Operation and Maintenance Manual: Panching Water Treatment Plant (Draft Copy R1)

PANCHING WATER TREATMENT PLANT (DRAFT COPY R1)
OPERATION AND MAINTENANCE MANUAL

This document is a set of Operation & Maintenance Instruction Manuals for Panching Water Treatment Works and comprised the following
SLUDGE DEWATERING PLANT & EQUIPMENT

1.0 INTRODUCTION
The sludge dewatering plant system is designed to handle the sludge generated by the plant. The complete system includes a sludge cake handling system to transfer the dewatered sludge from the mechanical dewatering equipment into bins where it will be transported out from the building storage yard.
The plant consists of the following equipments:Wash water recovery pumpset Decanters Submersible pumpset Submersible mixers Sludge scraper Decanter feed pumps and holding tank feed pump
1.1
OPERATING PRINCIPLES
The plant is designed for 24 hours continuous operation in automatic mode as programmed by the PLC at the respective plant. When required, the plant can also be operated under full manual mode by operator intervention.
PROCESS PLANT O&M MANUAL
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1.2 TREATMENT PRINCIPLES
The plant is designed with the following treatment processes to dewater the sludge prior to transfer out to the landfill:-
1.2.1 -Enhanced flocculation process. Polyelectrolyte is dosed as a flocculent aid. The dosing points are at the pipeline entering into thickener tanks and another at the pipeline entering decanters. The dosing of polymer solution is to aid in sludge thickening and to enhance the dewatering process.
2.0
SLUDGE DEWATERING PLANT DESCRIPTION AND CONTROL PHILOSOPHY
2.1
DESCRIPTION
Settled sludge from the 10 sedimentation tanks is piped to 2 Nos. sludge balancing tanks (1 duty & 1 standby) while filter backwash waste water is discharged into 2 Nos. washwater recovery tanks (WWRT) (1 duty & 1 standby). One WWRT is designed to hold the waste water from 2 filter backwashing. After the WWRT has collected 2 lots of wastewater, the inlet penstock is closed and the content is settled. The supernatant is pumped back to the inlet of aerator through a floating suction. The sediment from the WWRT is pumped to the sludge balancing tank. Settling operation at WWRT is carried out batch-wise. The sludge balancing tank (SBT) receives sludge transferred from the WWRT as well as sludge and chemical waste discharged directly from the 10 sedimentation tanks and chemical building respectively. Sludge particles are kept suspended in SBT by 2 submersible mixers. Sludge from SBT is fed to the sludge thickener tank (STT) by 2 Nos. submersible thickener feed pumps (TFP). In operation, either 1 or 2 feed pumps will run, depending on level at the
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SBT. When level is too low, both TFP will stop, but the submersible mixers are kept running. Sludge thickener tank (STT) concentrates the watery sludge to at least 4% dry solids. The sludge rake runs continuously as long as there is water or sludge in STT (liquid level above a pre-set level). Supernatant from the STT overflows and is diverted back to the WWRT. Solids carried over at STT overflow outlet is manually monitored and checked. The thickened sludge is transferred to the sludge holding tank (SHT) periodically by means of PC pumps under level control at the SHT. The PC pump and sludge transfer pipe shall be flushed whenever the PC pump stops and the flushed water is discharged directly into sludge holding tanks. The sludge holding tank (SHT) supplies a steady stream of sludge to the centrifuge decanters. Two PC pumps deliver sludge from a SHT to 3 units of decanters. Normally, only one decanter runs during the day and afternoon shifts; but if sludge load is heavy, 2 decanters may be running. The dewatered sludge cake from the decanter is collected in a dedicated arm roll bin by operating a screw conveyor. The collected dewatered solids are disposed out from the treatment works by trucks. The centrate from the decanter is discharged to the surface drainage. There is a polymer solution preparation system and dosing pumps at this sludge treatment plant. The dosing pumps supply polymer solution to the STT feed to assist in sludge thickening and to the centrifuge decanter to enhance the dewatering process.
2.2
WASH WATER RECOVERY TANK (WWRT)
2.2.1 FUNCTION The WWRT serves as a holding & sedimentation tank for filter wash-water. It enables the supernatant to be returned to inlet of the aerator and settled sludge to be transferred to SBT.
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2.2.2 OPERATION For each WWRT, there is an Auto/Manual selection switch on the SCADA screen to control the respective WWRP and STP. The position of the selection switch (on the SCADA screen) will determine how the associated equipment response. Normally, the Auto position shall be selected unless that WWRT is not available or under manual testing. When a WWRT is selected to Manual at SCADA, start/stop of the associated WWRP and STP shall be done on a fully manual basis via the SCADA or from the respective start/stop push-buttons at the MCC. The PLC control programme is not available at the Manual mode. When a WWRT is selected to AUTO at SCADA, the operation of associated WWRP and STP will be automatically controlled base on current PLC control programme. The selected WWRT will undergo an automatic Filling, Settling and Disposal sequence. The auto sequence will be described later. All WWRP and STP shall be provided with field mounted emergency stop push-button stations. The operation at WWRT is carried out batch-wise. There are 3 stages in this treatment process: (1) Filling with filter wash-water, (2) Settling the waste water and (3) Disposal of the settled waste-water. Under Auto mode, only 1 WWRT is selected to Filling state. At the Filling state, the WWRT inlet penstock is open to receive filter wash-water. After receiving 2 continuous filter backwashes and the level electrode detects high water level, the inlet penstock of the second WWRT is opened and the inlet penstock of the first WWRT is closed simultaneously. It will also trigger the "Settling" timer. [Note: Ultrasonic level sensor shall be used to monitor the water level of WWRT.) If there is any fault at the actuators of inlet penstock or penstock status not in line with sequence, corresponding alarms will be raised. Auto control sequence will still continue even when there is alarm.
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When the first WWRT enters the Settling stage and the second WWRT will go to the Filling state. Settling is purely time base and the pre-set time can be adjusted from SCADA. Suggested settling time is 120 to 240 minutes. (to be refined & checked during testing & commissioning). Most of the sludge solids in the filter wash water will settle under gravity during the prescribed duration.
After the first WWRT has completed its Settling, it moves on to the Disposal state. In Disposal state, the dedicated wash-water recovery pump (WWRP) will start and the discharge valve of the WWRP open. Status of WWRP & its discharge valve are monitored, and alarm is raised when unusual condition arises. The supernatant from the WWRT is recycled back to the inlet of the aerator. The recycle flow rate is monitored by a magnetic flow-meter & display on the system. The recycle flow is manually pre-set by throttling a valve. In case the recycle wash-water flow exceeds a pre-set high flow value (SCADA adjustable) for more than 5 sec, an alarm Recycle Flow High will be raised. Pumping shall still continue even in Hi Flow condition. Auto-stopping of WWRP is by level electrode. When the low limit contact is activated, the WWRP stops and the discharge valve is close. If WWRP fails before the water reaching low level, the No WWRP Available alarm will be raised and the control sequence will be suspended. Operator interference is required to rectify and normalise the situation. [One unit of WWRP is dedicated to each WWRT, there is no standby unit.] Under normal condition when the WWRP has stopped, the duty submersible sludge transfer pump (STP) will automatically start run until the low-low limit contact (of level electrode) is activated. Status of the STP is monitored. The stand-by STP will run if the duty pump were to fail. After the STP has auto stopped (when WWRT has been emptied), Disposal stage is completed and the WWRT is put to Stand-by (inlet penstock continues to remain close). It will remain in this state until the other WWRT is
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fully filled (water reaches high limit contact of level electrode).
2.2.3 Process Interlocks & Alarms / Failure Conditions: A. The WWRP is dedicated to one unit of WWRT. The 2 STP from the same WWRT may run together automatically (by manually switching both STP to 'Available to start'). B. Control sequence will normally continue even when there is an active alarm (except as in (C) below). C. Process control sequence is suspended with alarm raised when the WWRP or both the STP fail together. In this case, manual intervention is required. D. WWRT is not available when : (a) Inlet penstock or valve is not remote selected at actuator; or (b) The associated WWRP or both STP are not available, fail/fault. E. Alarm to be raised when : (a) Any pump, valve or penstock fails during operation. (b) Alarm is raised when both duty & standby pump fail. (c) Alarm is raised when both the WWRT are NOT available.
2.3
SLUDGE BALANCING TANK (SBT)
2.3.1 FUNCTION Sludge Balancing Tank (SBT) acts as a buffer tank for storage of sludge from clarifier, chemical waste from chemical building and sludge transferred from WWRT before it is fed to the thickener tank. This serves to even out the sludge feed rate to the 2 sludge thickening tanks. Dimension of a SBT = 9.00mW x 10.685mL x 2.80m Depth
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2.3.2 OPERATION When a SBT is put to Service from the SCADA screen, the associated inlet penstock will open. When the SBT is put to Standby or Out of Service, its inlet penstock will be closed. It is possible that while a SBT is Out of Service and yet its associated submersible thickener feed pump (TFP) and submersible mixers (SMX) are still running on Manual For each SBT, there is an Auto/Manual selection switch on the SCADA screen to control the respective TFP and SMX. The position of the selection switch (on the SCADA screen) will determine how the associated equipment response. Normally, the Auto position is selected unless that SBT is not available or under manual testing. When a SBT is selected to Manual at SCADA, start/stop of the associated TFP and SMX shall be done on a fully manual basis via the SCADA or from the respective start/stop pushbuttons at the MCC. The PLC control programme is not available at the Manual mode. When a SBT is selected to AUTO at SCADA, the operation of associated TFP and SMX will be automatically controlled base on the current PLC control programme. The PLC control programme is basically a level based program to start and stop the TFP and SMX. Further, whenever a TFP runs, the duty selected Thickener Polymer Dosing Pump (TPDP) shall be auto started and the polymer solution dosing valve shall open. The polymer solution will be dosed to the common TFP outlet. When two TFP on a same line are running, the control system shall automatically double the polymer dosage (double the TPDP running speed). All TFP and SMX shall be provided with field mounted emergency stop push-button stations. Operation at a SBT is essentially based on level status within the tank. The primary control element in each SBT is the level electrodes. Each SBT feeds into a dedicated sludge thickener tank (STT); SBT#1 feeds STT#1 and SBT#2 feeding to STT#2; cross over operation is not possible.
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Sludge solids are prevented from settling on SBT tank floor by two submersible mixers which are running perpetually as long as that SBT is put to Auto and the water level is above preset. (The said SBT can be put Out Of Service) Level electrode function: L1 : Longest electrode, serves as reference (100mm ftf) L2 : both SMX stop below this level (350mm ftf) L3 : both SMX start to run & both TFP stop (400mm ftf) L4 : First TFP auto starts on reaching this (1200mm ftf) L5 : Second TFP auto runs on reaching this (2000mm ftf) L6 : SBT Overflow alarm (2900mm ftf) ftf = from the tank floor Capacity of each TFP = 35 m3/hr @ 10m Plan area of each SBT = 9,000 x 10,685 mm SBT tank floor level = IL 31.00m Normal TWL at SBT = TWL 33.80m Estimated TFP run time = 30 minutes When a TFP runs, the associated motorised butterfly valve shall open. When the TFP stops, the discharge valve will close. The TFP can run as long as the dedicated sludge thickener tank (STT) is put to Service. Operation of TFP is not affected by level status or sludge density / concentration at the STT; it is only dependent on level at the SBT. Either one or two TFP may run, depending on level at the SBT. The operation of SMX is only dependent on the level at SBT. Both SMX will run or stop together. The spare unit is an off line item supplied loose. Both the TFP and the SMX may be started/stopped manually from the SCADA control screen. If the duty TFP fails before the pre-set level is reached, the stand-by TFP auto starts & continues to run until the pre-set level is reached. If the stand-by TFP is not available or fails after running for a while, No TFP Available alarm will be raised and control system is suspended. Operator interference is required to normalise the fault condition.
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2.3.3 Process Interlocks & Alarms / Failure Conditions: A. One SBT will serve only one dedicated STT. No cross over is permissible. B. One or both TFP may run simultaneously, depending on level control at the SBT. C. When a TFP runs, the duty selected thickener polymer dosing pump shall be running and the corresponding thickener polymer dosing valve shall open. D. Control action is still active even when there is an active alarm. E. SBT is not available when : (a) Inlet penstock is not remote selected at actuator; or (b) Both the TFP or both SMX are not available, fail/fault. F. Alarm to be raised when : (a) Any pump, valve or penstock fails during operation. (b) Alarm is raised when one SMX or both duty & standby pump fail. (c) Alarm is raised when both the SBT are NOT available. (d) When a TFP has started and none of TPDP is running, alarm Thickener Polymer Dosing Fail shall raised. System is allowed to continue. 2.4 SLUDGE THICKENER TANK (STT)
2.4.1 FUNCTION The Sludge Thickener Tank (STT) increases the solids concentration of sludge before it is pumped to the holding tank. The clear supernatant overflows the weir and is returned to WWRT by gravity. The STT can also act as sludge storage tank in case the sludge holding tank is full or temporary out of service.
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The STT is dedicated to receive sludge from only one SBT and the thickened sludge will only be pumped to one of the 2 sludge holding tank (SHT). Diameter of one Sludge diameter x 3.50m depth Thickening Tank = 25.00m
Volume of sludge, 1.0m depth in STT = 750 cu meter. 2.4.2 OPERATION For each STT, there is an Auto/Manual selection switch on the SCADA screen to interlock with the TFP. The position of selector switch (on SCADA screen) will determine how the TFP response. Normally the Auto position is to be selected unless that STT is not available or under manual testing. When the STT is put to Auto from SCADA, the scrapper or rake will run continuously; and corresponding TFP will receive a start permissible i.e. it is free to start & stop depending on level corresponding SBT. sludge the 2 signal; at the
When a STT is put to Manual, the sludge scrapper will retain its last status before the switch-over (i.e. scrapper will be running if it was running before or the scrapper will be stop if it was not running earlier) and the corresponding TFP is NOT start permissive (i.e. the TFP will not auto start/stop with level changes at the corresponding SBT.). However, the TFP can still be manually started if so wishes. There is no In service /Stand-by /Out of Service selection for the STT; the only available selection is Auto or Manual. The sludge feed to STT and discharge from a STT is not controlled by status at the STT itself. When the TFP runs, supernatant from the STT will overflow and return to the WWRT by gravity. When the SHT feed pump (SHTFP) runs, the concentrated sludge will be transferred to the sludge holding tank. The only equipment that is controlled from the STT is the sludge scrapper drive.
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Sequential time base control or level control is not applicable to STT system.
2.4.3 Process Interlocks & Alarms / Failure Conditions: The Auto/Manual selection state of a STT is interlocked to start permissive-ness of the corresponding TFP as described earlier. Whenever a Sludge scrapper fails or trips, an alarm must be raised. Sludge scrapper shall be provided with a remote mounted emergency stop button station. If the torque switch on the sludge scraper gearbox is activated, Alarm Sludge Scraper Tripped on Over-Torque is raised.
2.5
HOLDING TANK FEED PUMPS AND SLUDGE HOLDING TANK
2.5.1 FUNCTION A Sludge Holding Tank Feed Pump (SHTFP) transfers the concentrated sludge from the bottom of a STT to the sludge holding tank (SHT). There are 2 sets of dedicated STT, SHTFP and SHT; cross-over operation between these 2 sets of equipment is not possible. The SHT stores and provides a steady stream of thicken sludge of fairly uniform solids concentration for feeding to the centrifuge decanters. The 2 submersible mixers (SSMX) at each SHT prevent the sludge particles from settling. Dimension of a SHT: 7.50mL x 7.00mW x 2.35mD
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2.5.2 OPERATION For each SHT, there is an Auto/Manual selection switch on the SCADA screen to interlock with the SHTFP and SSMX. When Auto position is selected, the SHTFP can auto start/stop depending on the thickened sludge level in STT and sludge level at SHT, while the auto start/stop of SSMX depends on the sludge level at SHT. [Note: Thickened sludge level in STT to be monitored via sludge level probe.] The operation of SHTFP is independent of the status at the respective STT; and there is hardwired safety interlock at each SHTFP motor starting circuit to protect the pump. In case of dry running, a temperature switch embedded in the pump body will send a signal to trip the affected pump. When pump discharge pressure is too high, the common pressure switch will stop the pump. When selected to Manual, SHTFP and SSMX can only be started or stopped manually. The hard-wired interlock on SHTFP will still function, but control from level electrodes will be disabled. When a SHTFP stops, the sludge delivery line and pump shall be auto flushed before the pump is turned off. While the pump is still running, the flushing water inlet valve is open and the flushed water is discharged into SHT. After a time delay of several secs (adjustable) the common motorised pump suction valve is closed. Then the SHTFP runs for a further pre-set time (120 to 600s, adjustable) before the SHTFP is stopped. The flushing water inlet valve is closed after the pump has stopped. In case there is a valve actuator failure during the pump flushing sub-routine, the SHTFP will stop and the respective valve failure alarm is raised. Operator attention is required to check & reset. There are 2 SHTFP in a system, when a SHTFP fails during an auto running operation, the stand-by unit shall auto start and a SHTFP Failure alarm raised. Operator intervention is required on the failed pump to be repaired & manually flushed before returning to standby. The suggested level control set points#1 at sludge holding tank (SHT) for auto control are given below. These level
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set-points for electrode (measured from tank floor) are still subject to re-confirmation after site testing / commissioning. L1 L2 L3 L4 L5 L6 0.050 0.300 0.400 0.700 2.300 2.350 m m m m m m Reference level electrode Stop SSMX & start both SHTFP Start SSMX Start one SHTFP Stop all SHTFP SHT overflow alarm is raised
2.5.3 Process Interlocks & Alarms / Failure Conditions: The Auto/Manual selected state of a SHT will either enable or disable SHT level control of the corresponding SHTFP and SSMX. An equipment (pump, mixer & valve) failure alarm shall be raised whenever such an event arises. Except for SHTFP, the failure of the duty unit shall not cause the standby unit to run. Before a SHTFP stops on auto, the pump and the sludge delivery piping shall be auto-flushed as described.
2.6
DECANTER CONYEVOR
FEED
PUMPS
AND
SCREW
2.6.1 FUNCTION The decanter feed pump (DFP) transfers the sludge from the sludge holding tank to the centrifuge decanter (CD) for dewatering. Dewatered sludge as discharged from decanter is transported by a screw conveyor (SC) to a collecting bin. There are 4 decanter feed pumps and 3 centrifuge decanters in this system. One DFP shall run to supply the feed to one decanter. Each decanter will have its dedicated screw conveyor to transport the sludge cake to an arm-roll bin.
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When any CD or DFP runs, the duty selected decanter polymer dosing pump (DPDP) will auto start and the corresponding polymer inlet valve to CD will open. Normally only one centrifuge decanter shall be running, the other 2 units act as standby. However when the qualities of raw water deteriorates and sludge volume increases, two decanters may be operated in parallel (duty cycle). The sludge cake collected in the arm roll bin shall be transferred and stored at sludge disposal yard periodically by the arm roll truck.
2.6.2 2.6.2.1
OPERATION Selecting available equipment to duty
The suction pipeline is arranged in such that sludge holding tank No.1 (SHT #1) supplies feed to DFP#1 and DFP#2; while SHT#2 serves DFP#3 and DFP#4. Individual discharge pipeline of all DFP will join to a common 'ring main' and then equally distributes the feed to each CD. The provision of 'ring main' allows duty-cycle operation of the decanter feed pumps (DFP) and centrifuge decanters (CD). When only one unit centrifuge decanter need to be run, any available DFP and CD may be selected for the duty. Operator has to ensure the suction and delivery manual valves are open and then the duty DFP and CD are selected to Auto at the LCP or SCADA. The motorised suction valve of the duty selected DFP and the motorised inlet valve to the duty selected CD will auto open. The sludge cake screw conveyor (SC) of the duty selected CD shall be put to Auto as well, to enable remote control by the PLC. When two decanters are required in operation simultaneously, any 2 available DFP may be selected manually for the duty while the 2 duty CD units are automatically selected by PLC (based on available running hours). The setting of running hour is adjustable at SCADA/PLC. The default running hour setting shall be 8 hours per day for each CD. Total running hours for all three CD is 8 x 3 = 24 hours.
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When 2 sets of DFP and CD are running simultaneously, both DFP supplies feed to a common discharge line (ring main) and then equally distribute into both CD. The respective SC of both duty CD will automatically start via PLC remote control.
2.6.2.2 Operation of centrifuge decanter & related equipment. After the selected DFP, CD and SC are switched to Auto on the LCP and the correct isolation valves are open, the centrifuge decanter may be manually initiated to start from the decanter local control panel by pressing a push-button on the decanter LCP control touch-screen or remote initiation from SCADA. The decanter will start and undergo a normal starting sequence as described later. The motorised valves, feed pump and screw conveyor will be opened and started automatically at the correct sequence. Similarly, the decanter will go through an auto stop sequence when the Stop switch is activated. When the decanter is switched to Manual position, the standard decanter starting and decanter stopping sequences will be both deactivated. The associated motorised valves, feed pump and screw conveyor must be manually started or stopped at the proper sequence. A low level condition (L2) at SHT (sludge holding tank) shall to trigger the centrifuge decanter connected to this SHT to undergo a normal stop sequence on Auto.
2.6.2.3
Centrifuge Decanter standard starting sequence
When a decanter is initiated to start, the standard centrifuge decanter starting sequence is activated. A typical decanter starting sequence is as follows:
(1) Decanter start initiated from the LCP. (after checking manual valve position)
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(2) Start the main decanter motor drive & decanter scroll motor run. Decanter start timer is started. (3) Start the associated screw conveyor. (4) When decanter motor has reached full speed, a DFP Start signal is issued from the CD control panel. (5) With will (a) (b) (c ) (d) this DFP Start signal and the PLC control system Open the pump suction valve of the selected DFP. Open the decanter inlet motorised valve Open the decanter polymer solution inlet valve Check valve status, to sound alarm if required
(6) Start the associated DFP. (7) Send start signal to duty DPDP (if dosing pump not already in operation), or increase the polymer feed rate according sludge solids loading (when the 2nd decanter is started and the DPDP is already running). (8) Thickened sludge & polymer solution enter the running decanter; dewatering of sludge will take place. (9) Centrate liquid is discharged from the liquid end & the dewatered sludge cake drops from solid discharge port to the screw conveyor. (10) The centrifuge decanter control system will adjust the speed of decanter and monitor the differential speed in response to any variation in torque via automatic torque mode. Torque is affected by feed rate and solids content in feed. The decanter controller will monitor these operating conditions while the unit is running. (11) The decanter would remain in operation when there is a continuous stream of sludge feed and the decanter is healthy. (12) The decanter will undergo a normal stop sequence when the operator initiates the Stop button. The Emergency Stop button shall not be used to stop the unit under normal operating condition, unless it is an emergency. On pressing Emergency Stop, the unit
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will stop immediately without undergoing the flushing cycle.
2.6.2.4
Centrifuge Decanter standard stopping sequence
When a normal Stop command is received by the decanter controller, a standard stop sequence is activated. A typical decanter stopping sequence is as follows: (1) Decanter Stop is initiated from decanter LCP. (2) The DPDP will immediately stop and the suction valve of DFP is closed. After 5 seconds, the polymer inlet valve to the CD will be closed. (3) The corresponding DFP flushing water inlet valve is open; while the DFP and CD is still running. Flushing water displaces the sludge in DFP & delivery pipe to the decanter when the DFP is running. The DFP & CD flushing duration can be set from the LCP. [Note: If two decanters are running simultaneously, the initiation of "Stop" will cease the feeding of sludge for both DFP and flushing will take place in series for both DFP and CD.] (4) After the DFP & CD flushing duration has elapsed, the DFP will stop. (5) After 5 s, the flushing water inlet valve to the DFP is closed. (6) After a delay of 3 minutes (adjustable from LCP), the CD inlet valve is closed & the motor drive of the CD is stopped. (7) After another delay of 2 minutes (adjustable) when all the sludge cake has been transferred to the arm roll bin, the SC attached of the decanter is stopped. (8) The DC and its feed pump (DFP) are now in the stop position.
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2.6.3 Process Interlocks & Alarms / Failure Conditions:
(1) When two decanters are required in operation, the selection of duty decanter feed pumps (DFP) is done manually. The operator is required to check & confirm the manual valves of selected duty DFP are open before the decanter standard start sequence is operative. (2) An equipment (decanter, feed pump, screw conveyor & motorised valve) failure alarm shall be raised whenever such an event arises. The failure or tripping of an equipment shall not cause the standby unit to run on auto. The operator has to go to the field to investigate, clear the fault and normalise the equipment before starting again. This applies to all motorised equipment in this section, i.e. all equipment related to DCP and CD, except for the decanter polymer dosing pump (DPDP). (3) When sludge holding tank level is at L2 or below (see section 7.5.2 above), the operating centrifuge decanter connected to it will undergo a normal shutdown, with DFP & CD flushing prior to shut down; if the CD is selected to Auto. (4) When the screw conveyor (SC) associated with a running decanter trips, the operating centrifuge decanter connected to it will undergo a normal shutdown, with DFP & CD flushing prior to shut down; if on Auto. (5) When the DFP associated with a running decanter trips or fails, the operating decanter connected to it will stop immediately, without flushing (since flushing cannot be carried out when the DFP fails). At the same time the DPDP will stop or has its output halved if another decanter unit is still running. (6) Motorised valve failure(s) taking place after a decanter has completed its standard starting sequence will not cause the decanter to stop or trigger a CD stopping sequence. If valve failure takes place during a CD
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starting or stopping sequence, the start/stop sequence will be aborted and the affected unit will stop immediately.
2.7
POLYMER DOSING PLANT
2.7.1 DESCRIPTION
Two units of Packaged Raw Water Polymer Batching plant shall be installed for the works. Polyelectrolyte solution is dosed at a proportional to the plant inlet flow (raw common inlet channel of the clarifiers the respective clarifier via the respective controlled rate, water), into the before entering inlet penstock.
Prior to dosing into the raw water clarifier inlet chamber, the liquid polyelectroyte is diluted with carrier water via a common dilution water valve to assist dispersion. The amount of dilution water is regulated by manual valve and indicated locally by rotameter. The dilution water shall remain unaltered when changing the polyelectrolyte dose. From laboratory jar tests and pump calibration curves, the desired polyelectrolyte dose shall be set by the stroke adjustment hand wheel on the duty dosing pump manually. The dosing pump output can be periodically checked by using the portable Calibration Cylinder located at the suction pipework. The control of the polyelectrolyte dosing plant will be manual and automatic. Electrically operated valves shall only be provided for the respective dosing pump on the suction and storage tank outlet.
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2.7.2 CONTROL PHILOSOPHY
2.7.2.1 RAW WATER POLYMER PREPARATION SYSTEM
Preparation of the polyelectrolyte solution is designed for automatic batching, with control by the main PLC. The polyelectrolyte batching plant comprise of a storage hopper of about 100 kg c/w a feeder mounted at the bottomed. A vacuum powder loader is provided at the hopper for loading bagged powder into the hopper. The hopper shall be equipped with loadcells weigher for display of content weight. Two nos. of SS316 mixing tanks of approximately 5 m3 are constructed. A dedicated top mounted stirrer is provided for the mixing tank. The plant offered is designed for batch preparation of stock solution. A fixed speed dry feeder is provided to deliver a predetermined quantity of Polyelectrolyte powder into the mixing and mix with the incoming service water. The batching plant comprise of a hopper to store the required Polyelectrolyte powder. The powder storage capacity shall be 100 kg. The hopper is equipped with a vacuum powder for loading bagged powder into the hopper. A weighing system comprising of loadcells shall display the hopper content weight at the LCP. The operator will be able to select the required polymer batch strength (0.1 to 0.4% w/v). Upon selection of the strength to batch, the PLC shall compute the quantity of powder required and the feeder shall deliver accordingly to achieve the selected strength. The powder Polymer hopper shall fill by operating the vacuum powder loader with a local controlled switch at the hopper. The conveyor nozzle is manually inserted into a 25kg powder bag to effect the transfer.
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The preparation of polymer solution, at a pre-selected strength is automatically controlled by the PLC. The preparation sequence is initiated on low level only in the Mixing Tank as detected by a level switch. Upon manual initiation and a low level signal is detected, the sequence shall proceed as follows:Service water inlet valve opens to fill the Tank via a wetting device. The stirrer shall start when the feed commence feeding powder into the mixing tank. When a predetermined quantity is delivered into the mixing tank, the feeder shall stop. Service water continues to fill the mixing tank until the required level is achieved.
FAILURE CONDITION On power failure, the preparation sequence is interrupted. On restoration of power the batching sequence shall be restarted manually to continue.
2.7.2.2 POLYMER DOSING PUMPS
Two nos. of Polymer Dosing Pumps are provided with one duty and one standby for the works. Control of pumps and electrically operated valves are at the LCP. Two units of dedicated VSD are provided at the LCP to vary the pumping speed of the dosing pump via flow pacing control through a central PLC. The pump stroke setting shall be manually selected at the pump to suit. One no. of Polymer Dosing Pumps is a duty pump and the 2nd pump is served as a 100% standby dosing pump. In manual mode i.e. Local Manual, the duty tank outlet valve and the duty pump suction valve are operated at the LCP. The stroking speed of the dosing pump is directed
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varied at the VSD controller to achieve the required dose rate. The stroke setting shall be manually selected at the pump to suit. There are two auto modes available at the LCP i.e. Local Auto and Remote Auto. By Local Auto control, dosing sequence is activated at the LCP only and by Remote Auto control; the dosing sequence and dosing parameter are activated/changed at the Central SCADA only. Switchover of duty pump to the standby pump is automatic if Local Auto or Remote Auto is selected and control by the PLC timer. Under Local Manual mode at the LCP, the operator is able to select the duty dosing pump to start, as well as the duty variable speed drive units provided at the LCP. The dosing pump speed is manually adjusted at the VSD proportional to the plant raw water flow and stroke is manually adjusted to suit requirement. Selection of duty tank and duty pump are at the discretion of the operator by opening the selected tank outlet valve and the selected dosing pump suction valve at the LCP valves selector switches. Under Local Auto mode at the LCP, the operator shall only need to initiate an Auto start button. The PLC shall control the dosing sequence and dosing pump speed. Selection of pump stroke is done manually to suit requirement. Duty changeover of exhausted tank shall be automated by the duty tank level signal feeding to the PLC. Under Remote Auto mode, the operation will be the same as Local Auto except that the SCADA shall have full control of the plant i.e. duty tank and duty pump selection as well as initiation of Auto start and change of dosing parameter. Start and stop for the automatic mode are initiated manually by a Start/Stop button at the LCP or control centre MMI. Upon initiation of Start the auto sequence shall commence upon detection of flow and stop when flow ceased. Unless Stop is initiated, sequence shall resume when flow is re-established.
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In the auto mode, the dosing pumps flushing sequence is automatic each time the duty pump stops. The pump suction valve shall close and the flushing valve shall open to allow high pressure water through the pump and out for about 15 to 20 seconds.
FAILURE CONDITION On power failure the Polymer Dosing Pumps will stop and all valves position will maintain. On restoration of power supply, operation of the plant is reinitiated manually. When a duty dosing pump fails during operation under Local Auto or Remote Auto mode, the standby dosing pump will automatically take over the failed pump. The appropriate valves will automatically open or close respectively to correspond the operation requirement. On dosing pump failure, an appropriate alarm is raised at the LCP. Electrically operated valve failure (fail to open and fail to close), an amber failed light will be lighted on the respective valve status lights and the operator shall investigate and take appropriate action (to rectify or to switch over to next tank or pump). On VSD failure the appropriate alarm is raised at the LCP. The VSD shall be manually changeover.
2.7.2.3 POLYMER PLANT LCP The facilities for Manual Control and Local Auto are located at the LCP and complete with indication lights. The LCP have the following control functions and indications: 1) Power On status indicator lamp 2) Alarm Accept and Lamp Test push-button. 3) Hopper Weight Indicator 2 nos. 4) Running/Stopped/Tripped status indicating lights & Run and Stop buttons for :-
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a. b. c. d. Feeder No. 1 Feeder No. 2 Mixer No.1 Mixer No.2
5) Open/Close/Fault status indicator lights & Open and Close push buttons for :a. Pump Suction Valves 2 nos. b. Mixing Tank Outlet Valves 2 nos. c. Pump Flushing Valve 2 nos. d. Common Carrier Water Valve 1 no. e. Mixing Tank Inlet Valves 2 nos.
6) Running/Stopped/Tripped status indicating lights & Run and Stop buttons for :a. Dosing Pump No. 1 b. Dosing Pump No. 2 c. Dosing Pump Starter 2 nos. 7) Dosing Pump Starters 2 nos. 8) Variable Speed Drive Units 4 nos. 9) Local /Remote Selector Switch. 10) 11) Auto/Manual Selector Switch Local Start/Stop initiation push button
2.7.2.4 ALARM SUMMARY The following alarms shall be provided for Raw Water Polymer Dosing Pump LCP:1) 2) 3) 4) 5) Hopper Weight Low Hopper Weight High Mixing Tank Level High Mixing Tank Level Low Common Failed for Pump/Valve/VSD
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2.7.3 POLYMER DOSING PLANT START UP BATCHING PLANT START UP The batching plant is only operated in automatic mode. The initiation of the batching done manually at the local panel mounted on the skid. Selection of solution strength is also done on the local panel.
POLYMER DOSING PUMP START UP AUTOMATIC MODE Start-up of the plant in the automatic mode is initiated manually by a Start button at the LCP or at the control centre MMI. Upon initiation of Start button, the auto sequence commences when raw water flow is detected and stop when raw water flow ceases. Unless Stop is initiated, sequence will resume when raw water flow is re-established after the raw water flow ceased.
MANUAL MODE
The Polymer plant is designed to run only in Local Manual and Remote Manual is therefore not used. Start-up of the plant in the manual mode is done at the local control panel. The following steps shall be followed to commence the operation in manual mode:At the LCP under Preparation System, please select the switch to Local for duty tank Then select the selector switch next to it to Manual At the LCP under Dosing System section, please select the switch to Local
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Then select the selector switch next to it to Manual The operator shall at the field, check for manual valves for the storage tank and dosing pump that need to be opened The operator shall decide on the duty tank to be put in service by opening the corresponding motorized tank outlet valve at the LCP The operator shall decide on the duty pump to be put in service by opening the corresponding motorized suction valve at the LCP Ensuring raw water flow is established, the operator shall initiate Initial Start button at the LCP From the pump calibrated curve or chart provided, the operator shall vary the pump stroke setting and VSD speed manually to achieve the dosage that is required Once the pump is started, the operator shall at the LCP, opened the motorized carrier water valve and regulate the flow if necessary A plant started in manual mode shall be monitored closely by the operator as there will be no pump failed changeover or tank empty switchover that is automatically done in auto mode.
2.7.4 POLYMER DOSING PLANT SHUTDOWN AUTOMATIC MODE Shutdown of the plant in auto mode is initiated manually by an Initial Stop button at the LCP or at the control centre. Upon initiation of Initial Stop button, the auto stop sequence commences with the duty pump stopping and follows by the respective closing of motorized valves. When raw water flow ceases or not detected, the plant will also stop. Unless Initial Stop is initiated,
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sequence will resume when raw water flow is reestablished after raw water flow ceased. The dosing pumps shall be automatically flushed each time the dosing pump stops.
MANUAL MODE Shutdown in manual mode is done at the LCP by pressing the Initial Stop button or at the control centre. The following steps shall stop the plant operated in manual mode:After pressing the Initial Stop button, the duty pump suction valve shall be selected to Close to isolate the pump Select the duty tank outlet valve to Close to isolate the tank Then, select the common carrier water valve to Close to stop the carrier water The dosing pumps shall be manually flushed by selecting Open on the respective flushing valve located at the pump suction for about 10 to 15 seconds and Close after that
2.7.5 POLYMER DOSING PLANT MAINTENANCE The Polymer dosing plant basically consists of the batching plant complete with mixing and storage tanks, level sensors, motorized valves, a transfer pump and metering pumps. Manufacturers equipment manuals are included in this O&M manual for reference. The operators are advised to refer to the specific manual for proper maintenance procedure described in the relevant manual.
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It is recommended that mixing tanks should be emptied and cleaned on a half yearly basis to check and remove the hardened polymer stuck to the side of the tanks. On a monthly basis, the storage hopper should be checked for hardened polymer powder and removed to prevent obstruction to free flow of powder in the feeder screw. On a monthly basis, check the total weight of powder feed by the screw feeder during a batching sequence. For a 0.2% w/v solution strength, 1.2kg should be fed by the feeder for a single batched. Readjust the feeder frequency if required.
- On a monthly basis, the metering pump should be recalibrated to ensure the pumping rate is maintained. If flow rate is noticeably different from previous calibration, refer to manufacturer manual for pump fault. - On a monthly basis, the motorized valves should be tested to ensure they are able to close and open fully and the respective signal feedback status is displayed at the SCADA. - On a monthly basis, the mixing tank level probes should be tested to trigger the high-high, high and low level indication at the SCADA.
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2.7.6 POLYMER DOSING PLANT TROUBLE SHOOTING PUMP NOT STARTING (OR STOPS ITSELF) Possible Causes Remedial Action
1. Restart raw water pump. 2. Check flow meter and 2. Raw water flow signal rectify. loss. 3. Service tank sensor detected low-low. level 3. Initiate batching of polymer solution. level
1. Raw water flow ceased.
4. Switch on the power 4. MCC power to pumps to the pumps at the isolated. MCC. 5. Pump emergency switch 5. Reset pump operated. emergency switch. 6. Check for pump 6. Pump tripped/faulted. overload or possible short circuit.
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PUMP FLOW LOW Possible Causes Remedial Action
1. Pump diaphragm damaged. 2. Pump choked. suction
1. Inspect pump diaphragm and replace if necessary. 2. Check suction valve and pipe for blockage and clean.
3. Check pump stroke and VSD setting. 3. Readjust setting or recalibrate pump if necessary.
PUMPING SOUND ABNORMAL Possible Causes Remedial Action
1. Dampener diaphragm ruptured or deflated.
1. Inspect dampener air pressure, inflate or replace where necessary. 2. Check suction valve and pipe for blockage and clean.
2. Pump choked.
suction
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Operation and Maintenance Manual: Panching Water Treatment Plant (Draft Copy R1)

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PANCHING WATER TREATMENT PLANT (DRAFT COPY R1)