Electrochlor Ination System Operating and Maintenance

OPERATING & MAINTENANCE MANUAL
2 X 8.0 KG/HR HYPOPAC-M ELECTROCHLORINATION PACKAGE

Page No : 1 of 50
PIPA II DEVELOPMENT
Dynamic Producer Inc.
01 10-DEC-2009 For Information Dinesh Murali Murugan

Rev. Date Reason for issue Prepared Checked Approved
Document Status Code (CODE MUST BE IDENTIFIED) Owner Company Name / Logo
Dynamic Producer Inc.
Code Document status
IDC For IDC
X FI For Information I
P
FA For Approval D
FC For Construction
F Final / Certified
AB As built Sub Supplier Company Name / Logo
Code Approval status

FI For Information
A Approved without Comments Titanium Tantalum Products Ltd
B Approved with Comments Chennai- 600 073, India.
C Not Approved, Re-submit for Approval
Originator/Contractor Company Name/Logo TiTaN Document Number:
TTPL/TLSX010/ENG/PD/100000060/042-00
Originator / Contractor Document Number:
-
Document Title
Project No Originator no. Contract/PO no HYPOPAC - M Electrochlorination Package
2 x 8.0 Kg/hr
PS-05 80 P080102 OPERATING & MAINTENANCE MANUAL
System Area Discipline Doc. Type Client Doc. Number No of Sheets Doc.Status Revision
47 N/a Z MB DPI -80-Z-47-MB-0001 50 FI 01

2 x 8.0 KG/HR HYPOPAC-M ELECTROCHLORINATION PACKAGE
Sheet No: 2 of 50
OPERATING AND MAINTENANCE MANUAL
RT MARINE-S
2 X 8.0 KG/HR ELECTROCHLORINATION PACKAGE

Sheet No: 3 of 50
REVISION RECORD
REV DATE PREPARED CHECKED APPROVED DESCRIPTION

0 10.08.09 MD GM GM FOR INFO
Sheet No: 4 of 50
INDEX
S.NO PAGE NO
CONTENTS
1. INTRODUCTION 5
2. DESIGN BASIS 5
3. GENERAL DESCRIPTION 10
4. OPERATING PROCEDURE 16
5. PACKAGE OPERATION 19
6. STARTUP PROCEDURE 28
7. SHUTDOWN PROCEDURE 30
8. MAINTENANCE 32
9. HEALTH AND SAFETY 35
10. DOS & DONTS 40
11 ELECTROLYSER PERFORMANCE TESTING 42
ANNEXURE I ANALYSIS PROCEDURE

ANNEXURE II REFERENCE DOCUMENTS
Sheet No: 5 of 50
1.INTRODUCTION
Seawater is used extensively on offshore marine platforms, oilrigs and FPSO vessels for a variety
of different applications. Seawater causes biological growth and algae formation on wetted walls of the
Sea chests, cooling water pipe lines and inner surfaces of vessels. To control the biological growth and
algae formation, chlorine in the form of sodium hypochlorite shall be dosed at all the Sea chests of A, B,
C, D, E, F & G which is going to be installed at A1 Ship Shaped Oil production Storage and Drilling Unit,
DYNPOS-AUTR, E0, Heldeck. Sodium hypochlorite will be produced from seawater by electrolyzing the
Seawater, which predominantly has sodium chloride. The produced chlorine will be in the form of
sodium hypochlorite, which is a good disinfectant, and anti bacterial agent.
To achieve this, new electrochlorination package with inbuilt generating facility will be installed to
generate sodium hypochlorite and dose in seawater flowing area to control the biological growth in Sea
chest. RT MARINE-S is the most advanced TiTaNs MGPS (Marine Growth Preventing system)
comprising an HYPOPAC- M electrolyser that produces on-site generation of chlorine in the form of
safe sodium hypochlorite solution (equivalent chlorine) the active ingredient required for anti fouling.
Sodium hypochlorite solution will be used for the disinfections of seawater to prevent bio fouling by
destroying the growth of marine organisms in the seawater facilities.
This package has been designed to supply suitable capacity of the sodium hypochlorite as per
contract requirement, which consists of all required equipments, instruments, valves, piping its
accessories, etc for safe and smooth operation. This manual covers all the necessary design, sizing
basis, operating sequence, start-up & shutdown procedures, maintenance, troubleshooting,
instrumentation and its control logics sequences provided for safe and effective operation of
electrochlorination package. The 2 X 8.0 Kg/hr HYPOPAC M Skid Based Electrochlorination
System is supplied to:
Owner : Dynamic Producer Inc., (DPI)

Sheet No: 6 of 50
2.0 DESIGN BASIS
Project : MALAYAMPA PHASE 2 ASSET
INTEGRITY DEBOTTLENECKING
DPI Project No. : PS-05
TiTaN Job No. : TLSX010
Package : 2 x 8.0 kg/hr HYPOPAC - M
Electrochlorination package
(RT MARINE-S)
Type of the system : Seawater based
Operating mode : Continuous
Installation location : Ship-indoor
Filtered / Oil free seawater inlet supply : 11.0 m3/hr @ 11 bar.g
No. of hypochlorite generator units : 2 Nos (1W + 1S)
No. of electrolytic cell modules of each unit : 2 Nos
Sodium hypochlorite production capacity of each unit : 8.0 kg/hr
Concentration of available chlorine at each unit outlet : 727 ppm
No. of transformer rectifier unit : 2 Nos (1W + 1S)
Each transformer rectifier unit output : 60 V DC, 1000 A DC
No. of degassing tank : 1 No.
Capacity of degassing tank : 1 m3
No. of air dilution blower : 2 Nos ( 1W + 1S )
Air dilution blower capacity : 300 m3/hr

Sheet No: 7 of 50
2.1 PROCESS DESIGN CALCULATION
2.1.1. PACKAGE CAPACITY
Quantity of seawater to be treated (as per contract) = 2,610 m3/h
Continuous hypochlorite dosing concentration = 3 mg/l
Amount of hypo required to treat above quantity of seawater = 2,610x 1000 x 3
= 7830000 mg/h
= 7830000/10-6 kg/hr
= 7.83 kg/hr
Design capacity of the package = 8.0 kg/hr
2.1.2. HYPOCHLORITE CONCENTRATION
Design capacity of Hypochlorite generator unit = 8.0 kg/hr
= 8000 g/h
Seawater flow rate = 11 m3/h
Hypochlorite concentration in seawater = 8000/(11 x 1000)
= 0.727 g/l
= 0.727 x 1000 mg/l
= 727 mg/l
Sheet No: 8 of 50
2.1.3 BLOWER CAPACITY:
The electrolysis process, which will take place inside the electrolytic cell, will be as follows
NaCl + H2O NaOCl + H2
From the above equation,
When 1 mole of sodium hypochlorite generates, 1 mole of hydrogen will also generate.
In electrochlorination process, sodium hypochlorite will be measured in terms of equivalent

chlorine.
Hence, When 1 mole of chlorine generates, 1 mole of hydrogen will also generate.
Or
When 71 grams of chlorine generates, 2 grams of hydrogen will also generate.
Unit capacity is 2 X 8 kg/hr, 8 kg/hr or 8000 grams/hr will be in operation continuously.
Hence, 8000 gm/hr of equivalent chlorine generates = 2/71 x 8000
= 225.35 g/h of Hydrogen.
Density of hydrogen = 0.08 kg/m3
Volume of hydrogen generates = 0.22535 / 0.08
= 2.8168 m3/h
This hydrogen will be diluted using air to its 25% of LEL and vented to atmosphere.
Sheet No: 9 of 50
25% of LEL of hydrogen is = 1% (v/v) in air
Hence, we are diluting the above quantity of hydrogen with 100% (v/v) air.
Therefore, the volume air required = 2.8168 x 100
= 281.68 m3/h
Design capacity of blower = 300 m3/h
2.1.4 DEGASSING TANK CAPACITY:
The Design flow rate of seawater + hypochlorite coming to tank = 11.0 m3/h
Generally, 5 minutes minimum hold up volume of the flow rate will be considered for
capacity sizing of hypo storage tank in seawater based electro chlorination system.
Hence,
Volume of the tank = 11 x 5 / 60
= 0.9166 m3
= 1 m3
Design capacity of degassing tank = 1 m3

Sheet No: 10 of 50
3.0 GENERAL DESCRIPTION
The on-site generation of sodium hypochlorite solution from filtered seawater is performed by
electrochemical process providing electrolysis of sodium chloride contained in seawater, as it flows
through direct current energizing anodic and cathodic tubular electrodes.
Filtered and Oil free seawater is fed to the sodium hypochlorite generators (electrolyser) of
HYPOPAC-M unit. During normal operation, TiTaNs electrolyser produces designed sodium
hypochlorite solution by means of electrolysis via DC power supplied from transformer rectifier and
collected in the degassing tank. The amount of hydrogen gas generated along with sodium
hypochlorite disengages from the liquid phase in the upper part of the tank and it is diluted with air-
by air dilution blower in order to keep hydrogen concentration at about 1% v/v (25% LEL) when it is
vented to atmosphere. Finally sodium hypochlorite solution is delivered to the dosing point of
seachests by means of gravity flow from the degassing tank. The basic operations of
electrochlorination package is controlled / monitored in the Transformer rectifier and local control
panel.
Seawater at Battery Limits:
1. Seawater enters the package at the flow rate of 11.0 m3/hr at 11.0-bar.g pressure.
2. Seawater at the package inlet should be filtered free from suspended solids and oils.
Sheet No: 11 of 50
3.1 PACKAGE EQUIPMENT DESCRIPTION
The HYPOPAC-M Electrochlorination package consists of the following major equipments, which
are erected in two skids (to be fixed together at site) and it is to be placed in a well-ventilated closed
room.
3.1.1 Hypochlorite generator
3.1.2 Degassing tank
3.1.3 Air Dilution Blowers
3.1.4 Transformer-Rectifier
3.1.5 Local Control Panel
3.1.1 Hypochlorite Generator
The heart of the electrochlorination package is TiTaNs proprietary concentric tubular
HYPOPAC-M electrolyser (hypochlorite generator), which is suitable for installation in Offshore,
FPSO, commercial vessels, Oilrigs, drilling units and other ship-based applications.
The 2 X 8.0 kg/hr HYPOPAC - M electrochlorination package provides onsite generation of
sodium hypochlorite by electrolysis of seawater. There are two numbers of hypochlorite generator
(one operating [47-XQ-0001-A & 47-XQ-0002-A] mounted at the two side bottom and one standby
[47-XQ-0001-B & 47-XQ-0002-B]) at the two-side top, which are connected hydraulically parallel
with each other having equivalent chlorine production capacity of 8.0 kg/hr each. Each hypochlorite
generator is having two electrolytic cell modules of electrolytic cells connected electrically and
hydraulically in parallel. Each electrolytic cell module having an operating capacity of 4.0 kg/hr
equivalent chlorine which is fed with the DC power via individual transformer rectifier unit. All the
four numbers (two operating and two standby) of electrolytic cell modules are assembled in a
Sheet No: 12 of 50
separate metallic enclosure fixed in horizontal position, which will form continuous flow path through
electrodes. The electrodes are constructed from titanium seamless / welded tubes. The two outer
tubes are separated by an outer union and electrically insulated from each other one outer tube is
an anode (+) and the second is a cathode (-). The inner tube is bipolar serving as a cathode for the
outer anode and an anode for the outer cathode. The seawater flows in the cylindrical shaped
annular space between the inner and outer tubes acting as an electrolyte. The anodes of each cell
are coated with precious metal oxide coating, which is for excellent efficiency in the electrolysis
process and long durability. Inter electrode Gap between inner and outer electrodes is maintained
with the TEFLON spacer buttons in order to avoid the short circuit.
Complete electrode assembly is fixed inside a SS316L enclosure suitable for installing in harsh
marine environment. This enclosure is having required inlet and outlet process connections, DC
power cable entry holes and suitable vent & drain connections with plugs at the side and the bottom
of the enclosures respectively.
3.1.1.1 SALIENT FEATURES OF HYPOPAC -M ELECTROLYSER
High and Uniform velocity at fully turbulent flow
No acid cleaning required
Non corroding titanium electrodes with Platinized metal coating
Metallic Enclosure housing protection for harsh marine environment suitability
5 year warranty for anode life
Low Maintenance Design
Compact, adaptable installation

Sheet No: 13 of 50
3.1.2. Degassing Tank:
The degassing tank is an atmospheric vessel made out of FRB, sized for 1000 liters up to
overflow so that the hypochlorite received from the electrolyser at the nominal flow rate has a
residence time sufficient to dilute the entrained hydrogen with air and vented to atmosphere via vent
line provided at the top of the tank. The tank is vertical cylindrical design with integral flattop and
bottom. The tank is provided with a transparent level gauge, overflow, drain, vent, discharge / outlet,
hand hole, level switch and additionally one spare nozzle as well as transparent level gauge.
Design temperature of tank is 600 C, which is higher than the maximum temperature that any
part of the tank is likely to attain in course of operation. The tank is mechanically designed as per
BS 4994 1987 standard.
3.1.3 Air Dilution Blower:
Two horizontal centrifugal hydrogen air dilution blowers (one working + one standby) are
connected to the degassing tank. The blower is rated at 100% of flow and will provide 300 m3/hr @
150 mm WC discharge pressure and it is used to dilute the hydrogen gas to reduce the hydrogen
concentration in the atmosphere to 25% of its LEL. Both impeller and casing are made of SS316L.
The motor is a foot-mounted type with IP 55 protection with F class and direct on line starting at
690V, 3 ph and 60 Hz.

Sheet No: 14 of 50
3.1.4 Transformer Rectifier:
Transformer rectifiers (47-ET/ER-0001-A / 47-ET/ER-0001-B) are specifically designed to
feed HYPOPAC-M hypochlorite generators, which are continuously and automatically
controlled. Direct current can be adjusted within the range of 20% to 100 % of the fully rated
current. The Transformer rectifiers are provided with an automatic control system, which
stabilizes the direct current value.
The transformer rectifier is a forced air cooled type of thyristor based constant current
controlled unit with DC output of 1000 A DC and 60 V DC at input power supply of 690 V, 3 ph and 60
Hz. Unit is designed as per a IEC 600146 standard which is having efficiency of more than 80% at
rated output with a ingress protection of IP 44 rating. Local potentiometer provided at the rectifier
front panel is used to control the DC current and the digital DC voltmeter is used to measure the
voltage across the hypochlorite generator. The Voltage may vary depending on the resistance and
temperature of the seawater. The readings of the DC voltmeters are periodically taken, checked and
recorded as they reflect the working conditions of the hypochlorite generators and an early warning of
the exhaustion of the anode coating catalytic properties. Should the voltage across any hypochlorite
generator deviates from its normal operating value and approach a level which is dangerous to the
electrode metal structure, an automatic device installed in the transformer rectifier (47-ET/ER-0001-A/
47-ET/ER-0001-B) will signal the fault and/or shut off the electric power supply to the hypochlorite
generator before any damage occurs. Transformer rectifier enclosure is manufactured from Mild steel
with a grey color (RAL 7032) powder coated.

Sheet No: 15 of 50
3.1.5 Local Control Panel

Local Control Panel (47-IB-0001-A) has been specifically designed for continuous
controlling/monitoring the electrochlorination package through HMI with a battery back up from
UPS (Uninterrupted Power Supply), also it contains DOL feeders and power feeders which
feeds AC power to corresponding Motors and Transformer-Rectifiers. These units are supplied
as loose items. The operator interface to the process will be mainly provided via graphics
pictures on the monitor of HMI screens.
Main screens in HMI are,
Overall view
Seawater inlet section
Hypochlorite generator section
Hypo Tank & Blower section
Alarms
Parameter settings
Touching the graphical picture on the particular device on screen in which has sufficient buttons
like auto/manual, open/close, and feedbacks can control all equipments/instruments in this
electrochlorination package. Local control panel provides the basic dry contacts of the following
for client (DPI) DCS interfacing signals,
47-SDV-0001 (ON-OFF valve) OPEN/CLOSE
47-ET/ER-0001-A (Transformer Rectifier- working) RUNNING / STOP
47-ET/ER-0001-B (Transformer Rectifier- standby) RUNNING / STOP
47-ET/ER-0001-A (Transformer Rectifier -working) COMMON FAULT ALARM
47-ET/ER-0001-B (Transformer Rectifier- standby) COMMON FAULT ALARM

Sheet No: 16 of 50
4.0 OPERATING PROCEDURE
Seawater is allowed to feed into the electrochlorination package by opening the inlet on off
valve 47-SDV-0001.The selfactuated pressure control valve placed at the inlet of the package
reduces and controls the incoming pressure to 2.0 3.0 bar.g to suit the operation requirement. In
case of abnormal high pressure surge on electrochlorination system feed header, equipment/lines are
protected from damage by means of pressure relief valve set at 4.5 bar.g. Pressure gauge provided
at the inlet of package helps to monitor the controlled incoming pressure. The electrolyser operates
normally under constant seawater flow rate, while DC load is manually adjusted so as to meet the
required production of 8.0 kg/hr active chlorine.
The filtered/oil free seawater is fed into the hypochlorite generator (47-XQ-0001/0002-A/B). The
flow switches 47-FS-0001/0002 or 47-FS-0003/0004 monitors the set flow to the hypochlorite
generator. The required seawater flow through each hypochlorite generator shall be set through
respective flow meter and manual diaphragm control valve by operator manually. As a safety
precaution, once the minimum flow is passed through hypochlorite generator (electrolyser) by sensing
the flow in flow switches which are at the inlet of each electrolytic module, 47-FS-0001&0002 / 47-FS-
0003&0004, air dilution blower is started during start up and it is the last equipment which has to be
switched-off during shutdown.
The operator has to set the required amperage (up to 900 ADC) gradually from zero for the
production of sodium hypochlorite from the local control panel through HMI or from Transformer
rectifier panel (by local potentiometer). The Voltage may vary depending on the resistance in the
electrodes and temperature of the seawater.

Sheet No: 17 of 50
The production of sodium hypochlorite (available chlorine) is based on passing a direct current
through an aqueous solution of sodium chloride (NaCl) which is totally dissociate into Na+ and Cl-
the following chemical and electrochemical reactions occur
Free Chlorine is generated at the anode:
2 Cl- ---------------- Cl2 + 2e-
Hydrogen is evolved at the cathode with the corresponding formation of hydroxyl ion:
2H2O + 2e- --------- 2OH- + H2
The overall electrochemical reaction is:
2Cl- + 2H2O --------- Cl2 + H2 + 2OH-
Then chlorine and hydroxyl ions react chemically producing hypochlorite and chloride:
2OH- + Cl2 ---------- ClO- + Cl- + H2O
The overall chemical reaction can be expressed as follows:
2NaOH + Cl2 --------- NaOCl + NaCl + H2O
In the chemical literature hypochlorite concentration are commonly referred to in term of available
or active chlorine, i.e., the quantity of chlorine having the same oxidizing effect as the hypochlorite
when analysed by standard methods.

Sheet No: 18 of 50
When the Hypochlorite outlet temperature is more than 50C, then it will be detected by the
Temperature switch (47-TS-0001). High temperature in Electrolyser outlet of hypochlorite solution
will give an alarm and trips the transformer rectifier supply.
The hypo solution from the hypochlorite generator outlet is fed to the degassing tank (47-TA-0001-
A). The hydrogen generated with the hypochlorite gets separated in the tank where the hydrogen
evolved during the process will be safely disposed to atmosphere. Air dilution blower supplies
required air to dilute the hydrogen stream, so as to get a non-flammable mixture (25% of LEL).
The hypochlorite level in the tank is sensed/monitored by the level indicator (47-LI-0001) and level
switch (47-LS-0003).
The hypochlorite solution from the degassing tank is to be dosed through the dosing location of
sea chests by gravity flow from the tank. The local mounted flow meter at the hypo outlet line helps
to monitor the hypochlorite dosing flow.
REMARKS: MGPS (Electrochlorination) Package cannot operate unless it is full of liquid, and also
cannot operate unless there is liquid flow through it; In case of such mis-operation equipment will
get damage. Therefore isolation valve in the seawater inlet/outlet lines must be fully opened. Also
drain valves shall be tightly closed during normal operation.

Sheet No: 19 of 50
5.0 PACKAGE OPERATION
5.1 PACKAGE OPERATING MODE:
The electrochlorination package-operating modes of MANUAL, SEQUENCE & AUTO modes, and
START/ STOP and FAULT/TRIP signals are being controlled from the local control panel. This
electrochlorination package is usually started in MANUAL mode and put into AUTO / SEQUENCE
mode for process control parameters. In MANUAL mode, equipments are to be controlled manual
switching ON and OFF from the control panel pushbuttons & HMI screens with minimum interlocks.
In AUTO mode, all devices can be controlled switching ON and OFF from the HMI screens with
sequence full interlocks. In SEQUENCE mode, all devices are controlled automatically as per the
sequence with full interlocks.
Skid mounted instruments continuously monitor the system and in the event of an abnormality /
fault is being reported to the operator via local control panel.
Required feed amperage for the Electrolyser shall be set from the control panel or transformer
rectifier by the operator gradually. When start up in manual mode, all the devices can be switched
ON/OFF as per the pre-defined sequence.
5.2 SYSTEM PRE-START CHECK LIST
Conduct visual checks to see that all components of the system including electrical
connections and instruments are in place and in tact.
The area is safe, clean, and well illuminated.
Supply to the Transformer rectifier and local control Panel is available.
Flush the line before start of the unit.

Sheet No: 20 of 50
5.3 System Line up
STEP 1:
Before start up the following manual valves are to be kept in CLOSE condition for the normal
operation of the unit.
S. No. Valve No. Description Position
1 47-BA-0002 Manual Ball Valve Close

Sheet No: 21 of 50
Before start up the following manual valves are to be kept in OPEN condition under the normal
operation of the package,
S. No. Valve No. Description Position

1 47-BA-0001 Manual Ball Valve Open
3 47-SDV-0001 Shut down Valve Open
8 47-SDV-0002/0003 Shut down Valve Open
9 47-XX-0001/0002 Manual Diaphragm Valve Open
9 47-BA-0012/0019 Manual Ball Valve Open
10 47-BA-0013/0020 Manual Ball valve Open
15 47-BA-0026 Manual Valve Open
16 47-BA-0027 Manual Valve Open
17 47-BF-0001/0002 Manual Butterfly Valve Open
18 47-BF-0003 Manual Butterfly Valve Open

Sheet No: 22 of 50
26 47-XX-0003 Manual Diaphragm Valve Open*
* - Shall be opened and set the required dosing flow once after hypochlorite is collected in the
degassing tank.
STEP 2:
Seawater inlet Flow,
Allow the oil/grease free seawater flow into the package.
Set the required pressure and flow for the package by adjusting the all-
respective valves.
Set the required flow in the Rota meter flow meter 47-FI-0001 / 0002 by
throttling the diaphragm valve 47-XX-0001 / 0002
STEP 3:
Air Dilution Blower 47-KF-0001-A/B,
The selected Air dilution blower shall start.
Once flow through Electrolyser is ensured, start the air dilution blower.
The blower will off automatically with time delay when the transformer rectifier /
local control panel tripping is occurred during operation.

Sheet No: 23 of 50
If the air flow switch (47-FS-0005) senses low airflow from running blower, it
will START the stand - by air dilution blower.
STEP 4:
Transformer Rectifier (47-ET/ER-0001-A/B) ON
Transformer rectifier will be switched ON from its front panel or from local control
panel under AUTO mode.
Required feed amps are slowly raised based on the set point in the local control
panel HMI screen or using potentiometer located in the TR panel (in case of in
local mode).
It will trip when the following conditions are occurred,
Electrolyser inlet flow Low
Electrolyser outlet temperature high
Hypo Tank level high
ALARMS
Alarms are made to annunciate the fault conditions to the operator. The following conditions are
referred to generate the alarms in the hooter.
47-XQ-0001/0002-A/B Hypochlorite generator (Electrolyser) inlet flow is low
47-PDS-0001/0002 differential pressure is High
47-XQ-0001/0002-A/B hypo outlet temperature is High
47-TA-0001-A Hypo tank level is high
47-KF-0001-A/B air dilution blower flow is low
47-ET/ER-0001-A/B Transformer-rectifier trip

Sheet No: 24 of 50
47-KF-0001-A/B Air dilution blower trips
When phase loss occurs in the Transformer Rectifier panel
When over temperature indication in the TR panel
Package shut down
Manual Mode
For commissioning / maintenance purposes the system can be run in Manual Mode. Fully trained
and authorized personnel should only undertake this manual operation.
Individual Package Item can be started and stopped using the relevant push buttons on the HMI /
PLC panel.
Operator Interface
All operator controls and indications are via the touch screen type Human Machine Interface (HMI).
Selection of screens is performed via the push buttons provided in the touch panel.
For the above conditions, operators have to acknowledge the fault first, and find the reason and cause
for the alarm, Rectify the fault and restart the system cautiously.
Following Indications / Push Buttons / Selector Switches / Meters are available in the
Transformer Rectifier (47-ET/ER-0001-A/B) front panel,
S.No Indication Buttons Description
1 R, Y & B Lamp Three phase Lamp indication
2 Rectifier unit Trip Transformer Rectifier trip indication
3 Phase Loss Incoming three phase status indication
4 DC Overload/over current Indication for Over load/current

Sheet No: 25 of 50
5 DC Over Voltage Output DC over voltage indication
6 Rectifier Over temperature Indication while Over temperature occurred
S.No Illuminating Push Buttons Description
7 Fault / Fault Reset For acknowledge the faults and to reset the faults
8 Rectifier Start Transformer Rectifier START illumination
9 Rectifier stop To stop the transformer rectifier unit
S.No Push Buttons Description
10 Emergency stop Lockable Push Button to stop the complete Unit
11 Hooter accept For accept the fault alarm hooter
S.No Selector Switches Description
12 Auto / Manual Switch for selection mode of auto or manual
13 Ammeter Selector Switch for measuring amps between two phases
14 Mains ON/OFF Power ON/OFF the TR panel
S.No Meters Description
15 AC Voltmeter Digital Meter - Incoming Voltage indication
16 AC Ammeter Digital Meter - Incoming Current indication
17 DC Voltmeter Digital Meter DC Voltage indication

Sheet No: 26 of 50
18 DC Ammeter Digital Meter - DC Current indication
19 SET Current Value Potentiometer for adjusting amps
Following Indications / Push Buttons / Selector Switches / Meters are available in the
Local Control Panel ( 47-IB-0001-A),
S.No Indication Buttons Description
1 R, Y & B Three phase Lamp indication
2 47-KF-0001-A BLOWER-A TRIP Air dilution Blower A trip indication
3 47-KF-0001-B BLOWER-B TRIP Air dilution blower B trip indication
4 47-ET/ER-0001-A RECTIFIER A TRIP Transformer Rectifier A unit trip indication
5 47-ET/ER-0001-B RECTIFIER B TRIP Transformer Rectifier B unit trip indication
S.No Illuminating Push Buttons Description
6 47-KF-0001-A BLOWER-A START Air Dilution blower A START illumination
7 47-KF-0001-A BLOWER- A STOP Air Dilution blower A STOP illumination
8 47-KF-0001-B BLOWER-B START Air Dilution blower B START illumination
9 47-KF-0001-B BLOWER-B STOP Air Dilution blower B STOP illumination
10 47-ET/ER-0001-A RECTIFIER-A START Transformer Rectifier unit A START illumination
11 47-ET/ER-0001-A RECTIFIER-A STOP Transformer Rectifier unit A STOP illumination
12 47-ET/ER-0001-B RECTIFIER-B START Transformer Rectifier unit B START illumination
13 47-ET/ER-0001-B RECTIFIER-B STOP Transformer Rectifier unit B STOP illumination
14 SEQUENCE START Cycle START illumination

Sheet No: 27 of 50
15 SEQUENCE STOP Cycle STOP illumination
S.No Push Buttons Description
16 EMG STOP Latchable Push Button to stop the complete Unit
17 RESET To reset the fault condition
18 TEST For testing the local control panel
S.No Selector Switches Description
19 MANUAL/AUTO /SEQUENCE Switch for selection mode of manual/auto/sequence
20 47-KF-0001 BLOWER A/B Switch for selecting air dilution blower A / B
21 47-ET/ER-0001 RECTIFIER A/B Switch for selecting transformer rectifier A/B
22 Mains ON/OFF Switch ON/OFF the local control panel
S.No Meters Description
23 AC Voltmeter Analog Meter - Incoming Voltage indication
24 AC Ammeter Analog Meter - Incoming Current indication

Sheet No: 28 of 50
6.0 START UP PROCEDURE
6.1. MANUAL START UP SEQUENCE:
Before start up of the system ensure the TR and local control panel is in manual selection. All the
main process line valves should be kept in open condition as listed above (section 5.3) also
ensure all the drain valves and vent valves are kept in closed condition. The startup operation of
this HYPOPAC M electrochlorination package involves the following steps:
Allow the seawater into the package by opening the inlet manual valve 47-BA-0001 slowly.
Ensure the required pressure 2.0 3.0 bar.g is set in the self-actuated pressure control valve
(47-LC-0001) by monitoring the inlet pressure in the pressure gauge 47-PI-0003 provided at the
inlet of the package.
Set the process required flow of 11.0 m3/hr in the Rota meter flow meter by throttling the manual
diaphragm valve 47-XX-0001/0002
Hypochlorite generator (electrolyser) is then lined up by ensuring the inlet and outlet valves are
kept in open condition. At initial start up Electrolyser outlet vent valve is kept in open condition for
few seconds so that air lock or air bubbles in the line will be released completely.
Line up the seawater flow to the Electrolyser outlet line to the degassing tank ( 47-TA-0001-A)
Ensure that sample point valve and vent valves 47-BA-0025 and 47-BA-0017/0024 are in closed.
ENSURE THAT THERE IS NO AIR POCKETS OR AIR LOCKS IN THE PIPING. CHECK
THIS BY OPENING THE RESPECTIVE VENT VALVES.
Once adequate flow into Electrolyser is ensured start the air dilution blower 47-KF-0001-A/B
Allow seawater flow into the package through the pressure control valve, Pressure relief valve
and seawater strainers.
Sheet No: 29 of 50
Switch on the TR and Switchgears for Blowers in the Local Control panels; check for the
normalcy of Input supplies Voltage conditions and direction of rotation of the Motors.
Check the normalcy of the Rectifier by observing fault indications are getting off. If any fault
indication is ON, press fault RESET PBs. Also, check phase sequence of the equipment. If any
phase loss observes, change the any two input phase lines. (RB into YR or YB into BR or other
possibilities).
If all fault indications are getting off. Press Start PB in the Rectifier panel.
Adjust the current setting between 0 and 100% using the potentiometer knob provided in the
front panel of the TR. Always start with an initial setting not more than 50% Amperage Load.
Set the required amperage (it should not exceed 900 ADC) by gradually under normal operating
conditions.
Taking a sample from the sample line provided at the outlet of electrolyser and analyze by
iodometric laboratory analysis (as per the annexure), which ensures the concentration of the
sodium hypochlorite and accordingly hypochlorite production rate.
6.2. AUTOMATIC SEQUENCE:
Once the plant is started in the manual mode, stabilizing the process and can be put in the automatic
mode to govern all safety interlocks for the package process parameter.
Seawater inlet pressure as per preset value (47-PS-0001)
Hypochlorite generator outlet temperature is High (47-TS-0001)
Differential Pressure across Hypochlorite generators is high (47-PDS-0001/0002)
Seawater flow through Electrolyser as per preset value (47-FS-0001/0003 & FS0002/0004).
Set required DC amperage from the HMI panel.
Dosing flow by earths gravity

Sheet No: 30 of 50
6.3. NORMAL OPERATION:
Once the package is steady after start up, increase the amps setting from 50% to 100% or as
required for production.
Regularly monitor the following conditions to ensure proper condition of the Package.
Monitor the flow in 47-FS-0001/0003 & FS0002/0004 for proper throughput of feed through the
Electrolyser. (Once in shift)
Check the transformer rectifier Voltage and Amperage values (Once in shift).
Check the hypochlorite generator (electrolyser) outlet stream temperature ( Once in shift)
Monitor the tank level in level gauge (47-LI-0001)
Monitor the dosing flow
Periodic change over to the standby pumps by stopping the running pumps and clean the
strainer. This practice shall ensure tactfulness and availability of the standby system in
operation.
Daily check the hypochlorite generation concentration at the electrolyser outlet solution as per
given procedure in annexure.
7.0 SHUT DOWN PROCEDURE
Electrochlorination package having two shutdown processes
7.1. NORMAL SHUTDOWN:
Reduce the amperage setting to Zero by rotating the POT (which is in front panel of TR) in
anti-clockwise direction or decreasing the amps in HMI panel.
Stop the DC power supply by pressing Stop PB in the Rectifier panel.

Sheet No: 31 of 50
Switch OFF the transformer rectifiers power from local control panel.
After 20 minutes, switch OFF the air dilution blower (47-KF-0001-A/B)
Switch OFF the AC power to local control panel and transformer rectifier panel.
Ensure that all electrical drives are switched OFF.
Close the seawater supply to the Electrochlorination package, by closing the inlet valve 47-
BA-0001 after few minutes from TR stop.
Open all the manual Drain valves and vent valves. Drain the system completely.
Clean the Y-Strainer (47-ST-0001) filter and kept in functional for the subsequent startup.
Completely isolate the all-electrical feeder to the electrochlorination package.
Now the package shall be declared to be under complete shutdown and ready for maintenance.
7.2. EMERGENCY SHUTDOWN
Under emergency condition, please shutdown the transformer rectifier immediately by pushing the
emergency push button (while pressing the Emergency PB, keep the key provided for E-Stop PB safely,
for next operation this key will open the E-Stop Pushbutton) safeguard the package which will cut D.C
current to electrolyser, thus stopping hydrogen production also. Maintain air dilution blower in operation
to ensure hydrogen is completely removed from degassing tank.
Following steps carried out in emergency shutdown.
TR Trips with alarm.

Sheet No: 32 of 50
Air dilution blower switched off with time delay.
Operator to close the inlet manual valve 47-BA-0001 after few minutes
Then operator to acknowledge the fault by resetting the fault alarm push button and release
the emergency push button.
If the package needs to remain shutdown for longer period of more than 5 days, the above planned
shutdown procedure may be followed for draining out the system.
8.0 MAINTENANCE
Preventive Maintenance is a major step in the right direction for reducing non-scheduled
downtime and the following practices have been demonstrated as being useful.
Establish and enforce regular inspection schedules
Keep records of operating data, maintenance works and inspections
Accumulation of dust, dirt and corrosion, particularly on stand-by equipment may cause faulty
operation of many devices. Therefore, a periodic routine of cleaning and inspections should
be established.
Remove debris from electrical components. Heat build-up can occur when electrical devices
are covered with dust or concrete.
Ensure the normal operations of all instruments and equipments through HMI screen.
Ensure the direction (clockwise) of blower motor and cooling fan rotation in Transformer
rectifier / local control panel when the door is in closed condition.
Maintain the proper earthing of the junction box, transformer rectifier and local control panel.
The same will be connected to the instrument earth pit not with power earth pit.
Sheet No: 33 of 50
On a monthly basis, check all electrical connections and keep them tight. A loose wire either
in a panel or on the field instruments will cause electrical arching
For establishing a sound preventive maintenance is determining the frequency of inspection and testing.
MAINTENANCE TOOLS
No special tools are required.
8.1 Inspection Schedule
Though, Hypochlorite generator (electrolyser) is designed, as a free of maintenance, schedule of
inspection for electrolyser should be followed under normal operations as follows,
DAILY
S.No CHECKING PARAMETERS REMARKS
1 Ensure that daily log sheets are reporting to TiTaN OK Not OK
2 Check visually for any physical damage or leakage if any OK Not OK
Test Alarm lights on TR/PLC panel and rectify/troubleshoot the

3 OK Not OK
same as per the operating & maintenance manual.
WEEKLY
Check the healthiness of the power cable visually for any

1
physical damage.
OK Not OK
Check the healthiness of instruments like pressure gauge, flow

2 switch, temperature switch, level gauge, and flowmeter for any OK Not OK
physical damage visually.
Sheet No: 34 of 50
MONTHLY
1. Ensure that monthly log sheets are reporting to TiTaN OK Not OK
YEARLY
1 Check the tightness of all bolted connections OK Not OK
Check for correct operation of all protective devices (actuate

2 OK Not OK
them manually)
5 YEARLY

1 Refurbish / Replace the electrodes if required OK Not OK
Sheet No: 35 of 50
8.2 TROUBLE SHOOTING
EQUIPMENT DEFECT CAUSE REMEDY
a. Trouble in Rectifier a. Refer TR manual
b. Loose connection of b. Stop the operation of package.

copper strip. Check the tightness of copper
Strip Connection after
1. Over Voltage
opening the door.
c. Anode life
c. In case the voltage is still
HYPOCHLORITE higher than normal, contact
GENERATOR TiTaN technical support.
(ELECTROLYSER) Ph : 044-22781210,0211,0212
UNIT
a. High temperature Of a. Find out cause of increase in
feed seawater temperature. After reducing the
temp to normal level restart
operation.
2.Sodium
Hypochlorite b. Check & ensure the all main
Solution temp high line manual valve open. Also
check all the drain valves are
b. Insufficient flow of
kept in close condition so that
feed seawater
there wont be any flow through
drain lines.
Sheet No: 36 of 50
a. Check all the manual valves

are kept in fully open condition
without clogging or partial
openings.
Low pressure of feed

3.Seawater flow b. Check and ensure sufficient
seawater
low or no flow flow pressure into to the package
is sufficient by monitoring the inlet
pressure in the 47-PI-0001.
b. Find out the cause of low

pressure. After the pressure to
normal level, resume operation.
a. Check AC input voltage at

a. Input fuse blown
transformer rectifier terminals.
1. Will Not Start
b. If equipped with
overload, and tripped b. Push Fault RESET button.
PACKAGE
a. DC fuse blown a. Check DC Fuse
b. SCR not firing b. Check for faulty SCR and

2. No output
replace if necessary.
c. Current control knobs c. Adjust current control knobs
adjusted to zero to selected output voltage and
current.
Sheet No: 37 of 50
a. Discharged a. Check the outlet dosing valves
hypochlorite solution are not closed in condition, which
flow rate down. should be kept open.
1. Tank level
High b. Stuffing in discharge b. Blow out stuffing by opening
line. the vent valve 47-BA-0017 and
47-BA-0023
c. High flow rate of feed
seawater. c. Check normal inlet flow rate in
the Rotameter flow meter.
HYPO TANK
a. Low flow rate of a. Find out the cause of

feed seawater. Insufficient flow and rectify.
2. Tank level
b. Leakage from the b. Check the tank and outlet
low
connections of tank piping and rectify.
and/or piping.
a. Noise or other
AIR DILUTION Air Flow Low Refer blower manufacturers
problem in the blower
BLOWER manual and rectify the problem.
Sheet No: 38 of 50
9.0 HEALTH AND SAFETY
9.1. DATA FOR SODIUM HYPOCHLORITE
Substance Identification
Substance : Sodium hypochlorite solution 1000 ppm
Chemical family : Inorganic
Molecular formula : Cl-O-Na
Components and Contaminants

Component : Sodium hypochlorite + Seawater
Other contaminants : None
Physical Data
Description : Clear, light greenish-yellow liquid
Odor : Bleach
Boiling point : Decomposes
Specific gravity : 1.025
Solubility : Soluble in water
Fire and Explosion Data

Negligible fire hazard when exposed to heat or flame.
TOXICITY
Sodium Hypochlorite
Irritation Rate : 10 mg/kg eye-rabbit moderate. Skin rabbit moderate.
Carcinogen status : None
Local effects : Corrosive, inhalation, skin, eye.
Toxic level : Slightly toxic by ingestion
Sheet No: 39 of 50
9.2 HEALTH EFFECTS AND FIRST AID
A. Inhalation
Effects:
Acute exposure may cause severe bronchial irritation, sore throat with possible blistering, coughing,
stomatitis, nausea, laboured breathing, shortness of breath and Pulmonary Edema (extreme condition).
First Aid:
Removal from exposure area to fresh air immediately. If breathing has stopped, give artificial
respiration. Maintain airway. Administer oxygen if available. Keep warm. Obtain medical attention
immediately.
B. Skin Contact
Effects:
Extent of damage depends upon concentration and duration of contact. May cause redness, pain,
blistering in worst case. Prolonged exposure may cause Dermatitis.
First Aid:
Wash affected area with large amounts of water. Treat as for chemical burns if severe.
Sheet No: 40 of 50
C. Eye Contacts
Effects:
May cause redness, pain or blurred vision.
First Aid:
Wash eyes immediately with large amounts of water, occasionally lifting upper and lower lids, until no
evidence of chemical remains (at least 10-15 minutes). Continue irrigating with normal saline until pH
has returned to normal (20-40 minutes). Get medical attention as soon as possible.
D. Ingestion
Effects:
May cause irritation and erosion of the mucous membranes, vomiting and abdominal pain/spasm,
drop in blood pressure, shallow respiration, Edema of Pharynx, larynx and glossitis, confusion,
convulsions, delirium. Gyamasis and circulatory collapse are possible in extreme cases.
First Aid:
If conscious, give milk, melted ice cream or beaten eggs. Do not use antiemetic, acid antidotes or
sodium bicarbonate. Antacids such as Milk of Magnesia or aluminium hydroxide are also useful.
Maintain airway, respiration and blood pressure. Get medical attention immediately.
Antidote:
In severe cases only, hypochlorite poisoning may occur. A few ounces of 1% sodium thiosulphate
solution may be ingested and left in the alimentary tract. However contact a physician immediately.
Sheet No: 41 of 50
9.3. HAZARD PREVENTION
9.3.1 EXPLOSION HAZARD:
During normal operation the safety instruction of cell room and storage tank area, no smoking and no
use free flames are to be kept in mind.
Before maintenance, be sure that hydrogen has been previously and completely removed from the
area.
9.3.2 ELECTRICAL HAZARD:
The danger is minimized since the electric connection are covered by protection panels, but since the
electrolytic cell in operation are supplied with D.C voltage, the operators must wear rubber shoes and
rubber gloves for safety even in case of a hand touch. The energized parts shall not be touched.
Therefore no personnel except the operators shall be permitted to enter into the package area.
During the operation of the MGPS system no work except for switching, valve handling and sampling
shall be carried out. If metal tools or other conductive tools must be used near the electrolytic cells for
maintenance purposes, the supply of power to the electrolytic cells shall be stopped in advance to
prevent short circuit trouble and safety signal Do not operate unit under maintenance placed on
rectifier control cubicle.
9.3.3 SAFETY PRECAUTIONS:

Sheet No: 42 of 50
A first aid infirmary is to be foreseen. Before doing any preventive maintenance service, think about
your own safety and the safety of other people involved in doing the preventive maintenance service
of the equipment. Periodic preventive maintenance will extend the life of the equipment and reduce
the necessity of shutdown due to component failure. Before entering the equipment, for such
maintenance as fuse replacement, etc., be sure the external disconnect is in the OFF position.
NOTE: Do Not Service Unit With Power ON
9.4 SAFETY DEVICE
9.4.3 GENERAL SAFETY DEVICE:
The following safety apparatus should be foreseen in the area:
Safety shower provided with eyewash and drinking water.
Protection against fire. For fire see local rules. Within the unit it must be strictly forbidden to smoke
or to handle flames, welding machine etc.,
9.4.4 PERSONAL SAFETY DEVICE:
The individual protection equipment is essentially following:
Safety goggles in order to preserve completely eyes.
Hardhat or helmet.
Working dress with buttoned neck and cuffs.
Rubber gloves.
Rubber boots or shoes with rubber sole.

Sheet No: 43 of 50
The equipment must be always efficient and readily available for immediate use.
9.4.5 SITE SAFETY:
The installer must keep the electrochlorination package, surrounding area and all access routes
free from the accumulation of waste material and debris caused by the operations performed
during the work. Care must be taken not to include necessary items of equipment in those
materials taken for disposal during erection work.
Site safety rules shall be adhered to at all times.
10 DOS AND DONTS
10.1 Dos:
Always ensure the recommended or required flow through the Electrolyser.
Always check the inlet seawater pressure.
During package starts/restarts gradually increase the amps load from 0 to max. It shall reach the
maximum load after 10 mins from the package starts / restarts.
Always ensure that the system has been connected with appropriate AC power source.
Check / Analyze the concentration of hypochlorite in every shift by taking sample from sampling
point.
Sheet No: 44 of 50
Always ensure that the respective suction valves are in open position when switch ON the hypo
dosing pumps, discharge valves can open once pump is started.
Always ensure that the respective inlet and outlet valves are in open position when the TR cum
Control panel switched ON.
Always follow the instructions in the operating and maintenance manual for starting / restarting
the system.
Always record the operating parameters like amps load, cell voltage, seawater flow rate and
hypochlorite concentration in every shift.
10.2 DONTS:
Do not operate the system without any seawater or very low flow seawater.
Do not operate the system at very low amps load.
Do not switch ON the Transformer-rectifier cum Control panel with inlet / outlet valves closed
position.
Do not increase or decrease the DC amps load suddenly when start / restart the system.
Do not leave the system un-operated for longer duration.
Do not operate the pumps at dry conditions.
Do not handle any electrical items without safety tools during charged.
Sheet No: 45 of 50
11. ELECTROLYSER PERFORMANCE TESTING:
11.1. DAILY REPORT:
Seawater Outlet Available

Feed Operating Production Power
DATE inlet Flow Chlorine Remarks
Amps Voltage Capacity Consumption
rate Concentration
m3/hr A DC VDC gpl Kg/hr kWhr
Efficiency % = Seawater Flow rate (m3/hr) * hypo Concentration (ppm) * 100

1.323 * Actual Feed Current (ADC) * 8
Important Note:
This Daily report shall be forwarded to TiTaN for review and continuous monitoring to ensure healthiness
of the electrolysers. Otherwise, warranty given for electrolyser will be null and void.
Sheet No: 46 of 50
ANNEXURE I - ANALYSIS PROCEDURE

Sheet No: 47 of 50
DETERMINATION OF AVAILABLE CHLORINE CONCENTRATION
Aim:
To analyze the available chlorine concentration in the sodium hypochlorite solution.
Reagent And Indicator:
0.1 N Sodium thiosulphite solution (Na2S2O3) One Litre in Bottle
10% Potassium Iodide Solution (KI) 200 ml in Bottle
30% Acetic Acid solution (CH3COOH) 200 ml in Bottle
Distilled water 5 Litres in container
Apparatus Required:
Burette 25 ml with stand 2 Nos;
Conical Flask 200 ml 2 Nos;
Pipette 20 ml 2 Nos;
Pipette 10 ml 2 Nos;
Measuring Flask 250 ml 1 No.

Sheet No: 48 of 50
Procedure:
Pour 10 ml of 10% KI solution into a 200 ml flask.
Add 50 ml of distilled water.
Pour exact 20 ml of sample into 200 ml flask using a pipette
Add 10 ml of 30% acetic acid.
Titrate with 0.1 N sodium Thiosulphite.
The end point will be indicated by the stray yellow color solution turning colorless. To identify the
end point exactly for color change, add starch solution before the expected end point. (With
starch the end point is blue color changing colorless)
Calculation:
Concentration of available chlorine is obtained by the following equation.
Available chlorine concentration in gpl = 35.45 x V x N / S
Where,
V : Titer volume, ml
N : The factor of 0.1 N Na2S2O3 ( = 0.1)
S : Sample volume, ml (= 20 ml)
Result:
Available Chlorine in the Hypochlorite solution =.. gpl.

Sheet No: 49 of 50
ANNEXURE II REFERENCE DOCUMENTS

Sheet No: 50 of 50
S.No. REFERENCE DOCUMENT REFERENCE DOCUMENT No.
1. PIPING AND INSTRUMENTATION DIAGRAM DPI - 80-P-47-XB-0001

2. CAUSE & EFFECT DIAGRAM DPI -80-P-47-XR-0001
3. PLOT PLAN DPI-80-P-47-XF-0001
4 SKID LAYOUT & ARRANGEMENT DRAWING DPI -80-L-47-XE-0001
5. HYPOCHLORITE GENERATOR DATASHEET DPI -80-R-47-DS-0001
6. TRANSFORMER RECTIFIER DATASHEET DPI -80-E-47-DS-0001
7. DEGASSING TANK DATASHEET DPI -80-R-47-DS-0003
8. AIR DILUTION BLOWER DATASHEET DPI -80-R-47-DS-0002
8. SINGLE LINE DIAGRAM DPI -80-E-47-XJ-0001
9. TRANFORMER RECTIFIER MANUAL -
10. AIR DILUTION BLOWER MANUAL -
11. ALL INSTRUMENTS MANUAL -

Electrochlor Ination System Operating and Maintenance

Загружено:

Сведения о документе

Оригинальное название

Авторское право

Доступные форматы

Поделиться этим документом

Поделиться или встроить документ

Параметры публикации

Этот документ был вам полезен?

Это неприемлемый материал?

Авторское право:

Доступные форматы

Electrochlor Ination System Operating and Maintenance

Загружено:

Авторское право:

Доступные форматы

OPERATING & MAINTENANCE MANUAL

2 X 8.0 KG/HR HYPOPAC-M ELECTROCHLORINATION PACKAGE

Dynamic Producer Inc.

01 10-DEC-2009 For Information Dinesh Murali Murugan

Code Approval status

Originator / Contractor Document Number:

47 N/a Z MB DPI -80-Z-47-MB-0001 50 FI 01

OPERATING AND MAINTENANCE MANUAL

2 X 8.0 KG/HR ELECTROCHLORINATION PACKAGE

REV DATE PREPARED CHECKED APPROVED DESCRIPTION

9. HEALTH AND SAFETY 35

10. DOS & DONTS 40

11 ELECTROLYSER PERFORMANCE TESTING 42

ANNEXURE I ANALYSIS PROCEDURE

sodium hypochlorite, which is a good disinfectant, and anti bacterial agent.

destroying the growth of marine organisms in the seawater facilities.

basis, operating sequence, start-up & shutdown procedures, maintenance, troubleshooting,

electrochlorination package. The 2 X 8.0 Kg/hr HYPOPAC M Skid Based Electrochlorination

System is supplied to:

Owner : Dynamic Producer Inc., (DPI)

2.0 DESIGN BASIS

Project : MALAYAMPA PHASE 2 ASSET

DPI Project No. : PS-05

TiTaN Job No. : TLSX010

Package : 2 x 8.0 kg/hr HYPOPAC - M

Type of the system : Seawater based

Operating mode : Continuous

Installation location : Ship-indoor

Filtered / Oil free seawater inlet supply : 11.0 m3/hr @ 11 bar.g

No. of hypochlorite generator units : 2 Nos (1W + 1S)

No. of electrolytic cell modules of each unit : 2 Nos

Sodium hypochlorite production capacity of each unit : 8.0 kg/hr

Concentration of available chlorine at each unit outlet : 727 ppm

No. of transformer rectifier unit : 2 Nos (1W + 1S)

Each transformer rectifier unit output : 60 V DC, 1000 A DC

No. of degassing tank : 1 No.

Capacity of degassing tank : 1 m3

No. of air dilution blower : 2 Nos ( 1W + 1S )

Air dilution blower capacity : 300 m3/hr

2.1 PROCESS DESIGN CALCULATION

2.1.1. PACKAGE CAPACITY

Quantity of seawater to be treated (as per contract) = 2,610 m3/h

Continuous hypochlorite dosing concentration = 3 mg/l

Amount of hypo required to treat above quantity of seawater = 2,610x 1000 x 3

Design capacity of the package = 8.0 kg/hr

2.1.2. HYPOCHLORITE CONCENTRATION

Design capacity of Hypochlorite generator unit = 8.0 kg/hr

Seawater flow rate = 11 m3/h

Hypochlorite concentration in seawater = 8000/(11 x 1000)

= 0.727 x 1000 mg/l

2.1.3 BLOWER CAPACITY:

NaCl + H2O NaOCl + H2

From the above equation,

In electrochlorination process, sodium hypochlorite will be measured in terms of equivalent

Unit capacity is 2 X 8 kg/hr, 8 kg/hr or 8000 grams/hr will be in operation continuously.

Hence, 8000 gm/hr of equivalent chlorine generates = 2/71 x 8000

= 225.35 g/h of Hydrogen.

Density of hydrogen = 0.08 kg/m3

Volume of hydrogen generates = 0.22535 / 0.08

25% of LEL of hydrogen is = 1% (v/v) in air

Therefore, the volume air required = 2.8168 x 100

Design capacity of blower = 300 m3/h

2.1.4 DEGASSING TANK CAPACITY: