Dmwaters

PART 1
D.M.PLANT 1
(THERMAX SUPPLIEDPLANT)
CPP - UTILITY
RELIANCE INDUSTRIES
LIMITED.
HAZIRA.
INDEX
PART 1 ( Thermax Supplied DM Plant)
[1] Basic concept engineering and operation philosophy
[2] Specification of input/output and water balance
[3] Detail construction features of main equipment
[4] Sequential start-up and shutdown of plant
[5] Trouble shooting and remedies
[6] Instruments and their setpoints/interlocks
[7] Do and Donot
[8] Preservation of equipments
[9] Safety precaution & MSDS of HCl & NaOH
PART 2 (Ion Exchange Supplied DM Plant)
[1] Introduction with Schematic Diagram of DM Plant 3.
[2] General Description of DM Plant Vessels.
[3] Technical Datas.
[4] Control phylosophy of DM Plant 3.
[5] trouble Shootings
[6] SOP for DM water transfer form DM plant2 to DM plant1, PTA 1/2 and POY plants.
CHAPTER 1
BASIC ENGINEERING CONCEPT & OPERATION PHILOSOPHY
1.01 Introduction
Filtered water available from water treatment plant has no physical impurities but chemical
impurities like dissolved salt, silica and carbondioxide etc are there.
This water cannot be used in process, where high purity products are required and for high
pressure boilers to avoid scaling and corrosion. Chemical impurities are of cation like Ca,
Mg, Na and Anions like Cl, SO4, NO3, Silica etc. These are called Cationic and anionic load
respectively. Total of cations and anions are called Total Dissolved Solids (TDS). All these
are mentioned equivalent of CaCO3 ppm. Removal of total dissolved solids can be done by
distillation, reverse osmosis and demineralisation process. Out of these, demineralisation by
ion exchange is cheaper and easier. Different type of resins are used to remove cations and
anions.To remove cations, Hydrogen resin RH is used and to remove anions Hydroxide resin
ROH is used.
Following are the general reactions :
i. Cation exchange reactions
NaCl + HR -------- NaR + HCl
MgSO4 + 2HR -------- R2Mg + H2SO4
Regeneration reaction with HCl
NaR + HCl -------- HR + NaCl
MgR2 + 2HCl -------- 2HR + MgCl2
Produced HCl and H2SO4 go in anion exchanger units.
iii. Anion exchange reactions
RaOH + HCl -------- RCl + H2O
2RaOH + H2SO4 -------- R2SO4 + 2H2O
iv. Regeneration reaction with NaOH
RaCl + NaOH -------- RaOH + NaCl
R2SO4 + 2NaOH -------- 2ROH + Na2SO4
Three streams of DM water, in the plant are installed, each has capacity of 150 m3/hr for 20
hrs/day. This plant is supplied, erected and commissioned by M/s Thermax Ltd. Each
stream contains pressure sandfilter (PPS), activated carbon filter (FAC), strong cation
exchanger (SAC), Degasser tower (DGT) with degasser blowers (BDG) and degassed water
pump (PDG). Weak base anion exchanger (WBA) , Strong Base Anion (SBA) And Mixed
Bed (MB). To polish the condensate, condensate polishing plant is there. It contains
activated carbon filter (FAC-CP) and mixed bed exchanger (MBCP). To avoid damages of
resins due to high temperature, heat exchangers are fixed to cool condensate before
condensate polishing unit.
Materials of construction of piping and equipments upto inlet of SAC are MS and from SAC
outlet are MSRL or SS. D.M. Water tanks , treated condensate tank, and effluent neutralising
tanks are of MS/RCC with epoxy lining.
To measure quantity of filter water at PPS inlet and at MB outlet, flow integration, flow
indicator are fixed. To measure quality of DM water pH meter, conductivity meter, silica
analyser are fixed at outlet line of WBA, SBA and MB & MBCP.
1.02 b Design basis of condensate polishing unit.
Normal condensate recovery 74.0 m3/hr i.e. 1800 m3/day
Peak condensate recovery 97.00 m3/hr i.e. 2200 m3/day
Plant size is selected to polish 2400 m3/day condensate
1.02 c DM water and condensate storage tank
DM tanks 1600 m3 x 2 nos = 3200 m3. Assuring 12 hrs storage in normal condition of plant
cap. for storage.
Row condensate tank of 2000 m3 capacity assuring 20 hrs. storage.
1. Plant is designed considering 10% excess ionic load & silica 20 ppm as SiO2 in R.W.
2. Plant is designed considering outdoor installation.
3. Plant is semiautomatic.
4. Velocity in resin bed is considered max. 0.75 M/Sec.
5. Fluid velocity is max. 2M/sec. When three streams are running on peak load.
6. 33 - 18% HCI and 20% NaOH is used for regeneration and neutralising of effluent.
1.03 BRIEF DESCRIPTION

1.03.1 DM Water Plant
Filtered water from water treatment plant is coming to PPS to give good quality water to ion
exchanger to avoid the fouling/scale on resin. Scale of mud on resin reduces the ion
exchange capacity of resin. Different size of Pebbles and sand are used as filter media.
Outlet water from PPS goes into FAC. It contains activated carbon which removes COD ,
FRC , oil, grease and Fe if any. For measuring performance of PPS and FAC no instruments
are fixed but pressure gauges are fixed to know differential pressure between inlet and outlet
of each unit. From FAC, water goes to storage acid cation bed. It is MSRL, vertical counter
current pressure vessel, it contains 18150 litres of Tulsian resin of M/s Thermax. Counter
current means service water flow and regeneration flow are in opposite direction. Counter
current is preferred to ensure perfect regeneration of resin. Pressure gauges are fixed to
know pressure drop.
Backwash of SAC is optional and is not done in every regeneration cycle. Conductivity
meters show the exhaustion of resin started , which indicates the regeneration of unit is
required. Hydrogen from resin T-42 takes cation from water and gives out Hydrogen to from
acid.
Sodium is less reactive Ion. So leakage of Na+ (on starting exhaust of resin) occur first. To
know Na+ leakage from SAC, on line Na+ analyser or differential conductivity meter is fixed
in outlet of SAC.
One ppm of Na+ gives conductivity of 1.8 micro moh/cm. Bicarbonates are decompose in
CO2 and H2O. This produced CO2 is removed by degasser. So SAC outlet water is pumped
to degasser unit. SAC outlet has pH 3.5 to 5.0. Degasser contains two nos. of towers, one
degasser storage tank, three air blowers and four degassed water pumps (Three run and one
standby). Degasser towers are filled with 35-38 mm diameter * 35-38 mm length of
polypropylene reaching rings.
Water enters at the top of the towers and pumping of air by blowers from bottom of the
towers, free CO2 is removed by air and only dissolved CO2, 5 ppm equivalent of CaCO3
remain in water. Degassed water is stored in degassed storage tank, which is provided with
high and low level switches to maintain certain level in tank. Degassed water pumps are
pumping water to WBA. WBA is a cocurrent MSRL vertical pressure vessel. It contains
6000 lits of A-2X resin in each unit. Resin is only reactive with low pH i.e. strong acid like
H2SO4 and HCl. But not with weak acids like carbonic and silica. Conductivity meter with
high alarm is provided in outlet of WBA. Regeneration of the unit is done by through fare,
i.e. regeneration of WBA and SBA is done at a time and regenerant and slow rinse of SBA is
used in WBA. Outlet water from WBA goes to SBA, it is a counter current MSRL vertical
pressure vessel, it contains 3800 litrs. Of A-27 resin.
Strong anions are removed in WBA. Weak anions like silica and carbonic acids are removed
in SBA. Conductivity meter, silica analyser and pH meter with high alarm are fixed in outlet
of SBA. Till silica and carbonic acids are removed pH, remains high and rise in conductivity
due to CO2 but silica has no effect on pH and conductivity. Outlet water from SBA goes to
MB.
MB is MSRL vertical co-current pressure vessel, it contains cation T-42 and anion A-27
resin each of 1900 litrs.
Generally most of the ions are removed in SAC, WBA and SBA units. Extremely pure water
is produced by mixed bed, using relatively lower quantities of regenerant and almost
independent of feed water ionic load.
Characteristic of MB unit is that exhaustion point is very sharp when either of the resin
exhausted the conductivity rise sharply. At this stage MB should be cut out from service &
resins must be separated for regeneration.
Separation is achieved by back washing and distributing water flow evenly. Anion exchange
resin has got lower sp. Gravity than that of cation resin. So, two clearly define layers are
formed. Then allow the resin to settle. On completion of back washing MB has both types
of resin so it takes care even any ions are slipped from preceding ion exchanger and gives
good quality of water. In MB outlet , pH meter , silica analyser, conductivity meter with
high alarm are fixed to observe performance of MB working.
DM water outlet from MB has :
pH ------ 6.2 to 7.4
Conductivity ------ 0.2 microohms/cm
Silica ------ < 0.02 ppm as SiO2.
1.03.2 Condensate Polishing Unit

Condensate from boiler and process plants is being recovered to save DM water and to utilise
heat of condensate for generation of steam. Return condensate from plants contains Fe and
other chemical impurities due to small leakage in equipment / pipe exact analysis of raw
condensate is not available but plant is designed considering TDS-4 ppm and Silica - 1 ppm
as a SiO2. Condensate polishing unit contains 1 no. of activated carbon filter (FAC-CP) and 1
no. of mixed bed unit (MB-CP). Purpose and material of construction are same as of FAC
and MB units of DM plant.
Condensate from different plant is coming in condensate return header. Before going to raw
water condensate tank, return condensate is cooled from 90 deg C to 55 deg C in two nos. of
plate type heat exchangers with the help of treated condensate going to CPP, Condensate is
further cooled with the help of C.W. before going to Raw Condensate Tank.
Condensate from CPP comes directly to raw condensate tank . From raw condensate tank it
goes to Condensate Polishing Unit after cooling it from 70 deg C to 42 deg C in one no. of
plate type exchanger with the help of cooling water which is available at 34 deg C from
cooling tower. Plate type heat exchangers are supplied by Larsen & Toubro Ltd. Mixed bed
(MB) unit contains 1200 ltrs of T-42 cation and A-27 anion resin of each. These resin can
withstand upto maximum temperature for (continuous operation) of 55 deg C so, high
temperature alarm and tripping of condensate feed pump at high temp. Interlock is provided
as resin is highly sensitive of high operating temperature.
Pump of D.M. water and condensate plant are supplied by M/s Becon Wair Ltd, material of
construction of pumps for raw/treated condensate and DM water is SS 304.Cooled raw
condensate at 42 deg C is fed to FAC-CP where COD, oil, grease and Fe are removed.
Backwash of FAC-CP is done once/day. Pressure gauges at inlet and outlet are fixed . Outlet
condensate from FAC-CP is fed to MB-CP where cation, anions and silica are removed. pH
meter, conductivity meter and silica analyser with
high alarm are fixed in the outlet of MB-CP to see the performance of unit.
CHAPTER 2
2.1 RAW WATER INPUT & DM WATER OUTPUT SPECIFICATION
Sr. Parameters Units Raw Water DM water
No,. In put Outputt
1. Turbidity NTU 2.0 NIL

2. Total suspended solid MG/L NIL NIL
3. Total dissolved solid MG/L -- 0.5
4. pH -- 7-8 6.5 - 7.0
5. Electrical conductivity Micromhos/c --- 0.2
m
6. Dissolved oxygen Mg/L --- ---
7. Free carbon dioxide Mg/L --- ---
8. Oxygen consumed by org. Mg/L 4.5 ---
matters
9. Total hardness Ppm as CaCO3 134 NIL
10. M.O. Alkalinity -do- 187 NIL
11. Phenolphth alein -do- NIL ---
12. Bicarbonate -do- --- ---
13. Hydroxide -do- --- ---
14. Sulphate as SO4 --- 36.5 ---
15. Chloride as NaCl Ppm 45.1 ---
16. Nitrates Ppm as CaCO3 --- ---
17. PO4 (Phosphate) -do- --- ---
18. Calcium -do- 72 NIL
19. Magnesium -do- 62 NIL
20. Sodium -do- 135 ---
21. Sodium Ppm as CaCO3 0.9 0.009
22. Manganese -do- --- ---
23. Aluminium -do- --- ---
24. Copper -do- --- ---
25. Free Ammonia As NH3 ppm --- ---
26. Silica as SiO2 Ppm 20 0.02
* Oxygen consumed in organic matter is less than 0.1 PPM in drinking water.
2.2 SPECIFICATION OF RAW CONDENSATE&TREATED CONDENSATE

Sr No Parameters Unit Rawcond. Treated cond.
1. Total dissolved solid PPM 4.0 0.05
2. Silica as SiO2 PPM 1.0 0.02
3. Total Fe as Fe PPM --- 0.005
4. Total Cu as Cu PPM --- 0.003
5. Total Al as Al PPM --- 0.003
6. Conductivity Micromho/cm --- 0.2
7. Temperature deg C 45 45
2.3 SPECIFICATION & CONSUMPTION OF UTILITIES
(DESIGNCONDITION)
(A) HCl : IS262-1962.18-33$ concentration consumption on 100% basis.

Normal : 816 x 2 + 76x2 + 75 = 1729 kgs/day
7
Peak : 816 x 2 + 76 + 75 = 1783 kgs/day
(B) NaOH : Rayon grade 16 - 20% concentration 100% basis
Normal : 322 x 2 + 114 x 2 + 75 + (108.5 x 6 + 61.7 x 1) x 2 == 955 kgs/day
7 7
Peak : 322 x 2 + 114 + 75 + 61.70 + 108.5 = 1003 kgs/day
(C) Instrument Air : 450 NM3/Hr.
(D) Water Consumption for Regeneration
Equipment M3/Regen. Nos / d M3/d Normal M3/d Peak
PPS 45 2 90 90
FAC 20 2 40 40
SAC 187 2 374 374
WBA/SBA 74 2 148 148
MB 42 (for 7 days) 2 12 42
FAC-CP 20 1 10 20
MB-CP 41 1 41 41
Total 715 755
2.4 VOLUME OF INTERNALS
(A) PPS : 2 nos
Pebble : 40-25 mm 3.8 m3
25-15 mm 3.8 m3
12-8 mm 3.8 m3
8-6 mm 3.8 m3
Crushed gravel: 6 - 25 mm 2.8 m3
Banded sand : 6/16 inches 2.8 m3
Filling sand : 16/32 inches 17.0 m3
(B) FAC - 1 nos FAC-CP 1 no

FAC FAC-CP
Pebble ¾ - ½ inches 1.7 m3 0.85 m3
½ - ¼ inches 1.7 m3 0.85 m3
Coarse silex 1.7 m3 0.85 m3
Fine silex 1.7 m3 0.85 m3
(C) DGT - 2 nos
Rashing ring of polypropylene of 35. 38 mm diameter and 35-38 mm length.
(D) Resins
Name of Nos Liters of resin Volume and type of resin
Equipment for equipment T-42 A-27 A-2X
SAC 2 18150-1360* 363300+2720* --- ---
RBA 2 6000 --- --- 12000
SBA 2 3800 + 600* --- 9600+1200* ---
MB 2 1900+1900 3800 3800 ---
MB+DP 1 1250+1250 1250 1250 ---
Total 41350+2720* 12650+1200* 12000
*Inert Resin
CHAPTER 3
DETAILED CONSTRUCTION FEATURES OF EQUIPMENTS
SAC, SBA, WBA and MB are the main equipments of DM water plant. These have major
roll for designing. DM water has different pH at each stages. Ion Exchange is taking place
when the resin bed is compact so resin bed is under pressure during service. Minimum bed
height is maintained more than 1 meter considering water velocity and pressure drop across
the resin bed. Resin bed is expanding during back wash operation so 100% extra space is
maintained equal to resin bed volume to avoid loss of resin during back wash.
Due to Acid/Alkaline pH of water, these equipments are protected against corrosion by
rubber lining. Lining of 4.5 mm of natural rubber with store hardness of 60 deg + 5 deg is
provided. Before rubber line inside surface is sand blasted and brushed with wire brush. All
these equipment have maximum operating pressure of 5-5 kg/cm2g. Equipments are
designed at 6.5 kg/cm2 and tested at 9.75 kg/cm2 pressure. Material of construction is MS of
grade SA 515/516 grade - 70.
To avoid the resin losses during regeneration, nozzles are provided in inlet and outlet
distribution header. These nozzles also help to avoid channelling in resin bed, uniform flow
of acid/alkyl during regeneration, and uniform ionic load on resin.
SAC and SBA are counter current pressure vessel i.e. normal service water flow and
regeneration flow are in opposite direction. Opposite direction flow are required to get
better/high concentration acid/alkyl at the layer of resin from where last product in leaving.
This will give better quality of product. Due to this counter-current flow equipment to avoid
the thrust in bottom, bottom is filled with concrete. WBA and MB are co-current pressure
vessel and don’t require any concrete filling in bottom portion.
Where very low silica contain in DM water is required and only SBA is there SBA is
regenerated with higher concentration of alkyl and WBA is there SBA s regretted with
consumption of alkyl this will increase consumption of alkyl. To reduce the consumption of
alkyl thorough fare system is being used. In this system outlet alkyl and alkyl rinse of SBA
will be used for WBA. This will save the consumption of alkyl per regeneration.
CHAPTER 4
PROCEDURE FOR START UP/SHUTDOWN BACKWASHING &
REGENERATION
4.1 Start-up of plant
Check : All valves of all units are in closed condition.
4.1.1 Filter Water Pump
a. First of all suction valve should remain open.
b. Start filter water pump and slowly open discharge valve.
c. Ensure whether motor direction is correct or not.
d. The discharge pressure should be of 4 kg/cm2
e. Note ampere of the pump.
4.1.2 Pressure Sand Filter (PPS)
a. Filter water pump should be running on.
b. While starting of pressure filter (PPS) first of all open main inlet valve VM1 and then
open air release valve VM12, when air is completely removed and when water start coming
out from VM12, close it and open fast rinse valve VM31 for 10 minutes. After that open VM2
and note inlet cut let pressure.
4.1.3 Activated Carbon Filter (FAC)
a. Sand pressure filter (PPS) should be remain on service.
b. While starting of FAC first of all open main service inlet valve VM1 and then open air
release valve VM12. When air is completely removed and water start coming out from VM12
close it. Open rinse outlet valve VM31 for 10 minutes. Open outlet valve VM2 and adjust it
to get the required flow rate.
4.1.4 Strong Acid Cation (SAC)
a. FAC should be remain on service.
b. Before starting of SAC first of all put it on select regeneration ‘Filling & Fast Rinse”
at the time of filling open main inlet valve VA1 fully & air release valve VA12; when air is
completely removed and when water start coming out from VA12 close it , and take it on
service by opening valve VM2. Don’t take in service unless water quality of fast rinse is as
below:
F.M.A - Same betn two successive samples at 5 minutes interval or 89.7 +/-
0.1.
T/H - Nil
Na+ - Nil
pH - 2.5 - 3.5
4.1.5 Degasser
a. SAC should remain on service.
b. First of all start Degasser Air Blower (BDG) water is entering at the top of tower and
pumping of air blower (BDG) from bottom of tower. Free CO2 is removed by air and only
dissolved CO2 - 6 ppm equivalent of CaCO3 remain in water. Degassed water is stored in
Degassed Storage Tank (SDG) when level come high start degasser water pumps (PDG)
suction valve VM25 should remain open and then slowly open and control by discharge valve
VM26. Keep pressure between 3.2 to 3.8 kg/ cm2 and note ampere of the pump. CO2 after
DGT is 5 ppm.
4.1.6 Weak Base Anion (WBA)
a. PDG should be running on.
Before starting of WBA first of all put it on select regeneration “filling and fast rinse”. At
the time of filling open main inlet valve VA1 (full) and air release valve VA12. When air is
completely removed and when water start coming out from VA12 close it. And give fast rinse
at the time of fast rinse valve VA6 remain open. When quality become normal-i.e.
pH - 5.0 - 5.4
CL - Less than 1 ppm.
Then close fast rinse valve (VA6) and open service out let valve (VA2).
4.1.7 Strong Base Anion SBA
a. WBA should remain on service.
Before starting of SBA first of all put it on service. Select regeneration ‘filling & fast rinse’
at the time of filling open main inlet valve VA1 (full) and air release valve VA12. When air
is completely removed and water start coming out from VA12 close it. And give fast rinse,
at the time of fast rinse valve (VA6) remain open. When water quality becomes normal.i.e.
pH - 7.5 - 9.0
Cl - Nil
Silica - < 0.2 PPM as SiO2 and conductivity - 15 micro /cm then close fast rinse valve
(VA6) and open service out let valve (VA2) for service. And note outlet pressure and control
flow by outlet valve VA2.
4.1.8 Mixed Bed (MB)
a. SBA should remain on service.
Before starting of MB first of all put it on select regeneration ‘filling and fast rinse’ at the
time of filling open main inlet valve Va4 (full) and air release valve VA12. When air is
completely removed and when water start coming out from VA12. Close it, and give fast
rinse, at the time of fast rinse valve (VA6) remain open. When water quality becomes
normal. i.e.
pH - 6.2 - 7.4 CL - Nil (as CaCO3) Silica < 0.02 ppm as SiO2 and
conductivity < 0.2 micro mhos/cm, than close fast rinse valve (VA6) and open service outlet
valve (VA2) for service then note flow and inlet outlet pressure of exchange. Control flow
by VA2.
4.1.9 D.M. Water Tanks & D.M. Water Pumps
1) Open the inlet valve of D.M. Water Tank which is to be taken for service.
2) Ensure that inlet valve of idle tank is closed.
3) Ensure that drain valve of running tank is closed.
4) Start D.M. Water pump as per starting procedure of centrifugal pump.
5) If flow required in less than minimum flow of pump open recirculation valve.
6) Note pressure and ampere of running pumps.
7) Open D.M. water line valve for distribution header.
4.1.10 Starting of Condensate Polishing Plant
1) Check the drain valve of raw condensate tank is closed.
2) Open the inlet and outlet valves of row condensate tank.
3) Open the inlet and outlet valves of heat exchanger no. 1502 (2 nos) for raw
condensate line. Collect the condensate in raw water condensate tank.
4) Start the cooling water flow to heater EA-1503.
5) Close the valve in delivery line GA1502 going treated condensate tank.
6) Keep the condensate drain valve open and start raw condensate pump GA 1502 (as
per procedure). After some time close drain valve and open valve of EA 1503.
7) Adjust the cooling water flow to get outlet condensate temperature around 42 deg C.
8) Start FAC-CP as given procedure of FAC.
9) Start MB-CP as given procedure of MB.
4.1.11 Starting of treated condensate tanks and pumps
1) Ensure that drain valves of treated condensate tank FB 1502 is closed.
2) Open treated condensate valve and DM water coming to treated condensate tank.
3) Start treated condensate pump GA 1503 after getting sufficient level in tank as per
starting instruction of centrifugal pump.
4.2 Back Washing - Regeneration of Vessel
4.2.1 F.P.S.
4.2.1.a Air Scouring - (400 m3 for 10 minutes)
1) Close main inlet valve VM1 and outlet valve VA2.
2) Open valve 12
3) Open valve VA4 and allow water to drain down upto the inlet distribution header
level.
4) Open air blower drain valve VA31.
5) Open air blower discharge valve VA41 and start the blower.
6) Open valve VM11 and close VM31 keep the operation for 10 minutes.
7) Open valve VM31 and stop air blower.
4.2.1.b Backwash (120 m3/hr for 10 minutes)
1) Open wash outlet valve VM4 full.
2) Open wash inlet valve VM3 slowly and adjust the flow such that level in drain sump
is upto wash marker.
3) After 10 minutes till effluent is clear, then close wash and valve VM3 wash outlet
valve VM4.
4.2.1.c Refill
1) Open inlet valve VM land air release valve VM12 when water start coming from
VM12 close it.
4.2.1.d Rinse (150 m3/hr for 10 minutes)
1) Inlet valve VM- open since previous step.
2) Open and adjust rinse outlet valve VM31 such that the level of water in drain sump is
upto rinse market in V notch.
3) After 10 minutes, close rinse outlet valve VM31.
4) Open outlet valve VM2 to take the unit in SERVICE.
4.2.2 FAC
4.2.2.a Back washing (100 m3/hr for 10 minutes)
1) Close main inlet valve VM1 and outlet valve VM2.
2) Open wash outlet valve VA4.
3) Open slowly wash inlet valve AM3 and adjust it such that level of water in the drain
sump is upto wash marker.
4) After 10 minutes or till effluent is clear, then close wash inlet valve VM3 and wash
outlet valve VA4.
4.2.2.b Refill
1) Open inlet valve VM1 and air release valve VM12.
2) When water start coming out full bore from air vent line close VM12.
4.2.2.c Rinse (150 m3/hr for 10 minutes)
1) Inlet valve VM1 is open since previous step.
2) Open and adjust outlet valve VM31 such that the level of the water in drain sump is
upto rinse marker on V notch board.
3) After 10 minutes close rinse outlet valve VM31. Open outlet valve VM2 to take the
unit in SERVICE.
4.2.3 SAC
Main inlet valve VA1 and main outlet valve VA2 remain open. Comparator conductivity
meter will show the ratio of conductivity at the outlet line and resin bed. This ratio will help
to determine and the point of service and to start regeneration.
BACKWASHING WASHING : SAC is regenerated in counter current type of regeneration ,
so backwashing of vessel during every cycle of regeneration is not essential. Generally
backwashing is given after every 7 cycle, but it also depends on site condition. Backwashing
is to be carried out only when it is absolutely necessary. Following are the cut of points of
carrying out backwashing. It is noted that double regeneration is required after backwashing.
1. Excessive pressure drop on exchanger.
2. Inconsistency in quality during service.
3. Excessive fines/foreign particals accumulation during the number of cycle of service.
If required, backwash to be carried out on extended time not by increasing flow rate.
BACKWASHING (OPTIONAL - 3 mts - flow 72 m3/hr)
Select regeneration switch from PLC for SAC A or B service water inlet valve VA1, and
outlet valve VA2 remain close. Backwash inlet valve VA3, acid inlet valve VA7 (full open
full open near MHL1) and backwash outlet valve VA4 remain open. Water can be controlled
by inlet flow indicator. Back wash is continues till outlet backwash water is clear. During
backwashing water will inlet through resin bed from bottom to top and carry mud with it.
- Once in 6 months open - extended backwash to be given for removal of fines.
BEFORE PUTTING THE SAC INTO REGENERATION Following are the pre-condition
to be carrying out -
A. One SAC is to be put into regeneration mode.
B. Acid in MHL/A/B is to be taken by opening VM7 upto high level if it is 18%.
Otherwise at low level for 33% and by adding SBA outlet water by opening VM14 upto high
level.
C. One FPS has to be put in service mode to come into service as and when required.
D. PDG & BDG is to be put in auto mode.
STEP-1 : MIDDLE COLLECTOR WASH (5 mts flow 60 m3/hr)

Middle collector inlet valve VA13 (part and back wash outlet valve VA4 (full) remain open.
This is carriedout to clear the Buttons which are filled on the middle collector. Adjust the
flow by VA13.
STEP-2 : SETTLE BED (2 minutes)
All valves remain closed in this step. The bed is allow to settle after middle collector wash.
STEP-3 : POWER WATER INJECTION (3 mts - flow 51 m3/hr)
Following valves will open :-
1. Acid injector valve VA7.
2. Middle collector outlet valve VA-14.
3. Down flow VA - 15 (part).
4. MHL1 A/B and power water valve VA32 PDG pump and BDG blower put on auto
will come into service immediately.
Down flow is must as it is counter current of regeneration and acid will be injected from
bottom so to keep the resin bed compact, control the power water flow through injector as in
next step acid is to be sucked.
STEP-4 : ACID INJECTION (30 mts flow 150 m3/hr)
Apart from those valve mentioned in step no. 3 one more valve acid outlet valve VA2 of
MHL1 A/B will open. The strength of acid entering the vessel would be between 4 to 5%
this can be checked by specific gravity indicator. The strength of 4% acid solution is 1.018
and that of 5% acid solution is 1.023.
If all acid is consumed in 20-25 mts (i.e. set time) and measured by low level switch, then the
acid outlet valve will close automatically but the step will continue. However, if the level of
acid does not fall to the low level even at the end of set time, the step will change
automatically to the next step, without bothering to wait for the acid measuring to fall to low
level. However, the operator can put the step to hold mode by pressing the hold mode button
on the sequential controller thereby freezing the timer, and release the hold button after as
certaining that all acid has been consumed.
STEP-5: SLOW RINSE (30 mts flow 51m3/hr and down flow 50m3/hr)
Following valves remain open -
1. Acid injection valve VA7.
2. Middle collector outlet valve VA14.
3. Down flow VA15.
4. Power inlet valve VA32 of MHL1 A/B valve VA32 of MHL1 A/B remain closed.
This required to displace the acid from the vessel.
STEP-6: FINAL RINSE (30 mts flow - 150 m3/hr)
Water inlet valve VA1 (full) and rinse outlet valve VA6 (part) will open this step is required
to wash off traces of acid from the vessel. The quality of water coming out from the vessel
can be checked by checking free mineral acidity (FMA). The value of FMA must be same
between two successive reading. If not, rinse must be continued.
STEP-7: OFF
This is the last step and all valve remain closed. At the end of this step, end of SAC
regeneration displace will be given. Then SAC will be taken for service.
BACK WASH & REGENERATION TABLE
Sr Step Flow Time Water Type of water
Rate (hrs) consumed (m3)
(m3) (m3)
1 Middle collector wash 60.0 5 12.0 Degassed
2 Back wash (optional) 72.0 3 3.6 Degassed
3 Settle bed - 2 - -
4 Power water 51 2 - Degassed
5 Acid injection 51.0 25.5 Degassed
Down flow 50.0 2550.0 Filter water
6 Acid rinse 51.5 24.0 Degassed
Down flow 50.0 3025.0 Filter water
7 Final rinse 150.0 30 75.0 Filter water
4.2.4 WBA/SBA
THROUGH FARE REGENERATION
The rinse and service operation instruction are same as given in the individual vessel section.
Here both the SBA and WBA will be regenerated at the same time.
Here the regenerant sodium hydroxide will enter SBA and from SBA it will be taken to
WBA. It is worth to noting that SBA is regenerated in counter current type and WBA is co-
current type. SBA need not be back washed during every time of regeneration but WBA has
to be back wash without fail.
Since dilution of alkali is required , water has to be added to alkali and to ensure proper
mixing of alkali. A mixer is provided on each of the measuring tank (Presently not in service
as we get 20% Caustic from T/F directly, so no need of any dilution). The feeding of water
and alkali is manually by VM1 and VM9 respectively without alkali measuring the operator
can not start the through fare regeneration.
BACK WASH OF SBA (optional 10 mts - flow 15 m3/hr)
Following valve remain open -
1. Back wash inlet valve VA3 (part).
2. Back wash outlet valve VA4 (full).
The degassed water will be supply by PDG pumps.
REGENERATION OF WBA/SBA VESSEL
STEP-1 : WBA - BACK WASH & SBA - Middle Collector Wash (10 mts/5mts)
Following valves will open -
1. Back wash inlet valve VA3 of WBA (open partly flow 22 m3/hr)
2. Back wash outlet valve VA4 of WBA (full).
3. SBA middle collector inlet valve VA13 (part open flow 15 m3/hr) SBA wash outlet
VA4 of SBA is full open. Selected PDG pump will run and ensure sufficient level in SDG
and alkali measuring tank MAK1 A/B.
STEP-2 WBA & SBA SETTLE BED (2 MTS)
All the valve of WBA and SBA remain close in this step with the pump being off.
STEP-3 WBA - Idle SBA - Power Water (3 mts)
Middle collector outlet valve VA14 (full open), down flow valve VA15 (part open flow 8
m3/hr), Alkali inlet valve VA9 (full open), and power water inlet valve VA32 of SBA (part
open flow 14 m3/hr) remain open. All valves of remain closed. This step is same as power
water that of SAC.
STEP-4 SBA-Idle SBA Alkali Injection (5 mts)
WBA -- All valve remain close.
SBA -- Middle collector outlet valve VA14 (full open), down flow valve VA15 (part
flow 8m3/hr). Alkali inlet valve VA9 (full) power water inlet valve VA32 (part 14m3/hr)
and VA2 alkali outlet valve of MAK1 A/B are open. Sp. Gravity of 4% NaOH - 1.040 and
5% NaOH 1.054 will be measured by sp. Gravity indicator.
STEP-5 WBA - Alkali Injection (25 mts)
SBA - Alkali Injection Continuous (20 mts)
WBA  Power water outlet valve VA32 on WBA (part open flow 30 m3/hr). Alkali inlet
valve VA9 (full) and rinse outlet valve VA6 (full open) remain open.
SBA Middle collector outlet valve VA14 remain closed and alkali outlet valve VA10
remain open and other valve remain open as per step no. 4.
STEP-6 Rinse - WBA Alkali Transfer - SBA (30 mts)
The valve states for WBA remain the same the valve status for SBA remain the same.
Expect that the alkali outlet valve VA2 of MAK1 A/B remain closed.
STEP-7 WBA and SBA Settle Bed (2 mts)
All the valve and pumps remain the same.
STEP-8 WBA - Fast Rinse, SBA - Idle (10 mts)
WBA inlet valve VA1 (full) and rinse outlet valve VA6 (part) remain open. This will wash
traces of alkali from WBA. SBA all the valves remain close.
STEP-9 WBA Service SBA - Fast Rinse (10 mts flow 150 m3/hr)
WBA Main inlet valve VA1 (full) and outlet valve VA2 (part) remain open.
SBA Service water valve VA1 full and rinse outlet valve VA6 (part open).
The regenerated WBA comes into service, supply water to rinse the traces of alkali in SBA
continue the rinse till quality become acceptable.
STEP-10 OFF SBA-WBA
In this step all the valves remain closed.
Description of WBA SBA
operation
Flow m3/hr Time minutes Flow m3/hr Time inutes
Backwash 22 10 15 10 or till
(optional) water is
clear.
Middle collector wash NA NA 15 5
Alkali injection Idle Idle 14 5
Down flow Idle Idle 8 5
Alkali inje(contd) 30 25 14 20
NA NA 8 20
Alk transfer/Alk rinse 47 25 14 30
down flow. NA NA 8 30
Final rinse 150 10 Idle Idle
Final rinse Service - 150 10
4.2.5 MB MIXED BED

MB has both cation and anion resin in mixed condition. So it is essential to back wash the
unit before regeneration to separate both cation and anion resin. Before starting the
regeneration operator has to do the following things :-
1. Acid has to be measured in MHL2 A/B by operating VM7 upto low marked level and
water to high level by VM14.
2. Alkali has to be measured in MAK 2 A/B by operating VM7 low level and water upto
high level. Before putting MB for regeneration following points to be ensured by operator.
I. Ensure acid and alkali have been measured correctly in volume in specific gravity.
II. One PDG pump to be put in the auto mode.
III. One BDG blower is to be started.
IV. One PPS, SAC, WBA, SBA should be in the service mode.
STEP-1 MIDDLE COLLECTOR WASH (5 mts 25 m3/hr)
Middle collector inlet valve VA13, back wash outlet valve VA4 remain open.
STEP-2 BACK WASH (15 mts 30 m3/hr)
Back wash inlet valve VA3 (part) and back was outlet valve VA4 remain open. This is an
import step as the resin have to be separated before regeneration. This is achieved by proper
back washing only. If back washing is proper the anion will settle above middle collector
and cell cation before it.
STEP-3 SETTLE BED (3 mts)
All the valves remain closed in this condition.
STEP-4 ALKALI POWER WATER (3 mts - 3.5 m3/hr & up flow 9.0 M3/hr)
All volume remains close in this step. Following valves remain open -
1. Middle collector outlet valve VA14 (full open)
2. Alkali up flow valve VA16 (part) open.
3. MAK2 A/B power water inlet VA32.
4. Alkali inlet valve VA9.
Upflow is to be maintained. Alkali will be injected from top and collected through middle
collector. Up flow is generated from ballon of vessel and collected to middle collector.
STEP-5 ALKALI INJECTION (15 mts - Flow 4.5 m3/hr)
All valves of stop no. 4 remain same and also new valve MAK-2 A/B alkali outlet valve
VA2 open.
STEP-6 ALKALI RINSE (20 mts - 4.5 m3/hr, up flow 9.0 m3/hr)
Middle collector outlet valve - 14 alkali upflow VA16 MAK 2 A/B power water inlet valve
VA32 and alkali inlet valve VA9 remain open. This step is to ensure proper displacement of
alkali.
STEP-7 SETTLE BED (2 mts)
All valves remain closed.
STEP-8 ACID POWER WATER (3 mts flow 3.5 m3/hr)
The following valves remain open -
1. Rinse outlet valve VA-6 (full open)
2. Acid inlet valve VA-7
3. Acid down flow valve VA-15 (part) and power inlet water VA-32 one of PDG pumps
selected will remain on.
STEP-9 ACID INJECTION (15 mts. injection flow 4.5 m3/hr, & down flow
3.6 m3/hr)
Rinse outlet valve VA6 acid downflow VA15 acid inlet VA7, acid outlet valve of MHL-2
A/B VA2 and VA32 will remain open.
STEP-10 ACID RINSE (15 mts rinse flow 15.0 m3/hr, down flow 3.6 m3/hr)
All valve status is same as step no. 9, but except MHL2 A/B acid outlet valve VA2 remain
closed.
STEP-11 DRAIN DOWN (6 mts)
Wash out valve VA-4, air release valve VA-12 and drain valve VA-17 remain open.
STEP-12 AIR MIXING (20 mts, flow 280 m3/hr)
Wash outlet valve VA4, air inlet valve VA11 from MB and air release valve VA12 remain
open the air from the blower will mix the separated anion and cation resin.
STEP-13 REFILL (2 mts)
Main inlet valve VA1, rinse outlet valve VA-6 and air release valve VA-12 remain open i.e.
water is tilled after air mixing.
STEP-14 FINAL RINSE (15 mts, flow 150 m3/hr)
Main inlet valve VA1 and rinse outlet valve VA6 remain open.
STEP-15 OFF
All the valve remain closed.
BACK WASH & REGENERATION OF FAC-CP AND MB-CP
Condensate polishing unit has FAC-CP and MB-CP regeneration procedure and steps are
same as that of DM water plant FAC and MB respectively. Only MHL-3 and MAK-3 will
be used instead of MHL-2 A/B and MAK-2 A/B respectively.
Stepwise water flow, time and water consumption figure are as follows :-
REGENERATION OF MB/MB-CP UNIT
Step Steps Flow rate Time minutes
m 3/hr
1 Middle collector wash 25/20 5/5
2 Back wash 30/22 15/15
3 Settle bed -/- 2/2
4 Alkali power water 3.5/14 3/2
5 Alkali injection up flow 4.5/15 & 9.0/20 15/12
6 Alkali rinse up flow 4.5/15 & 9.0/20 20/20
7 Settle bed -/- 2/2
8 Acid power water 3.5/7.5 3/2
9 Acid injection down flow 4.5/9 & 3.6/9 15/12
10 Acid rinse down flow 4.5/7.5 & 3.6/9 15/15
11 Drain down -/- 6/6
12 Air injection 280/280 20/20
13 Refill 150/120 2/2
14 Final rinse 150/140 15/15
15 Off -/- 1/1
4.2.6 SHUT DOWN

When total plant is to be stopped for annual shut down stop the plant as below :-
1. Close delivery valve of running treated condensate pump.
2. Lose delivery valve of running raw condensate pump, DM water pump, and the
pumps thereafter.
3. Close outlet valve VA-2 of SAC and MB to make the plant idle.
4. Close individual manual isolation valve to make the respective equipment idle.
5. To make idle any instrument, pump, blower and rotameter close their respective
isolation valves.
BACKWASH : F.P.S.
Steps Flow Rate Time Minute FPS-1 FPS-2
M3/Hr. From To From To
Air scouring 400 10
Backwash 120 10
Rinse 150 10
Off/Service …. 01
BACKWASH : FAC
Step Flow Time Minutes FAC-1 FAC-2
M3/hr From To From To
Back wash 100 10
Rinse 150 10
Off/service … 01
BACKWASH : SAC
Step Flow Time Minutes FAC-1 FAC-2
M3/hr From To From To
Middle 60 10
collector
Back wash 72 3
Settle bed - 2
Power water 51 3
Acid injection 15 20
Down flow 50 20
Acid rinse 51 30
Down flow 30 -
Final rinse 150 30
Off - 1
WBA/SBA - Regeneration
Step SBA WBA SBA-1 WBA-1 SBA-2 WBA-2
Flow Time Flo Time
Rate Mts w Mts
Back wash 22 10 15 10
Middle - - 15 5
collector
wash
Alkali injector Idle - 14 8
Down flow Idle - 14 8
Alkali injector 30 25 14 20
Down flow - - 8 20
Alkali transfer 47 30 4 30
Down flow - - 8 30
Final rinse 150 10 Idle Idle
Final rinse Service 150 10
MB/MB-CP REGERATION
Step Flow Rate Time Mts. MB-1 MB-2 MB-CP

M3/Hr
Fro To Fro To Fro To
m m m
25/20 5/5
30/22 15/15
2/2
3.5/14 3/2
4.5/4.5 15/12
9/20
4.5/15 20/20
9/20
-/- 2/2
3.5/7.5 3/2
4.5/4.5 15/12
3.6/9
4.5/7.5 15/15
-/- 6/6
280/280 20/20
150/120 2/2
150/140 15/15
-/- 1/1
CHAPTER 5
TROUBLE SHOOTING
Sr. Defects Causes Remedies
No.
1. Decrease a. Increase in ionic load. a. Check by analysing every
in capacity between two month.
successive
regeneration. b. Flow recorder b. Check it
defective.
c. Insufficient c. Check it.
chemical used.
d. Resin dirty. d. Give prolonged
backwash.
e. Plant being used
intermittently. e. Avoid this.
f. Channelling in
bed. f. Check and ensure
uniform. Distribution/
collection.
g. Resin fouled. g) If cation given HCL

wash if anion resin
give alkaline brine
treatment.
h. Resin deteriorated. h. Check and replace
charge.
i. Resin quantity i. Check and put up.

insufficient in unit.
2. Treated quality put upto a. Cation exhausted. a. Check

the standard. b. Anion exhausted. b. Check
c. M.B. exhausted. c. Check
d. M.B. resin not in d. Check and repeat air
unform state. mix and rinse.
e. Some valve like e. Check
back wash leaking.
f. Na slip from f. Check raw water
anion is high. analysis change in Na/To &
S/02/TA ratio use more
chemicals.
g. Unit idle g. Check
h. Unit not h. Rinse to satisfactory
sufficiently rinsed. quality.
i. Excessive low i. Adjust to between
flow rate. min/max flow rate.
j. Channelling j. Check and ensure
uniforms collection/
k. Resin fouled. distribution.
k. Check resin and give
I. Resin deteriorated. alkaline brine/ HCl treatment.
l. Check resin and
replace.

No.
3. Mixed red quality not a. Resin not a. Give extended back
good. separated during back wash after exhausting the bed.
wash property. b. Repeat
b. Air mix not c. Repeat
proper.
c. Final rinse not d. Check and examine.
proper.
d. Some valve may
be leaking and
contaminating the treated
water.
4. High residual CO2 from a. It can be due to a. Check of clean filter.

degasser. choked suction filter of
degasser air blower.
b. Improper air flow b. Check damper speed
to the degasser. of blower and discharge
pressure.
c. Degasser blower c. Check and operate
not in operation. blower.
d. Air seal not fitted/ d. Check or replace
broken resulting in short fitting.
circulating of air.
5. Unit rinse take long time. a. Flow rate a. Increase flow rate.
b. Unit exhausted. b. Regenerate unit.
c. Backwash valve c. Check and rectify.
passing.
d. Anion resin d. Give alkaline brine
organically fouled. treatment.
e. Mixed bed not e. Carry out air mix once
satisfactory. again.
f. Acid/alkali in f. Faulty design check
unit. and rectify. Back wash
(followed by ) and rinse
again.
6. Flow Rate a. Checked valve a. Check.

and suction strainer of
pump. b. Check.
b. in the pump. c. Check pump.
c. Low inlet d. Check.
pressure.
d. Distribution or e. Check and clean.
collecting system choked
e. Resin trap at f. Increase off take.
outlet choked.
f. Control valve
due to low off take.
No.
7. Pressure drop across the a. Defective valves a. Check
bed increasing day by b. Packed resin bed b. Give extended back
day. and fines present. wash with open manhole and
scrap off fines from top
surface of the resin.
c. Collecting system c. Check, repeat back
choked. wash.
d. Pressure gauge
defective. d. Check and rectify or
replace.
8. Flooding in degasser a. Very high air a. Reduce air flow rate

flow. by adjusting damper.
b. Open and check.
b. Packed tower
choked due to dirt or
broken packing materials.
9. Resin being lost. a. Excessive a. Check inlet pressure

backwash pressure/flow. and reduce it.
b. Faulty collecting b. Examine same for
system. breakages.
c. Inlet strainer c. Choke of replace.
damaged.
d. Excessive fine. d. Run the plant at design
flow rate.
10. Ejector not working e. Low power water e. Check this.
damaged.
f. Air lock in the f. Back wash and open
unit. air release.
g. Examine & rectify.
g. Checked and
defective valves. h. Check
h. Ejector nozzle
may be checked. i. Check for choke of
i. Topmost back collecting system outlet valve.
pressure from unit. j. Check & rectify.
j. Bulge in pipe
lining.
11. Incorrect reading from a. Checked orifice a. Check and clean.
rotameters. sub-orifice or inpulse
line. b. Check and clean.
b. Dirty glass and
float.
13. Level electrodes system a. Improper contact a. Check contact and

for measuring and between electrodes and rectify.
dilution tank not function control cabling.
properly. b. Shorting of the
two electrodes due to b. Clean and dry the
moisture or any foreign contacts of moisture & dist.
material.
Improper working at the
level controllers. a. Check.
No.
14. Leakage from acid a. Improper a. Check and adjust.
injection unloading adjustment of the
transfer pump. mechanical seal. b. Check concentration
b. Low strength of and take appropriate action.
sulphuric acid of
presence of ferrous
sulphate.
15. Corrosion in a) Low a. Check silica gel. reather in

concentrated acid tanks concentration of acid storage tank and replace
and lines. sulphuric acid. silica gel charge if exhausted.
b. Rectify.
b) Lining of HCL
tank/ pipe line damaged.
16. Improper operation and a. Defective solenoid a. Check

closing of pneumatically valves.
operated valves. b. Leakage in air line b. Check
from solenoid valve to
the respective control
valve.
c. Improper contact a. Check
of micro switch giving
false indication to the
panel.
CHAPTER 6
INSTRUMENTATION AND CONTROL
D.M. Plant is controlled by programmable logic controller (PLC) mounted in control room.
There is no back up control panel for D.M. Water Plant PLC has got redundant control
process units which will achieve simultaneously. It has also got graphic page with all alarm
pages. Operator can operate the plant from control room by PLC. Power for PLC will from
UPS system.
Plant is semi automatic i.e. backwashing of FPS and FAC will be done manually but all
regeneration steps will be done by PLC. Interlocks arrangements are provided for starting,
stopping or closing/opening of valves pumps blower or units when any parameter like
quality, pressure level goes out of specified limits. List of ANNUNCIATIONS AND
INTERLOCKS is as attached.
When compressed Air/PLC will fail, regeneration can be done by operating wheels of
Pneumatic Control Valves. Filling of acid and alkali in measuring tanks will be done
manually as nod auto valves are provided.
6.1 LIST OF ANNUNCIATORS
Sr No Discription
[1] [2] [3] [4] [5]
1. Inlet raw water PSL-051 Pressure Low

2. Degassed water pump, discharge PSL-052 Pressure Low
header.
3. Inlet totalized water at FPS-1 FOW-051A Qty Exceeded
4. Inlet totalised water at FPS-2 FQH-051A Qty Exceeded
5. Cond. ratio at SAC-1 CCAH-051A Qty High
6. Cond. Ratio at SAC-2 CCAH-051B Qty High
7. Degassed water storage tank LSL-051 Level High
8. Degassed water storage tank LSL-052 Level Low
9. Conductivity at WEA-10 outlet CCIH-052A Level High
10. Conductivity at WBA-2 outlet CCIH-052B Level High
11. Cond. At SEA-1 outlet CCIH-053A Level High
12. Cond. At SEA-2 outlet CCIH-053B Level High
13. Cond. At MB-1 outlet CCIH-054A Level High
14. Cond. At MB-2 outlet CCIH-054B Level High
15. Cond. At MB-CP outlet CCIH-055 Level High
Sr No Discription
[1] [2] [3] [4] [5]
16. pH Valve at SBA-1 outlet FPIH-051A Level High
17. pH value at SBA-2 outlet PHIH-051B Level High
18. pH value at MB-1 outlet PHIH-052A Level High
19. pH value at MB-2 outlet PHIH-052B Level High
20. pH value at MN-2 outlet PHIH-053 Level High
21. pH value at neut. Fit outlet PHIH-054 Level High
22. pH value at neut. Fit outlet PHIL-054 Level Low
23. Totalised flow at MB-1 outlet FQH-052A Qty Exceeded
24. Totalized flow at MB-2 outlet FQH-052B Qty Exceeded
25. Silica at SBA-2 outlet AIH-001 Qty Exceeded
26. Silica at SBA-2 outlet AIH-002 Qty High
27. Silica at MB-1 outlet AIH-004 Qty High
28. Silica at MN-2 outlet AIH-005 Qty High
29. Silica at MN or outlet AIH-007 Qty High
30. Acid measuring tank MHL-1A LSH-059A Level High
31. Acid measuring tank MHL-1A LSL-089A Level Low
32. Acid measuring tank MHL-1B LSL-089B Level Low
Sr No Discription
[1] [2] [3] [4] [5]
34. Alkali measuring tank LSL-053A Level High
35. Alkali measuring tank LSL-053A Level Low
36. Alkali measuring tank LSL-053B Level High
37. Alkali measuring tank LSL-054B Level High
38. Acid measuring tank MHL-2A LSH-060A Level High
39. Acid measuring tank MHL-2B LSL-060A Level Low
40. Acid measuring tank MHL-2B LHS-060B Level High
42. Alkali measuring tank MAK-2A LSH-055A Level High
43. Alkali measuring tank MAK-2A LSL-056A Level Low
44. Alkali measuring tank MAK-2B LSH-055B Level High
45. Alkali measuring tank MAK-2B LSL-056B Level Low
46. Alkali measuring tank MAK-3 LSH-057 Level High
47. Alkali measuring tank MAK-3 LSL-058 Level Low
48. Acid measuring tank MHL-3 LSH-061 Level High
49. Acid measuring tank MHL-3 LSL-061 Level Low
50. Degassed water pump PDG-1 … Tripped
51. Degassed water pump PDG-2 …. Tripped
52. Degassed water pump PDG-3 …. Tripped
53. MB air blower BMB-1 …. Tripped
Sr No Discription
[1] [2] [3] [4] [5]
54. MB air blower BMB-2 …. Tripped
55. Effluent tank pump PEP-1 …. Tripped
56. Effluent trans. Pump PEP-2 …. Tripped
57. Degasser air blower BDG-1 …. Tripped
58. Degassed air blower BDG-2 …. Tripped
59. Degasser air blower BDG-3 …. Tripped
60. Regeneration sequence (common …. …. Failed
for all the vessels)
6.2 LIST OF INTERLOCKS (REF. P AND I DIAGRAM DRG.NO. 6F)
INTER Discription (00296/B) AC NO.
1. If pressure drops below, then the regeneration should PSL-051
not start.
2. If con. ratio increase, then service cycle of that SAC OOAH-051A, 051B
vessel to trip.
3. If SDG level drops low the PDG pumps to trips. LSL-052
4. If PDG header pressure drops below set points, then PSL-052
the PDG pump selected in AUTO should start.
5. If the outlet conductivity increased, then the set point, OOIH-052A,052B
then the service cycle should stop. OOIH-053A,053B
OOIH-054A,054B
OOIH-055
6. If the totalized flow increases, then the set point, then FQH-052A, 052B
the service cycle of MB to trip.
7. If liquid level in the tank is high, then along with LSH-059A, 059B
alarm it should give mimic indication. LSH-060A, 060B
LSH-061
LSH-053A,053B
LSH-055A,055B
LSH-057
8. If liquid level in the tank drops below low set point LSL-089A, 089B
with injection, then its outlet valve VA-2 should be LSL-060A, 060B
closed, and the step should get changed. LSL-061
LSL-054A, 054B
LSL-056A, 056B
LSL-058
11. Acid/Alkali Measuring tank should be selected before MHL-1A-1B
the start of regeneration, so that particular vessel MHL-2A-2B
outlet valve and power water inlet valve will get MHK-1A-1B
operated. MAK-2A-2B
12. Each pressure vessel has an outlet valve VA-2. The KA-2 if SAC-1 & 2
limit switch is installed on that valve at close side, it WBA-1 & 2
the valve VA-2 does not closed fully then the MBA-1 & 2
regeneration should not start. MBC P
13. While doing MS regeneration standby WBA and SEA WBA/SBA of the
vessel should be selected in Auto service, otherwise other streams.
MB regeneration shall not start.
CHAPTER 7
DO AND DONOT
SN. Particulars DO DO NOT
1. Any centrifugal pump 1. Stop delivery Do not start pump.

trips valve of pump. Immediately without
2. Check level in rectifying the defect.
tanks if LSL is provided
and get sufficient level.
3. Check over load
relay if trip due to
overload and check
pump.
4. Check load in all
three phase for same Do not start polishing
current. unit before lowering
5. Temp. of down temp. below 4500.
condensate to be lowered
if GA/502 trip due to
over temp.
2. Of counter current After back washing of Do not back wash counter
exchanger unit. counter current current exchanger
exchanger (SAC & SBA) (WBA&MB) at every
regenerate the exchanger regeneration.
double volume of
regeneration.
3. Current Exchanger Unit Backwash the current Do not give double …..of
exchange (WAB & MB) regeneration.
every regeneration.
4. Running of Ion Exchange Run the units upto design Do not mean the unit
Unit. production through the more than design
resin is not exhausted. production.
5. Regenerant concentration Maintain concentrate of Do not prepare

and time. Acid/Alkali measuring Acid/Alkali solution
tank between 45%. between specified.
6. SAC injection Maintain minimum Injection time should be

injection time. not less than 15 mints.
Do not take SAC on
service if BMA variation
is three in two same of 5
mts. Interval.
8. Backwash Increase the basic Do not increase the flow

washing time if rate during back wash for
necessary. better back washing.
SN. Particulars DO DO NOT
9. Condensate Polishing Run the polishing till the Do not run the
temp. condensate below condensate polishing unit
45 deg C. if temp of condensate is
more than -5 deg C.
10. DM Water Parameter Run the plant upto design Do not run the plant if
production through any parameter is out of
parameters in the range. range before the design
production.
CHAPTER-8
PRESERVATION OF EQUIPMENTS/ MATERIAL
1. RESIN:
Resin should be stored in wet condition only. Put polyethylene bag in drum and fill
the resin and water and close the lid.
2. If any exchanger is made idle for short time and resin is inside, hold some water
inside the vessel by a closing outlet and fast rinse valve.
3. If PPS and FAC are idle, keep them wet to avoid hard mass on upper layer bed by
closing of outlet valve or stop them after backwashing of PPS and FAC.
4. If neutralising pit is idle for long time, keep HDPE lines cleaned to avoid blocking of
aeration holes, electrical rotor is removed from its position electrical connection for space
heater should be provided.
5. If electrical motor is removed from its position electrical connection for space heater
should be provided.
6. All rotating equipments lubricating material (oil/grease) should be replaced with good
one if they will be not in use for a long time.
7. If plant is idle for long time, keep measuring tanks empty.
8. If blower (MB Blower) is idle for long time, clean and grease the tubes to avoid
further rusting.
CHAPTER-15
SAFETY PRECAUTIONS
1. Unauthorised entry should be stopped in plant.
2. Do not move in plant without wearing safety helmet and safety shoes.
3. Always wear protective face shield and clothing while working on or near chemicals
injection pumps.
4. Wear face shield/rubber gloves while handling any chemical.
5. Do not wear loose cloths.
6. Maintain good housekeeping.
7. Check pumps coupling guards are properly fixed.
8. Use hand gloves while operating valves.

PART 2
D.M.PLANT 2 & 3.
(ION EXCHANGE SUPPLIED PLANT)
CPP - UTILITY
RELIANCE INDUSTRIES
LIMITED.
HAZIRA.
GENERAL DESCRIPTION OP THE EQUIPMENTS :
.1 ACTIVATED CARBON FILTER (Tag No.FA-1158 A/B/C) :

This is a mild steel pressure vessel internally painted. It is externally fitted with MS pipe
work, diaphragm and butterfly valves, pressure gauges at inlet and outlet. A differential
pressure indicating switch provided across the carbon bed. Activated carbon filter is provided
to remove free residual chlorine and non-polar organic matters.
Internally the ACF units fitted with header lateral type bottom collecting system which
consists of a mild steel epoxy painted (externally and internally) header to which PVC
laterals are screwed. Small holes are drilled throughout PVC laterals towards bottom for
collecting filtered water.
For inlet water distribution, inverted bellmouth type distributor is provided. This distributor
is mild steel construction, painted by epoxy paint externally and internally. This distributor
acts as an effluent collector during backwash operation of regeneration. Different layers of
underbed materials like pebbles, silex etc. are charged as supporting media. Dechlorination
grade activated carbon is charged on top of underbed media. The ACF needs to be
backwashes when pressure drop across the bed exceeds 0.7 bar
Step-1 : Backwash :
During this operation water is passed through filter bed from bottom to top. Entrapped
suspended particles, dirt etc. are remove while passing water from bottom to top and then to
drain. Backwash to be continued till the effluent coming out is clear. Flow maintained during
this operation is 91.6 m3/hr.
Step-2 : Rinse :
Daring this step water is passed from top to bottom and drained. this oparatlon to be
continued till effluent is clear.
2. STRONG ACID CATION UNIT : Tag No.FA-1159 - A/B/C
This is a mild steel vessel lined internally with rubber. It is externally fitted with rubber lined
pipe work, diaphragm aalve, pressure gauges at inlet and sampling valves at inlet and outlet.
A calibrated orifice board in the drain sump is also provided for controlling various
regeneration flows. The water is distributed from the top. The middle collector is of header
lateral type. The header is of mild steel rubber lined and rubber covered to which PVC
laterals are fitted. Strainers which prevent resin from escaping are screwed to the bottom of
the laterals. Bottom collecting system is of strainer on plate type. Double decker (button
type) strainers have been used for bottom collecting system whereas mark 871 (disc type)
strainers have been used for middle collecting system. The vessel is charged with strongly
cationic resin (Indian 225). When the desirea output is obtained or when the quality of outlet
water from SAC with respect to sodium ions is deteriorated. Then the unit should be
regenerated.
QUALITY OF CATION TREATED WATER :
pH : 2.0 - 3.0
Total Hardness : Nil
Sodium + Pottasium : Lesa than 2 mg/l
A resin trap is provided at unit outlet to trap Ion exchange resins in unlikely event of bottom
collecting system failure.
The regeneration is carried out as follows :

a) Sub-surface wash / backwash :
Backwash operation is carried out to loosen the bed and to remove the suspended impurities
from the resin. Backwash operation is carried out once after 7 regenerations or when
pressure drop across the unit increases beyond acceptable limits of 1 bar whichever occurs
earlier. When backwash is given to SAC, 120 kg/m3 regeneration level is to be employed to
ensure bottom layer of resin is highly regenerated. Sub-surface wash is carried out for each
regeneration.
backwash is given at 102 m3/hr for 10 minutes and subsurface wash is given at 102 m3/hr for
5 minutes.
b) Acid Pre-injectionbuffer down flow :
The operation is carried out to set the power water flow rate to the required flow before
injecting acid.
c) Acid Injectionbuffer down flow :
HCl of 5% concentration is injected at 95.43 m3/hr into SAC, by means of an acid injection
ejector. The acid is injected through SAC bottom collecting system and effluent is taken out
through middle collector to drain sump. During injection to prevent fluidisatior of SAC bed,
a down flow of water is maintained at 95. 43 m3/hr. This injection is carried out for 20
minutes.
d) Slow Rinse :
The excess acid in SAC unit after acid injection is displaced with degassed water at a flow
rate of 95.43 m3/hr. Down flow of water is maintained during this stage also. Duration of this
step would be 37 mins.
e) Final Rinse :
This operation is carried out to remove excess acid and liberated cations from SAC unit. The
operation is carried out for 5 minutes at a flow rate of 200 m3/hr.
3. WEAK BASE ANION (WBA) : Tag No. FA-1161 - A/8/C.
This is a mild steel vessel lined internally with rubber. It is externally fitted with rubber lined
pipe work, diaphragm valves, pressure gauge at the inlet and outlet , conductivity indicator at
the outlet and sampling valves both at inlet and outlet.
A calibrated orifice board in the drain sump is also provided for controlling various
regeneration flows. The water is distributed from the top and each arm is provided with PVC
bell mouth which will also act as backwash collector. Alkali distributor is also of three arms
(inverted bends with PVC spacers and blank flange) made out of mild steel and lined
internally as well as externally with rubbers. Bottom collecting system is of strainer on plate
type. Mark 79 strainers are directly fitted on the bottom plate. The vessel is charged with
weak base anion resin (Indian 850). The regeneration of the unit is done in thoroughfare with
SBA. A resin trap is provided to trap ion exchange resins in the unlikely event of the bottom
collecting system failure. Flow indicate- is provided at the inlet.
4. STRONG BASE ANION UNIT : Tag No.FA-1162 - /B/C.

It is a mild steel vessel lined internally with rubber. It is externally fitted with rubber lined
pipe work, diaphragm valves, pressure gauge at the inlet and sampling valves at inlet and
outlet A calibrated orifice board in the drain sump is also provided for controlling various
regeneration flows.
Backwash outlet and service inlet provided internally, essentially consists of rubber lined
rubber covered bell mouth. .
The bottom collecting system is of strainer on plate type. Mark 79 strainers are used for
bottom collecting system. Thus bottom collecting system is acting as distributor for caustic
solution. Middle collecting system is provided with header lateral assembly. The header is
mild steel rubber lined rubber coated to which PVC laterals with Mark 871 strainers are
fitted. This middle collecting system is acting as a collecting system for regenerant, during
regeneration. The vessel is charged with strongly basic anion resin FFIP when the desired
output from the pair of units (SBA & WBA) is obtained or when the quality of treated water
from SBA outlet with respect to silica is deteriorated then the unit should be regenerated in
thoroughfare with WBA using NaOH as regenerant. A resin trap is provided to trap ion
exchange resins in the unlikely event of failure of bottom collecting system. A conductivity
indicator is provided at the outlet of the unit to give alarm in case the conductivity increased
beyond the acceptable limit.
Flow Indicator is provided at the inlet. Regeneration of SBA and WBA is carried out
simultaneously.
The regeneration is carried out in 6 stages.
SBA Treated Water Quality :
pH: : 7.5 to 9.5

Conductivity: : less than 10 us/cm
SiO2 : less than 0.2 Pam
a) Backwash/Sub-surface wash :
The operation ia carried out to loosen the resin bed and to remove the suspended impurities
from the resin. Backwash operation is carried out at 24.12 m3/hr for 5 minutes in WBA unit.
SBA backwash shall be done only once in 7 regenerations at 15.93 m3/hr flow for 10
minutes. The sub-surface wash is carried out for each regeneration of SBA unit at 15.93
m3/hr for 5 minutes.
b) Caustic Pre-injection :
This operation is carried out to set the power water flow rate before injecting alkali. The
pre-injection flow is 77. 5 m3/hr in WBA and 35.23 m3/hr in SBA unit for 2 minutes. Down
flow is given at 42.28 m3/hr flow to prevent fluidisation of resin in SBA.
c) Caustic Injection :
Specified quantity of caustic is injected by means of ventury ejector to regenerate the

exhausted resins. 3. 33% caustic solution at flow of 42.28 m3/hr is injected in SBA unit for
30 minutes.
d) Slow Rinse :
This operation is carried out to ensure optimum utilization of alkali injected. The unused
alkali in SBA unit after caustic injection, is transferred to WBA with the help of power water
. Caustic transfer from SBA unit is carried out at 35.23 m3/hr for 23 minutes into WBA unit.
Down flow at 42.28 m3/hr is maintained during this stage also.
e) Rinse :
This operation is carried out to remove excess caustic and liberated anions from both SBA
and WBA units. The operation is carried out separately. WBA unit is rinsed at 200 m3/hr for
18 minutes and SBA at 200 m3/hr for 8 min.
1.5 MIXED BED UNIT : Tag No.FA-1163 - A/B/C.
This is a mild steel vessel internally lined with rubber. It is externally fitted with rubber lined
pipe work, diaphragm and butterfly valves, pressure gauaes and sampling valves at inlet and
outlet. Also a conductivity inidcator , pH indicator and silica analyser are provided at each
unit outlet. At common outlet header of mixed bed a flow indicator integrator is provided.
A calibrated orifice board in the drain sump is also provided for monitoring various
regeneration flows.The middle collector and bottom collecting system are of header lateral
type. The header is of mild steel, rubber lined and rubber covered to which PVC laterals are
fitted. Strainers which prevent escape of resin are screwed to the bottom of the laterals. Mark
‘V’ strainers have been used.
Inlet water distributor is of three arms with strainers to avoid escape of resins during back
washing. Bottom dished end portion of the vessel is fitted with concrete which acts as dead
weight and prevents the division plate from buckling due to weight of water and resin.
The vessel.is charged with a mixture of both strongly acidic cation (Indian 525) and strongly
basic anion (Indian FFIP). When desired output from the unit is obtained or when the quality
of outlet water with respect to either silica or conductivity is deteriorated, then the unit
should be regenerated. Cation resin is regenerated with HCl and anion resin with NaOH.
A resin trap is provided to trap ion exchange resins in the unlikely event of failure of bottom
collectlnc system.
Regeneration of MB is carried out as follows :
a) Backwash :
This operation is carried out to separate the resins prior to injection of chemicals. Due to
difference in densitities, the resins get separated in two layers during the back washing, with
cation forming lower layer and anion forming upper layer. Backwash is carried out for 10
min. at a flow rate 40.68 m3/hr.
b) Sub-surface Wash :
This operation is basically carried out to clean the middle collector strainers to ensure proaer
distribution / collection during injection of chemicals. Duration of this step is 5 min and flow
rate maintained shall be 40.68 m3/hr.
c) Acid Pre-injectiondown Flow :
Water flow for acid injection is established through acid ejector at a flow rate of 8.14 m3/hr.
A down flow is maintained at a flow rate of 6.78 m3/hr to prevent diffusion of acid into
anion resin region Effluent is collected by the bottom collecting system and drained to the
drained valve Duration of this stea is 2 mins.
d) Acid Injection/Downflow :
Once the pre-injection flows are established , 5% HCl is fed to the unit through middle
collecting assembly. Ejector section valve of AMT-2 is adjusted to have the required
concentration . Concentration of aad ejector delivery is monitored. Duration of this step is 10
mins
e) Acid Rinse/Downflow :
After completion of the acid injection water is continued to pass at a flow rate of 18 08 m3fhr
to displace / fully utilize the regenerant Downflow is continued to maintain during this step.
Duration of this step is 15 minutes.
f) Alkali pre-injection/upflow :
Water flow for alkali injection is established through alkali ejector at a flow rate of 25.47
m3/hr. An up flow is maintained at a flow rate of 20.34 m3/hr to prevent diffusion of alkali
into cation resin region. Eafluent is collected by the middle collector system. Duration of this
step is 2 minutes.
g) Alkali anjectioo/Upflow :
Once the pre-injection flows are established, 3.33% Nash is fed to tae unit through alkali
inlet located at the top of resin bed. Ejector section valve of CDT-2 is adjusted to have the
required concentration. Concentration of alkali at ejector delivery is monitored. Duration of
this step is 15 minutes.
h) Acid Rinse/Upflow :
After completion of alkali injection water is continued to pass at a flaw rate of 50.43 m3/hr to
displace / fully utilize the regenerant. Up flow is continued to maintain during this step.
Duration of this step is 20 minutes.
i) Drain Down :
Water from the vessel is drained upto about 300 mm above the top surface of resin bed
(aparox. half of top inspection winaow). Duration of this step would be approx. 10 minutes.
j) Air Mix :
Air is passed from the bottom of the unit to mix both the resins thoroughly. The mixing and
movement of the resin bed can observed through inspection windows. Duration of this step is
10 minutes.
k) Forced Settle :
Resin bed is forced to settle with down flow of inlet water. Faster settling will prevent
re-separation of resin bed. Duration of this step is 2 minutes.
l) Refill :
The unit is filled with feed water before rinsing the unit. Duration of this step is 4 minutes.
m) Final Rinse :
Service water is taken from inlet and drained from the rinse outlet for 10 minutes to remove
traces of regenerantes and liberated ion from the bed.
n) Rinse Recycle :
At the end of final rinse, rinse water is not allowed to drain and taken back to Degasser
Water Tank. This operation is continued till desire quality of treated water is obtained.
2.0 TECHNICAL DATA :
1. DESIGN WATRR ANALYSIS (FOR DM3)
PARAMETERS Raw Water D.M. Water
pH 7 to 9 7 +/- 0.2
Conductivity Us/cm at Amb.Temp. - 0.2
Turbidity as NTU 2 Nil
TDS (ppm) 386 0.05
Dissolved Oxygen (ppm) 7.6 Negligible
Total Hardness ppm as CaC03 160 Nil
M. Alkalinity - do -- 200 Nil
Sulphates - do -- 42 Nil
Chlorides - do -- 106 Nil
Phosphate - do -- Nil Nil
Calcium - do -- 60 Nil
Magnesium - do -- 100 Nil
Sodium - do -- 187 Nil
Iron as Fe 0.5 0.005
Silica PPM as SiO2 25.2 < 0.02
Free Chlorine PPM < 0.8 Nil
Organic Matter PPM < 0.1 Negligible
Colloidal Silica as SiO2 0.2 -- Do --
2.2 ACTIVATBD CARBON FILTER (ACF) : Tag No.FA-1158 A/B/C :
Number Off : Three

Diameter : 3600 mm
Height on straight : 2300 mm
Material of construction : M.S. Epoxy painted.
Type of collecting system : Strainer on plate.
Nett Treatment Flowunit : 200 m3/Hr.
Time of service cycle : 24 Hrs.
Time of Regeneration Cycle : 15 min.
Capacity between regeneration : 4000 m3.
Regeneration Flows :
Backwash : 91.6 m3/hr Time : 5 - 10 min.
Rinse :122 m3/hr Time : 5 min.
2.3 STRONG ACID CATION EXCHANGER (SAC) : Tag No. FA-1159 A/B/C
Number off : Three

Diameter : 3800 mm
Material of construction : MSR/L
Capacity between regenerationunit : 4000 m3
Period between regenerationunit : 20 hours
Time for regeneration / unit : 74 mins
Resin Type : Indion 225 H
Resin quantity / unit : 30.61 m3
Regenerant quantity / unit : 1590.20kgs Hal as 100%
Type of bottom collecting : Strainer on Plate
Type of valve operation : Semi-automatic (PLC Based)
Operation Flow (m3/hr) Time (Min.)
Backwash (optional) 102.06 5

Middle collecter wash 102.06 5
Acid pre-injection 47.71 2
Down flow 95.43 2
Acid Injection at 5% 95.43 20
Down flow 95.43 20
Acid Rinse 95.43 37
Down flow 95.43 37
Final Rinse 200 5
2.4 DEGASSER TOWER (DOT) : (Tag No.GB-1153 A/B/C) :
Number Off : Three

Diameter : 2000 mm
Packed Bed : Pall Rings
Pall Rings Quantity per unit : 9 m3
2.5 DEGASSED WATER TANK (DGWT) : (Tag No.PB-1161)

Number off : One
Diameter : 12000 an
Height on Straight : 4400
2.6 WEAR BASE ANION EXCHANGBR (WBA) : (Tag No.PA-1161 - A/B/C)
Number off : Three

Diameter : 3200 mm
Time for regenerationunit : 73 mins (Thoroughfare)
Resin Type : Indion 850
Resin quantityunit : 13.15 m3
Regenerant quantity/unia : Throughfare with SBA
Type of bottom collecting : Strainer on Plate
Operation Flow (we/hr) Time (Min.)
Backwash 24.12 5
Caustic pre-injection 77.84 2
Caustic Injection (1.2%) 84.56 30
Caustic Rinse 77.55 23
Rinse 200 8
2.7 STRONG BASE ANION EXCHANGER (SBA) : (Tag No FA-1162 A/B/C)
Number off : Three

Diameter : 2600 mm
Time for regenerationunit : 73 minutes
Resin Type : FFIF
Resin quantityunit : 6.11 m3
Regenerant quantityunit : 704.7 as loOa Nash
Type of bottom collecting : Strainer on plate
Regeneration Flows:
Backwash aoptaonal) 15.93 5

Sub-surface wash 15.93 5
Caustic pre-inaection 35.23 2
Down flow 42.28 2
Caustic Injection (3.3%) 42.28 30
Down flow 42.28 30
Caustic Rinse 35.23 23
Down flow 42.28 23
Final Rinse 200.0 8
2.8 MIXED BED EXCHANGER (MB) : (Tag No.FA-1163 A/B/C)

Numher off : Three
Diameter : 2400 mm
Nett Treatment Flow rate / unit : 200 m3/hr
Period between regeneration / unit : 280 hours
Capacity between regeneration / unit : 56000 m3
Resin Type / quantity : 2.26 m3 of Indion 225H
4.203 m3 of Indion FFIP
Chemicals per Regeneration : 135.6 kg as 100% HCl
252.2 kg as 100% NaOH
Time for regeneration : 106 min.
Type of valve operation : Semi Automatic
Backwash 40.68 5
Middle collector flush 40.68 5
Acid pre-injection 8.14 2
Downflow 6.78 2
Acid Injection 5% 16.27 10
Downflow 6.78 10
Acid Rinse 18.08 15
Downflow 6.78 15
Alkali Prelnjection 25.47 2
Upflow 20.34 2
Alkali injection 30.56 15
Upflow 20.34 15
Alkali Rinse 50.43 20
Upflow 20.34 20
Draindown/Air Mix - -
Forced settle 200 3
Refill 200 3
Final Rinse (recycle) 200 3
2.9 DEGASSBR AIR BLOWER (DGB) : (Tag No.GB-1153 A/B/C/S)
Number off : Four

Capacity : 94 m3/min.
Discharge Head : 50 mmwg
Material : MS
Type : Datta Air System
Make : Ion Exchange
Model : 411A/25
Medium : Air
RPM : By cliant
Motor : By Client
2.10 DEGASSED WATER PUMP : (GA-1160 A/B/C/S)
Number off :4
Capacity : 215 m3/Hr.
Discharge Head : 70 mmwc
Material : SS 316
Type : Horizontal - Centrifugal.
Make : SAM Turbo Industry ltd.
Model : CPH 100/260.
Medium : Degassed water
RPM : 2900 RPM
Motor : By cliant.
2.11 MB AIR BLOWER : (GB-1154 - A/S)
Number Off : Two

Capacity : 9 m3/Min. at o.4 kg/cm2 (g)
Material of Construction : Cast Iron
Type : Possitive Displacement Twin Lobe
Motor Speed : 1460 RPM
Blower Speed : 1060 RPM
Make : Everest.
Model No. : 610
Medium : Air
Motor : By cliants.
2.12 ACID MEASURING TANK FOR SAC : (FB-1155) A/B)
Number Off : Two

Diameter : 2800 mm
Depth : 3000 am
Material of construction : PP/FRP
Concentration o' acid in tank 10% Hcl
2.13 ACID MEASURING TANK FOR MB (TAG No.FB-1157A,8
Nuber Of f : Two
Diameter : 1200 mm
Depth : 1500 mm
Material of construction : PP/FRP
Concentration of acid in tank : 10% HCl Acid
2.14 CAUSTIC DILUTION TANK FOR SBA (Tag No.FB-1154 A,B)
Number of f : One
Diameter : 1800 mm
Depth : 1600 mm
Material of Constructtion : MSR/L
Fluid Stored : Caustic Soda 20 %.
2.16 CAUSTIC DILUTION TANK FOR MB (Tag No.FB-1158A,B)
Number off : Two

Diameter : 1200 mm
Depth : 1400 mm
Material of Constructtion : MSR/L
Capacity / Fluid Stored : Caustic Soda 20a
2.17 Neutralizing pit
Number Off : Two

Size : 14500x9000x4800 Deep
Material of Construction : RCC Acidalkali Proof Lined
2.18 WASTE WATER DISPOSAL PUMP (Tag No.Ga-1159 A/B)
Number Off : 2 Nos.

Capacity : 150 m3/hr
Material of construction : CI R/L
Type : Horizontal Centrifugal
Model No. : CPP 150 *100- 315RAL
Make : SU Motors Pvt. Ltd.
MOTOR (By Clients) :
2.19 ACID MEASURING TANK FOR N-PIT (AMT3) FB1159
Numbers off :One

Height :1400 mm
Moc :PP/FRP
2.20 CAUSTIC MEASURING TANK FOR N-PIT (CDT3) FB1160

Numbers of f : One
Diameter : 1400 mm
Height : 1400 mm
Moc : MSRL
LIST OF INSTRUMENTS WITH TECHNICAL DATA
2.21 FLOW INDICATING TRANSMITTER (FIT)
Number offered : 2 Nos.

Make- model Rosemount : 1151DP4J22BIMI
Type :Variable Capacitance ( 2 Wire )
Power Supply : 24Y DC,600 OHMS
Output Signal : 4-20 MA DC (Linear)
Accuracy : -/+ 0.25% of span
Range : 0 - 2500 mm WG
Material of construction : SS 316
Tag No Location Qty.
11-FT-580 Filter Water Inlet Header 1 No

11-FT-522 MB Outlet Header 1 No
2.22 pH INDCATING TRANSMITTER :
pH MONITOR ;
Quantity
Make : Rousement
Range :0 to 14 pH
Mounting :Field
Input Power supply :24 V DC
Output :4 - 20 mA Liner
Accuracy :+/- 0.02 pH
Temp. Compensation :Automatic
Model ;1181PH-01-07-11
Tag ao. Location
11 PHIT-580 A/B/C SBA7a8/9 Outlet
11 PHIT-581 A/B/C MB7/8/9 Outlet
11 PHIT-582 Waste Disposal Pump Disch
2.23 pH SENSOR ASSBMBLY :
Quantity :7 No
Type :Flow through
Model : 399PH- 0&-11
(Tag no -11PHE 580A/B/C)
Make :Rosemount
2.24 PRESSURE INDICATOR (PI)
Type : Bourdon tube

Element Material : SS 316
Accuracy :+/- 1 % of full scale range (for PG-
29,30,31, 32-1.5% of FSR)
Make : H. Guru
Connection : 1/2” NPT(M) Bottoom
Dial Size : 150 mm
Over range Protection : 125%
Tag No Location Range Qy.
11 PI-1580 A/B/C ACF7,8,9inlet 3

11 PI-581 A/B/C ACF 7,8,9 outlet 3
11 PI-582 A/B/C SAC 7,8,9 inlet 0-10 Kg/cm2 3
11 PI-583 A/B/C SAC 7,8,9 outlet 0-10 Kg/cm2 3
11 PI-584 A/B/C SAC 7,8,9utlet 3
11PI-587 A/B/C WBA 7,8,9 inlet 0-10 Kg/cm2 3
11 PI-588 A/B/C WBA7,8,9outlet 0-10 kg/cm2 3
11PI-589A/B/C WBA7,8,9outlet 0-10Kg/cm2 3
11 PI590A/B/C/ SBA7,8,9 inlet 0-10Kg/cm2 3
11 PI-591 A/B/C SBA7,8,9 outlet 0-10 Kg/cm2 3
11 PI-592 A/B/C SBA7,8,9 outlet 0-l0 Kg/cm2 3
11 PI-593 A/B/C MB 7,8,9 inlet 0-10 Kg/cm2 3
11 PI-594 A/B/C MB 7,8,9 outlet 0-10 Kg/cm2 3
11 PI -595 A/B/C MB 7,8,9 outlet 0-10 Kg/cm2 3
11 PI- 586 A/B/C/S Deggassed water 0-10 Kg/cm2 4
pump discharge
11PI-596 A/B Waste water 0-4 Kg/cm2 2
pump discharge
11 PI-597 A/S MB Blower A,S 0-0.6Kg/cm2 2
11-PI-598A/B Regeneration 0-4 Kg/cm2 2
water pump discharge
11-PI-599 Instrument air 0-10 Kg/cm2 1
header
Type : Discharge type

Quantity : 4 nos
Make : WITRIV
Range : 0-250mmwc
Tag no Location
11 PI 85 ABCS Degasser Blower
2.24 Differential Pressure gauge (DPI):
Type : Differential pressure gauge

Qty : 2 Nos.
Make : Switzer
Range : O-3000 mmwc
Model : 106-UE-06-FC
Tag no Location
13DP 1750Across AVGF sand bed

13DP 1751 Across AVGF sand bed
2.25 SILICA ANALYSER (SIA-1,2) :
Quantity : 2 Nos.
Type : On line calorimetric
Make/model Hach / series : 5000,60000
Power Supply : 110V AC,50HZ
Output : 4 -20 MA DC
Enclosure : IP 65/NEMA 4X
Range : 0-5000 PPBas SIO2
Display : Digital;
Accuracy/resolution : 2 PPB /1 PPB Respectively
Mounting : Bench Top
Tag No. Location

11 SIA-581 SBA Outlet - common header
11 SIA-580 MB Outlet - common header
2.26 SODIUM ANALYSER : Qty Make Model
Qty : 1 no.
Make : Polymetron
Model : 9073 with'k’ kit
Tag no. Location

11 Na A580 SAC Outlet
2 .27 CONDUCTIVITY INDICATING TRANSMITTER :

Numbers Off : 9 Nos.
Make : Rosemount
Model : 150-03-19-54
Power Supply : 24V DC
Type : 2 aire indicating type
Sensitivity : < 0.07% span
Stability : < 0.05%
Mounting : Field
Output from monitor: 4 -20 MA DC
Tag No. Location

11 CIT-580 A/B/C WBA 7, 8, 9 outlet
11 CIT-581 A/B/C SBA 7, 8, 9 outlet
11 CIT-582 A/B/C MB 7, 8 , 9 outlet
2. 28 a LEVEL INDICATOR :
Type : Float & Cord Type
Make : Revathi Electronics
Material of Construction : Float SS 316
Wire Rope : Nylon
Location : Degassed Water Tank
Tag no. : 11 LIFB 580
2. 28 Magenetically coupled level indicator:
b) Make : Revathi Electronics

Type : Roller magnet type
Scale : Linear marking
Location c-c dist Qty Moc Tag no
AMT1-A,B 2750 2 Polypropylene 11 LI 580 A,B

AMT2-A,B 1300 2 Polypropylene 11 LI 581 A,B
AMT3 1200 1 Polypropylene 11 LI 584
CDT1-A,B 1400 2 SS 304 11 LI 582 A,B
CDT2-A,B 1200 2 SS 304 11 LI 583 A,B
CD3 1200 1 SS 304 11 LI 585
2 .29 LEVEL SWITCH :
a) Type : Externally side mounted magnetic type float operated

Model
Contacts : 5 Amps - 110V AC
Material of Construction : SS 316
Range : 0 - 4400 mm
Tag No. Location
11 LS-580 Degassed Water Tank (HL)
11 LS-581 Degasaed Water Tank (LL)
2 .29 LEVEL SWITCH :

b) Quantity : : 8 Nos.
Type : Top Mbunted Magnetic float operated
Material of Construction : SS 316 for CTD, PP for AMT
Contacts : 5 Amps, 110 V AC
Tag No. Location No. of floats
11 LS-584A/B CTD-1 A/B 2
11 LS-585A/B CTD-2 A/B 2
11 LS-582A/B AMT-1 2
11 LS-583 A/B AMT-2 2
2.30 TOP MOUNTED LEVEL SWITCH INDICATOR :
Qty : 2 no
Make : Revathi
Range : 5300 am stem len
Tag no Location
11 LIS 586 A NPA
11 LIS 586 B NPB
2. 31 DIFFERENTIA PRESSURE INDICATING SWITCH :

Qty : 3 nos
Make : Switzer
Range : 0-0.75 kg/cm2
Model : LL-C-A-1-HA2-2
Tag no Location
ll DPIS 580 Across ACF
2.32 RATE OF FLOW INDICATOR :

Make : Trac
Range : 0-250 m3/hr
Tag no Location Model
11 FI 580 A,B,C ACF 7,8,9 Inlet TG-250-111-CCS
11 FI 581A,B,C SAC 7,8,9 Inlet
11 FI 582 A,B,C WBA 7,8,9 Inlet TG 250BP-
111TG-250BP 111XXSN
11 FI 583 A,B,C SBA 7,8,9 Inlet ,,
11 FI 584 A,-B,C MB 7,8,9 Inlet ,,
b) Range:0-100 m3/hr AMT 1A,B Ejector ”
11 FI 585 A,B power water inlet
(c) Range:0-25m3/hr CDT 1A,B Ejector ,,
(d) Range:0-50 m3/hr CDT 1A,B Ejector ,,
(e) Range : 0-60 m3/hr CDT2A,B Ejector ,,
(f) Range: 0-180 m3/hr ` Inlet to AVGF PA 1363 16-250BP-111CCSN
13 FI 750
(g) Range: 0-200 m3/hr Inlet to AVGF PA 1365 16-250BP-111CCSN
Inlet to AVGF PA 1365 16-250BP-111CCSN
13 FI 751
2.32 PRESSURE SWITCHES :
Quantity : 5 nos.
Type : Bellow Sensing Type
Make : Switzer
Material of construction : SS 316 bellows,
other parts SS 316
Tag No. Model Location
11 PS-580 GM201-02 A7K-22 Filter Water Inlet Header

11PS-581 GM201-02C3R-22 DM water Inlet Header
11 PS-582 GM201-02C3K-22 DM water Outlet Header
11 PS-583 GM201-02A7K-22 Instrument air header
11 PS-584 GM201-02A7K-22 Degassed water
pump discharge header
3. CONTROL PHILOSOPHY-DM WATER PLANT III
Data Sheet No.A4-A70096-12-25
Following are the salient features of control philosophy for operation of

Demineralisation Plant III
1. BASIC CONTROLS AND SYSTEM
The instrumentation and control system are provided formonitoring and controlling
various process variables related to each equipment and sub-system. .
Operation of the Demineralisation Plant is done semiautomatically through a

Programmable Logic Controller (PL), which is used for the purpose of regeneration
and service operation of various equipments like SAC, WBA/SBA, MB, Chemical
Measuring Tanks and inaection systems. Signals for various alarm condition like
high totallsed flow, high conductivity, high Sodium, high Silica, high or low pH,
high or low levels of various process tanks and low pressure will go to the PLC. PLC
shall accept all digital and analog signals from the field. A few signals shall be
repeated for remote monitoring on DCS as described later in this write-up.
The Demineralisation Plant comprises of three streams. Each stream consists of

Activated Carbon Filter, Strong Acid Cation exchanger, Degasser unit, Week
Base Anion exchanger, Strong Base Anion exchanger and Mixed Bed. Acid
Measuring Tanks, Alkali Measurina aanks, Regenerant Iniection Systems and
Effluent Disposal SaJstem is common for all streams.
At a time, only one stream can be regenerated. At least one of the other two streams
shall be in operation during regeneration of one stream. Any one of SAC (A/B/C)
and any one of WBA/SBA (A/B/C) can be regenerated one by one or
simultaneously. Normally, WBA/SBA of a particular chain is operated as a pair.
However, provision is made in PLC software sothat any combination of
SAC,WBA, SBA can be selected for regeneration. Selection of required combination is
done through keyboard. For regeneration of Mixed Bed (A/B/C) , any one of WBA/SBA
unit should be in service. Regeneration is carried out for individual units as
selected.
The starting of the regeneration operation is initiated through PC key board for
individual units. Operator intervention is provided at appropriate stages to hold,
reset, advance , skip or dwell in stages.Refer to Valve Sequence Chart
No.A3-A70096-08-01/0a/03 for details about sequence of valve operations and
durations.
2. CONTROL LOGIC
The Control Logic is described for each unit or sub-system starting with Activated
Carbon Filter. The procedure follows the process stream flow path ; it is not
necessarily reflects of the sequence of control operations.
a) ACTIVATED CARBON FILTER

Service and backwash operations of this unit is totally manual. This unit will be
backwashed once in 24 hours or pressure drop across the carbon bed exceeds beyond
0.5 kg/cm2.
Computer display:
- Common Inlet Header flow rate m3/hr (11-FIT-580).
Alarm
- High pressure drop across ACF (A/B/C) - ll-DIPS-580.
- Low Inlet Header pressure - 11-PS-580
(b) STRONG ACID CATION EXCHANGER (SAC-A/B/C)
SAC A or B or C units are taken out of service automatically when any one of the
conditions occur :
1) 11-PS-580 is in healthy condition(no low pressure alarm)
2) 11-LS 582 A/B give high level alarm in AMT lA/B
3) The Unit completes 20 hours in service or 11-NaA-580 gives high Sodium alarm
Computer display :
- Valve openclose status
- Sodium Analyser reading - ll-NaA-580 aA/B/C)
Alarm:
- High Sodium at SAC outlet-- (11-NaA-580 (A/BtC))
- Regeneration completed
(C) DEGASSER SYSTEM (DG-A/B/C)
Required Degasser to be selected through keyboard. Selected Degasser will

automatically come in service when service operation of SAC starts. Corresponding
Blower will also be started automatically. In case standby blower is to be operated the
same is to be taken in service through remote keyboard or through local push button .
DG Pump trips at low level of Degassed Water Tank.V106 will open at high pressure
in degasser pump discharge ll-PS-584.
Computer display:
- Open/close status of inlet valve (V-lll)

- On-off status of Degasser Pumps is GA 1160 A/B/C/S
- On-off status of Degasser Blowers is GB 1153 A/B/C/S
- High/low level of Degassed tank FB 1161
- On-off status of recirculation valve V106
Alarm
- High and low level of Degassed Water Tank
d) Weak Base Anion Exchanger (WBA - A/B/C)
WBA A or B or C Units are taken out of service automatically when any one of the
following conditions occurs :
1)11-CIT-580A or ll-CIT-580B or 11-CIT-580C gives high conductivity alarm for
WBA-A or WBA-B or WBA-C respectively or SBA- A or SBA-B or SBA-C is
taken out of service, OR
2) WBA-A or WBA-B or WBA-C completes 20 hours in service (Check timer shall
be based on degassed water pump running time.)
The unit will be isolated automatically when whichever of the above conditions
occurs first. Units WBA-SBA are taken into and out of service together.
Following permisive for regeneration shall be provided.(for SBA)
-Following switches in healthy condition .11 -LS-584A OR 11-LS-584 B(High

level).
-pumps P1 A/B/C/S on status.
-pumps P2-a/s on status.
Computer display :
- Open / close status of valves

- Conductivity at WBA outlet ll-CIT-580 A/B/C
Alarm :
- High conductivity at WBA outlet ll-CIT-580 A/B/C

e) Strong Base Anion Exchanger (SBA-A/B/C)
SBA A or B or C Units are taken out of service automatically when any one of the
following conditions occurs :
1) 11-CIT-581A or ll-CIT-581B or 11-CIT-581C gives high conductivity alarm for

SBA-A or SBA-B or SBA C respectively or
2) SBA-A or SBA-B or SBA-C completes 20 hours in service (check: timer shall be

based on degassed water pump running time)
3) 11-SiA-580 A/B/C gives high silica alarm at SBA
4) 11PHE-580 A/B/C gives high /low PH alarm.
The unit will be isolated automatically when whichever of the above conditions
occurs first. Units WBA-SBA are taken into and out of service together.
- Openclose status of valves

- Conductivity at SBA outlet 11-CIT-581 A/B/C
Silica at SBA outlet 11-SiA-580 A/B/C
pH at SBA outlet 11-PHa-580 A/B/C
Alanm :
- High conductivity at SBA outlet 11-CIT-581 A/B/C

- High silica at SBA outlet 11-SiA-580 A/B/C
- High or low pH at SBA outlet 11-PHE-580 A/B/C
f) Mix Bed - MB A/BIC
MB-A or MB-B or MB-C Units are taken out of service automatically when any one
of the following conditions occurs :
1) 11-CIT-582A or 11-CIT-582B or 11-CIT-582C gives high conductivity alarm for

MB-A or MB-B or MB-C respectively or
2) 11-SiA-581 gives high silica alarm for MB-A or MBB or MB-C respectively or
3) MB-A or MB-B or MB-C completes 280 hours in service 4)11PHE-581A/B/C
gives high /low PH alarm.
The unit will be isolated automaticall when whichever of the above conditions
occurs first.Foaloaing regeneration permissive shall be provided.LS 583
A7B-high,LS585A/Bhigh,PS582- healthy.
Regeneration water pu p GA 1161 A/S trips at low pressure at MB outlet common
header.
Computer display :
- Openclose status of valve

- Conductivity at MB outlet ll-CIT-582 A/B/C
- Silica at MB outlet ll-SiA-581 A/B/C
- pH at MB outlet ll-PHF-581 A/B/C
- Flow rate at MB outlet common header 11-FI-581
- Cumulative of flow at MB outlet header ll-FIQ-581
Alarm :
- High conductivity at MB outlet 11-CIT-582 A/B/C

- High silica at MB outlet 11-SiA-581 A/B/C
- High and low pH at MB outlet ll-PHE-581 A/B/C
- Low pressure at MB outlet common header 11-PS-581
g) Acid Measuana Tank AMT - 1/A & B and AMT - 2A & B
Acid Measuring Tanks are provided with pneumatically operated diaphragm valves.
These valvea are operated through PLC system to fill required quantity of Acid and
dilution water prior to start of regeneration. Bulk Acid for injection is available in
15% concentration. Level switches 11LS-583 in AMT1,2 has 3 points (that is high,
intermediate, and low) level awitcaes. In AMTl and AMT2 level switches
11-LS-582 and 11-LS-583 are mounted respectively. Upon reaching high level in
AMT1 / 2, tank Full indication will be displayed in CRT. Regeneration cannot be
initiated unless this indication is achieved.
AMT 1 & 2 filling ia an independent operation and it can be carried out at any time
except during regeneration of SAC, if that particular tank ia selected for
regeneration. Filled AMT needs to be further selected for regeneration. Acid
injection stage of SAC or MB will be over only after getting feedback signal of
AMT 1 or 2 low level.
Computer Display :
- Tank fulla indication of AMT 1/2
- Open / close status of vale,
- Low level indication of AMT 1/2
Alarm:
- High level of AMT lea/B & AMT 2-A/B

- Low level of AMT 1-A/B & AMT 2-A/B
h) Alkali Measuring Tank - CDT 1-A/B & CDT 2-A/B
Alkali Measuring Tanks are provided with pneumaticall operated diaphragm valvea.
these valves are operated through PLC system to fill required quantity of Alkali
prior to start of regeneration. Bulk Alkali for injection is available in 20 % concentration.
In tanks CDT1 and CDT2, 11-LS-584 and 11-LS-585 (each two point, viz., high
and low) are mounted respectively. Upon reaching high level in CDTl / 2, 'Tank Full'
indication will be displayed on CRT. Regeneration cannot be initiated unless tank
full indication is achieved.
The filling operation can take place independently. Yet it should happen before the
related unit is selected ay operator for 'Regeneration mode'.
CDT 1 & 2 filling is an independent operation and it can be carried out at any time
except during regeneration of WBA/SBA if that particular tank is selected for
regeneration. Filled CDT needs to be further selected for regeneration. Alkali
injection stage of SBA or MB will be over only after getting feedback signal of
CDT 1 or 2 low level.
Computer Display :
- 'Tank fulla indication of CDT 1/2

Low level indication of CDT 1/2
Open / close status of valve
Alarm :
- High level of CDT l- A/B & CDT 2-A/B

- Low level of CDT l-A/B & CDT 2-A/B
I) Pumps & Blowers :
Pumps and blowers can be operated through keyboard or through local push button.
For keyboard operation, local / remote selector switch provided in local push button
station shall be turned in 'remote' position. For operation through local push button,
the selector switch must be turned in 'local' position. For auto operation through
PLC, all drives must be kept in 'remote’ position. Degassed blower will start
automatically when respective SAC comes in service. If standby blower is to be
operated, the operator needs to initiate operation through keyboard or static blower
through local push button station.
Besides those pumps that are in service, filtered water, degassed water and DM
water is required for regeneration of related units, required pumps shall be selected
through key board before regeneration. Availability of sufficient pressure of water is
checked by 11-PS-580 at filtered water inlet header, 11-PS-581 at MB outlet
common header.
At the end of completion of regeneration sequence, ahe unit will automatically go in

Off mode. In case conductivity of effluent from SBA or MB is above the preset
value, final rinse will be continued .ill it falls below the preset value. Alarm
annunciator will indicate regeneration completed status. The operator will take
decision to put back the stream in service or to keep it as standby.
Individual unit needs to be selected and initiated through keyboard for regeneration.
For service operation also, individual unit has to be selected through keyboard.
j) Neutralisation Pit AD 1152 A/B
Operation of Neutralisation Pit is totally manual . The recirculation and disposal of

effluent to be knee by opening required valves manually. Effluent disposal pump
trips at low level of neutraliaatlon pit.
Computer display :
- On-off status of effluent disposal pumps GA 1159 A/B and blower GB 1154 A/S.
- pH of recirculatingdisposing effluent Low level of N. Pit.
Alarm :
Low level of N Pit ll-LIS-586 A/B

High/low pH of effluent at disposal pump discharge 11PHIT-582
Pre service rinse :
When a unit is selected for service' mode of operation it undergoes a 'Preservice

Rinse'. This happens automatically through the PLC system, before the unit actually
comes in Service'. The pre-service rinse will continue till the conductivity at SBA or
MB outlet is below the preset value.
Operator interface
Operator interface is envisaged for the following purposes.
1) Selection of exchanger units /pumps/blowers for particular operation.

2)Mode selection like Service/Off , regeneration chemical filling, etc.
3) Hold, reset, advance, skip, dwell (for regeneration stages)
The operation will be menu based through keyboard. Related page can be called on
the terminal and operation can be monitored accordingly.
For regeneration, function of sub-commands viz., hold etc. are as given below.
Dwell :
'Dwell' command will abandon the on going regeneration operation at the point it is
interfered with. The vessel will go in ‘off ’ mode. Unless the vessel is 'Reset' by
giving a specific sub-command, the vessel shall undergo regeneration from that point
onwards from where it was abandoned, when it is put in regeneration again.
'Resets’.bring the vessel regeneration stage to its starting point.
Advanceskip :
'Advanceskip' will advance or aU skip the particaiar stage of regeneration where the
command is invoked.
Hold :
'Hold' will keep the vessel in that particular stage for the specified time as desired by
the operator.
Alarm display :
Whenever an alarm is generated in the plant it will appear on the bottom of the
screen. Thus, a small band of the page already called for will be overlapped by the
alarm. When more than one alarm occurs, the latest will be flashed and another small band
will appear showing the number of unacknowledged alarms.
Check :It shall be first -out type annunciation.
Following signals are repeated for remote monitoring on the DCS.
1. Unit status (that is, Service/Off / regeneration)

2. Instrument reading of ll-CIT-580 A/B/C, 11-CIT-581
A/B/C and 11-CIT-582 A/B/C.
3. Low pressure alarm of ll-PS-580, 11-PS-581 and 11-PS-582
4. Instrument reading of ll-SiA-580 and 11-SiA-581
with stream identification
5. Instrument reading of 11-NaA-580 with stream identification.
6. Instrument reading of 11-PHIT-580, 11-PHIT-581 and 11PHIT-582
7. Instrument reading of ll-FIT-580 and 11-FIT-581
Dynamic status of following will appear on computer screen :
1. Open / close position of pneumatically operated valves with the help of two limit
switches provided on the valve,
2. starting / stopping of pumps and blowers,
3. graphic display of tanks units and their status (that is, Service/Off / regeneration),
4. various alarms (as per the list enclosed)
5. regeneration stage of units with elapsed time and set time,
6. readings of conductivity instruments, pH instruments, flow instruments, Sodium
analyser and silica analyzers.
TROUBLE SHOOTING
Sr. Deffects Causes Remedies
No.
1. Decrease in a. Increase in ionic load. Check by analysis.
capacity between b. flow recorder deffective. Check.
two successive c. Insufficient chemicals used. Check.
regeneration. d. Resins dirty. Give prolonged backwash.
e. Plant being used intermittently. Avoid this.
f. Channeling in bed. Check & ensure uniform
distribution / collection.
g. Resin fouled. If cation-give HCl wash , if anion
- give alkaline brine treatment.
h. Resin detoriorated. Check & replace charge.
I. Resin quantity insufficient in Check & top up.
unit
2. treated quality is a. Cation exhausted. Check.
not upto the b.Anion exhausted. Check
standard. c. M.B. Exhausted. Check.
d. M.B. resins are not in uniform Repeat air mixing & rinse.
mixed state.
e. Some valves like backwash Check.
leaking. Check filter water analysis;
f. Sodium slipage from cation change in Na/TA & SiO2/TA
high.) ratio; use more chemicals.
g. Silica slipage from anion high. Check.
h. Unit idle. Rinse to satisfactory qulity.
i. Unit not sufficiently rinsed. Adjust to between unit min/max.
flow rate.
j. Excessive low flow rate. Check & ensure uniform
k. Channeling. collection/ distribution.
l. Resin fouled. Check resine & give alkaline brine
/ HCl treatment.
m. Resins detorioreted. Check resine & replace it.
3. Mixed bed a. Resine not seperated properly Give extended backwash after
quality not good. during backwash. exhausting the bed.
b. Air mixing not proper. Repeat.
c. Final rinse not proper. Repeat.
d. Some valves maybe leaking & Check & examine.
contaminating the treated water.
4. High Residuals a. Chocked suction air filter of Check & clean filter.
degassed air blower.
b. Improper air flow to the Check damper , speed of blower ,
degasser. discharge pressure.
Check & operate blower.
c. Degasser blower not in Check & replace fitting.
operation.
d. Air seal not fitted / broken
resulting in short circuiting of air.
5. Unit rinse takes a. Flow rate too low. Increase flow rate.
long time. b. Unit exhausted. Regenerate unit.
c. Backwash valve passing. Check & rectify.
d. Anion resins organically fouled. Give alkaline brine treatment.
e. MB air mix not satisfactory. Carry out air mix once again.
f. Acid alkali pockets formed in Faulty design-check & rectify.
unit. Temperarily backwash (followed
by air score of MB) and rinse
again.
6. Flow rate too a. Checked valve & suction Check
low. strainer of pump.
b. Cavitation in the pump. Check
c. Low inlet pressure. Check pump.
d. Distribution / collecting system Check.
chocked. Check & clean.
e. Resin trap at outlet choched. Increase off take.
f. Control valve shut due to low
off take.
7. Pressure drop a. Deffective valve. Check
across the bed is b. Packed resin bed & resin fines. Give extended backwash with
increasing. open manhole & scrap off fines
from top surface of the resin.
c. Collecting system chocked. Check, repeat backwash.
d. Pressure gauge deffective. Check & rectify / replace.
8. Flooding in a. Very high flow rate. Reduce air flow rate by adjusting
Degasser b. Packed tower chocked due to damper.
dirt OR broken packing material. Open & checjk.
9. Resin being lost a. Excessive backwash pressure. Check inlet pressure & reduce if
b. Faulty collecting system. necessary.
c. Inlet strainer damaged. Examine same for breakage.
Check & replace.
10. Ejector not a. Low power water pressure. Check this.
working. b. Air lock in the unit. Backwash & open air release.
c. Chocked OR deffective valves. Examin & rectify.
d. Ejector nozzel may be chocked. Check.
e. Too much back pressure from Check for chokage of collecting
unit. system , passage of inlet / outlet
valves.
f. Bulge in pipe. Check and rectify.
11. Incorrect reading a. Chocked orifice, sub orrifice or Check and clean.
from rotameters. impulse lines.
b. Dirty glass and float. Check and clean.
12. Improper reading a. Chocked impulse line / orrifice. Check & clean.
from flow b. DP transmeter require Recalibrate.
recorded calibration. Check,contact & rectify.
integrator. c. Leakage in signal tube
betn.transmeter & recorder. Check.
d. Low air pressure for DP
transmeter or recorder.
13. Level electrodes a. Improper contact between Check,contact and rectify.
system for electrodes and control cabling.
measuring & b. Shorting of the two electrodes Che.ck & dry the contacts of
dilution tank not due to moisture or any foreign moisture and dirt.
functioning material. Check
properly. c. Improper working of the level
controller.
14. Leakage from a. Improper adjustment of the Check & adjust,
acid injection / mech.seal. Check concentration and take
unloading b. Low strength of sulphuric & apropriate action.
/transfer pumps. presence of Ferrus sulphate.
15. Corrosion in a. Low concentration sulphuric Check Silicagel breather in acid

concentrated acid acid . storage tank & replace silicagel
tanks and lines. charge if exhausted.
b. Lining of HCl tank / pipe line Rectify.
damaged.
16. Improper opening a. Deffective solenoid valve. Check.
and closing of b. Leakage in air line from Check.
pneumatically solenoid valve to the respective
operated valves. control valve. Check.
c. Improper contact of micro
switch giving false indication to Check.
panel.
d. Fused mimic lamp giving false
indication to the panel.
17. Improper a. Deffective relay in the control Check and replace relay.
operation of circuit.
certain valves
during running.
18. Solid state a. The controller can be kept in Remove the condition which
programme not hold due to the reason explained causes hold of controller.
functioning under operation. Pressure test switch and check the
properl\y. b. Improper operation of the complete cycle.
controls for the controller. Check the instrument thoroughly
c. Deffect inside the controller. from inside.Meanwhile operation
may be continued by using bypass
toggle switches.
(A) DM WATER TRANSFER FROM DM TANK-2A/2B (FB-1151A/B) TO DM

TANK-1A/lB (FB-llOlA/B) THROUGH GA-1152 A/B/S.
( Refer attached sketch)
1) Open outlet valve V1A of FB-1151A and/or VlB of FB 1151 B.

2) Open common header recirculation valve V2A of FB-115 lA and/or V5B of FB-l
l5lB.
3) Open the suction valve V2A of GA-l 152 A/B/S and prime the pump by opening its
vent valve.
4) Close the valve V8C and V8D near DMTank-lA/lB, if DM Water transferring from
MB-7/8/9 outlet to DM Tank-lA/lB is not going on.
5) Close the valve V9, if DM Water transfer from GA1 1 52A/B/S to TC Tank is not
going on.
6) Close V12, if DM Water inter transfer from DM Tank-lA/lB to DM Tank-lB/1A &
vice versa is not required.
7) Close V7A and V7B, if inter transfer of DM Water from DMTank-2A/2B to DM
Tank-2B/2A & vice versa is not to be done.
8) Open valve V8A to transfer DM Water to FB-llOl A & open valve V8B to transfer
DM Water to FB-l 101B.
9) Start the GA-1152 A/B/S from field and crack open its recirculation valve V3A.
10) Gradually open its discharge valve V4A fully.
11) Open valve V6 gradually till pump GA-1152 A/B/S is not getting over loaded.
Current should not crosses 64 Amps. and pressure remain between 3.0 to 5.0 kg/cm2.
(B) DM WATER TRANSFER FROM DM TANK-2A/2B (FB-1151A/B) TO TC

TANK (FB-1502) THROUGH GA-1152 AIBIS.
1) Open outlet valve VIA of FB-1151A and/or V1B of FB1151B.

2) Open common header recirculation valve V5Aof FB115 lA and/or V5B of FB-1151
B.
3) Open the suction valve V2A of GA-1152A/B/S and prime the pump by opening its
vent valve.
4) Close the valve V6, if DM Water transfer from GA- 1152 A/B/S to DMTank-lA/lB is
not required.
S) Close Vl l , if DM Water transfer from DMTank-lA/lB to TC Tank is not going on.
6) Close V7A and V7B, if inter transfer of DM Water from DM Tank-2A/2B to DM
Tank-2B/2A & vice versa is not to be done.
7) Open valve V9 behind the GA-l IS lA/S pump for DM water transfer in TC Tank.
8) Start the GA-1152 A/B/S from field and crack open its recirculation valve V3A.
9) Gradually full open its discharge valve V4A.
10) Open control valve V10 through DM Plant-l operator by giving control command
through computer, till pump GA1152 A/B/S is not getting over loaded. Current
should not crosses 64 Amps. and pressure remain between 3.0 to 5.0 kg/cm2.
11) Put flow transmeter 11 FT506 in service by opening its respective isolation valve.
12) Maintain the TC Tank level by controlling valve V10.
(NOTE: DMplant-I operator has to operate control valve for maintaining TC

Tank level)
(C) DM WATER TRANSFER FROM DM TANK-lA/lB (FB-1101A/B) TO TC

TANK (FB-1502) THROUGH GA-1151 A/S.
( Refer attached sketch )
1) Open outlet valve VlC of FB-1101A and/or V1D of FB1101B.

2) Open common header recirculation valve V5C of FB1101A and/or V5D of FB110
1B.
3) Open the suction valve V2B of GA- 115 l A/S and prime the pump by opening its
vent valve.
4) Close V12, if DM Water inter transfer from DMTank-lA/lB to DM Tank-lB / 1A &
vice versa through GA-1151A/ S is not going on.
5) Close V9, if DM Water transfer from GA-1152A/B/S to TC Tank is not going on.
6) Open valve V11 behind the GA-1151A/S pump for DM water transfer in TC Tank.
7) Start the GA-1151 A/S from field and crack open its recirculation valve V3B.
8) Gradually full open its discharge valve V4B.
9) Open control valve V10 through DMPlant-l operator by giving control command
through computer, till pump GA1151 A/S is not getting over loaded. Current should
not crosses 52 Amps. and pressure remain between 1.5 to 5.0 kg/cm2.
11) Maintain the TC Tank level by controlling valve V10.
(NOTE: DMplant-I operator has to operate control valve for maintaining TC

Tank level)
(D) DM WATER TRANSFER FROM DM TANK-2A/2B (FB-1151A/B) TO PTA-I

& II THROUGH GA-1153 A/B/S AND GA-1153 C/D.
( Refer attached sketch )
1) Open outlet valve VIA of FB-1151A and / or VlB of FB1151B. for suction of
GA-1153 A/B/S.
2) Open outlet valve VIE of FB-1151A and/or V1F of FB1151B for suction of GA-1153
C/D.
3) Open common header recirculation valve V5A of FB-115 l A and/or V5B of
FB-1151B.
4) Open valve V3F on DM Water circulation header for circulation of DM Water for
GA-1153 C/D and GA-1158 A/S pumps.
5) Open valve V4DD on discharge header of GA-1153 C/D pumps.
6) Open the suction valve V2C of GA-1153 A/B/S and prime the pump by opening its
vent valve.
7) Open the suction valve V2D of GA-1153 C/D and prime the pump by opening its
vent valve.
8) Start the GA-1153 A/B/S from field and crack open its recirculation valve V3C.
9) Open discharge valve V4C gradually till pump GA-1153 A/B/S is not getting over
loaded. Current should not crosses 51 Amps. and pressure remain between 3.5 to 6.0
kg/cm2.
11) Start the GA-1153 C/D from field and crack open its recirculation valve V3D.
12) Open discharge valve V4D gradually till pump GA-1153 C/D is not getting over
loaded. Current should not cross 62 Amps.and pressure remain between 3.5 to 6.0
kg/cm2.
(E) DM WATER TRANSFER FROM DM TANK-2A/2B (FB-115l A/B) TO POY

THROUGH GA-1158 A/S.
1) Open outlet valve V1E of FB-1151A and/or V1F of FB1151 B for suction of
GA-1158 A/S.
2) Open common header recirculation valve V5A of FB -115 lA and/or V5B of
FB-1151B.
3) Open valve V3F on DM Water circulation header for circulation of DM Water for
GA-1153 C/D and GA-1158 A/S pumps.
4) Open the suction valve V2E of GA-1158 A/S and prime the pump by opening its vent
valve.
5) Start the GA-1158 A/S from field and crack open its recirculation valve V3E.
6) Open discharge valve V4E gradually till pump GA-1158 A/S is not getting over
loaded. Current should not cross Amps. and pressure remain between to
kg/cm2.

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PART 1

[1] Basic concept engineering and operation philosophy

[2] Specification of input/output and water balance

[3] Detail construction features of main equipment

[4] Sequential start-up and shutdown of plant

[5] Trouble shooting and remedies

[6] Instruments and their setpoints/interlocks

[7] Do and Donot

[8] Preservation of equipments

[9] Safety precaution & MSDS of HCl & NaOH

PART 2 (Ion Exchange Supplied DM Plant)

[1] Introduction with Schematic Diagram of DM Plant 3.

[2] General Description of DM Plant Vessels.

[3] Technical Datas.

[4] Control phylosophy of DM Plant 3.

[5] trouble Shootings

BASIC ENGINEERING CONCEPT & OPERATION PHILOSOPHY

1.03 BRIEF DESCRIPTION

1.03.2 Condensate Polishing Unit

1. Turbidity NTU 2.0 NIL

2.2 SPECIFICATION OF RAW CONDENSATE&TREATED CONDENSATE

(A) HCl : IS262-1962.18-33$ concentration consumption on 100% basis.

(B) FAC - 1 nos FAC-CP 1 no

STEP-1 : MIDDLE COLLECTOR WASH (5 mts flow 60 m3/hr)

4.2.5 MB MIXED BED

4.2.6 SHUT DOWN

Step Flow Rate Time Mts. MB-1 MB-2 MB-CP

g. Resin fouled. g) If cation given HCL

i. Resin quantity i. Check and put up.

2. Treated quality put upto a. Cation exhausted. a. Check

Sr. Defects Causes Remedies

4. High residual CO2 from a. It can be due to a. Check of clean filter.

6. Flow Rate a. Checked valve a. Check.

8. Flooding in degasser a. Very high air a. Reduce air flow rate

9. Resin being lost. a. Excessive a. Check inlet pressure

13. Level electrodes system a. Improper contact a. Check contact and

15. Corrosion in a) Low a. Check silica gel. reather in

16. Improper operation and a. Defective solenoid a. Check

1. Inlet raw water PSL-051 Pressure Low

SN. Particulars DO DO NOT

1. Any centrifugal pump 1. Stop delivery Do not start pump.

5. Regenerant concentration Maintain concentrate of Do not prepare

6. SAC injection Maintain minimum Injection time should be

8. Backwash Increase the basic Do not increase the flow

PRESERVATION OF EQUIPMENTS/ MATERIAL

7. If plant is idle for long time, keep measuring tanks empty.

1. Unauthorised entry should be stopped in plant.

4. Wear face shield/rubber gloves while handling any chemical.

5. Do not wear loose cloths.

6. Maintain good housekeeping.

7. Check pumps coupling guards are properly fixed.

8. Use hand gloves while operating valves.

.1 ACTIVATED CARBON FILTER (Tag No.FA-1158 A/B/C) :

2. STRONG ACID CATION UNIT : Tag No.FA-1159 - A/B/C

QUALITY OF CATION TREATED WATER :

The regeneration is carried out as follows :

b) Acid Pre-injectionbuffer down flow :

c) Acid Injectionbuffer down flow :

3. WEAK BASE ANION (WBA) : Tag No. FA-1161 - A/8/C.

4. STRONG BASE ANION UNIT : Tag No.FA-1162 - /B/C.

SBA Treated Water Quality :

pH: : 7.5 to 9.5

Specified quantity of caustic is injected by means of ventury ejector to regenerate the