TRAINING SESSION ON WATER TREATMENT

COMMONLY USED TERMS IN WATER TREATMENT

1. 2. 3. 4. 5. 6. 7. 8. 9. OBR: OUTPUT BETWEEN TWO SUCCESSIVE REGENERATIONS. TDS: TOTAL DISSOLVED SOLIDS TSS: TOTAL SUSPENDED SOLIDS HARDNESS: TOTAL OF CALCIUM & MAGNESIUM FLOW RATE: VOLUME IN M3/HR REQUIRED TO BE TREATED. CATIONS: POSITIVELY CHARGED IONS IN WATER. ANIONS: NEGATIVELY CHARGED IONS IN WATER. DM PLANT: DEIONISATION / DEMINERALIZATION PLANT. EXCHANGE CAPACITY: THE CAPACITY OF RESIN TO REMOVE THE DISSOLVED IMPURITIES. 10. REGENERATION: THE RECHARGING OF ION EXCHANGE RESIN BY USE OF ACID OR CAUSTIC.

COMMONLY USED TERMS IN WATER TREATMENT

1. 2.

RO PLANT: REVERSE OSMOSIS PLANT. GFD: GALLONS OF WATER FROM RO PLANT PER DAY PER FT SQUARE AREA OF RO MEMBRANE.

3.

FOULANTS: THE ELEMENTS IN WATER THAT IS LIKELY TO CAUSE DAMAGE TO THE TREATMENT EQUIPMENT (RESIN/MEMBRANE).

4.

CONDUCTIVITY: THE ELECTRONIC MEASUREMENT OF DISSOLVED IONS.

5.

CLEANING: THE CHEMICAL CLEANING OF RO MEMBRANE TO RESTORE THE OPERATING CONDITION.

6. 7.

M3: 1000 LITRES. GALLONS: US GALLONS 3.785 LITRES.

RAW WATER APPRAISAL

SOURCES LIKE BORE WELL,SHALLOW WELL,RIVER,LAKE,SEA,MUNICIPAL. DIFFERENT SOURCES HAVE DIFFERENT CHARACTERISTICS. IONIC IMPURITIES VARY FROM SOURCE TO SOURCE. TWO WELLS IN SAME PREMISES SHALL BE DIFFERENT. IMPURITIES: SOLUBLE,NONSOLUBLE,ORGANIC ORIGIN. IMPORTANT TO UNDERSTAND RAW WATER.
4

RAW WATER SOURCES & THEIR PECULIARITIES SOURCE DEEP WELL WATER SHALLOW WELL WATER RIVER LAKE SEA MUNICIPAL EFFLUENT DISSOLVED SUSPENDED ORGANIC IMPURITIES IMPURITIES IMPURITIES HIGH LOW LOW MODERATE LOW MODERATE V. HIGH LOW HIGH LOW HIGH SEASONAL MODERATE MODERATE LOW HIGH MODERATE MODERATE HIGH MODERATE LOW HIGH

NOTE: THIS IS TO GIVE THE GENERAL IDEA. THERE CAN BE EXCEPTIONS.

TYPICAL RAW WATER ANALYSIS

HOW A RAW WATER ANALYSIS REPORT LOOKS LIKE ? PARAMETER TEMPERATURE TDS TSS TOTAL HARDNESS CALCIUM MAGNESIUM SODIUM CHLORIDES SULPHATES ALKALINITY SILICA NITRATES COD BOD FREE CHLORINE BOREWELL 25 30 DEG C 800 PPM 5 PPM 200 150 50 200 350 15 240 35 5 10 2 0 RIVER 25 - 30 150 50 50 40 10 80 60 2 35 10 0 80 15 0 SEA 25 - 30 35000 50 2000 500 1500 20000 22000 650 230 15 25 30 10 0 EFFLUENT 25 30 3000 150 800 550 250 1800 1500 100 350 45 10 300 80 0

CLASSIFICATION OF RAW WATER ANALYSIS IN VARIOUS CATEGORIES NON DISSOLVED IMPURITY DISSOLVED IMPURITY TSS, TURBIDITY, COLLOIDAL SILICA, COLOR, SMELL TDS, CALCIUM, MAGNESIUM, SODIUM, SILICA, CHLORIDES, SULPHATES, NITRATES, ALKALINITY, TOTAL HARDNESS COD, BOD, COLOR, SMELL

ORGANIC IMPURITY TOTAL HARDNESS

CALCIUM, MAGNESIUM

EACH OF THESE REQUIRES DIFFERENT TREATMENT FOR REMOVAL.

7

WATER TREATMENT METHODS AVAILABLE & WHICH IMPURITY IT CAN REMOVE. TREATMENT METHOD TUBE SETTLER & CLARIFIERS FILTERS SOFTENER DM PLANTS IMPURITIES REMOVED TSS, TURBIDITY, COLLOIDAL SILICA

TSS, TURBIDITY TOTAL HARDNESS TOTAL HARDNESS, TOTAL DISSOLVED SOLIDS, CALCIUM, MAGNESIUM, SILICA, ALKALINITY, CHLORIDES, SULPHATES TOTAL HARDNESS, TOTAL DISSOLVED SOLIDS, CALCIUM, MAGNESIUM, SILICA, ALKALINITY, CHLORIDES, SULPHATES BOD & COD FREE CHLORINE, COD, BOD, COLOR, SMELL ALKALINITY

RO PLANTS

CHLORINATION ACTIVATED CARBON FILTER DEGASSER TOWER

WHICH METHOD OF TREATMENT TO CHOOSE ?

RAW WATER ( INLET ) PARAMETERS
TREATED WATER QUALITY REQUIRED APPLICATION OF TREATED WATER ECONOMIC OPERATIONAL COST

FILTERS:

Diameter (Mtrs.)= (FLOW RATE M3/HR / VELOCITY M/HR) 0.785

HEIGHT OF FILTERS IS USUALLY FIXED AT 1500 MM OR 2000 MM. SOFTENER: REQUIRES SOME CALCULATIONS AS FOLLOWS: FLOW RATE IN M3/HR =F DURATION BETWEEN REGENERATION HRS = T HENCE OUTPUT BETWEEN REGENERATION= F X T REFER TO SOFTENER RESIN GRAPHS TO GET REGENERATION LEVEL = SAY 150 G/L EXCHANGE CAPACITY = SAY @ 50 HENCE QUANTITY OF RESIN REQUIRED IN SOFTENER ( LITRES): = OUTPUT BETWEEN REGENERATION NET EXCHANGE CAPACITY

SELECT THE SOFTENER WITH THE NEAREST RESIN QUANTITY FROM SOFTNER CHART.

10

SIZING DM PLANTS: REQUIRES DETAILED CALCULATIONS. STEPS AS FOLLOWS: DATA: FLOW RATE IN M3/HR DETAILED CATIONIC & ANIONIC ANALYSIS HRS OF OPERATIONS BETWEEN REGENERATION QUALITY OF WATER REQUIRED DESIGN STEPS DECIDE THE SCHEME RESIN QUANTITY CALCULATIONS EQUIPMENT SIZING REGENERATION EQUIPMENT SIZING CHEMICAL CONSUMPTION

11

SIZING RO PLANTS: REQUIRES DETAILED CALCULATIONS. STEPS AS FOLLOWS: DATA COLLECTION: FLOW RATE IN M3/HR DETAILED CATION & ANIONIC ANALYSIS HOURS OF OPERATIONS QUALITY OF WATER REQUIRED DESIGN STEPS: RO PROJECTION FROM SOFTWARE DECIDE ON THE OVERALL SCHEME EQUIPMENT SIZING CHEMICAL CONSUMPTION SIZING CALCULATIONS

12

COMMONLY OCCURING PROBLEMS IN A WATER TREATMENT SYSTEM

1. REDUCTION IN FLOW RATES 2. REDUCTION IN THE OUTPUT BETWEEN REGENERATION 3. QUALITY DETERIORATION 4. LEAKAGES & OTHER MECHANICAL PROBLEMS 5. PROBLEMS RELATING TO INSTRUMENTS & CONTROL 6. CHOCKING OF FILTERS & MEDIA LEADING TO FREQUENT BACKWASH. 7. HIGH PRESSURE DROP

13

IT IS ESSENTIAL TO UNDERSTAND THE CONSTRUCTIONAL DETAILS & OPERATING STEPS IN ORDER TO SOLVE THE PROBLEM

14

EQUIPMENT DESCRIPTION FOR FILTERS

PRESSURE VESSEL INLET DISTRIBUTION SYSTEM BOTTM COLLECTION SYSTEM SUPPORT MEDIA FILTRATION MEDIA FRONTAL PIPEWORK SERVICE OPERATION BACKWASH OPERATION

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EQUIPMENT DESCRIPTION FOR SOFTENER

PRESSURE VESSEL INLET DISTRIBUTION SYSTEM BOTTM COLLECTION SYSTEM STRAINERS SOFTENING RESIN REGERATION SOLUTION TANK FRONTAL PIPEWORK SERVICE OPERATION BACKWASH OPERATION REGENERATION OPERATION
46

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EQUIPMENT DESCRIPTION FOR DM PLANTS

PRESSURE VESSEL INLET DISTRIBUTION SYSTEM BOTTM COLLECTION SYSTEM STRAINERS CATION & ANION RESIN REGERATION SOLUTION TANK FRONTAL PIPEWORK SERVICE OPERATION BACKWASH OPERATION REGENERATION OPERATION
55

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DM REGENERATION SEQUENCE
OBJECTIVES OF REGENERATION
1 TO REMOVE ACCUMULATED FOREIGN
MATERIALS AND RESIN DUST. 2 TO INJECT ACID OR ALKALI TO CONVERT RESIN IN TO ACTIVATED FORM.

3 TO REMOVE EXCESS ACID / ALKALI FROM RESIN.

65

STEPS OF REGENERATION
1 BACKWASH.
2 REGENERATION INJECTION. 3 SLOW RINSE. 4 FAST RINSE

66

BACKWASH
RESIN IS FLUIDISED TO 40 TO 50 % BED EXPANSION. - ACCUMULATED DIRT, RESIN FINES

REMOVAL.
- RESIN BED IS HYDRAULICALLY

CLASSIFIED.

67

REGENERATION INJECTION.
- ACID OR ALKALI IS USED SAC : HCL OR H2SO4 WBA : NaOH SBA : NaOH

CONCENTRATION
WEAK RESINS : 0.5 % - 2.5% STRONG RESINS : 3.0 % - 5%

- TIME TO BE SUFFICIENT FOR ADEQUATE CONTACT.

68

REGENERATION LEVEL

KGS OF 100% REGENERANT INJECTED FOR EVERY M3 OF RESINS.

- IMPORTANT FOR ONLY STRONG

RESINS ( SAC & SBA)

- R/L RANGE IS 30-160 KG/M3

69

REGENERATION QUANTITY
FOR STRONG RESINS. RESIN VOL. (M3) X REGENERATION LEVEL (KG/M3).

- FOR WEAK RESINS.

WORK DONE BY RESIN.= IONIC LOAD (As CaCO ) X OBR M3
3

1000 X 1.25 OR 1.37 (TO CONCERT FROM CaCO3 TO EQUIVALENT)

X 115

70

TYPES OF REGENERATION SEQUENCES.

CO-FLOW COUNTER FLOW DOWN FLOW, PACKED UPFLOW , CONVENTIONAL

71

FAST RINSE
- PURPOSE IS TO REMOVE EXCESS
REGENERANT FROM RESIN BED. SERVICE INLET WATER IS USED. FAST RINSE IS CONTINUED TILL DISIRED OUTLET QUALITY IS

OBTAINED
72

CO FLOW REGENERATION.
SERVICE INLET REGENERANT INLET

SERVICE OUTLET

REGENERANT OUTLET.
73

COUTER REGENERATION DOWN FLOW

SERVICE OUTLET REGENERANT INLET

SERVICE INLET

REGENERANT OUTLET.
74

COFLOW REGENERATION
- LEAKAGE OF IONS IS HIGH
- TREATED WATER QUALITY IS NOT CONSISTENT. THROUGH OUT CYCLE.

- REQUIRES VERY LARGE QUANTITY OF REGENERANT

FOR QUALITY IMPROVEMENTS. - REGENERATION EFFICIENCY IS LOWER ( 30-45%)

75

COUNTER REGENERATION ( DOWNFLOW)

- HAS ALL ADVANTAGES OF UPFLOW COUNTER CURRENT REGENERATION. - UP FLOW COUNTER CURRENT REGENERATION.

- BACKWASH IS NOT POSSIBLE BECAUSE OF LACK

OF FREE BOARD. - FEED WATER TURBIDIY SHOULD BE LOW ( < 1 NTU )

76

COUNTER REGENERATION
- LEAKAGE OF IONS IS LOW. - TREATED WATER QUALITY IS CONSISTENT THROUGHT THE RUN.

- REDUCED REGENERANT QUANTITY ALSO

PRODUCES IMPROVED QUALITY. - REGENERATION EFFICIENCY IS HIGHER (80-90%)

77

EQUIPMENT DESCRIPTION FOR RO PLANTS

FILTER ACID & ANTISCALENT DOSING SETS MICRON FILTER HIGH PRESSURE PUMP RO PRESSURE TUBES RO MEMBRANES CLEANING SYSTEM INSTRUMENTATION & CONTROLS PIPING MANIFOLDS
78

ADVANTAGES OF A REVERSE OSMOSIS SYSTEM OVER DM We would like to propose an RO based treatment scheme in place of DM based system. We would like to highlight that the R.O. based treatment system shall be more beneficial in terms of following parameters : 1. Very less operating cost. (Enclosed an annexure on typical operating cost calculations for DM & RO) Less chemical handling and storage. Very less operational needs thus the manual Reverse Osmosis Plant shall suffice in place of an automatic DM Plant. Less civil work. Less area requirements. Reverse Osmosis system can take the marginal variations in feed water quality without affecting the treated water parameters. No need for any neutralisation pit. The RO reject & MB regeneration effluents can be directly taken to guard pond.

2. 3.

4. 5. 6.

7.

79

REVERSE OSMOSIS ( RO )
TOPICS :
- PRINCIPLES OF RO. - PRETREATMENT FOR RO. - OPERATION & MAINTAINANCE. - TROUBLE SHOOTING. - CASE STUDIES & DISCUSSIONS.

PRINCIPLES OF RO
- RO BASICS.
- TYPICAL RO ARANGEMENT - OPERATING ARANGEMENT. - DESIGN PARAMETERS. - SELECTION OF RO MODEL.

Reverse Osmosis
P

DILUTE SOLUTION

CONCENTRATED SOLUTION

P >

Reversing osmotic flow by applying a pressure in excess of the osmotic pressure

TYPICAL RO ARRANGEMENT.

PRETREATMENT

RO

POST TREATMENT

Block Diagram of RO
SALT WATER

PRODUCT WATER (PERMEATE )

HIGH PRESSURHE PUMP

REJECT WATER (CONCENTRATE)

OPERATING PARAMETERS
RECOVERY = PERMEATE FLOW = 0.75 OR 75 % FEED FLOW 10 M3/HR FEED PERMEATE 7.5 M3/HR

CONCENTRATE 2.5 M3/HR

OPERATING PARAMETERS
RECOVERY = PERMEATE FLOW = 0.75 OR 75 % FEED FLOW PERMEATE 7.5 M3/HR 50 PPM

10 M3/HR

FEED
1000 PPM

SALT PASSAGE

= PERMEATE TDS FEED TDS = 0.05 OR 5 % SALT REJECTION = 100 - SALT PASSAGE = 95 %.

CONCENTRATE 2.5 M3/HR 3850 PPM

OPERATING PARAMETERS
RECOVERY = PERMEATE FLOW = 0.75 OR 75 % FEED FLOW 10 M3/HR FEED PERMEATE 7.5m3/hr.
OF 50 PPM AT 5 PSI

1000 PPM 230 PSI

SALT PASSAGE = PERMEATE TDS FEED TDS = 0.05 OR 5 % SALT REJECTION = 100 - SALT PASSAGE = 95 %. P = FEED PR - CONC. PR

CONCENTRATE 2.5 M3/HR OF 3850 PPM AT 215 PSI

= 230 - 215 = 15 PSI

DESIGN PARAMETERS
FLUX GFD L/M2H

GFD
GFD

=
=

0.59 * L / M 2 H
8-10 FOR WASTE WATER &

SEAWATER.
< 14 FOR SURFACE < 18 FOR WELL WATER < 25 FOR PERMEATE.

DESIGN PARAMETERS

BETA FACTOR = MAXIMUM

1.16 FOR LAST ELEMENT AT CONCENTRATE SIDE

Typical Applications Of Reverse Osmosis

Industrial process water Production of potable water Food processing Waste treatment

Membrane manufactures
Dow Filmtec.,U.S.A. Fluid systems U.S.A. Hydranautics U.S.A. Osmonics inc U.S.A. Trisep USA. Saehan KOREA

CROSS SECTION OF SPIRAL WOUND MEMBRANE

Permeate Tube
Membrane Backing

O Ring

Mesh Spacer
Permeate Carrier Membrane

Outer Cover

CROSS SECTION OF THIN FILM COMPOSITE MEMBRANE

POROUS SUPPORT SEMIPERMEABLE MEMBRANE

BACKING MATERIAL

THIN-FILM COMPOSITE MEMBRANES

Polyamide Polysulfone 0.2 micrometer

Ultrathin Barrier Layer Microporous Polysulfone 40 micrometer

Reinforcing Fabric

120 micrometer

Membrane Assembly
In board connector

End cap

o rings

Outer bord connector Feed tube

Reverse Osmosis Membranes - Types Cellulose Acetate Thin Film Composite Polysulfones

THIN FILM COMPOSITE MEMBRANE CHARACTERISTICS

Lower Operating Pressure High Salt Rejection Available for Sea Water Stable to pH 11 Sensitive to Oxidants

Benefits of R.O.

High recovery rates. Predictable water quality--regardless of TDS content. Simple operation and control. Limited chemical problems. No daily regeneration hassels. Can be skid mounted,hence less space. Very few components for maintenance. Less operator attention

Critical Design Parameters For RO

Source of Water
Surface water
Lake or Pond River

Well Water
Shallow well Deep Well

Treated Effluent

Silt Density Index - SDI

How to measure SDI Quanitifies particles of range 0.45 to 5 microns Dual media removes upto 50 microns. Multimedia with garnet removes down to 25 microns.

Feed Water Analysis

Need to know the trend in the increase. Onsite pH. Appearance of water as drawn Organics. Biological activity of water.

RO System Design
Parameters required for designing :
Temperature (Max, Min & Average) Chlorine Residual Turbidity Suspended solids Color. Silt Density Index pH colliform Count (bacteria) Total Plate Count Calcium Magnesium Pottashium Iron

Manganese Barium Strontium Chlorite Sulfate Nitrate Ammonia Phosphate Fluoride Silica Total Dissolved Solids Hydrogen Sulfate Carbon Di Oxide

Note : Variation in these parameters should be noted and odours, traces of industrial pollutant, clay, sand, rust, or other unusual characteristics should be described.

Reverse Osmosis System Design

System Design
The Reverse Osmosis system design process consists of three principal steps. Membrane selection Defining the R.O. configuration and operating conditions. Determining pretreatment requirements

MEMBRANE SELECTION BASIS

Application or end use Quality Desired Water Temperature

4-2-1 Array
1st Bank
Feed 2000 mg/L 173 gpm

8231 HR, 90% Recovery

2nd Bank
3rd Bank
Concentrate 18,211 mg/L 17 gpm 638 mg/L 16 gpm

89 mg/L 98 gpm

239 mg/L 42 gpm

Permeate 187 mg/L 156 gpm

RO System components
The basic expanded design of a single system includes the following: Raw water feed pump to supply water to the pre treatment Pre treatment system for Turbidity,TSS,Colloidal particles & Organic matter. Cartridge filter to remove micron size particle to control the SDI( Silt density index) of feed water Anti scalant dosing system. High pressure pump&feed control valve to pressurize the feed water. Membranes housed in Pressure tubes. -----continued.,

A reject control valve to control the recovery of the RO system. Askid to mount to all mechanical equipment . Flow indicators to measure permeate and reject flowrates. Pressure gauges for monitoring the differential pressures across the RO feed, reject and intermediate stages. Conductivity & pH meter for measuring the quality of the permeate water. And other necessary instruments for monitoring easy operation and critical parameters. A cleaning system consisting of Tank,CF,Pump and necessary instruments.

PRETREATMENT FOR RO PLANT

CHLORINATION.

USE OF SODIUM HIPO CHLORITE.

- TO GET MAXIMUM FRC 0.5 PPM AT THE POINT OF BISULPHITE DOSING. - EFFECTIVE REACTION TIME 20 - 30 MIN.

PRETREATMENT FOR RO PLANT

DE - CHLORINATION - TOLERANCE < 1 PPM MAX - ACITIVATED CARBON FILTER. - BISULPHITE DOSING WITH ORP METER. - 1 PPM OF F.R.C REQUIRES 1.46 PPM OF NaHSO3
.

PRETREATMENT FOR RO PLANT

pH

- ACID DOSING / ANTISCALENT CHEMICALS.

- HCL / MAXTREAT CHEMICALS. - AS PER PROJECTION.

PRETREATMENT FOR RO PLANT

OIL & GREASE & COD / BOD REQUIREMENT - NIL

- IF IT IS PRESENT- REF : MATTER TO H.O. PEG. IRON & Mn - LESS THAN 0.1

PRETREATMENT FOR RO PLANT

REMOVAL METHODS FOR Fe (Iron)

1. BY MnO2 FILTER UP TO 1 PPM. 2. OXIDATION BY AIR, FOLLOWED BY FILTERATION MORE THAN 3 PPM

3. OXIDATION BY CHLORINATION - UP TO 2 PPM.

Reverse osmosis system

Cleaning tank Pump (SS)

Pretreatment
Cartridge filter Dosing system
De-chlorination Filteration Pressure tubes Coagulation Clarification

Cartridge filter

RO hydra block
Membrances

Cleaning system

DM plant pH adjustment Degassification

HP pumps
Control pannel

Post treanment

Schematic diagram of RO unit for brackish water

Lime or lime - soda coagulant aids Sand filter Activated carbon filter S.H.M.P. Acid

coagulation and sedimentation

DESALATION SECTION Membrane modules

Mn greensand filter Polishing filter

Product water

High pressure pump

Waste brine

Operating Parameters
.Feed Pressure Concentration pH Temperature Concentration Flow Pressure Flow Pressure Concentration

Permeate

Concentrate

System Profile
The System Profile is a measurement of the permeate concentration from each individual vessel. Identifies which vessels in an array have high salt passage. A System Profile should be taken at startup, as a baseline record. Record complete system data whenever a System Profile is performed.

PROBING
Probing is done while the system is operating at normal conditions. Insertion is normally done from the end opposite the permeate collection manifold.

PROBING
Feed Con c.
Permeate

CONDUCTIVITY

INTERPRETATION OF CHANGES IN PARAMETERS

CHANGE IN PRESSURE DROP CHANGE IN PERMEATE TDS CHANGE IN FEED PRESSURE CHANGE IN FEED CHEMISTRY

CHANGE IN PRESSURE DROP

HIGHER LOWER LOWER FLOWRATES HIGHER FEED TEMPERATURES

BIOFOULING SCALING INORGANIC FOULING HIGHER FLOWRATES LOWER FEED TEMPERATURES

CHANGE IN FEED PRESSURE

HIGHER
SCALING PLUGGAGE FOULING HIGHER FEED TDS LOWER FEED TEMPERATURE IMPROVER VALVING

LOWER HIGHER FEED TEMPERATURE LOWER FEED TDS MEMBRANE DAMAGE

CHANGE IN FEED CHEMISTRY

pH TOO HIGH
Ph TOO LOW

= MEMBRANE DAMAGE
= MEMBRANE DAMAGE

CHLORINE ABOVE = VENDORS SPEC

MEMBRANE DAMAGE

SCALING IONS ABOVE SPEC = SCALING INCREASED SDI OR TURNIDITY = FOULING

TROUBLESHOOTING OF RO SYSTEM
Too high system recovery : Concentration Polarization Localized Salt Concentration Causes : Operator error Flow meter out of calibration Unnoticed change in Feed water composition

Troubleshooting of RO System
Common causes for high pH
Buildup of bacteria
RO element manufacturing problem Elements moved from their original marked position .

Troubleshooting of RO System
Causes of uniform rejection decline :

Oxidising agent Exposure to direct sunlight

Cleaning mistakes

Troubleshooting of RO System
Severe membrane multiple problems: deterioration or

TIMELY CORRECTIVE ACTION

Instrumentation
Instruments used in an RO system pH Conductivity Rota meter. Pressure gauges. ORP Thermometer Level switches Flow switches Pressure switches Electrical control

R. O. PLANT LOGSHEET FORMAT (TYPICAL) DATEO/P R. W. AREA SMBS D. P. ANTI.D. P. G.F./D.M.F. C. F. R. O. BLOCK AREA HRS. NaOCl D. P. I/L FLOW I/L PR. O/L PR. O/L FRC ON/OFF ON/OFF O/L PR. O/L SDI O/L FRC ORP READING FEED PR. REJ. PR. PERMEATE FLOW REJ. FLOW PERMEATE COND. ON/OFF (LPM) (KG/CM2) (KG/CM2) (PPM) (KG/CM2) (PPM) (KG/CM2) (KG/CM2) (LPM) (LPM) (Microsiemens/cm)

SIGN. OF OPERATOR

SIGN. SUPERVISOR

130

D. M PLANT LOGSHEET FORMAT (TYPICAL) O/P HRS. R.W. AREA ALUM D.P. NaOCL D.P.I/L FLOW ON/OFF ON/OFF (M3/HR) DMF ACF I/L PR. O/L PR. I/L PR. O/L PR. O/L FRC (KG/CM2) (KG/CM2) (KG/CM2) (KG/CM2) (PPM) DATE SAC SBA I/L PR. O/L PR. I/L PR. O/L PR. O/LCOND. O/L Ph (KG/CM2) (KG/CM2) (KG/CM2) (KG/CM2) (m/cm2)

SIGN. OPERATOR

SIGN. OF SUPERVISOR

131

132

133

ALKALI BOIL OUT PROCEDURE

undesirable substances. The interior of a boiler is sometimes covered with an oil film to avoid corrosion during storage or transport. Lubricating grease is used when the tubes are rolled in the shell, cutting oils are used during manufacture, cleaners and rust inhibitors also employed; a special powder is used finally for the PRELIMINARY STAGES assembly of piping. 1. The interior of boilerproducts must be remain checked in order remove The excesses of the all these inside the to boiler. any remains. Moreover, scale, wood, Inaccessible places reached by in using water or air paper, rags and any should kind of be debris remain the boiler. It is under pressure. obvious that the elimination 2. Replace the glass level gauge a temporary gauge for the of these materials is necessary inby order to not infringe on good duration of the operation conditions. treatment. 3. Close the boiler. Fill the boiler with good quality feed water. In order to avoid any thermal shock, the temperature of water should be within a maximum of 10C (22F)

4.

Determine the quantity of water added to the boiler and add a sufficient quantity of Melrose Chemicals, Ltd A-420 or F-685 for the treatment in progress. Refer to the Technical Bulletin of the product used to know its solubility. When the necessary quantity of A-420 or F-685 is added, alkalinity "M" will be 3000 to 4000 ppm. 5. A concentrated solution of the cleaner can be added proportionally to the feed water while filling of the boiler. If there is an economiser in the system, the concentrated solution must be added to there directly. In the case of small boilers or when the conditions allow it, the concentrated solution can be added through a manhole or any other opening located at the top of the boiler. Do not add solids to a boiler. The use of A-420 liquid for an alkaline boil-out eliminates any problem from deposits incurred by the use of solid chemicals. 6. Read and follow closely the instructions of the manufacturer of the boiler concerning the firing stages and the evacuation of the vapours during an alkaline boil-out. 7. In the case of new boilers, the drying of refractory materials can be combined with the alkaline boil-out. Light a fire with wood to dry the boiler lining. Leave the chimney open until vapour appears - then close. If wood cannot be used, use oil. In installations where the oil is pulverized, it is often necessary to use a more easily controllable fuel.

The temperature of the furnace during the preliminary stages of boil-out must be low in order to obtain uniform drying - then can be gradually increased by varying the rate of fuel addition or firing period to maintain the minimum pressure necessary during the boil-out. The suggested maximum pressure is approximately 50% of the limit of pressure for the valve operating with the lowest pressure. This pressure will create sufficient circulation in boilers having a waterwall and a network of complicated internal piping.

8. It is difficult to precisely determine the optimal duration of an alkaline boiling. Experience shows that 1 to 3 days are generally necessary for the internal cleaning of a boiler. One prolonged period is better if drying of refractory materials is also carried out. The state and the appearance of the blowdown water of the boiler are the best indication in knowing if the treatment should be continued or stopped. 9. For the duration of the boiling, all the safety measures must be observed with regard to the superheaters, the economisers, etc. in order to avoid any damage with the equipment. The superheaters and the economisers should be operated in the same way as when the system is operating. Detailed attention should be given to the

at least every 8 hours. The total quantity of water removed from all these points should be roughly a quarter of the level indicated on the gauge, this quantity being also divided between the various drains and the continuous blowdown. First drain the continuous blowdown, then progressing toward the drains on lower level of the boiler. Following this operation, the water level in the boiler should be restored by using water containing the alkaline cleaner, so that the concentration of the cleaner in the boiler is not reduced by these regular purges. 11 At the end of the boiling, cool the boiler gradually, then drain and flush the system by using a water under high pressure. Check the cleanliness of the system and make sure that there are no remaining oils or greases. Experience showed