Softening & R.O Plant Startup and Shutdown Procedures

Doc. #: PROD-CHM-750-01 Doc. Name: Softening & R.
O Plant Start up And Shut Down Edition: 2
TNB LIBERTY POWER LIMITED, MIRPUR MATHELO

STANDARD OPERATING PROCEDURE
SOFTENING AND RO PLANT STARTUP AND SHUT DOWN

Procedure Name:
Date Issued: May 29,2013 Approved By: GM (Plant)
Document Number: PROD-CHM-750-01 Edition: 2
Department: Section: Prepared By: Date:

PRODUCTION CHEMICAL MASOOD AHMED May 29,2013
CONTENTS
1. PURPOSE & INTRODUCTION

2. SCOPE
3. RESPONSIBILITIES, USERS & INTERFACING
4. DEFINITIONS AND ABBREVIATIONS
5. PROCEDURES OR WORK INSTRUCTIONS
6. QUALITY RECORDS
7. ATTACHMENTS / REFERENCES / RELATED DOCUMENTS
CHANGE RECORD
Edition Date Responsible Person Reason / Description of Change
1 29.06.2011 Masood Ahmed Initial Release

2 29.05.2013 Masood Ahmed Review and Update
Doc. #: PROD-CHM-750-01 Doc. Name: Softening & R.O Plant Start up And Shut Down Page 1 of 19
Doc. #: PROD-CHM-750-01 Doc. Name: Softening & R.O Plant Start up And Shut Down Edition: 2
1. PURPOSE & INTRODUCTION
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:
2RcSO3 Na + Ca(HCO3)2 = (RcSO3)2Ca + 2NaHCO3

(Calcium (Calcium ion (Sodium
(Sodium ion Bicarbonate in Exchange Bicarbonate in
Exchange Raw Water) Exhausted Soft Water)
Regenerated Resin)
Resin)
The sodium ion exchanger contains only a finite number of exchangeable sodium ions. This number is
known as the capacity of the resin. When this capacity has been exhausted, i.e., sodium ions have been
replaced by calcium or magnesium, regeneration of the resin back to sodium form becomes necessary.
Resin bed is regenerated with a upward flow of brine. Later, resin bed is rinsed to free off brine. The
chemical reaction is as under:
(RcSO3)2 Mg + 2Na+Cl- = 2RcSO3Na + MgCl2

CaCl2
(Exhausted (Brine) (Regenerated (Effluent)
Resin) Resin)
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. RESPONSIBILITIES, USERS & INTERFACING
3.1. Responsibilities
3.2. Senior Plant Chemist is responsible to develop and continually review the content of this
procedure.
3.3 Users
The users of this document are Sr. Plant Chemist, Assistant Plant Chemist, SROP, and all
production staff of TNB LPL
Interfacing
Senior Shift Charge Engineer

Management
4. DEFINITIONS AND ABBREVIATIONS
PPM - Parts Per Million

SOP - Standard Operating Procedure
R.O - Reverse Osmosis
OEM - Original Equipment Manufacturer
APHA - American Public Health Association
SSCE - Senior Shift Charge Engineer
SROP- Softener Reverse Osmosis Operator
5. PROCEDURES OR WORK INSTRUCTIONS
5.1 RESPONSIBLE PERSONNEL FOR SOFTENER OPERATION
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.
5.2 PROCESS DESCRIPTION
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
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.
5.3 DESIGN SPECIFICATION
5.3.1 Raw Water Quality
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.
Treated Water Quality

5.3.2
Hardness leakage (Average) < 20 ppm as CaCO3
Softener Vessel Data

5.3.3
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)
5.3.4 Resin Specification
Resin make Rohm & Haas

Resin type Amberlite IR-120
Resin volume/Softener 5250
Regeneration mode Counter Current -flow
Regenerant NaCl
Regenerant concentration 10 % W/W NaCl
Regeneration Level 133 g Salt / Liter Resin
NaCl consumption per regn. 700 Kg (100 % W/W)
Raw water limitations for ion exchange resin

5.3.5
Maximum free chlorine – less than 0.05 ppm

Maximum iron and heavy metals – 0.1 ppm
Maximum turbidity – 5 APHA Units
Regeneration Data
5.3.6
Salt Consumption:
700 Kg 100 % W/W NaCl

3044 Kg 23 % W/W NaCl Solution
7000 Kg 10 % W/W NaCl Solution
Required Salt Quality:
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
Regeneration Steps details.
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
Fast rinse (Purge) 15 90000

Total 90
WORK INSTRUCTIONS
5.4 PRESTART UP CHECK LIST
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.
 The plant has been thoroughly washed and cleaned

 The ion exchange vessel has been filled with the required quantity of ion exchange
resin.
 All instrument has been checked and where needed have been recalibrated to the
required standards.
 23% w/w Nacl is ready in the brine dosing tank.
 To be ready for next regeneration after previous exhaustion
 The filtering media in the brine dosing tank must cover the brine-well slots; this helps
to prevent its chocking.
 The Regenerant chemicals are available in quantity sufficient for uninterrupted
operation of the plant.
 Raw water of specified quality, quantity and pressure is available.
 Treated water supply is connected to the treated water storage tank.
 Electric power of specified level is available.
PUTTING SOFTENER INTO SERVICE THROUG PLC
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
Equipment No. Description

00GCB11AA001 SOFTENER "A" INLET MANUAL VALVE
00GCB11AA002 SOFTENER "B" INLET MANUAL VALVE
00GCB11AA003 SOFTENER "C" INLET MANUAL VALVE
00GCB11AA004 SOFTENER "D" INLET MANUAL VALVE
3. Open the manual service out valve completely. Given below are the details of all service
out let valves installed on softeners.
Equipment No. Description

00GCB11AA013 SOFTENER "A" OUTLET MANUAL VALVE
00GCB11AA024 SOFTENER "B" OUTLET MANUAL VALVE
00GCB11AA035 SOFTENER "C" OUTLET MANUAL VALVE
00GCB11AA046 SOFTENER "D" OUTLET MANUAL VALVE
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)
Now the system is ready to be put into service through PLC
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 carried out when either of below situation is observed.
1. Hardness in soft water is observed more than 10 ppm

5.5
2. Softener has completed eight hours of continuous operation on auto or softener has
completed the service length of 720 m3
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.
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.

Time Rate
Liter/
hr Code Code Code Code
5.5.2 - - - - - - - - -
5
- - - - - - - - -
Injection
In this cycle Regenerant 10% NaCl is dosed into the softener vessel for the regeneration of
resin from bottom of vessel and discharge from nozzles which are fitted at the middle of vessel.
The following valves will open during this process.

Time Rate
Liter/h
5.5.3 r Code Code Code Code
5200 AA009 00GCB11A AA020 00GCB11A AA031 00GCB11A AA042 00GCB11A
30 (23%) A009 A020 A031 A042
D.W A010 A021 A032 A043
(10%) A049 A049 A050 A050
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.

Time Rate
Liter/h
5.5.4 OEM KKS Code OEM KKS Code OEM KKS Code OEM KKS Code
r Code Code Code Code
00GCB11A 00GCB11A 00GCB11A 00GCB11A
AA009 AA020 AA031 AA042
A009 A020 A031 A042
30 7884
00GCB11A 00GCB11A 00GCB11A 00GCB11A
AA010 AA021 AA032 AA043
A010 A021 A032 A043
In this cycle the fresh water will enter from the top of the vessel and remove all remaining
particles of regenerant. The following valves will open during this process.
Flow Valve to be Opened

Cycle Rate Softener A Softener B Softener C Softener D
Time Liter/h OEM OEM OEM OEM
r KKS Code KKS Code KKS Code KKS Code
Code Code Code Code
15 90000 AA005 00GCB11 AA016 00GCB11 AA027 00GCB11 AA038 00GCB11A
AA005 AA016 AA027 A038
AA011 00GCB11 AA022 00GCB11 AA033 00GCB11 AA044 00GCB11A
5.5.5 AA011 AA022 AA033 A044
Probable Challenges During Regeneration:
Air Low Pressure
At this situation the air low-pressure switch gives signal to PLC and system will shut down.
Booster Pump Suction Low Pressure
At this situation the low-pressure switch gives signal to PLC and regeneration of desired
5.5.6 softener will stop.
SHUT DOWN PRECAUTIONS:
Ion Exchange Resin Protection
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:
Resin should be left in the exhausted form during plant shutdown.
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
Necessary Parameters are logged into given below log sheets
 Softener R.O plant log sheet

 Daily Laboratory Log sheet
WORK INSTRUCTION FOR RO OPERATION
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
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
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
Feed Water Quantity : 29m3/hr

Permeate Water Quantity : 20m3/hr
Recovery : 70%
Feed Water Temperature: 28° C
Mode of Operation : Automatic
5A.5
FEED WATER ANALYSIS
5A.5.1
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
TREATED WATER QUALITY
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.
Silt Density Index
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.
Acid Dosing System
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.
Anti-Scalant Dosing System
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.
5A.6.4 PLANT STARTUP AND SHUTDOWN
PRESTARTUP CHECK LIST
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
The raw water intake must be stable with respect to:
 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):
 All PTW has been closed

 All piping and equipment is compatible with design pressure.
 All piping and equipment is compatible with design pH range (cleaning).
 Softener has been regenerated and available for service.
 New / Clean cartridge filter is installed directly upstream of the high pressure pump.
 Feed line, including RO feed manifold, is purged and flushed, before pressure vessels are
connected.
 Chemical addition points are properly located.
 Dosing chemicals tanks are filled with right chemicals.
 Provisions exist for preventing the RO System from operating when the chemicals dosing
tank achieves low level.
 Provisions exist for preventing the dosing pumps from operating when the RO system is
shutdown.
 Planned instrumentation allows proper operation and monitoring of the pretreatment and
RO system.
 Planned instrumentation is installed and operative.
 Instrument calibration is verified.
 Interlocks and indication lights on panel are properly set.
 Pressure vessels are properly piped both for operation and cleaning mode.
 Pumps are ready for operation: aligned, proper rotation.
 Fittings are tight.
 Cleaning System is installed and operative.
 Permeate line is open.
 Reject Flow control valve is in open position.
 Feed flow valve is throttled and / or pump bypass valve is partly open to limit feed flow to
less than 50% of operating feed flow.
 Permeate water supply is connected to the treated water storage tank.
 Electric power of specified level is available.
CHEMICALS SOLUTION PREPARATION & DOSAGE
ANTISCALANT
Recommended Antiscalant : RA 0786
Feed Line Flow rate : 28.57 m3/hr.

Solution Strength : 10%
Dosing Rate : 5 ppm
5A.8 Dosing Quantity : 1.45 lit./hr.
Dosing Pump Size @ 12 bar : 1.5 lit./hr.
5A.8.1 Dosing Pump Size @ 3 Bar : 2.9 lit./hr.
Approx. Frequency : 50%
Duty : During System Operation
Remarks: The RA 0786 is supplied in 100 % concentration and is required to prepare 10%
concentration with permeate water.
ACID
Recommended Acid : Hydrochloric acid

Feed Line Flow Rate : 28.57 m3/hr
Dosing Pump Size : 7.0 lit/hr at 7 bar
Dosing Pump Size at 3 Bar : 7.5 Lit/ hr
Approximate Frequency : As per requirement
5A.8.2 Duty : During System Operation
Note: Actual dosing rate to be adjusted as per feed water characteristics, Moreover as we are
using soft water so dosing of Hcl has been stopped under the guidelines of OEM.
CAUSTIC
Recommended Chemical : 10% Sodium hydro oxide

Permeate Line Flow Rate : 20 m3/hr
Dosing Pump Size : 5.0 lit/hr at 5 bar
Dosing Pump Size at 3 Bar : 7.0 Lit/ hr
5A.8.3
Approximate Frequency : As per requirement
Duty : During System Operation
Note: Actual dosing rate to be adjusted as per permeate characteristics
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.
(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.
(C) Ensure that the concentrate control valve is open.
(D) Slowly crack open the feed pressure control valve.
(E) Start the high-pressure pump.
(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.
(M) Allow the system to run for one hour.
(N) Take the first reading of all operating parameters.
(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.
(Q) Confirm proper operation of mechanical and instrumental safety devices.
(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
The system will shut down due to following process disturbance.

 Low suction pressure at R.O feed pump inlet.
 Low Air Pressure
5A.11
 Power failure.
 Manual OFF RO system.
Shutdown due to low Suction Pressure
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.
The following data is recorded and logged in to a data sheets when R.O is put in service.
 Date, Time and hours of operation

 Pressure drop per array
 Feed and concentrate pressure of each stage.
 Conductivity of the feed water and permeate.
 Permeate and concentrate water flow and many others in Daily Softener R.O plant Log
Sheet
6. QUALITY RECORDS
Record Ref. Location of Retentio

Record Name
Number storage n Period
PROD-CHM-750-
Daily Softener R.O Plant Log Sheet Laboratory 6 -Year
01-QR-01
PROD-CHM-750-
Daily Laboratory Log Sheet Chemist Office 6- Year
01-QR-01
7. CHECKLISTS / ATTACHMENTS / REFERENCES / RELATED DOCUMENTS
7.1. CHECK LIST
N.A
7.2 ATTACHMENTS:
1. Daily Softener R.O Plant Log Sheet

2. Daily Laboratory Log Sheet
7.3 REFERENCES / RELATED DOCUMENTS:
 WEMS R.O MANUAL

 WEMS SOFTENER MANUAL
TNB LIBERTY POWER LIMITED, MIRPUR MATHELO

STANDARD OPERATING PROCEDURE
SOFTENING AND RO PLANT STARTUP AND SHUT DOWN

Procedure Name:
Document Number: PROD-CHM-750-01 Edition Number: 2
DOCUMENT APPROVAL FORM (DAF)
Reason for change: Review and Update
Requester / Document Writer Name : _________________________ ……………………………..

Date: _________________________ (Signature)
No. Designation Vet by: (Signature)

1. Document Controller
2. Senior Shift Charge Engineer
7. Senior Engineer (Facility & Balance of Plant)
8. Senior Engineer (Electrical, Inst.& Control, IT)
9. Senior Engineer (Mechanical)
10. Manager (Administration)
11. Senior Manager (Maintenance & Engineering)
12. Senior Manager (Production)
Approved by:
…………………………………
Date approved: ……………………… General Manager (Plant)

Softening & R.O Plant Startup and Shutdown Procedures

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Softening & R.O Plant Startup and Shutdown Procedures

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Doc. #: PROD-CHM-750-01 Doc. Name: Softening & R.

O Plant Start up And Shut Down Edition: 2

TNB LIBERTY POWER LIMITED, MIRPUR MATHELO

SOFTENING AND RO PLANT STARTUP AND SHUT DOWN

Date Issued: May 29,2013 Approved By: GM (Plant)

Document Number: PROD-CHM-750-01 Edition: 2

Department: Section: Prepared By: Date:

1. PURPOSE & INTRODUCTION

Edition Date Responsible Person Reason / Description of Change

1 29.06.2011 Masood Ahmed Initial Release

1. PURPOSE & INTRODUCTION

2RcSO3 Na + Ca(HCO3)2 = (RcSO3)2Ca + 2NaHCO3

(RcSO3)2 Mg + 2Na+Cl- = 2RcSO3Na + MgCl2

3. RESPONSIBILITIES, USERS & INTERFACING

Senior Shift Charge Engineer

4. DEFINITIONS AND ABBREVIATIONS

PPM - Parts Per Million

5. PROCEDURES OR WORK INSTRUCTIONS

5.1 RESPONSIBLE PERSONNEL FOR SOFTENER OPERATION

5.2 PROCESS DESCRIPTION

5.3 DESIGN SPECIFICATION

5.3.1 Raw Water Quality

Treated Water Quality

Hardness leakage (Average) < 20 ppm as CaCO3

Softener Vessel Data

5.3.4 Resin Specification

Resin make Rohm & Haas

Raw water limitations for ion exchange resin

Maximum free chlorine – less than 0.05 ppm

700 Kg 100 % W/W NaCl

Required Salt Quality:

Regeneration Steps details.

Fast rinse (Purge) 15 90000

5.4 PRESTART UP CHECK LIST

 The plant has been thoroughly washed and cleaned

PUTTING SOFTENER INTO SERVICE THROUG PLC

Equipment No. Description

Equipment No. Description

Now the system is ready to be put into service through PLC

Regeneration of softener is carried out when either of below situation is observed.

1. Hardness in soft water is observed more than 10 ppm

Cycle Flow Valve to be Opened

Cycle Flow Valve to be Opened

Cycle Flow Valve to be Opened

Flow Valve to be Opened

Probable Challenges During Regeneration:

Air Low Pressure

Booster Pump Suction Low Pressure

SHUT DOWN PRECAUTIONS:

Ion Exchange Resin Protection

Resin should be left in the exhausted form during plant shutdown.

Necessary Parameters are logged into given below log sheets

 Softener R.O plant log sheet

WORK INSTRUCTION FOR RO OPERATION

Feed Water Quantity : 29m3/hr

TREATED WATER QUALITY

Silt Density Index

Acid Dosing System

Anti-Scalant Dosing System

5A.6.4 PLANT STARTUP AND SHUTDOWN

PRESTARTUP CHECK LIST

The raw water intake must be stable with respect to: