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1.1. Purpose
The purpose of this procedure is to outline start-up and shutdown procedure of softener plant, it
includes guidelines for smooth operation, regeneration and monitoring of water quality of feed
and product water.
1.2. INTRODUCTION
The softening of water by ion exchange involves the replacement of calcium and magnesium
ions in water by an equivalent number of sodium ions. This eliminates the undesirable
characteristics of hardness in water, as sodium salts do not form scale. The chemical reaction is
as under:
2. SCOPE
The scope of this procedure covers all mandatory steps need to be taken by SROP for smooth
start up, operation and safe shut down of softeners plants.
3.1. Responsibilities
3.2. Senior Plant Chemist is responsible to develop and continually review the content of this
procedure.
3.3 Users
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The users of this document are Sr. Plant Chemist, Assistant Plant Chemist, SROP, and all
production staff of TNB LPL
Interfacing
1. SROP is responsible to run all softeners according to the guidelines given in this SOP, for
details OEM manual can also be consulted
2. SROP is responsible to take necessary corrective action and carry out trouble shooting in
case of disturbed water chemistry.
3. Assistant Plant Chemist / SROP are responsible to carry out necessary water testing
required by each water treatment unit, and summarize all results in Daily Water Analysis
Log Sheet (PROD-CHM-823-QR-01).
4. Assistant Plant Chemist / SROP will take guidance from Senior Plant Chemist, if he finds
any problem in operating parameters or issue in chemical dosing.
5. SROP shall responsible for all above activities during gazetted holidays and after general
shift.
This is a cyclic process involving four stages of operation, namely, service, backwashing,
regeneration and rinsing.
During exhaustion (service run), clear raw water flows downwards through the softener vessel
wherein hardness ions in water are exchanged for an equivalent amount of sodium ions
attached to the ion exchange resin. At the outlet of the softener, the water obtained is soft
having hardness leakage
< 20
When the hardness at the outlet rises above the defined limit, the resin is exhausted and it no
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longer produces soft water. It is then regenerated. First step in regeneration is backwashing.
During backwashing, resin bed is expanded by an upward flow of water, which removes any
particulate matter and resin fines. Moreover, it re-orientates the bed, which could otherwise
cause channeling.
After backwashing, resin bed is regenerated with up ward flow of brine for restoration to its
desired Sodium form. The resin after rinsing is ready for another cycle of exhaustion. This way,
the softening cycle is repeated continuously.
Parameter Value
PH 7.5
Conductivity µS/cm 2600
Total Dissolved solids ppm 1820
Total suspended solids ppm 10
Calcium hardness ppm as CaCo3 210
Magnesium hardness ppm as CaCo3 180
Total hardness ppm as CaCo3 390
P Alkalinity ppm 20
M Alkalinity ppm 400
Chloride 330
Sulphate ppm 370
Iron ppm 0.1
Silica ppm 25
Note: In case raw water quality is worse than that given above, both the treated water quality
and quantity are likely to be adversely affected.
Quantity 4
Capacity/Softener 90 m3 / hr
Service time/Softener 8 Hr
Regeneration time/Softener 2 Hr
Output/Regeneration/Softener 720 m3
Operating Pressure 3.5- 4 bar(g)
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Regeneration Data
5.3.6
Salt Consumption:
Description Recommendation
Purity 97%
Insoluble matter 0.10%
Sulphate 1%
Ca+2 & Mg+2 0.50%
Soluble iron Not detectable
Sand or clay Nil
Soluble alkalinity as
-
CaCO3
Time
Description Flow Rate (Liters/Hr)
(Min.)
Backwashing 15 75000
Settling 5 -
Brine injection (23 % W/V NaCl) 30 5200
Dilution water (30) 7884
Brine injection (10 % W/V NaCl) (30) 13085
Slow rinse 30 7884
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WORK INSTRUCTIONS
There are four softeners installed in the system, the production, shutdown and regeneration is
5.4.1 accomplished through PLC. So before taking softeners in to service please complete the pre
start-up check list as given below.
5.4.2 1. Choose the softener to be put into service. There is provision available to take three
softeners into service simultaneously.
2. Open the four to five thread of manual service inlet valve of selected softener to get the
pressure of 2-2.5 bar. Given below are the KKS# of all service inlet valves
3. Open the manual service out valve completely. Given below are the details of all service
out let valves installed on softeners.
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4. Open the cooling tower make up valve if soft water is planned to make up the cooling
tower basin. The valve can be throttled to adjust the flow accordingly.
5. Open the suction valve of high pressure pump completely, if soft water is planned to feed
R.O system (options given 4 & 5 can be utilized simultaneously)
6. Give the start command on PLC for the selected softeners, service inlet valve and product
outlet valve of chosen softeners should be open as given below.
VALVE TO BE OPENED
PLC IN SERVICE SERIVCE
OEM DESCRIPTION
MODE TIME KKS CODE
CODE
480 min AA005 00GCB11AA005 SOFTENER "A" PRODUCT INLET VALVE
SOFTENER 'A'
(8 hours) AA006 00GCB11AA006 SOFTENER "A" PRODUCTION OUTLET VALVE
480 min AA016 00GCB11AA016 SOFTENER "B" PRODUCT INLET VALVE
SOFTENER 'B'
(8 hours) AA017 00GCB11AA017 SOFTENER "B" PRODUCTION OUTLET VALVE
480 min AA027 00GCB11AA027 SOFTENER "C" PRODUCT INLET VALVE
SOFTENER 'C'
(8 hours) AA028 00GCB11AA028 SOFTENER "C" PRODUCTION OUTLET VALVE
480 min AA038 00GCB11AA038 SOFTENER "D" PRODUCT INLET VALVE
SOFTENER 'D'
(8 hours) AA039 00GCB11AA039 SOFTENER "D" PRODUCTION OUTLET VALVE
7. Check and confirm the relevant valves of chosen softeners have been opened, if valves are
not opened call I&C or Mech. for assistance.
8. Check the designated test of product water, continue the operation if soft water qualify the
lab tests.
9. Stop the water production from PLC when there is no further requirement.
10. Close the manual service inlet valve.
REGENERATION OF SOFTENERS
Regeneration of softener is consist of five steps i.e Back Wash, Settling, Brine injection , Slow
Rinse, Fast Rinse. There are four softener in this system A, B, C and D respectively, in which
three softeners will in working and one will stand by after regeneration. The system will
operate with PLC that operate control valves which shown in P&I diagram. The booster pumps
are included for brine injection in to softener vessel. Pressure switch has also installed at the air
inlet and suction side of booster pumps, for maintain feed pressure to ejector, for proper dosing
of brine. During the regeneration cycles the opening and closing of valves is as under.
Back Wash
After 8 hours of working the softener will start regeneration. Back wash is the first cycle of
regeneration in which the water enters from the bottom of the vessel. The back wash is used for
removal of suspend, that settle at top of resin bed. The following valves will open during this
process.
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5.5.1
Cycle Flow Valve to be Opened
Time Rate
Liter/
Softener A Softener B Softener C Softener D
OEM KKS Code OEM KKS Code OEM KKS Code OEM KKS Code
hr
Code Code Code Code
15 7500 AA007 00GCB11A AA018 00GCB11A AA029 00GCB11A AA040 00GCB11A
A007 A018 A029 A040
min 00GCB11A 00GCB11A 00GCB11A 00GCB11A
AA008 AA019 AA030 AA041
A008 A019 A030 A041
Settling
In this cycle all the valves will remain close and resin is allowed to settle down.
Slow Rinse
In this cycle Regenerant will be replaced with fresh water, the water will enter from bottom of
vessel and discharge from nozzles that are fitted at the middle of vessel. The following valves
will open during this process and booster pump will also remain in service.
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At this situation the air low-pressure switch gives signal to PLC and system will shut down.
At this situation the low-pressure switch gives signal to PLC and regeneration of desired
5.5.6 softener will stop.
Necessary precautions should be taken with the ion exchange unit in case of prolonged
shutdown. Points of concern are:
Dehydration
Biological proliferation
5.6 Note: Water of suitable quality, i.e., free from suspended materials and turbidity should be used
for conditioning or treating the resins and for preparation of the recommended solutions.
5.6.1
Prevention from Dehydration
Keep the unit filled with water. If for any reason it has to be drained, it is important that the unit
be sealed to maintain the resin in moist condition.
Microbiological Protection
Microorganisms (algae, bacteria etc.) tend to proliferate in plants shutdown for prolonged
periods, if conditions in the plant are favorable (presence of organic matter, mineral salts, pH,
temperature etc.).
5.6.2
The slimes or deposits arising from the growth of such microorganisms may partially or
completely choke the resin bed causing flow, quality and capacity problems when the plant is
re-started. There is also strong possibility that the resin may be completely ruined.
5.6.3 These phenomena vary considerably according to the quality and temperature of water and the
length of the shut down period.
To maintain ion exchange resin beds in good working order, the following precautions should
be taken prior to shutdown for extended periods:
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The resin bed should be backwashed to remove any suspended material or debris, which may
have accumulated during service.
The resin bed, vessel, pipe work etc. should be filled with 0.5 % solution of formaldehyde. It is
advisable to check from time to time during the shut down period that the formaldehyde
concentration does not fall below 0.2 %.
RECORDKEEPING
RESPONSIBILITY
5.7
6. SROP is responsible to run reverse osmosis unit according to the guidelines given in this
SOP, for details OEM manual can also be consulted
7. SROP is responsible to take necessary corrective action and carry out trouble shooting in
case of disturbed water chemistry.
8. Assistant Plant Chemist / SROP are responsible to carry out necessary water testing
5A.1 required by each water treatment unit, and summarize all results in Daily Water Analysis
Log Sheet (PROD-CHM-823-QR-01).
5A.2
9. Assistant Plant Chemist / SROP will take guidance from Senior Plant Chemist, if he finds
any problem in operating parameters or issue in chemical dosing or any other operational
challanges.
10. SROP shall responsible for all above activities during gazetted holidays and after general
shift.
R.O PROCESS
The phenomenon of osmosis occurs when pure water flows from a dilute saline solution
through a membrane into a higher concentrated saline solution. The phenomenon of osmosis is
illustrated as follows:
A semi permeable membrane is placed between two compartments. Semi-permeable means; the
membrane is permeable to some species and not permeable to others. Assumed that this
membrane is permeable to water but not to salts. Then, place a salt solution in one compartment
and pure water in other compartment. The membrane will allow water to permeate through it to
5A.3 either side. But salts cannot pass through the membranes. As a fundamental rule of nature this
system will try to reach equilibrium. That is it will try to reach the same concentration on both
sides of the membrane. The only possible way to reach equilibrium is for water to pass from
the pure water compartment to the salt containing compartment, to dilute the salt solution. It
shows that osmosis can cause a rise in the height of the salt solution. This height will increase
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until the pressure of the column of water is so high that the force of this water column stops the
water flow. The equilibrium point of this water column height in terms of water pressure
against the membrane is called osmotic pressure. If a force is applied to this column of water,
the direction of water flow through the membrane can be reversed. This is the basis of the term
reverse osmosis. Note that this reversed flow produces the pure water from the salt solution.
Since the membrane is not permeable to salt.
A simplified reverse osmosis process consists of a high-pressure pump and membrane module.
High pressure Pump pressurized saline feed water to the module system. Within the module
consisting of the pressure vessel and a membrane element, the feed water will be split in a low
saline product, called permeate and a high-saline brine, called concentrate or reject. A flow
regulating valve called concentrate valve, control the percentage of feed water that is going to
the concentrate stream and the permeate which will be
Obtained from the feed. In case of spiral wound module consisting of a pressure vessel and
several spiral wound elements, pressurized water flows into the vessel and through the channels
between the spiral windings of a spiral wound element. Up to seven elements can be connected
together within a pressure vessel. The feed water becomes more and more concentrated and
will enter the next element, and at last exits from the last element to the concentrate valve
where the applied pressure will be released. Permeate of each elements is collected in the
common permeate tube installed in the center of each spiral wound element and flows to
permeate collecting pipe outside of the pressure vessel.
SYSTEM OUTLINE
Water from softeners first fed to RO system through feed pumps. Prior water enters to
Cartridge Filters is conditioned by dosing antiscalant/antifoulant and Acid. Conditioned water
is further boosted by high-pressure pump and fed into the R.O. module for achieving the
required product water flow.
Pressurized water enters into three Pressure vessel housings each comprising of four 40” long
and 8” diameter high flux thin film membranes arranged in series. 42% permeate is produced
from this stage and its reject water is passed through 2 nd stage, comprising of two pressure
vessel each having four membrane elements. The second stage further produces 28% of product
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5A.4 water. Thus overall 70 % recovery is achieved having a permeate flow of 20m3/hr.
Since during separation process water chemistry for both streams are changed, therefore both
streams need‘s chemical treatment. For reject stream antiscalant and acid is added at RO feed
water, while pH of permeate is raised by adding caustic.
DESIGN PARAMETERS
PLANT SPECIFICATIONS
pH : 7.5
Conductivity : 2600 μ S/cm
TDS : 1820 ppm
TSS : 10 ppm
Chlorides : 330.0 ppm
Sulphate : 370.0 ppm
Calcium Hardness : 210.0 ppm
5A.5.2
Magnesium Hardness : 180.0 ppm
Total Hardness : 390.0 ppm
Alkalinity as CaCO3 : 420.0 ppm
Iron : 0.10 ppm
Silica : 25.0 ppm
pH : 6.0 ± 0.5
Chlorides : < 15 ppm
TDS : ≤ 50 mg/L
TREATMENT SCHEME
PRETREATMENT
5A.5.3
To increase the efficiency and life of a reverse osmosis system, effective pretreatment of the
feed water is required. Pre-treatment is designed to control the following parameters in RO
module.
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5A.6
Langelier Saturation Index (LSI)
5A.6.1
Biological Fouling
The net result of the above shall be the optimization of Product flow, Salt Rejection, Recovery
and Operating Cost. The following pre-treatment has been incorporated for this particular R.O.
Plant.
In order to control LSI value in reject stream acid is being dosed to lower feed water pH. A feed
water pH in range of 7.0 to 7.2 is to be maintained in RO feed water line. Hydrochloric acid is
dosed to water prior it enters to filtration system. Since RO feed water is soft water, therefore
acid dosing may not be required.
5A.6.2
Scale inhibitor also known as antiscalant is used to control carbonate, sulfate and calcium
Fluoride scaling. Scale inhibitor has “Threshold Effect” which means that minor amount
adsorbed specifically to the surface of micro crystals thereby preventing further growth and
precipitation of the crystals. Modified scale inhibitor has also property to disperse the Iron
oxide and other foulant in water.
Since water is being concentrated in reject stream and this concentration depends upon the
5A.6.3 recovery of the system. The unit is designed to operate at 70% conversion therefore water is
being concentrated 3.3 times). To prevent from scaling and fouling, 5 PPM antiscalant in feed
stream is dosed.
POST TREATMENT
Water treated through RO having different divalent ions to mono-valent ions ratio as compared
to RO feed water. RO rejects ions up to 99.5% but dissolved gasses are 100% passes from the
membranes. This will affect the general properties of water. Buffering capacity has been
reduced and pH of outcome decreased, this increases the corrosion property of water. In order
to increase the pH caustic is dosed.
Ensure that all membranes elements have been loaded into the pressure vessels and before
starting up of the membranes unit, make sure that the whole pretreatment section is working in
accordance with the specification. If the pretreatment involved changing of the chemical
characteristics of the raw water, then fully analysis of the water entering the membrane unit
5A.7
must be made. Furthermore, absence of chlorine, tolerance limit turbidity and SDI must be
determined.
5A.7.1
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Flow
SDI
Turbidity
Temperature
pH
Conductivity
Bacteria (Standard Plate Count)
The following checks of the pretreatment system and the membrane unit are recommended for
the initial start up (results to be included in the startup report):
ANTISCALANT
Recommended Antiscalant : RA 0786
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Remarks: The RA 0786 is supplied in 100 % concentration and is required to prepare 10%
concentration with permeate water.
ACID
CAUSTIC
PLANT OPERATION
The initial system start-up is typically performed just after the element loading. Before the
start-up of the plant verification of feed water analysis is required to be done by comparing the
actual analysis with design basis. In case of any variation the plant operating and performance
parameter shall be adjusted accordingly.
5A.9
Proper start-up of reverse osmosis (RO) water treatment systems is es sential to prepare the
membranes for operating service and to prevent membrane damage due to over-feeding or
hydraulic shock. Following the proper start-up sequence also helps ensure that system’s
operating parameters conform to design specifications so that system water quality and
productivity goals can be achieved. Measurement of initial system performance is an important
part of the start-up process. Documented results of this evaluation serve as benchmarks against
which ongoing system operating performance can be measured.
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(A) Use low-pressure water at a low flow rate to flush the air out of the elements and
pressure vessels. Flush at a gauge pressure of 30 to 60 psi.
(B) After the system has been flushed for a minimum of 30 minutes, close the feed pressure
control valve.
(F) Slowly open the feed pressure (control valve, increasing the feed pressure and feed
flow rate to the membrane elements until the design concentrate flow is reached.
(G) During the flushing operation, check all pipe connections and valves for leaks.
Tighten connections where necessary.
(H) Slowly close the concentrate control valve, open feed pressure valves. Set the ratio of per-
meate flow to feed flow to design value (0.70), but does not exceed, the design ratio (recovery).
Continue to check the system pressure to ensure that it does not exceed the upper design limit
(Permeate flow 20m3/hr. (88 GPM) and Reject Flow 09m3/hr. (39.5 GPM)
(I) Repeat step ‘H” until the design permeate and concentrate flows are obtained.
(J) Calculate the system recovery and compare it to the systems design value.
(K) Check chemical additions of scale inhibitor, Measure feed water pH.
(L) Check the Langier Saturation Index (LSI) in reject water by measuring pH, TDS, calcium
hardness, and alkalinity levels. Compare system performance to design values.
(O) Read the permeate conductivity from each pressure vessel and identify any vessels that do
not conform to performance expectations (e.g., vessels with leaking O-rings or other evidence
of malfunction).
(P) After 24 to 48 hours of operation, read all plant performance data such as feed pressure,
differential pressure, temperature, flows, recovery and conductivity readings. This base line
data should be mentioned in the R.O. data sheet for future reference and developing normalized
data during further operation data.
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(R) Switch the permeate flow from drain to the normal operating position.
(S) Put the system into automatic operation. The plant start-up and shut down should be
controlled through level control switch at permeate water storage tanks. In case, the provision
of level control switch is not available the plant on/off control should be done manually.
Use the initial system performance information obtained as a reference for evaluating
future system performance. Measure system performance regularly during the week of
operation to ensure proper performance during this critical initial stage.
PLC OPERATION
The heart of the plant operation is PLC, has been designed to control the operational sequence
of the plant. The operational sequence is as follows:
1. Switch on MCCB panel board.
2. Put selector switches “Manual OFF Auto” of feed pump, high pressure pump and chemical
5A.10 dosing pumps to auto position.
3. Push system ON push button, feed and antiscalant dosing pumps will start. Inlet solenoid
valve and flushing solenoid valve will open. Pressure switch will energize and after two
minute high-pressure pump will start and flushing valve will close.
4. Acid dosing pump will also start with high-pressure pump.
SHUT DOWN
System will shut down as pressure pump suction decrees from 20 PSI. To restart check causes
of low pressure and push reset button. The unit will start again.
Manual shutdown
5A.11.1
Push ON/OFF button to OFF position. High-pressure pump and acid dosing pump will stop and
flushing valve will open. After two minutes feed pump and antiscalant dosing pump will stop.
Inlet and flushing valves will also close.
5A.11.2
RECORD KEEPING
In order to be able to follow the performance of the RO unit, it is necessary that all relevant
data are collected, recorded and kept in file. Apart from keeping track of the performance, the
log sheets are also valuable tools for the troubleshooting and compare the historical data with
5A.12 existing parameters.
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The following data is recorded and logged in to a data sheets when R.O is put in service.
6. QUALITY RECORDS
N.A
7.2 ATTACHMENTS:
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Approved by:
…………………………………
Date approved: ……………………… General Manager (Plant)
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