the residual
resin in the missed bed will not be more than 0.1%.
The prefilter system and high speed mixed bed system will be equipped with one set of
100% capacity bypass system respectively. Two units share the same set of external
regeneration system and auxiliary system.
2. Technical parameters
2.1 Design basis
2.1.1 The Condensate water volume each unit needs to treat:
Rate: 1390m
3
/h
5

Maximum: 1506 m
3
2.1.2 The inlet pressure of the condensate polishing system:
/h
Rate: 3.1 MPa
Maximum: 3.9 MPa
2.1.3 The temperature of the Condensate water:
Rate: 35.8
Maximum: 40.8
2.1.4 Water quality at the Condensate polishing system outlet
Typical start up Normal running
Item
Required guaranteed value of
the output water
Required guaranteed value
of the output water
Suspended solid g/L 100 5
Total dissolved solid matter (excl.
dissolved solid matter)(g/L)
50 20
SiO
2
50 (g/L) 10
Na (g/L) 5 1
Total Fe (g/L) 100 5
Total Cu (g/L) 15 3
Cl (g/L) 10 1
Cation electrical conductivity(25, after
cation pollar s/cm)
0.15 0.10
pH(under 25 the mixed bed runs in
form of H/OH.)
6.57.5 6.57.5
2.1.5 Chemicals (provided by the buyer)
2.1.5.1 HCl
Total acidity (based on HCl) 31
Iron (based on Fe)
%
0.01
Sulphate (based on SO
%
4
) 0.007%
6

Arsenic (based on Sn) 0.0001
2.1.5.2 NaOH
%
NaOH (based on NaOH) 30
Sodiumm carbonate (based on NaCO
%
3
) 0.06
NaCl (based on NaCl)
%
0.007
Fe
%
2
O
3
(based on Fe
2
O
3
) 0.0005
Sodium chlorate
%
0.002
Calcium oxide
%
0.0005
Aluminum oxide
%
0.0006
SiO
%
2
0.002
Fe
%
2
O
3
(based on Na
2
SO
4
) 0.002
2.1.6 Resin
%
2.1.6.1 The resin shall comply with the quality requirements on resin used for the
Condensate polishing system in the latest version of Technical Codes on Chemical
Design of the Thermal Power Plant.
2.1.6.2 The cation and anion resins filled inside the high speed mixed bed shall have good
physical and chemical natures and the dynamics properties.
2.1.6.3 Volume ratio of the cation and anion resins: 2:1
2.1.6.4 Total height of the resin bed layers: 1000mm
2.1.7 Power supply
Power supply: The buyer shall provide AC 400/230V three phase four wire power
supply.
2.1.8 Air supply:
7

Pressure: generally 0.5-0.8MPa
Dew point: The dew point under working pressure is 10 lower than the min.
temperature under the working environment.
Dust content: The diameter of the dust particle inside the purified air shall not be larger
than 3um.
Oil content: the oil content in the air delivered out by the air resource facilities shall be
under 8ppm.
2.1.9 The demineralized
The
water resource of the Condensate polishing system
demineralized
2.2 Technical requirements
water for the Condensate polishing system is from the make-up water
tanks of the 2#unit.
2.2.1 When the load is bigger and the Condensate polishing system is dirty, the pressure
at the inlet and outlet main pipes of the polishing system shall not exceed 0.35MPa; when
the units are running at the rated flow rate and the Condensate polishing system is clean,
the pressure at the inlet and outlet main pipes of the polishing system will not exceed
0.20MPa.
2.2.2 When the resin inside the Condensate polishing system is completely output,
namely the mixed bed becomes invalid; the mixed resin removed from the mixed bed
shall be 99.9%.
2.2.3 The separation efficiency of cation and anion resin inside the regeneration system,
namely:
the anion resin contained in the cation resin layers (volume ratio): <0.1%;
the cation resin contained in the anion resin layers (volume ratio): <0.1%
2.2.4 Under the maximum flow rate, the quality of the output water shall cater for the
requirements in item 2.1.4.
2.2.5 The high speed mixed bed will be designed as H
+
/OH

model with full
considerations on the operation of NH
+
/OH

model.
8

2.3 Lists of the main equipments
2.3.1 Prefilter system
2.3.1.1 Main equipments of the prefilter (one unit)
Item KKS code Description Specifications Qty
1 10/20LDB22BB001
10/20LDB23BB001
10/20LDB24BB001
1#, 2#& 3#
prefilters
1760X30,Q=753m
3
3 sets /h
2 Run the filtering
elements
50X1778,folding type,
PP skeleton, 204 pieces in
each filter
612 pieces
3 Start up the filtering
elements
50X1778,filtering
elements
612 pieces
shared by two
units
2.3.1.2 Bypass of the prefilter element (one set)
Item KKS code Description Specifications Qty
1 10/20LDB21AA201 Motor-driven regulating
butterfly valve
DN400,CLASS300 1 set
2 10/20LDB21AA501/502 Manual isolating valve of
the motor-driven butterfly
valve
DN400,CLASS300 2
sets
3 10/20LDB21AA503 Manual bypass valve DN400,CLASS300 1 set

2.3.2 Mixed bed system
2.3.2.1 Main equipments of the mixed bed system (one set)
Item KKS code Description Specifications Qty
1
10/20LDF22BB001
10/20LDF23BB001
10/20LDF24BB001
High speed mixed
bed
3056X28,Q=753m
3
3 sets /h
2
10/20LDF22BB002
10/20LDF23BB002
Resin trap 628X14,Q=753m
3
3 sets /h
9

10/20LDF24BB002
3
10/20
LDF20AP001
Recirculating pump
HZE200-250,Q=470m
3
1 set
/h,
h=32m,75kW
2.3.2.2 Bypass of the mixed bed element
Item KKS code Description Specifications Qty
1 10/20LDF21AA201 Motor-driven regulating
butterfly valve
DN400,CLASS300 1 set
2 10/20LDF21AA501/503 Manual isolating valve of the
motor-driven butterfly valve
DN400,CLASS300 2 sets
3 10/20LDF21AA502 Manual bypass valve DN400,CLASS300 1 set
2.3.3 Regeneration system
Item KKS code Description Specifications Qty
1 00LDP14BB001 Resin separation tank 2420x10/1620x10 1 set
2 00LDP13BB001 Anion regeneration tank 1516X8 1 set
3 00LDP12BB001 Cation regeneration tank 1820X10 1 set
4 00LDP10BB001 Waste water resin trap 1212X6 1 set
5 00LDP11BB001 Resin dosing hopper V=0.15 m 1 set
3

6 00LDP11BN001 Resin Injector 1 set
2.3.4 Regenerative auxiliary system
Item KKS code Description Specifications Qty
1 00LDT12BB001 Electric water heater
1820X10 V=7.5m
3
1set
heater
4x40KW
2 00LDN11BB001
Acid unloading
buffer tank
812X6 V=0.5m
3
1set
3 00LDN11AP001
Acid unloading
pump
40FSB-20,Q=11m
3
1set
/h h=20m, 3kW
4 00LDN11BB002 Acid storage tank 2520X10 V=20m
3
1set
5 00LDN21AP001/002 Acid metering pump
MBH642, Q=2500L/h,h=0.50MPa
2.2kW
2 sets
6 00LDN11BB003 Acid fume absorber DN700 1set
10

7 00LDN12BB001
Caustic unloading
buffer tank
812X6 V=0.5m
3
1set
8 00LDN12AP001
Caustic unloading
pump
SAJ 50-32-125,Q=12m
3
1set
/h
h=18m, 3kW
9 00LDN12BB002
Caustic storiage
tank
2520X10 V=20m
3
1set
10 00LDN22AP001/002
Caustic metering
pump
MBH561, Q=1500L/h,h=0.50MPa
1.5kW
2sets
11 00LDB10AP001/2 Backwashing pump
HCZ80-160, Q=110m
3
2sets
/h
h=35m ,22kW
12 00LDP10AP001/2 Flushing pump
HCZ65-200, Q=100m
3
2sets
/h
h=50m ,30kW
13 00LDN21AM001 Acid mixing tee 10-15t/h 1set
14 00LDN22AM001 Caustic mixing tee 5-10t/h 1set
15 00LDC21/22AN001 Roots blower 9.36m
3
2sets /h,0.08MPa 22KW
16 00LDC12BB001
Compressed air
storage tank for
filtering
1816X8 V=10m 1set
3

17 00LDC13BB001
Compressed air
storage tank for the
mixed bed and the
regeneration
1816X8 V=10m 1set
3

18 00LDC11BB001
Compressed air
storage tank for
control
1616X8 V=8m 1set
3

19 00LDY10AZ001 Safety shower 1set
20 00LDR11/12AP001 Waste water pump
80WFB-A, Q=60m
3
1set
/h
h=30m ,15kW




11

3. Overview of Condensate Polishing System
3.1 Meaning of condensation water: The condensation water generally refers to the water
cooled and condensed through circulating cooling water after work is done by turbine for
the steam generated from boiler. In fact, the condensation water in the hot well of
condenser also includes the drain (the drain refers to the water condensed after feed water
enters into heater and is heated) from high-pressure heater (normal drain cant reach hot
well) and low-pressure heater. Since there are water vapor losses for thermal system
inevitably, a certain quantity of makeup water (the water is from the demineralization
water tank) is needed to be supplemented to the thermal system. So the condensation
water mainly includes: the condensation water after work is done by steam in the turbine,
all kinds of drains and boiler makeup water.
3.2 Purpose of condensation water polishing treatment
The condensation water will suffer from a certain degree of contamination for some
reasons, there are approximately the following points:
1) Seepage or leakage of condenser
The main reason for the pollution of condensation water is the cooling water leaks into
the condensation water from the untight part of condenser. The untight part of condenser
is generally at the junction of tube bundle and tube plate inside the condenser. Since the
variation of working conditions of unit can generate mechanical stress inside the
condenser, even if the manufacturing and installation quality is good for the condenser,
the phenomenon of seepage or leakage of circulating cooling water might also occur in
use. While there are many suspended matters, colloids and salts in the cooling water, so
the water quality of condensation water will be affected inevitably.
2) Contamination of metal corrosion products
The pipeline and equipment of condensation water system will be corroded for some
reasons, so there are often metal corrosion products in the condensation water, mainly the
oxides of iron and copper (there are basically no copper materials in the thermal system
equipment of our company). The forms of iron are mainly Fe
2
O
3
and Fe
3
O
4
, they are in
suspended state and colloidal state; moreover, there are all kinds of ions of iron. The
content of corrosion products in condensation water is related to the operational state of
12

unit. There are many corrosion products in the condensation water at the initial stage of
unit startup; moreover, the content of impurities may also increase under unstable unit
load.
3) The makeup water of boiler brings a few impurities.
The effluent of demineralized water treatment mixed bed is the makeup water of boiler,
generally, supplemented to thermal system through condenser. Due to the strict control in
the operation of effluent of mixed bed, there is little impurity content in the makeup water,
the water quality is required: DD0.2s/cm, SiO220g/L. If the effluent of mixed
bed is unqualified, contamination may be caused to the condensation water.
There is more or less contamination in the condensation water due to the above reasons,
while in terms of the unit exceeding critical parameters, due to its high requirements for
the quality of feed water, deeper purification to the condensation water is needed, namely
condensate polishing treatment.
3.3 Introduction to condensate polishing treatment equipment
Condensate polishing system adopts medium pressure condensation water mixed bed
system, for details, the prefilter is in series connection with high-speed mixed bed,
350% tubular prefilter and 350% spherical high-speed mixed bed is set for each unit.
The Fullsep method external regeneration system will be adopted after the failure of
mixed bed resin. Of which, No.1 and 2 units use one set of regeneration device for
precision processing. The regeneration system mainly includes Resin Separation Tank,
anion regeneration tank and Cation regeneration Tank; moreover, it also includes acid-
base equipment, Electric Water Heater, Flushing Pump, roots blower and air tank, etc.
4. Equipment structure and principle
4.1 Prefilter
4.1.1 Function
It is used to remove the matters in the condensation water such as suspended matters,
colloids, corrosion products and oils. It is mainly used for deironization and silicon
washing to the condensation water when unit is started, shortening commissioning time
13

of unit. Moreover, the matters with large partical size are removed which will prolong the
operational cycle and service life of resin.
4.1.2 Structure and operating principle
The whole prefilter is straight cylinder shape and adopts carbon steel structure. The
internal filter element is tubular. There are total 204 tubes (tube bundles) fastened
between the upper and lower ends of prefilter vertically. There are several water pores in
each tube and polypropylene fiber filtering media are twined outside the tube, the
filtration precision of filtering media is 1m. The water enters among the tube bundles
from the bottom of prefilter, through fiber filtering media, the impurities are held back on
the filtering media; the water flows into the pores and the water in tube bundles
converges outside the prefilter. When the differential pressure at inlet and outlet of
prefilter reaches the set value, the prefilter will need backwashing. The water enters the
tube from the water outlet at the bottom to conduct backwashing to the filtering media,
and the water is discharged from the water inlet (contrary to the flow direction of running
water). In addition, the air suction from the bottom will loosen the filtering media,
enhancing the backwashing effect of prefilter. In order to ensure the even air distribution
upon air backwashing, there are total four air inlets are set below the equipment;
meanwhile, quick opening pneumatic butterfly valve is set for the air outlet at the top to
be beneficial to the generation of aeration to break away the dirt attaching the filter
element from the surface of filter element, convenient for the cleaning upon backwashing.
4.1.3 Fiber filtration principle
The fiber filtration is a relatively new-type filtration technology. The prefilter of this
project is vertical suspension type prefilter, it can make the water current flow from
macropore filtering layer to micropore filtering layer, improving the sewage interception
capacity and reducing water current resistance and effluent quality is also improved
largely (relative to granular material filtration, such as the air scrubbing filter chamber at
purification station, double-media prefilter in makeup water treatment equipment, etc.).
The filtering media of the prefilter in the project is a kind of high polymer chemical fiber
material, called polypropylene fiber, having the advantages of small filtering media
diameter and large free energy for specific surface area and specific surface of the
14

filtering media, increasing the contact opportunities of impurity particles in the water
with the filtering media and the adsorption capacity of filtering media. It has stable
chemical property and doesnt have any active functional group. The movement of the
suspended matters in the water to the surface of fiber filtering media not only has
physical adsorption but also has chemical adsorption.
This material has no special activity to the suspended particles in the water, mainly
playing the role of physisorption which is similar to the grainy filtering media such as
quartz sand, the combination potential energy for adsorption is weak, so the sludge
adsorbed on the fiber surface can be removed with the physical method such as flushed
with water and scrubbed with compressed air. The diameter of polypropylene filament is
only several microns and its surface area is far larger than the grainy filtering media such
as quartz sand.
4.2 High-speed mixed bed
4.2.1 Function
It is mainly used to remove the salts (namely all kinds of anions and cations), in addition,
it can also remove the sundries like suspended matters and colloids leaked from prefilter .
4.2.2 Structure and operating principle of high-speed mixed bed
The high-speed mixed bed of our company adopts the spherical mixed bed with the
diameter of 3000mm and the inflow water distribution device is perforated plate with
water valve bonnet; there are total 96 water valve bonnets which can not only ensure the
evenness of inflow water distribution, but also prevent the water current directly washing
the surface of resin resulting in surface roughness, thus arousing drift current and
reducing the cyclic water yield and effluent water quality of mixed bed. The water enters
into the bed body from the top of mixed bed and flows out from the water outlet device at
the bottom after passing through the resin. The water outlet device is designed to be
butterfly plate with water valve bonnet, there are total 196 water valve bonnets. It has two
functions: firstly, the water can flow through the resin lay due to the even distribution of
water valve bonnets in the equipment, each part of resin is made full use of and the water
yield can reach the maximum limit; secondly, the smooth arc stainless steel perforated
15

plate can reduce the adhesive force to the resin, making the transmission of resin
thorough. After the mixed bed loses effectiveness, the resin is outputted from the bottom,
after delivery, the standby resin in cation regeneration tank of the regeneration system
will be inputted from the top of mixed bed, entering into the next operational cycle.
When the mixed bed is put into operation, it shall be forward washed through
recirculating pump by circulation, only after the effluent is qualified can it be put into
operation.
4.2.3 Demineralization principle
The mixed bed is equipped with mixed resins of strong acid cation resin and strong alkali
anion resin. The cations in condensation water are removed through reactions with cation
resins and anions are removed through reactions with anion resins. The cation and anion
resins are represented by R-H and R-OH respectively, the reactions are as follows:
Reaction of cation resinR-HNa
+
Ca
2+
/Mg
2+
RNaCa
2+
/Mg
2+
Reaction of anion resinR-OHCl
H+
-
SO4
2-
/NO
3
-
/HSiO
3
-
RClSO4
2-
/NO
3
-
/HSiO
3
-
OH
Overall reactionR-HR-OHNa
-

+
Ca
2+
/Mg
2+
Cl
-
SO4
2-
/NO
3
-
/HSiO
3
-

RNaRClH
2
When the resin exhausted, the cation resin will be regenerated by acid and anion resin
will be regenerated by alkali. The regeneration chemical reactions are the reverse ones of
above reactions.
O
4.3 Resin trap
4.3.1 Function:
When the broken resin is leaked or resin leakage accident occurs for the effluent device
of mixed bed, the resin trap will hold back the resin to prevent the resin leaking into
thermal system and affect the water quality in the boiler. Resin is macromolecule organic
matter, apt to decompose harmful matters to the system in high temperature and high
pressure; if leaked into water supply system, it will inevitably result in large influence on
thermal system.
16

4.3.2 Structure and operating principle:
The internal filter element of trap is basketry structure and the gap of wire wrap of filter
element is 0.25mm; the water with a few resins flows out through filter element, the
resins are held back by the filter element. The equipment is designed to be the structure
easy to be dismounted with circular skeleton, in the condition of no need to dismount
pipeline for overhauling, the tank can be opened for check and the filter element can be
taken out to remove the blocking dirt, convenient for operation and maintenance. When
the differential pressure of inlet and outlet of trap exceeds the set value, backwashing is
needed.
4.4 Recirculating pump
It is used for circular forward washing when the mixed bed is put into operation. The
inflow of recirculating pump is directly effluent from the mixed bed without through
resin trap, then flow into the mixed bed through recycle valve to form a cycle. The
function of recirculating pump: firstly, the water quality is unqualified at the initial stage
of putting into operation of mixed bed, the operation can be put into only after recycle
until qualified; secondly, after starting recirculating pump, compact the bed layers evenly
with less flow to prevent the occurrence of drift current in operation while large flow is
hard to make the bed layers compacted evenly. There is one recirculating pump for each
precision processing system of unit respectively, its output is 470m
3
4.5 Resin Separation Tank
/h.
4.5.1 Function:
When air scrubs resin, the suspended impurities and corrosion products are rubbed off;
water backwashing makes the separation of anion and cation resins and removes the
suspended impurities and corrosion products; store a small amount of mixed resin layer
not separated completely for separation next time.
4.5.2 Structure and operating principle:
The Resin Separation Tank is welded with carbon steel and rubber lining is adopted. Its
structural features are big top and small bottom the bottom is a long barrel and the top is
cone-barrel type. The structural design can make full use of water current characteristics
17

in backwashing to separate the anion and cation resins thoroughly. 1m high mixed resin
layer is reserved in the middle of equipment to avoid the cross contamination of anion
and cation resins in transmission. There are exhausted resin inlet, anion resin outlet,
cation resin outlet, upper water inlet (also as upper compressed air inlet and upper water
outlet) and lower water inlet (also as lower air inlet and lower water outlet). The
capitation at the bottom is designed to be double-butterfly plate with water valve bonnet,
the gap width of wire wrap or water valve bonnet is 0.25mm which will make the
distribution of water current even; the upper water distribution device is branch and
mother pipes type and the backwashing drainage device is made of trapezoid wire wrap
screen tube, convenient for forward washing inflow and backwashing drainage. There are
also seven sight glasses set for Resin Separation Tank, to observe the resin state in the
tower.
The special structure of Resin Separation Tank has the following advantages:
Even columnar flow is formed when in backwashing, not forming large perturbation
inside; there is enough backwashing space for the cone-barrel structure at the top of Resin
Separation Tank, beneficial to backwashing; there is no intermediate header device which
can cause perturbation and affect the separation of resins; when in backwashing,
sedimentation and transmission of resin, internal perturbation is decreased to be the
minimum; the section of Resin Separation Tank is small and the cross contamination area
of resin is small; there are many peepholes for Resin Separation Tank, convenient for
observing resin separation; the water current with different backwashing intensities can
be provided by bottom main inflow door and auxiliary inflow adjusting door, beneficial
to the reparation of resins.
After the exhausted resin in high-speed mixed bed is inputted into Resin Separation Tank,
scrub and loosen resin through the air inflow at the bottom, make the suspended
impurities and metal corrosion products separate from resin, and back wash through the
inflow at the bottom until effluent is clear. Then through water backwashing with
different flows to make the separation of anion and cation resins until one layer of
interface occurs. Anion resin is inputted into anion regeneration tank from the top and
cation resin is inputted into cation regeneration tank from the bottom, anion and cation
18

resins regenerate in anion and cation regeneration tanks respectively. The remaining
interface resin is mixed resin layer, reserved to participate in separation in next
regeneration.
4.6 Anion regeneration tank
4.6.1 Function: to conduct air scrubbing, backwashing and regeneration to anion resins.
4.6.2 Structure and operating principle
The water distribution device at the top of anion regeneration tank is baffle type and the
water distribution device at the bottom is stainless steel butterfly-type perforated plate
with water valve bonnet which not only ensures the even water and air distribution when
equipment is in operation but also makes the resin is thorough and clean when outputted
from the equipment. The distribution device of alkali is T type wire wrap branch and
mother pipes structure (also called fishbone type). Its gap not only can make the
regeneration alkali liquor distribute evenly but also make the resin with complete
particles not leak and remove the small and broken resins and dirt scrubbed by air.
After the anion resin in Resin Separation Tank is sent to anion regeneration tank, the
anion resin will be scrubbed through bottom air suction and back washed through bottom
inflow until the effluent is clear. Then feed in alkali from the top of resin for regeneration,
replacement and rinsing.
4.7 Cation regeneration Tank
4.7.1 Function: to conduct air scrubbing and regeneration to cation resin; to mix anion
and cation resins; to store the standby resins which have been prepared.
4.7.2 Structure and operating principle (the structure is the same as the anion regeneration
tank)
After the cation resin in Resin Separation Tank is sent to cation regeneration tank, the
cation resin will be scrubbed through bottom air suction and back washed through bottom
inflow until the effluent is clear. Then feed in acid from the top of resin for regeneration,
replacement and rinsing; after resin regeneration in anion regeneration tank is qualified,
the anion resin is delivered into cation tank and mix with cation resin, becoming standby
resin.
19

4.8 Regeneration auxiliary equipment
4.8.1 Polishing System acid (caustic) unloading buffer tank
The material is steel lining rubber, there is one acid and caustic tank respectively with the
volume of both 0.5 m
3
4.8.2 Polishing System acid (caustic) storage tank
ensuring the inlet of pump without pressure, preventing acid and
caustic unloading pump idle and damage pump when tank car is pumped out.
The material is glass fiber reinforced plastics; there is one acid and caustic tank
respectively with the volume of both 20m
3
4.8.3 Polishing System acid (caustic) unloading pump
used to store acid and caustic.
There is one set of acid and alkali measuring tank respectively, the flows are both 11m
3
4.8.4 Polishing System acid (caustic) metering pump
/h
used to send the acid and alkali into acid (alkali) storage tank.
There are two sets of acid and caustic metering pumps respectively, the flow of acid
metering pump is 2500L/h and the flow of caustic metering pump is 1500L/h, resin is
transmitted into regeneration system through acid (caustic) metering pump when resin is
regenerated.
4.8.5 Polishing System Acid Fume Absorber
For concentrated hydrochloric acid is volatile acid, Acid Fume Absorber is set to prevent
the acid fume corroding equipment and building and damaging human health. Introduce
the exhaust of air outlet in measuring tank, absorb the acid mist after stuffed with water
spraying. The acid water absorbing acid mist is drained into precision processing waste
liquor pool.
4.8.6 Polishing System acid (caustic) mixing tee
Its function is to dilute the acid (caustic), make acid (caustic) mix with water fully, then
enter into regeneration system.
4.8.7 Polishing System Electric Water Heater
The volume of Electric Water Heater is 7.5m
3
and there are four electric heaters inside
which are used to improve the temperature of alkali liquor thus improve the regeneration
effect of anion resin. It must be filled with water when in operation and the heaters
20

conduct timing heating according to the temperature of Electric Water Heater. The
heaters will stop automatically when heating to high limit set value and when the water
temperature is lower than the set value, the heaters will restart automatically. The cold
water enters into the Electric Water Heater from the bottom and the hot water comes out
of the top to the alkali ejector. The outlet temperature of alkali ejector is controlled by the
three-way valve at the outlet of Electric Water Heater, at 40 or so.
4.8.8 Waste water resin trap
The equipment is open container type and acid and alkali-resistant rubber is used for
lining; metal net tube is set with the net gap of 0.40mm which can hold back the resins
flowing out due to improper flow control of Resin Separation Tank, anion tower and
cation tower in resin scrubbing or water backwashing, preventing resins discharging into
waste liquor pool and resulting in pollution. A liquid level switch is set in the equipment,
when the liquid level is high and alarm is given, the operator is reminded of blocking of
filter element of trap.
4.8.9 Flushing Pump and backwashing pump
There are two Flushing Pumps and two backwashing pump for Polishing System
regeneration system of No. 1 and 2 units. The output of Flushing Pump is 100m
3
/h and
the output of backwashing pump is 110m
3
4.8.10 Roots blower
/h. The water source of wash-water
(backwashing) pump is demineralized water, from the water tank of demineralized water;
the Flushing Pump is used for the backwashing, cleaning and transmission of resin,
cleaning of pipeline and dilution of regenerant; the backwashing pump is used for the
backwashing after the prefilter loses effectiveness.
There are two roots blowers for Polishing System regeneration system of No.1 and 2
units with the air volume of 9.36Nm
3
/min. The roots blower is a kind of volumetric
power machinery. A pair of impellers in meshing separate the air inlet and outlet, driven
by synchronizer gear, the two impellers are in reverse rotation with constant speed in the
cylinder. In the process of rotation, the air in air inlet is continuously pushed by the
impellers to the air outlet, thus reaching the purpose of forced exhaust.
21

The roots blower is used for the scrubbing looseness of resin and mixture of resins. Its air
source is air; there is filter screen for inlet to prevent the access of impurities. There are
mufflers at front and back, beneficial to reducing noise released. When roots blower
needs to be started for regeneration steps, pre-startup is often conducted to blow the
sundries in air ducts, at this moment, the air exhaust door in air duct shall be opened.
4.8.11 Polishing System Air Tank
There are two 10m3 air tank and one 8m3 air reservoir for the Polishing System system
of the project, of which one air tank is set for prefilter system (10m
3
one air tank
10m
3
is set for mixed bed and regeneration system, one air tank 8m
3
4.8.12 Resin Dosing Hopper: used for the addition of resins in anion tower and cation
tower. It makes use of the flow of water to draw the resin into the tank; 0.15m
is set for
air using of valve instrument. Its air source is the compressed air from workshop.
3
4.8.13 Waste water pump
volume of
resin is filled each time.
Two waste water pumps are set with the output of 60m3/hdelivering the waste water
from Polishing System and regeneration system to unit drainage channel for centralized
processing.
5. Design description
5.1 Description of system design
The impurities in the Condensate water mainly includes two kinds: one is the dissolving
salt which is composed by effluent residual salt from demineralized water plant, the salt
together with the steam and the salt leaked from the condenser; the other kind is
corrosion products from the metal parts of the thermodynamic system such as iron and
copper dioxide. In order meet the requirements of the quality of water supply; the
Condensate water must be deeply treated. For this project, prefilter s +external
regenerative high speed mixed bed system will be used. The resin regeneration system is
equipped with the resin separation tank. We choose the Fullsep separation system for
resin separation.
22

5.1.1 Mixed bed system for the Condensate polishing system:
5.1.1.1 Each Condensate polishing system consists of 350% prefilter s, 350% high
speed mixed beds, three resin traps, one recirculating pump and two bypass systems. Two
of the prefilter s and high speed mixed beds respectively will be running and the rest one
respectively standby. At the beginning of starting up the unit, the iron content in the
suspended solid in the Condensate water will be higher. If a big mount of Condensate
water including iron flows into the tube filter (prefilter system), unrecoverable damages
will appear for the filter elements in the filter, and the filter elements cannot be cleaned
completely, as a result the original functions of filter elements will be damaged.
Therefore, the Condensate water will pass through the bypass system of filter and the
mixed bed, and drained out. When the total iron content in the Condensate water
decreases to 10001500g/L, the prefilter can be started up. There are some certain
requirements on the Condensate water entering into the mixed bed. When the total
suspended solid and iron is less than 500g/L at the inlet of the Condensate water, it can
be allowed flow into the mixed bed. When the units are running normally, and if the
outlet water quality of the mixed bed at the beginning of starting is not satisfied, the
water shall be recycled in the recirculating pump and then flows back to the inlet of
mixed bed. When the outlet water quality of the mixed bed is qualified, it can only flow
into the system. Two sets of automatic bypass systems (one for prefilter system and the
other for mixed bed respectively) are equipped for each Condensate polishing system.
There is a resin trap at the outlet of each mixed bed, used to trap the resin passing through
the outlet device of the mixed bed. When the resin inside the mixed bed leaks
dramatically, the resin trap can trap the resin to avoid it enters into the thermodynamic
system.
5.1.1.2 According to the requirements in the technical agreement and the process
systems:
There are differential pressure transmitters installed at the front of and at the back of the
bypass valve in prefilter, mixed bed and the resin trap. The differential pressure
transmitter installed at the front of and at the back of the bypass valve of the prefilter will
monitor the differential pressure of the water passing through the prefilter. When the
23

differential pressure exceeds 0.12Mpa, the bypass will open to make 100% Condensate
water flows through the bypass system; when the differential pressure exceeds 0.1Mpa,
the standby prefilter will be activated. After the activation succeeds, the exhausted
prefilter will quit in the program and perform the backwashing process. The differential
pressure transmitters installed at the front of and at the back of the bypass valve of the
mixed bed will monitor the differential pressure of the mixed bed system. When the
differential pressure exceeds 0.35Mpa, the mixed bed system will be stopped, and the
bypass valve will open to make 100% Condensate water flows through the bypass
system; when the differential pressure exceeds 0.175, the standby mixed bed will be
activated. After the activation succeeds, the exhausted mixed bed will quit in the program,
and then transfer the exhausted resin to the resin separation tank for separation and
regeneration. And then it again transfers the standby resin to the mixed bed and resumes
its standby status. The differential pressure transmitters installed at the front of and at the
back of the resin trap will monitor the differential pressure of the resin trap. When the
differential pressure exceeds some setting value, the standby mixed bed will be activated.
After the activation succeeds, it will quit the exhausted mixed bed, and backwash the
related resin trap.
1) Temperature transmitters and pressure transmitters are installed on the main
pipe at the inlet of the Condensate polishing system. The temperature
transmitter is used to monitor the temperature of the Condensate water in
the main pipe at the inlet of the system. When the temperature exceeds
50, two bypass valves will be 100% opened at the same time, and each
inlet and outlet valves of the mixed bed and prefilter will be shut. And
100% Condensate water will pass through the bypass system to avoid
damage to the filter, filter elements, the resin and the mixed bed. The
pressure transmitter is used to monitor the pressure of the Condensate water
at the inlet of the mixed bed. When the pressure exceeds 4.0MPa, two
bypass valves will be 100% opened, and each inlet and outlet valves of the
mixed bed and filter will be shut. And 100% Condensate water will pass
through the bypass system.
2) Flow meters will be installed at the outlet of each filter and the inlet and
24

outlet of each mixed bed, and the pressure balance bypass valve (DN15)
shall be installed at the inlets of each prefilter and mixed bed. The flow
meter is used to monitor the flow rate of the Condensate water in the
prefilter and the mixed bed and the output signals passing the flow meter,
and it can also accumulate the water treatment quantity in each period. The
pressure balance bypass valve is used to slowly raise the pressure at the
inlet of the prefilter and the mixed bed prior to activation of the prefilter
and the mixed bed to avoid the impact to the inner structure of the prefilter
and the mixed bed from the pressure. Differential pressure switch will be
installed before and after the pressure balance valve. When the differential
pressure decreases to 0.02MPa, the inlet valve open automatically, pressure
balance valve shut down. Besides, the change of pressure will be measured
by the local pressure meter.
3) The cation conductivity meter, silica meter (share with the main condensate
water pipe), are installed at the outlet of each mixed bed. These meters are
mainly used to monitor the quality of the outlet water from the mixed bed.
When one of them is not satisfied, the standby mixed bed will be activated
and make the exhausted mixed bed stop.
4) The Specific conductivity meter, cation conductivity meter, silica meter,
sodium analyzer and pH meter are installed at main pipe of the mixed bed
to monitor the quality of the water from the Condensate polishing system.
5) The liquid level switches are installed on the main vent pipe of the prefilter
and the mixed bed to automatically monitor if the water in the mixed bed or
prefilter is full.
5.1.2 The regeneration system of the Condensate polishing system:
5.1.2.1 The mixed beds of two units will share the same regeneration system which
mainly meets all requirements on thorough separation, cleaning and complete
regeneration of the resins for the mixed bed under NH
4
+
/OH
-
model. Besides, it will not
cause unnecessary damages to the resin.
25

5.1.2.2 The regeneration system mainly composes of the resin separation tank, Anion
regeneration tank, cation regeneration tank (also as the standby resin storage tank) and
the waste water resin trap. The resin separation tank will thoroughly separate the mixed
resin through high speed water flow. The cation and anion resins will be transfer to the
Anion regeneration tank and cation regeneration tank respectively through upper and
lower water incoming method. After the cation and anion resin is thoroughly cleaned in
cation regeneration tank and anion regeneration tank respectively, the two resins will
regenerate the rinse at the same time. After the resins are qualified, it will transfer the
resin to the cation regeneration tank for mixing and rinsing. After the specific
conductivity is qualified, the resin will be stored for spare using. The waste water resin
trap will prevent the resin in the regeneration tank from leaking into the waste water
system through trapping the resin in the regeneration tank.
5.1.2.3 According to the requirements of the process system:
1) The optoelectronic switch is installed on the body of the resin separation
tank to monitor the interface between the resin and water, and control the
transfer end point of the cation resin according the different reactions of the
resin and water reflected light to the optoelectronic switch.
2) The specific conductivity meter will be installed on the drainage pipe of the
regeneration tank to monitor if the resin regeneration and cleaning are
qualified in the regeneration tank.
3) The liquid level switch is installed on the main vent pipe of the regeneration
tank to automatically monitor if the water in the regeneration tank is full.
4) A flow meter is installed on the flushing water pipe of the cation and Anion
regeneration tanks to monitor the flushing water flow in the tower.
5.1.2.4 In order to guarantee the quality of the outlet water from the mixed bed and the
mixed bed can be running at NH
+
4
/OH
-
1) Use
model, the resin must be completely washed at a
higher regeneration degree and after the completely regeneration of the resin. The
following measurements are adopted for this project:
high purity HCl to regenerate the cation resin, and use high purity ion diaphragm
26

Caustic to regenerate the anion resin, and reduce the pollution to the water due to the
impurities in the regenerant.
2) Thorough air scrubbing method will be used prior to regeneration. The particle
diameter of the metallic oxides attached on the face of the resin is relatively big, and
the different kinds of metallic oxides have different densities. Normal backwashing is
hard to flush the metallic oxide away. Air scrubbing method can scrub away the
metallic oxides on the face of the resin in the resin separation tank, and then
downward flushing method will drain the relatively heavier impurities away from the
downside. And then air scrubbing method is used again to flush the regeneration tank
of the anion resin after the resin is separated so as to remove the impurities and take
away the relatively lighter oxides in a manner of sealed air. The foreign
contamination with a relatively big density will fall away from the downside. This
method can be used to thoroughly remove the pollutants on the resin from the
metallic oxides and the fragmentary resin as well so as to regenerate the resin easily.
3) Arc perforated plate structure and air-water transfer of resin: the arc perforated plate
of the mixed bed and the regeneration equipment not only satisfy the uniformity of
the water distribution for the equipments but also generate a smooth transfer of the
resin. When the exhausted resin or the regenerated qualified resin is transferred into
the resin separation tank or the mixed bed, the compressed air is used to disturb the
resin together with the water and then transfer the resin and water together into the
tank. At last, water flushing equipments and pipes are used to transfer completely the
residual resin. This way can completely transfer the resin in the running mixed bed or
the regeneration tank, and the transfer percentage can reach 99.9%.
4) The Fullsep separation method: after the exhausted resin is transferred into the resin
separation tank for air scrubbing, at first the regulating valve is opened to backwash
at a big flow rate. After backwashing flow rate reaches about 30m/h, the cation and
anion resins are lifted to the cone under this flow rate. Then the regulating valve
gradually reduces the flow rate of the backwashing lower than the critical fall velocity
of the cation resin. At last the flow rate will be reduced until it is lower than the
critical fall velocity of the anion resin. This way can make the cation and anion resins
27

separated completely. After the backwashing and sedimentation, the anion resin
completely separated in the resin separation tank and will be transferred into the
Anion regeneration tank from the side of the resin separation tank, and then transfer
the cation resin. The transfer end point will be controlled by the optoelectronic switch
which will be installed on the suitable position on sides of the resin separation tank.
This device will generate different actions according to the different reflectivity of the
light to the water and the resin. Different reactions of the optoelectronic switch
control the cation resin transfer valve so as to control the transfer end point of the
cation resin.
5) Air scrubbing again after regeneration of resin: the same method as the air scrubbing
in the air room of the anion and cation regeneration tanks prior to regeneration. It is
good for remove the foreign contamination leached out from the voids of the resin
during regeneration of cation and anion resins. Meanwhile, it can remove the residual
regenerant and completely clean the cation and anion resin after regeneration.
5.1.3 Auxiliary system of the Condensate polishing system:
5.1.3.1 The mixed beds for two units share the same auxiliary system which can satisfy
the requirement on separation, cleaning, water, air and regenerant for regenerating the
resin in the mixed bed resin transfer system and the regeneration device.
5.1.3.2 The auxiliary system composes of the flushing pump, electric water heater, Roots
blower, compressed air tank, acid & caustic metering devices, acid & caustic storage
devices, and acid unloading and caustic unloading devices. The flushing pump can meet
the requirement of water for resin transfer system of the mixed bed, maximum
backwashing in the resin separation tank, simultaneous regeneration of cation and anion
resins. The electric water heater can satisfy the 40C dilution water needed for the
primary regeneration of resin and strengthen the elution rate to the silicon by the anion
resin as a result the regeneration rate of the anion resin is improved. Roots blower
provides the air flow for air scrubbing in the regeneration tank and the mixing of cation
and anion resins in the regeneration tank. The compressed air tank provides the air flow
for transferring the resins to the mixed bed and the regeneration tank. The acid & caustic
28

metering devices, storage devices, and acid unloading and caustic unloading devices will
provide the acid and caustic liquids needed for regenerating the cation and anion resins.
5.1.3.3 According to the technical agreement and the process system:
1) The flow meter is installed on the acid & caustic dilution water pipe, when open
the regulating valve, the flow meter indicates the flow rate.
2) Acid and Caustic concentration meter is installed on the acid & caustic dilution
water pipe to indicate the concentration of the acid and Caustic liquids.
3) A flow meter is installed on the outlet main pipe of the flushing pump to indicate
the flow rates to different sections after start up of the pump.
4) A temperature transmitter is installed on the caustic liquid dilution water pipe. The
output signal from the temperature transmitter can control the opening of the three-
way control valve.
5) The temperature transmitter and liquid level switch are installed on the electric
water heater. The output signal from the temperature transmitter controls the
switch-on/off and activated groups of the heaters. The liquid level switch controls
the liquid level in the electric water heater to avoid damaging the heaters when the
liquid level is lower,
6) Magnetic shutter liquid level meter with remote transmitting signal is installed on
the acid and caustic storage tanks, which not only has the function local display of
the liquid level but also has the function of displaying the higher and lowers liquid
levels on the CRT screen after the signal is input into the PLC.
5.2 Description of the structural design of the equipment
5.2.1 Prefilter
The equipment is designed so that the filter elements can be easily changed. Manhole
design shall be adopted so that only opening the manhole can make the replacement and
maintenance of filter elements smoothly. The water inlet shall be designed at the bottom
of the equipment, and the water outlet shall also be designed at the down dish head.
When the flow passes through the equipment, it can filter away most of the impurities
29

and suspended solids in the water. In order to achieve the purpose of smooth and average
distribution of the air during backwashing, four air inlets will be designed at the bottom
of the equipment. Meanwhile, the exhaust outlet at the top shall be provided with a
pneumatic butterfly valve to generate the aeration air to separate the dirty matters
attached on the filter elements and make it easier to cleaning during backwashing.
5.2.2 Mixed bed
The mixed beds inside the polishing system are provided with the water inlet device and
water outlet device.
The water inlet device shall be of baffle perforated plate turning strainer type. It can not
only ensure the average distribution of the inlet water but also prevent the water flow
directly flushing the resin layer to cause unevenness and inclined flow and lessen the
water treatment quantity in each cycle and the quality of the outlet water in the mixed bed.
The water outlet device shall be of arc perforated plate strainer type, and the whole
device will be made of the stainless steel with two functions: firstly the strainers are
averagely distributed inside the equipment so the water can flow averagely through the
resin layers and make full use of the resins in each layer and generate the most output of
water treatment quantity; secondly the smooth arc perforated plate will lessen the
adhesion of the resin to make it completely transferred.
5.2.3 Resin trap
The equipment is designed to be the dismountable surrounding skeleton structure. During
repair and maintenance it is not necessary to dismantle the pipe if the operator wants to
open the resin trap to check and take out the filter elements to remove the blocking dirty
matters. It is easy to make it running and maintaining.
If the water outlet device of the mixed bed leaks the fragmentary resin or resin, the resin
trap can retain the resin to prevent the resin entering into the thermodynamic system and
affecting the water quality inside the boiler.
5.2.4 Resin separation tank
The resin separation tank is designed to be of upper bigger and lower smaller inverted
cone containers. The diameter of the smaller end is 1620, and the bigger end 2420.
30

This design can make full use of the flow characteristics of the water of the backwashing
to make the cation and anion resins completely separate. About 1.0m mixed resin layer
will be remained in the middle of the equipment to avoid cross-contamination
The captation device at the bottom of the equipment is designed to be the arc perforated
plate strainer type, which makes the flow distribute averagely. The inlet and backwashing
drainage device on the top are ladder-shaped wire winding pipes so as to conduct the
flushing and backwashing.
of cation
and anion resins during resin transfer.
In order to make it easy to maintain the tower, manholes are designed on the top and at
the bottom of the tower.
5.2.5 Anion regeneration tank
The water inlet device for this device is designed to be baffle type. The captation device
at the bottom of the equipment is designed to be the arc perforated plate double speed
strainer which not only ensures the average distribution of water and air during running
but also makes the resin completely drain out off the equipment. The Caustic feeding
device shall be of the fishbone type. The branch pipe shall be of ladder-shaped wire
winding structure with the voids enabling to averagely distribute the regenerated caustic
solution but also preventing the leakage of the whole size resins. And the fragmentary
resin and dirty matters by air scrubbing shall be removed. The manhole is designed on the
top and bottom of the equipment.
5.2.6 Cation regeneration tank (mixed resin storage tank)
The structure of this equipment is similar to the regeneration tank of the anion resin
regeneration tank. The water inlet device for this device is designed to be baffle type. The
captation device at the bottom of the equipment is designed to be the arc perforated plate
double speed strainer. The Caustic feeding device shall be of the fishbone type. The
branch pipe shall be of ladder-shaped wire winding structure. The manhole is designed on
the top and bottom of the equipment.
5.2.7 Waste water resin trap
31

This equipment is an open type container. When resin leakage happens inside the
regeneration tank, all resins inside will be retained to prevent the resin flowing into the
waste water pipe and causing damages. A liquid level meter is installed on this equipment.
The alarm of the liquid level meter can remind the operator of the blocked filter elements.
6. Instrument & Control requirements
The Instrument & Control of the Condensate polishing system mainly controls the
Condensate polishing system and the regeneration system.
6.1 Condensate polishing system
6.1.1 Prefilter and the bypass system
6.1.1.1 When the temperature of Condensate water in the inlet main pipe exceeds 50,
two bypass valves will be 100% opened at the same time, and each inlet and outlet valves
of prefilter and the mixed bed will be shut. And 100% Condensate water will pass
through the bypass system to avoid damage to the prefilter , filter elements, the resin and
the mixed bed.
6.1.1.2 At the beginning of the unit start-up, the iron content in the suspended solid in the
Condensate water will be higher. If a big mount of Condensate water including iron flows
into the tube filter (prefilter ), unrecoverable damages will happen for the filter elements
in the prefilter , and the elements cannot be cleaned completely, as a result the original
functions will perish. Therefore, the Condensate water will pass through the bypass
systems of the prefilter and the mixed bed, and then drained out. When the total iron
content in the Condensate water decreases to 10001500g/L, the prefilter can be
started up.
6.1.1.3 When the temperature of Condensate water is lower than 50C, the prefilter and
mixed bed systems of the Condensate polishing system shall be started. After it confirms
that two filters and mixed beds are operated, it will automatically shut down the bypass
valve.
6.1.1.4 When the differential pressure of the prefilter system exceeds 0.12MPa, the
bypass will open to make 100% Condensate water flows through the bypass system;
when the differential pressure exceeds 0.1MPa, the standby prefilter will be activated.
32

After the activation succeeds, the standby prefilter will make the existing running filter
invalid and perform the backwashing operation.
6.1.2 mixed bed and the bypass
6.1.2.1 At the beginning of the unit start-up, when the iron content exceeds 500g/L, the
water shall not flow into the mixed bed system. The bypass of the mixed bed shall be
opened, and the 100% Condensate water shall be discharged through the bypass system
of the mixed bed system. After the operator checks the iron content in Condensate water
and finds that the Condensate water quality meets the requirement on quality of
Condensate water inlet, the Condensate water may flow into the mixed bed system. When
two mixed beds are confirmed in running state, the bypass valve can be completely shut
off.
6.1.2.2 When the differential pressure of the bypass of the mixed bed exceeds 0.175, the
standby mixed bed will be activated. After the activation succeeds, the standby mixed
bed will make the existing running mixed bed exhausted, and then transfer the exhausted
resin to the resin separation tank for separation and regeneration. The differential
pressure transmitters are installed at the front of and the back of the resin traps will
monitor the differential pressure of the resin traps. When the differential pressure exceeds
some setting value, the mixed bed at the same side as the resin trap will quit in the
program. And then the standby mixed bed will be activated. After the activation is
affirmed, it will quit the invalid mixed bed, and backwash the resin trap.
6.1.2.3 The condensate polishing system mixed bed runs until: a. the differential pressure
>0.175MPa, b. outlet water Na>1g/L, c. SiO2>5g/L, d. cation conductivity (25C)
>0.2s/cm, e. the accumulation of the treated water quantity reaches to the setting value;
if any of these conditions appears, the upper computer will make the alarm to remind the
operator to quit the related mixed bed. When quitting the mixed bed, it is necessary to
confirm the bypass of the mixed bed is open.
6.1.3 Resin trap
In order to prevent the outlet water with resin from the mixed bed flowing into the
thermodynamic system, a resin trap is installed at the outlet of the mixed bed. When the
33

resin trap encounters the differential pressure 0.1MPa, the upper computer in the control
room will make alarms on high differential pressure of the resin trap, and firstly open the
bypass of the mixed bed, and shut down the inlet and outlet valves of the mixed bed after
confirm the bypass is open. And then the programming will stopped automatically. The
operator can change over the stored program control to inching operation. After the
blocking is removed manually, the operator can manually open the inlet and outlet valves
of the mixed bed, and then shut down the bypass of the mixed bed, and then change over
to the stored program control.
6.1.4 Recirculating pump
At beginning of the mixed bed activation, if the water quality of mixed bed outlet is bad,
and the water shall not be permitted to flow into the thermodynamic system, a
recirculating pump shall be installed in the Condensate polishing system. Prior to
activation of the mixed bed, recirculation process can be conducted that the water from
the mixed bed will be transferred into the inlet main pipe of the mixed bed through the
recirculating pump. After it recirculates for several minutes and the quality of the water is
ok, the related mixed bed can be activated to ensure the quality of the outlet water from
the mixed bed.
6.2 condensate polishing regeneration system
6.2.1 Totally 6 sets of resin are set for two units of this project including four sets running
and two sets standby inside the mixed beds. When the resin in one mixed bed is
exhausted, the standby mixed bed will be activated. After the activation is confirmed, the
invalid mixed bed will quit in program, and the resin in this mixed bed will be transferred
into the regeneration system trough the resin transfer pipe, and at last the regenerated
resin will be transferred into the mixed bed. And then this mixed bed will become
standby state again.
6.2.2 Inside the Resin separation tank, primary air scrubbing shall be firstly conducted for
the resin to remove the impurities attached on the resin, and eliminate the accumulation
of cation and anion resins. And then backwashing shall be conducted. First of all, control
the backwashing flow at the setting value for commissioning to float all cation and anion
resins in water and on top of the resin separation tank. And then use program to control
34

the backwashing flow rate and reduce the flow rate in many stages until the backwashing
gate is completely shut down so as to thoroughly separate the cation resin from the anion
resin. A clear interface between cation resin and anion resin will be formed in the resin
separation tank.
6.2.3 Simultaneous water inflow transfer method on the top and at the bottom: transfer
the anion resin from the resin separation tank to the anion regeneration tank, and then use
the upper air inflow and bottom water flow method, the optoelectronic liquid level switch
will be used to transfer the cation resin to the cation regeneration tank (mixed resin
storage tank). The mixed resin layer will be left into the resin separation tank for the next
separation.
6.2.4 Air scrubbing and air-water flushing will be conducted for the cation and anion
resin in the cation resin generation tank (mixed resin storage tank) and anion resin
generation tank. The repeated times will be determined by the operator according to the
conditions of the resins. After that, acid and caustic solution will be injected in the cation
and Anion regeneration tanks for regeneration. After the replacement of acid and caustic
solution is finished, air scrubbing and water-air flushing shall be conducted to the cation
and anion resins respectively, at last fast speed conventional flushing shall be conducted
to make the conductivity in the cation regeneration tank is lower than 10s/cm, and that
in the Anion regeneration tank lower than 5s/cm. If the conventional flushing is not
qualified, it is necessary to conduct air scrubbing and water-air flushing again for the
resin, and then re-regeneration and re-flushing shall be conducted.
6.2.5 After the regeneration of cation and anion resins is finished, water-air transfer
method shall be used to transfer the anion resin to the cation resin generation tank (mixed
resin storage tank), and then the Roots blower can be activated to mix the cation and
anion resins. After the conductivity of the outlet water based on flushing is lower than
0.2s/cm, it will become standby state, and the whole regeneration process is finished.
7. Running and operating procedures for the system
7.1 The running and operating procedures for the system are referred the details in
program control table of condensate polishing system and the related document number
is VA1-DEC-00100-M-M1D-LST-8203.
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The flow rates and time data listed in the program control table are only references, and all data shall
be finally determined according to the site commissioning.
7.2 Running recommendations
7.2.1 There are certain requirements for the Condensate water flowing into the prefilter
and mixed bed. During starting the new unit, the suspended solid and iron content in the
system is high, and the water shall be drained out. When the iron content in the
Condensate water at the inlet is lower than 1000-1500g/L, the Condensate water may be
allowed to flow into the prefilter . When the total suspended solid and iron content at the
inlet is lower than 500g/L, the Condensate water may be allowed to flow into the mixed
bed.
7.2.2 When the conductivity of the Condensate water at the outlet of the mixed bed
during normal running exceeds the limit, sometimes it cannot regenerate the resin, the
recirculating pump shall be used to circulate it until it is qualified. And then the mixed
bed may be continuously running.
7.2.3 Abnormalities and solutions during running the mixed bed:
Item Abnormality Analysis of reasons Solutions
1 The quality of
the outlet water
in the mixed
bed is not
qualified.
a. Mixed bed becomes
exhausted.
b. Deterioration of the
Condensate water.
c. Bad regenerated resin.
a. Stop and regenerate the related
mixed bed.
b. Check whether there is leakage in
the condenser or other systems.
c. Check the content and
concentration of the regenerant and
the foreign contamination.
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2 The treated
water quantity
in a cycle
obviously
declined
a. same to item 1
b. bias flow
c. Bad regeneration and
separation.
in the mixed
bed
d. high pH value at the
inlet
a. same to item 1
b. Check the safety of the inside
parts to eliminate the bias flow
c. Check and make measures
d. Lessen the pH value at the inlet
3 Differential
pressure of the
mixed bed
increases
dramatically
a. Many impurities at the
inlet of the Condensate
water
b. Dirty resin
c. High flow rate
d. Much fragmentary
resins
a. External air scrubbing
b. Internal air scrubbing
c. Reduce the flow rate
d. J udge the reasons of fragmentary
resins and make measures
8. Installation and commissioning of the process system
8.1 Precautions for installation
8.1.1 The system shall be installed according to the requirements in the drawings and the
relative regulations in the power plant construction codes. The equipments with rubber
lining shall not be stored under exposed conditions and shall be stored at the temperature
range 530C. During installation, impact or direct weld on the surface are forbidden.
8.1.2 When accessing into the tank, the operator shall wear rubber shoes and the sand
under the shoes shall be removed away.
8.1.3 Wooden ladder shall be used. If metal ladder is used, the bottom end of the ladder
shall be padded with rubber cushion.
8.1.4 Heavy tools and instruments shall not fall on the lined part.
8.1.5 Prior to stopping the unit, if the Condensate polishing system plan to quit for a
relatively long time (one week or longer), it shall keep running until the resin becomes
exhaust. During suspension of the Condensate polishing equipments, the tank shall be
sealed to avoid the resin becoming dry due to water loss. If the tank could be frozen,
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saturation salt water shall be filled into the tank. When restarting up the unit, the salt
water shall be discharged at first, and then conduct many times of valid regenerations. If
this equipment just stops for a short time (over night or the weekend), it is ok just to stop
it. When restarting up the unit, recirculating can be conducted until the quality of the
outlet water meets the normal setting value.
8.2. Precautions for the commissioning
8.2.1 Necessary conditions for commissioning
8.2.1.1 All equipments, pipes (including the hangers and the insulation layer), valves,
pumps and fans are already installed, and the temporary devices used for transport and
installation are already dismantled, and the site is clean and the ground is tidy, and the
road is free from barriers.
Note: switch on/off test shall be conducted for all valves especially the motor-driven
valves and the pneumatic valves prior to installation. After they are confirmed to be
normal, they may be installed to the system.
8.2.1.2 After installation of the system is finished, the operator shall check the
correctness of installation for the system and the equipments, and perform acceptance
according to relative regulations. All internal parts for all equipments shall be inspected
to check whether the connecting flanges are tightened and sealed, whether the scrap iron
inside the pipe are cleaned completely, whether the lining rubber layer is good, whether
there is damage to the wire winding, sieve tube and strainer, and whether the strainer is
tightened firmly. The inside of the equipment shall be cleaned completely, and no
impurities shall remain inside. All impurities inside the pipelines must be removed
completely.
8.2.1.3 The compressed air system for the instrumentations and equipments is running
normally, and the air source is sufficient, dry and clean. And the air pressure is stable.
8.2.1.4 The electrical, thermal measurement meters and chemical measurement meters
are installed, and the indications are correct, and they can be used.
8.2.1.5 The power supply is normal, and the rotation directions of all motors are correct
and normal.
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8.2.1.6 The trenches and blind wells shall be smooth covered and not be blocked.
8.2.1.7 Illumination is available.
8.2.1.8 Chemical agents and the regenerants are sufficient, and the quality shall be as
required.
8.2.1.9 Service water and flushing water shall be sufficiently supplied.
8.2.1.10 the operators shall be qualified after training, and shall have the operation
permits,
8.2.1.11 Conditions of chemical analysis shall be available.
8.2.2 Preparation works prior to commissioning
8.2.2.1 Thoroughly clean the whole system: firstly shut the inlet and outlet of the
equipment, flushing the pipe to avoid foreign contamination entering into the equipments
with the flushing agent; then flush the equipment firstly with backwashing method to
completely remove the impurities and followed by conventional flushing. During
flushing, the operator shall:
1) Use the demineralized water as the flushing water;
2) Flush the pipelines segment by segment, and flush the equipment separately.
8.2.2.2 Trial running of the system
1) Trial running for the recirculating pump, backwashing pump, flushing water
pump and the Roots blower;
2) Conduct open/close tests for all valves, and confirm the operation is normal.
8.2.3 Hydrostatic test
8.2.3.1 The sealed hydrostatic test for the mixed bed in site shall be based on the pressure
5.0MPa (including 1.0MPa for the sealed hydrostatic test for the compressed air piping
and 0.6MPa for the sealed hydrostatic test for the flushing water).
8.2.3.2 The sealed hydrostatic test for the container of the regeneration system shall be
based on pressure 0.75MPa.
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8.2.3.3 Water filling test shall be conducted for the acid and caustic storage tank and the
waste water resin trap in site.
8.2.4 Feeding the resin, pretreatment and regeneration of the resin
Resin feeding hopper and resin injector can be used directly to manually feed the resin
into the regeneration equipments. Pretreatment and regeneration shall be conducted
strictly according to the relative regulations of the resin manufacturers.
Note: If the cation resin is supplied in the form hydrogen status, the anion resin shall be
supplied in form of oxyhydrogen. The manufacturer has already conducted the
pretreatment, and the resin is authorized by the manufacturer, the resin can be directly
used without regeneration.
8.3 Items and contents of the commissioning
8.3.1 The objective of the commissioning is to make the running performances of the
equipments meet the design requirements and obtain better running parameters through
running adjustments.
8.3.2 Items of adjustment test
8.3.2.1 Test of the ratings the prefilter of the Condensate polishing system and bypass
valve of the mixed bed.
8.3.2.2 Regeneration commissioning of the exhausted resin
1) Air scrubbing for the exhausted resin; determine the scrubbing times and
frequency.
2) Determination of the flow rate of the backwashing layers for the exhausted
resin.
3) Adjustment test for the acid & caustic solution concentration, flow rate for
resin regeneration.
8.3.2.3 Determination of the duration of transferring and flow rate during the transfer of
the resin.
8.3.2.4 Adjustment of the opening of all kinds of valves in the system.
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Note: The detailed requirements on adjustment running must be conducted according to
the commissioning guideline.
8.3.2.5 After all adjustment data are determined; the parameters of the procedures shall
be amended accordingly.
9. Instructions of installation
Before the commissioning of condensate polishing system, the operator must read and
understand the contents in this article, and must comply with these rules at any time to
avoid personnel death & injuries and damage to the equipments.
9.1 The operator of the equipment must have the experiences of running the equipments
and training on hazardous chemical matters before he operates the equipment.
9.2 Be especially careful when using the acid and caustic regenerant. Contact to these
corrosive chemical reagents will cause severe burning or even blindness.
9.3 Approaching to the containers and the equipments
9.3.1 The operator shall be especially careful when he works near the container. Once
any part of the handle of the valve, the sampling pipe and other exposed parts contact any
part of the body, it will cause severe injury. When working under the pipes and
surrounding the equipment, the operator shall wear safety helmets and safety goggles.
They shall be careful when removing the equipment.
9.3.2 If the equipment is installed or running, and if the height is out of reach of the
operator, safe and checked ladder or lifting device shall be used to reach to the indicated
zone.
9.3.3 The operator shall not use extended or single face ladder to approach the container.
Generally the round container cannot provide an even stable supporting face for the
single face ladder. If possible, wide and stable folding (free to place) ladder shall be used.
This ladder shall be fixed on the container or the pipe.
9.4 The operator shall be especially careful to open the container and remove the heavy
cover of the manhole. If there is no lifting rod, pulley chain and other lifting device can
41

be used to move away the cover. Prior to confirming that the cover is safely lifted and
supported firmly, the operator must not dismantle all bolts on the cover plate.
9.5 If the resin falls on the ground during transfer the resin, the operator shall clean it to
avoid slipping.
9.6 When working on the motor, control panel or other electrical elements, the operator
and the workers must be careful. All these parts must be connected rightly and reliably
grounded, and shall not contact the process liquid or other liquids.
9.7 During delivery, the blowers and pumps are not assembled, and must be correctly
installed to avoid any movement and excessive shocking.
10. Others
The process control parameters involved in this instruction are only for reference, and the
detailed data shall be finalized by the site commissioning.


Note: this system description also includes the Operation and Maintenance Instructions
for whole condensate polishing system.