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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
OPERATION, MAINTENANCE & TROUBLESHOOTING MANUAL CLIENT
:
IFFCO PHULPUR
PROJECT
:
ACTIVATED CARBON FILTER FOR AMMONIA & POWER PLANT
PLANT
:
CONDENSATE POLISHING UNIT
CAPACITY
:
150M3/HR
REFERENCE
:
OC NO 200134
Thermax Limited, (C&W Service & Solutions Group) Thermax House, Mumbai Pune Road, Shivaji Nagar, Pune - 411005 Tel. : 020-25511010, Fax. : 020-25511236. WATER TREATMENT PLANT
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Improving Your Business Is Our Business On Thermax Group: Thermax’s vision is to be a globally respected high performance company offering sustainable solutions in energy and environment. The Thermax Group provides business to business solutions in the areas of heating, cooling, captive power, water treatment, air pollution control, waste management & resource recovery, and chemicals to a wide range of industry in Indian and international markets. In the energy business, Thermax executes projects in the areas of process heat, captive power and waste heat recovery. It also offers a range of heating equipment; energy efficient chillers and customized products such as waste heat and exhaust gas boilers. Thermax’s integrated expertise in energy has made GE to choose it as the ‘vendor on first call’ for its global Combined Heating Power and Cooling (CHPC) projects... Thermax offers industry its expertise over a hundred fuels including oil, gas and a wide variety of solid fuels including biomass. The Group’s Joint Venture, Thermax Babcock & Wilcox (TBW) has emerged as a leading and reliable project management companies with installations the world over; in the US, Saudi Arabia, Thailand, Egypt, Philippines and several other countries. Leveraging its leadership position in electricity saving vapor absorption technology, it offers process industries and commercial establishments like hotels, shopping malls and offices vapor absorption chillers a boon in power‐starved areas. These Eco‐friendly, energy efficient equipment have found prestigious customers such as BBC, Mercedes Benz, Audi, Bosch, Panasonic, Henry Ford Museum. In the environment area Thermax offers waste management expertise for solid, liquid and air pollution. Thermax provides solutions from pre‐treatment to waste water treatment and chemical conditioning of water for boiler and cooling water systems. Water recycling is a thrust area for Thermax. Hi‐grade resins from Thermax have found niche customers in US and Japanese markets. Thermax has an extensive international marketing network. Headquartered in Pune (Western India), Thermax's eleven international offices are located in South East Asia, Middle East, Africa, Russia, UK and the US. Thermax’s 4 overseas subsidiaries play a significant role in generating business in the International market: Thermax (Rus) Ltd., Thermax (Europe) Ltd., OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
2
THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Thermax Inc., USA and ME Engineering, UK. Around 20 per cent of the group’s turnover come from exports – to the US and European markets, Japan, East Africa, the Middle East, South East Asian and CIS countries. The Thermax group’s manufacturing facilities. Spread over 14 plants, measuring a covered area of over 65,000 sq. Mts., are ISO 9000 and ISO 14001 accredited. Thermax manufactures to international standards like ASME, BS, DIN, and GOST. The facilities have been inspected by Lloyds, Bureau Veritas, SGS, and TUV. Thermax’s business is inspired by the conviction that ‘Improving your business is our business.’ Water & Waste Solutions MAKING INDUSTRY GREEN AND COMPETITIVE Cost competitive and Environment friendly technology innovated and developed through continuous research to keep industry green and competitive. Excellence in Technology and stringent quality control measures are the hallmarks in all projects undertaken by Thermax Water & Waste Solutions Division. Thermax Water & Waste solutions division takes on Retrofitting and Revamping orders to extend life of all aging plants. Our comprehensive service program is the first of its kind in India. It is a program that evaluates and then enhances the economical performance of all water & waste treatment plants. Thermax Water & Waste Solution Division’s wide spectrum of products and technology covers Pretreatment Process Water Treatment Ion Exchange Resins Reverse Osmosis and Electro dialysis Condensate Polishing Thermal Desalination Waste Water Treatment Sewage Treatment Recycling of water Range of Cooling Water Chemicals Range of Polyelectrolyte Incinerators. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
TABLE OF CONTENTS 1 : Water Treatment Fundamentals ………………………….…... ……………………… 6 1.1 : Water treatment general write up & Basic water chemistry ………………….6 1.2 : Importance of Water Analysis …….………………………………….……………...7 2 : Plant Configuration and Details …………………………………………………………...13 2.1 : System Details ………………………………………………….……………..………...13 3 : Control Philosophy …………………………………………………………………………15 3.1 : System Description ……..…..…………………………………………………………..15 3.2 : Process ……………………………………..…………………………………………...16 4 : Operation & Maintenance of "ACF Filter" ………………..………………………...17 4.1 : System operation for ACF ……………………………..……..………………………17 4.2 : Process flow diagram …………………………………………………………………...35
4.3 : Operation Conditions checks for ACF…………………..…………………………36 4.4 : Troubleshooting Guide (ACF) …………………..…………………………………..37 4.5 : Maintenance (ACF) ………………………………..…………………………………38 5 : Laboratory Details …………..……………………………………………………………39 5.1 : Laboratory Analysis ……..…………………………………………………………….39 5.2 : Daily Log- Sheet …………………………………………………………....................72 6: P & I Drawings .…..….………………………….…………………………………………...73 7: Valves Operating procedure………………………………………………………………...75 8 : Whom to Contact ……….………..……………………………….……….………………..76 (for support In case of problem)
Note: For operation and maintenance of individual equipments like pumps, blowers, motors, instruments etc please refer to the instruction manual of the respective equipments.
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 I N T R O D U C T I O N The Operation & Maintenance Manual gives a brief introduction to the total system supplied and gives instructions and guidelines for smooth, long lasting and trouble free operation of the plant. The O&M manual is prepared to make the operator familiar with the system/plant supplied (ACF unit) and its operation and maintenance of the Plant. The chapter Chemical Control describes the various laboratory tests and their procedures, to be carried out in the laboratory to understand quality of feed water to the plant and quality of product water. The regular analysis also helps in analyzing individual units' performance and total plant performance vis‐à‐vis output water produced and chemicals consumed. The maintenance of various equipment in general and resin units in particular are detailed in this O&M manual along with details of trouble shooting, safety precautions, etc. It is also to be noted that this O&M manual covers all areas relevant to the system supplied in general and certain problematic areas, in particular, with respect to operation and maintenance, based on our experience, as far as possible. In case of problems, which are not covered, and peculiar, the same can be referred to us or the various manufacturers as and when they arise. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
1. WATER TREATMENT FUNDAMENTALS 1.1 WATER TREATMENT GENERAL WRITE – UP & BASIC WATER CHEMISTRY: INTRODUCTION: The natural water contains solid, liquid and gaseous impurities and therefore, this water cannot be used for the generation of steam in the boilers. The impurities present in the water should be removed before it’s use in steam generation The necessity for reducing the corrosive nature & quantity of dissolved and suspended solids in feed water has become increasingly important with the advent of high pressure, critical & supercritical boilers. IMPURITIES IN WATER: ‐ The impurities present in the feed water are classified as given below •
Undissolved and suspended solid materials.
•
Dissolved salts and minerals.
•
Dissolved gases.
•
Other materials (as Oil, Acid) either in mixed or Unmixed forms.
•
Undissolved and suspended solid materials.
a) Turbidity and Sediment Turbidity in the water is suspended insoluble matter including coarse particles (mud, sediment, sand etc.) That settles rapidly on standing. Amounts ranges from almost zero in most ground waters and 60,000 ppm in muddy and turbulent river water. The Turbidity of feed water should not exceed 5 ppm. These materials can be removed by settling, coagulation and filtration. Their presence is undesirable because heating or evaporation produces hard stony scale deposits on the heating surface & clog fluid system. Both are objectionable as they cause damage to the Boiler system standard amount of measurement of hardness is taken as being the amount of Calcium Carbonate (CaCO3) in the water and is referred to in part per million (ppm) or grains per gallon (grains/gallon * 17.1 = ppm). b) Sodium and Potassium Salts These are extremely soluble in water and do not deposit unless highly concentrated. Their presence is troublesome as they are alkaline in nature and accelerate the corrosion. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 c) Chlorides Majority of the chloride causes increased corrosive action of water. d) Iron Most common soluble iron in water is ferrous bicarbonate. The water containing ferrous bicarbonate deposits becomes yellowish and reddish sediment of ferric hydroxide if exposed to air. Majority of ground surface water contains less than 5 ppm but even 0.3 ppm can create trouble in the feed water system by soft scale formation and accelerating the corrosion. e) Manganese It also occurs in similar form as iron & it is also equally troublesome. f) Silica Most natural water contains silica ranging from 1 to 100 ppm. Its presence is highly objectionable as it forms very hard scale in Boilers and forms insoluble deposits on turbine blades. In modern high pressure Boilers its presence is reduced as low as 10‐50 ppb. g) Microbiological Growth Various growths occur in surface water (lake & river). The microorganisms include diatons, moulds, bacterial slimes, algae, manganese & sulphate reducing bacteria and many others. These can cause coating on Heat Exchanger and clog the flow passages and reduce the heat transfer rates. h) Colour Surface waters from swampy areas become highly coloured due to decaying vegetation. Colour of feed water is objectionable as it causes foaming in Boilers and may interfere with treatment processes. It is generally removed by chlorination or adsorption by activated carbon. Dissolved Salts and Minerals Calcium and Magnesium Salts The Calcium and Magnesium salts present in the water in the form of carbonates, bicarbonates, and sulphates and chlorides. The presence of these salts is recognized by the hardness of the water (hardness of water is tested by soap Test). The hardness of water is classified as temporary and permanent hardness. The temporary hardness is caused by the bicarbonates of calcium and magnesium and can be removed by boiling. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 The boiling converts the soluble bicarbonates into less soluble carbonates, which can be removed by simple blow down method. The permanent hardness of the water is caused by the presence of chlorides, sulphates and nitrates of calcium and magnesium and they can not be removed just by boiling because they form a hard scale on heating surfaces. Dissolved Gases Oxygen It presents in surface water in dissolved form with variable percentage depending upon the water temperature and other solid contents in water. Its presence is highly objectionable, as it is corrosive to iron, zinc, brass and other metals. It causes corrosion and pitting of water lines, boiler exchangers. Its effect is further accelerated at high temperatures. b) Carbon Dioxide The river water contains 50 ppm and well water contains 2 to 50 ppm of CO2. It also causes the corrosion of stream, water and condenses lines. It also helps to accelerate the corrosive action of oxygen. The other gases are H2S, CH4, N2 and many others but their percentages are negligible, therefore, their effects are not discussed here. 4. Other Materials Free Mineral Acid Usually present as sulphuric or hydrochloric acid and causes corrosion. The presence is reduced by neutralization with alkalis. b) Oil Generally, the lubricating oil is carried with steam into the condenser and through the feed system to the Boiler. It causes sludge, scale and foaming in Boilers. It is generally removed by strainers and baffle separators. The effects of all the impurities present in the water are the scale formation on the different parts of the Boiler System and corrosion. The scale formations reduces the heat transfer rates and clog the flow passage and endanger the life of the equipment’s by increasing the temperature above safe limit. The corrosion phenomenon reduces the life of the Plant rapidly. Therefore, it is absolutely necessary to reduce the impurities below a safe limit for the proper working of the power plant.
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
1.2 Importance of Water Analysis Water analysis The process of determining how much of various substances (impurities) are present in given sample of water is known as Water Analysis. Need for Water Analysis Water analysis is essential for the following reasons: a) Raw water source selection. b) Analysis of raw water determines the type of treatment and unit size. c) Treated water analysis indicates the efficiencies of various units of water treatment. d) Designing of most economical water treatment plant. To design a water treatment plant knowing the impurities present in the water to be treated is needed. Complete analysis helps in determining the degree of pretreatment required in Ion Exchange and other process like reverse osmosis etc. Minor constituent like silica is very important since it may have influence on the regeneration technique used and can affect the capacities that can be obtained. Analysis of Iron and chlorine is important for reverse osmosis design. Definition used in water analysis pH: It is common practice to express hydrogen ion concentration in terms of pH. By definition the pH is the negative logarithm of hydrogen ion concentration to the base of l0. pH = ‐ log10 (H+) = log (1/H+) Ionic product of water Kw has a value of 1 x 10 ‐ 14 and in neutral water H + concentration is equal to OH ‐ concentration. Kw = H + x OH‐ = 1 x 10‐ 14 ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ (1) For neutral water = (H+) = (OH‐) = 1x10 ‐ 7 The equilibrium represented by equation (1) occurs universally in aqueous solution regardless of the equilibrium or the solutes present. Hence equation (1) should always be satisfied. Thus the terms pH expresses the acidity or basicity of water. Neutral water has a pH of 7. pH lower than 7 indicates acidity and greater than 7 is alkaline. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Alkalinity: As mentioned earlier alkalinity in water is due to presence of HCO‐3. CO‐3 and OHions. In raw water alkalinity is mostly due to HCO‐3, but in some cases CO‐3 ions also may be present. It is important to note that out of the three ions only two ions can exist in any system. That is HCO‐ 3, CO‐3 or OH‐ can exist alone or in combination with one more ion. Any water analysis reporting the presence of all three ions should be discarded. Alkalinity of water is determined by titration with phenolpthalein and methyl orange indicator. The result of titration with methyl orange indicator is called Total Alkalinity or MAlkalinity. M. Alk. = Total Alk = HCO‐3 + CO‐3 + OH‐. The result of titration with phenolpthalein indicator is called P‐Alkalinity. P. Alk = OH + 1/2 CO3. Hardness Calcium and Magnesium salts impart hardness to water. Hard water is defined as a water which does not lather or foam with soap easily. The salt of calcium and magnesium which causes hardness is divided in two parts. 1. Temporary hardness or carbonate hardness. 2. Permanent hardness or non‐carbonate hardness. The sum of temporary and permanent hardness is called Total Hardness. Total Hardness = Carbonate hardness + Non Carbonate hardness Carbonate Hardness It is mainly due to presence of bicarbonates of Calcium and Magnesium. Alkalinity in raw water is normally due to bicarbonate ions. Therefore, carbonate hardness (Alkalinity) plus Non Carbonate hardness is equal to total hardness. 1) Carbonate hardness = Alkalinity, when alkalinity is less than total hardness. 2) Carbonate hardness = Total hardness, when alkalinity is greater or equal to total hardness. Conductivity: The conductivity of water is dependent on the ionic content of water, specifically on the ability of ionic impurities in the water to conduct electricity. Ionic impurities have the ability to conduct electric current and thus there is direct linear relationship between ionic impurities and conductivity which help in determining the ionic impurities in water. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Conductivity is also related to TDS empirically = Conductivity x 0.65 = TDS. Total Dissolved Solids This represents all the soluble inorganic solids in water expressed in ppm. Total Solids Total solid is defined as SUM of soluble and insoluble solids. Electrolytes This is total ionizable dissolved solids in water. Total electrolyte is numerically equal to total cation or total anions (not sum of both). Total electrolyte does not include CO2 and silica. Total Cations Sum of calcium, magnesium, sodium and potassium all measured in the same unit. Total Anions Sum of alkalinity (HCO‐3 + CO‐3 + OH‐) + Cl + SO4 + NO3 all measured in the same unit. Total Cation = Total Anion = Total Electrolyte Equivalent Mineral Acidity (EMA) The equivalent mineral acidity, EMA is equal to the sum of equivalent concentration of sulphates, chloride and nitrate. It is also called sometimes as Total Mineral Acidity. Free Mineral Acidity (FMA) Free mineral acidity is equal to (EMA ‐ Sodium leakage). EMA ‐ Sodium leakage = FMA EMA ‐ FMA = Sodium leakage. Method of reporting water analysis There are various ways of reporting water analysis, but in general four methods which are commonly used are, 1. As ppm ion or mg/litre. 2. EPM or M.Eq./litre (Mill equivalent per litre) 3. ppm as CaCo3. 4. Grains per gallon as CaCo3. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Water analysis Report Water analysis can be reported in many ways but most laboratories give in the format as given below. WATER TREATMENT PLANT Format for Reporting water Analysis Physical pH ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Colour ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Hazen Unit Taste and Odour ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Turbidity ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ NTU Conductivity ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ μmhos or milli mhos Chemical Suspended Solids ‐ in ppm Calcium ‐ as ppm CaCO3.* Magnesium ‐ as ppm CaCO3.* Hardness ‐ as ppm CaCO3.* M.Alkalinity ‐ as ppm CaCO3.* P.Alkalinity ‐ as ppm CaCO3.* Chloride ‐ as ppm or mg./litre. Sulphate ‐ as ppm or mg./litre. Nitrate ‐ as ppm or mg./litre. Silica ‐ as ppm or mg./litre. Iron ‐ as ppm or mg./litre. TDS ‐ as ppm CO2 ‐ as ppm * Sometimes calcium and Magnesium can be reported as in ppm as Ca or Mg. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
2. PLANT CONFIGURATION AND DETAILS 2.1 SYSTEM DETAILS ‐ PLANT DATA DESIGN DATA S.No
Description
Design Value
1
Unit Name
Activated Carbon Filter
2
No of Stream
01
3
Design Flow rate
150 M3/Hr
4
Specification
4 M Dia & 2.6 HOS
4
Design pressure
12.5 Kg/cm2
6
Design temperature
80C
OPERATING DATA S.No
Description
Design Value
1
Unit Name
Activated Carbon Filter
2
No of Stream
01
3
Flow rate
150 M3/Hr
4
Operating Time
20 Hrs
5
Operating pressure
9 – 11 Kg/cm2
6
Operating temperature
60C
7
Operation Mode
Manual
8
Backwash Time
30 min
9
Feed Water
Condensate outlet water
10
Differential pressure in vessel
0.6 Kg/cm2
11
Differential pressure in Basket filter
1.5 Kg/cm2
12
Blower for ACF
600m3/Hr at 0.4 Kg/cm2
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 ANALYSIS DATA S.No
Description
Inlet parameters
Outlet parameters
1
Ph
9.0 – 9.5
9.0 – 9.5
2
Conductivity
30 µS/Cm
30 µS/Cm
3
Oil & Grease
<1.0 ppm
NIL
4
Turbidity
<1.0 NTU
<1.0 NTU
5
Silica
<0.02 ppm
<0.02 ppm
EQUIPMENT DATA S.No TAG NO
Description
QTY
SPECIFICATION
MOC
1
ACF
ACF VESSEL
1 NOS
4 M Dia & 2.6 HOS
MSEP
2
BS ½
BASKET STRAINER
2 NOS
FOR 150 M3/HR CAP
SS
3
ACFB 1
ACF AIR BLOWER
1 NO
600m3/Hr at 0.4 Kg/cm2
CI
DPT 351,
DIFFERENTIAL PRESSURE
DPT 352
TRANSMITTER
2 NOS
ACROSS VESSEL & BS
‐‐
5
FT 401
FLOW TRANSMITTER
1 NO
DP TYPE IN INLET
‐‐
6
FI
FLOW INDICATOR
1 NO
ROTAMETER IN INLET
‐‐
PRESSURE GAUGE
3 NOS
BOURDEN TYPE
‐‐
4
PG 101, 7
PG 102, PG 103
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
3. CONTROL PHILOSPHY 3.1 SYSTEM DESCRPTION: ACTIVATED CARBON FILTER BASICS Activated Carbon works by attracting and holding certain chemicals as water passes through it. Because AC is a highly porous material, it has an extremely high surface area for contaminant adsorption. The contaminant is more likely to diffuse into a pore and become adsorbed. The two principal mechanisms by which activated carbon removes contaminants from water are adsorption and catalytic reduction. Organics are removed by adsorption and residual disinfectants are removed by catalytic reduction. Activated carbon is proven technology for the removal of naturally occurring organics and residual disinfectants. Activated carbon filters are using granular activated carbon as media. Activated carbon filtration is most effective in removing organic contaminants from water. Organic substances are composed of two basic elements, carbon and hydrogen. Because organic chemicals are often responsible for taste, odor, and color problems. AC filtration can generally be used to improve aesthetically objectionable water. AC filtration will also remove chlorine. AC filtration is recognized by the Water Quality Association as an acceptable method to maintain certain drinking water contaminants within the limits of the EPA National Drinking Water Standards. Overall this study showed that activated carbon filters are extremely effective as primary filters and have the added benefit of organics reduction resulting in cost savings with reduced chlorine demand and safer water with reduced THM formation and cleaner distribution systems. Activated carbon beds are filters and need to be backwashed periodically. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
3.2 PROCESS (ACF) The ACF filter has a Activated Carbon Media, one of the most widely used media for adsorption of impurities. The Activated carbon is employed for_ • Dechlorination • Removal of Organics • Removal of Odour The residual chlorine in the water, where chlorination is used for Organics removal, as adsorbed by Activated Carbon Filter. Chlorination of water is widely used in Drinking Water Plants, Pretreatment of DM plant and Ro plants and effluent treatment plants. The VERSA ACF removes almost all of the residual chlorine in the water. The VERSA ACF also helps in removal of Organic matter from the water. It is used in treatment plants for Drinking water as polisher unit at the outlet of the plant and removes objectionable odours. The Activated carbon media has finite capacity of absorption and shall exhaust on prolonged usage depending upon the inlet impurity load. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
4. OPERATION AND MAINTENANCE OF ACF FILTER 4.1 SYSTEM OPERATION FOR ACTIVATED CARBON FILTER (ACF) The ACF unit for manual operation shall be divided into the following operations: 1. SERVICE cycle of ACF unit 2. BACKWASH operation of ACF unit 3. AIR RELEASE operation of ACF unit SERVICE CYCLE OF ACF UNIT: •
Ensure that the ACF filter is backwashed and is ready for service.
•
Ensure feed water is available in rated quantity/quality and pressure.
•
In the service mode Service Inlet Valve VM‐1 and the service outlet valve VM‐2 remain open.
The service cycle of ACF is 20 hours or differential pressure across the filter 0.6kg/cm2. SERVICE STEPS 1. RINSE 2. REFILL 3. SERVICE 1. RINSE: In this step Service inlet valve VM‐1 and Rinse outlet valve VM‐6 remains open. The step is carried out with the condensate outlet water for 5 minutes at the flow rate is 150 m3/Hr. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 2. REFILL: In this step the service inlet valve VM‐1 and air release valve VM‐12 remain open. All the other valves are in closed condition. Refill is carried out at the service flow rate till full bore of air comes from the air release line. The time set for refill is 2 minutes. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 3. SERVICE: The unit is taken into service. It remains in service for a cycle of 1200 min. After this it is taken into regeneration mode. Service inlet valve VM‐1 and Service outlet valve VM‐2 remain open. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 BACKWASHING OF ACF After completion of design service run hours (20 hours) or depending up on the differential pressure across the filter i.e Difference between inlet and outlet pressure gauge readings of 0.6 kg/cm2, the vessel is taken in backwash mode. BACKWASHH IMPORTANCE: The waste wash water drains should be kept free of clogging or sediment. The requisite up‐flow velocity of backwash water should be maintained at the design rate for proper cleaning of the media. Backwashing of filters should not be based on arbitrarily fixed time scheduled but the frequency should be in accordance with the filtrate quality and head loss measurement. Duration of cleaning should be dependent upon the turbidity of the wasted water. For better performance, carry out extended backwash for 30‐45 minutes once in a week or till backwash effluent is clear.
BACKWASH STEPS Backwash steps are as follows, 1. DRAIN 2. AIR SCOURING 3. STEAM 4. BACKWASH 5. SETTLE BED 6. RINSE STEP OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 BACKWASH STEPS 1. DRAIN: The backwash mode is initiated with the drain step. In this step Backwash Outlet Valve (VM‐ 4) and drain outlet valve or rinse outlet valve (VM‐6) remains open. All the other valves remain closed. The drain step is for a period of 5 minutes. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 2. AIR SCOURING: Air scouring step starts and is done through ACF Blower (ACFB‐1). Backwash outlet valve (VM4), Air Inlet valve (VM‐5) and Air release valve (VM‐12) remain open in this step. The step is carried for 5 minutes. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 3. STEAM: Steam scouring step starts and is done through steam inlet line. Backwash outlet valve (VM4), Steam Inlet valve (VM‐30) and Air release valve (VM‐12) remain open in this step. The step is carried for 10 minutes. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 4. BACKWASH: In this step the Backwash Inlet Valve (VM‐3) and Backwash Outlet Valve (VM‐4) remain open. The backwash is done through the Condensate outlet valve. The backwash is carried out at a flow rate of 150 m3/hr for 10 minutes. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 5. SETTLE BED: In this step the bed is allowed to settle for a period of 2 min. All the valves remain closed in this step. 6. RINSE STEP: The rinse step of ACF in backwash mode is carried out with the condensate outlet water. In this step VM‐1 of ACF remains open & rinse water is drained out through the rinse outlet valve VM‐ 6 of ACF. The rinse step is carried out for 5 minutes at the flow rate of 150m3/hr. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 AIR RELEASE OPERATION: Air release operation is an independent operation carried out to release the entrapped air from within the vessel. This single operation; when opened the Air release valve VM 12 in 2 min and the air release valve also gets closed manually after 2 mins. BASKET STRAINER IMPORTANCE: The Filtered/Treated Water is first passed to Basket Filter. This unit is provided for removal of fine suspended particles. This is a SS vessel housing with the SS screen Filter elements which prevents micron size particles up to 100 µ. If the differential pressure on the inlet to Basket Strainer sensed by DPT 352 is high value alarm is 1.5 Kg/cm2. ACF feed water valve close/trips in this case. ACF OUTLET FILTERED/TREATED WATER After Filtered/Treated water of ACF outlet water is sent directly to make up water day tank of the power plant for BFW make up in boiler through deaerator. After Filtered/Treated water of ACF outlet water is sent directly to make up water day tank of the ammonia plant for BFW make up in waste heat boiler through deaerator. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
4.2 PROCESS FLOW DIAGRAM SCHEMATIC DIAGRAM FOR ACTIVATED CARBON FILTER UNIT SURFACE CONDENSER CONDENSATE WATER INLET BASKET FILTER 1
ACF
TREATED WATER OUTLET BASKET FILTER 2
TO DEAERATOR
PROCESS STEPS: Process condensate water from surface condenser outlet to deaerator. SURFACE CONDENSER – ACF – BASKET FILTER – DEAERATOR. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
4.3 OPERATING CONDITION CHECKS FOR ACF YNIT PRE‐REQUISITE CONDITION ‐ OPERATION (MANUAL) ‐ ACF UNIT •
Check the all manually operated valves open or close condition such as VM‐1, VM‐2, VM‐3, VM‐4, VM‐5, VM‐12, VM‐30 & VM‐26.
•
Ensure all Pressure Gauge isolation valve (VM‐41) are open for all the Units & of Rotary equipment’s.
•
Ensure all Flow Indicators’ / Flow transmitter DP transmitter isolation valves (VM‐46) are open for all the Units.
•
While in service Condensate outlet header valve and ACF outlet header valve is open.
•
Inlet water pressure should not exceed 12 kg/cm2. Do not exceed the Max Operating Flow rate of 150 m3/hr, as this may deteriorate the quality of outlet water.
•
Inlet water temperature should not be more than 80 Deg.C
•
Check the differential pressure across the vessel & across the basket filter before start up the unit.
Now ACF unit is ready to take in to operation. MAINTENANCE CHECKS: •
Analyze inlet / outlet water in periodically i.e., hourly, shift basis, daily, weekly basis.
•
Ensure Air blower are sufficiently lubricated and continued oil levelers are filled up.
•
Inspect the vessel, piping externally once in year for damage to the painting.
•
Inspect the filter media every year, and replaced if required.
•
Give extended backwash to the filter once in a week for more than 45 min or till clear water.
•
Give air scouring to the filter media once in six months or if the filter is found heavily chocked, as described in maintenance section.
•
Use genuine spares (THERMAX SPARES).
•
Repaint as necessary.
•
Inspect vessel internally once in a year for any damaged in internals system or not. And repair the internals if found damaged.
•
If found consistently more than the design limit, consult THERMAX representatives.
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
4.4 TROUBLESHOOTING GUIDE (ACF) S.No
DEFECT
CAUSE
REMEDY
1
Condensate water
a. Filter not backwashed
a. Backwash filter regularly
quality not up to
b. Inlet Suspended Solids load b. Check inlet water quality.
the standard
increased
You may have to increase backwash
c. Excessive Flow Rate
frequency. Also Consult Thermax.
d. Channeling Collection/distribution
c. Please do not cross unit max service
e. Disturbed media layers.
flow rate. d. Check and ensure sufficient pressure. e.
Check
and
ensure
proper
segregated media layers 2
Backwash Frequency
a. Inlet Suspended Solids load a. Check inlet water quality. You may
Required is high
increased
have to increase backwash frequency. Also Consult Thermax.
3
Unit Rinse takes long time a. Flow rate too low
a. Adjust the flow rate to the normal
b. Improper Backwash
b. Give proper backwash as given in OPERATION section till clear water is observed.
4
Pressure Drop across bed a. No or Insufficient backwash is increasing day by day
b. Inlet Suspended Solids load b. Check inlet water quality.
increased
You may have to increase backwash frequency. Also Consult Thermax.
5
a. Backwash filter regularly.
Media comes out
a. Improper media charging at
a. Remove and recharge media
from bottom outlet
the time of erection
properly
b. Too much excessive backwash b. Always maintain backwash flow. flow rate/Pressure
Too much backwash flow rate/
c. The gap in collection box and dish Pressure can disturb media layers. is more than 5 mm. ( This should c. Remove the entire media, adjust have
been
checked
installation)
before the gap to 5 mm, segregate the media by type and recharge the media.
TREATMENT PLANT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
4.5 MAINTENANCE (ACF) The routine maintenance of the filters should include the following _ VALVES At periodic intervals (say one month) open out the valves and check seating, gate, etc. Attend to gland packing. Replace if necessary, do routine lubrication of spindle. EXTENDED BACKWASH Once in a week extend the backwash operation to at least 45 minutes to keep the bed clean. AIR SCOURING AND CLEANING OF THE FILTER MEDIA Once in six months, open the manhole and examine the condition of the media. Throw away any lumps formed on the top of the bed. On units where no regular air scouring facilities are provided, air scouring should be done as follows – a. If compressed air supply is available, take a temporary tapping (say 1” hose). Attach the hose to a M.S. pipe about 1 M long with water level inside vessel about 3“above the level of the bed, insert the pipe into the bed till it is about halfway through. The media will be seen getting violently agitated. Move the pipe all over the bed. Carry out the air scour for a period of about 10 minutes. b. Drain the water till the surface of the bed and scrape off any fine dust. c. Close the manhole. TREATMENT PLANT DO’S AND DON’T’S • Never exceed the filter service flow • Analyses Inlet water for Turbidity regularly • Always check Inlet water for Oil & Grease content. Don’t allow exceed the limit. • Inlet Water Temp should not exceed 80 Deg.C • Do annual Media Check up and replacement as required. • Backwash the filter regularly as per Manual • Never allow corrosive liquids to pass through the Filter. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
5. LABORATORY DETAILS 5.1 LABORATORY ANALYSIS CONTENTS 1. pH 2. TURBIDITY 3. COLOUR 4. ELECTRICAL CONDUCTANCE 5. TOTAL DISSOLVED SOLIDS 6. SUSPENDED MATTERS 7. HARDNESS 8. SILICA 9. CHLORIDE 10. OILS AND GREASE 11. RESIDUAL CHLORINE 12. REAGENTS OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 1. pH: It is common practice to express hydrogen ion concentration in terms of pH. By definition the pH is the negative logarithm of hydrogen ion concentration to the base of l0. pH = ‐ log10 (H+) = log (1/H+) Ionic product of water Kw has a value of 1 x 10 ‐ 14 and in neutral water H + concentration is equal to OH ‐ concentration. Kw = H + x OH‐ = 1 x 10‐ 14 ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ (1) For neutral water = (H+) = (OH‐) = 1x10 ‐ 7 WATER TREATMENT PLANT The equilibrium represented by equation (1) occurs universally in aqueous solution regardless of the equilibrium or the solutes present. Hence equation (1) should always be satisfied. Thus the terms pH expresses the acidity or basicity of water. Neutral water has a pH of 7. pH lower than 7 indicates acidity and greater than 7 is alkaline. METHOD A – pH Indicator:
A pH indicator is a halochromic chemical compound that is added in small amounts to solution so that the pH(acidity or basicity) of the solution can be determined visually. Hence a pH indicator is a chemical detector forhydronium ions (H3O+) or hydrogen ions (H+) in the Arrhenius model. Normally, the indicator causes the colour of the solution to change depending on the pH. These commercial indicators (e.g., universal indicator and Hydrion papers ) are used when only rough knowledge of pH is necessary. METHOD B‐ PH CELL ( pH Meter): A pH meter is an electronic device used for measuring the pH (acidity or alkalinity) of a liquid (though special probes are sometimes used to measure the pH of semi‐solid substances). A typical pH meter consists of a special measuring probe (a glass electrode) connected to an electronic meter that measures and displays the pH reading. This is containing a pair of electrodes. The sample to be tested is poured into this cell. There are many forms of cell. There are several satisfactory commercial models. Operators, less they have adequate facilities, would be well advised to purchase a readymade instrument. P
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 2. TURBIDITY OUTLINE OF THE METHOD The sample is matched against standard suspensions of fullers earth in water. TERMINOLOGY For the purpose of this test, the following definition shall apply. Scale Unit ‐ Turbidity imparted by 1 mg of fullers earth when suspended in 1000 ml of distilled water. PREPARATION OF TURBIDITY STANDARDS Mix slowly with constant stirring 5.000 g of fullers earth previously dried and shifted through 75 micron IS Sieve with distilled water and dilute it to 1000 ml. Agitate intermittently for one hour and then allow to stand for 24 hours. Withdraw the supernatant liquid without disturbing the sediment. Vaporate about 50 ml of the removed liquid, dry the residue at 105 + 2 Deg. C and weigh the residue to determine the amount of clay in suspension. Prepare turbidity standards with this standardized stock suspension with distilled water. A drop of saturated mercuric chloride solution may be added as preservative. The standards are stable for three months. PROCEDURE Pour the sample after thorough shaking into a clear glass bottle of suitable capacity, say 1 lit. Compare it with the turbidity standards contained in similar bottles, holding them against a suitable background and using a source of light which illuminates them equally and is placed so that no rays reach the eye directly. The sample and the standards shall be shaken simultaneously immediately before comparison. If the sample has turbidity over 100 units, dilute it with distilled water before testing and multiply the result with an appropriate factor. NOTE Comparison of turbidity may also be done with the help of suitable instruments. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 3. COLOUR OUTLINE OF THE METHOD The colour of the sample is matched against a series of standards containing potassium chloroplatinate and cobalt chloride. TERMINOLOGY For the purpose of this test, the following definitions shall apply: True Colour
Colour due to substances in solution, after removal of suspended matter.
Apparent Colour
Colour due to substances which are in solution as well as in suspension. Colour obtained in a mixture containing either on milligram of Patinum or
Hazen Unit
2.49 mg of potassium chloroplatinate along with 2 mg of cobalt chloride (CoCl2.6H2O) in 1 litre of the solution.
APPARATUS Nessler Tubes ‐ Flat‐bottom tube of thin colourless glass. Two types of tubes are required. The longer tubes shall be 45 cm tall and 2.5 cm in internal diameter. The shorter tubes shall be 30 cm tall and 1.7 cm in internal diameter. Tubes of any one type shall be identical in shape, and the depth measured internally from the graduation mark to the bottom shall not vary by more than 2 mm in the tubes used. REAGENTS Platinum or Potassium Chloroplatinate Aqua Regia ‐ prepared by mixing one part by volume of concentrated nitric acid (conforming to IS: 264‐1950) with three parts by volume of concentrated hydrochloric acid (conforming to IS: 265‐ 1962). Cobalt Chloride‐Crystalline, with the molecular composition CoCl2.6H2). TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 PROCEDURE PREPARATION OF COLOUR STANDARDS Dissolve 0.500 g of metallic platinum in aqua regia and remove nitric acid by repeated evaporation to dryness on water bath after addition of excess of concentrated hydrochloric acid (conforming to IS:265‐1962). Dissolve the residue with 1.0 g of cobalt chloride in 100 ml of concentrated hydrochloric acid to obtain a bright solution, if necessary by warming. Dilute the solution to 1000 ml with distilled water. This stock solution has a colour of 500 Hazen units. A more convenient way of preparing the same solution is by dissolving 1.245 g of potassium chloroplatinate and 1.0 g of cobalt chloride in distilled water and diluting to 1 litre. Prepare a set of colour standards having colour 5, 10, 15, 20, 25, 30, 35, 40, 50, 60 and 70 Hazen units by diluting the stock solution with water. Protect these colour standards from evaporation and contamination when not in use. The colour standards shall be freshly prepared for each determination. But in routine practice, they may be used repeatedly, provided they are protected against evaporation and contamination when not in use. PROCEDURE FOR CLEAR SAMPLES For samples having turbidity under 5 mg/l, match the colour of the sample against the standard colours in the longer Nessler Tubes. Fill the tubes to mark and compare the colour by looking vertically downwards against a pure white surface. If the colour is found to exceed 70 units, dilute the sample with distilled water before comparison and multiply the result by appropriate factor. As matching is very difficult when the colour of the sample is below 5 Hazen units, report the colour as less than 5 Hazen units in such cases. When the colour of the sample exceeds 30 Hazen units, the comparison may, if desired, be made in the shorter Nessler tubes. TREATMENT PLANT PROCEDURE FOR TURBID SAMPLES If the sample has turbidity over 5 mg/l it becomes impossible to measure the true colour accurately by the method prescribed in PROCEDURE for clear samples and if an attempt is made, the value found shall be reported as "apparent colour". In the presence of turbidity, the true colour shall be determined after centrifuging. The sample shall be centrifuged until the supernatant liquid is clear. The centrifuged clear sample shall be compared by the method prescribed in PROCEDURE for clear samples. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 NOTE For estimating true colour, filter paper shall not be used since that leads to erroneous results. REPORT The results of colour determination shall be excess in whole numbers and shall be recorded as follows: Hazen Units Less than 5 Reports as "Less than 5 Hazen Units" 5 to 50 Reports to the nearest 1 Hazen Unit 51 to 100 Reports to the nearest 5 Hazen Unit 101 to 250 Reports to the nearest 10 Hazen Unit 251 to 500 Reports to the nearest 20 Hazen Unit NOTE The colour determination shall be made as early as possible after the collection of samples as certain biological change occurring in storage may affect the colour. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 4. ELECTRICAL CONDUCTANCE GENERAL The unit of conductance is the mho or reciprocal ohm. Specific conductivity is the conductance at a specified temperature across a column of a liquid 1 cm2 in area and 1 cm long, and is expressed mhos per centimeter. This is an inconveniently large unit for water testing and it is usual to use the micromho per centimeter known as the "dionic unit", which is one‐millionth part of a mho per centimeter. APPARATUS Several kinds of apparatus are available. They generally consist of two parts. CONDUCTIVITY CELL This is containing a pair of electrodes. The sample to be tested is poured into this cell. There are many forms of cell. One of the most convenient types is provided with a funnel for filling, a drain for emptying, and an overflow for maintaining constant level. Electrodes for use with samples having very low dissolved solids (such as condensates) should not be coated with platinum black. Platinum black which has been heated to redness until it is grey is suitable. Bright platinum or gold or heavily gold plated electrodes may be used. Some instruments are designed to work with particular form of conductivity cell, and are then calibrated directly in conductivity units. Other instruments, primarily introduced for more general application, are calibrated on conductance units and their readings require multiplication by a factor known as the "cell‐ constant" which shall be determined by experiment. Measuring Instrument ‐ For measuring the electrical conductance (or the resistance which is the inverse of conductance) between the electrodes of the cell. There are several satisfactory commercial models. Operators, less they have adequate facilities, would be well advised to purchase a readymade instrument. TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 PROCEDURE Determine the cell constant if necessary, either directly with a standard potassium chloride solution (say 0.002 N) or by comparison with a cell the constant of which is known accurately. (In the latter case, the concentration and nature of the electrolytes in the liquid which is used for the comparison should be the same and should be similar respectively to those of the liquids with which the cell is likely to be used in practice). Use some of the samples to wash out the conductivity cell thoroughly. Fill the conductivity cell with the sample. Calculations FOR INSTRUMENT READING RESISTANCE : 1 x 106
Electrical conductance, in dionic units (or micromhos per centimetre) = rk Where r = Resistance in ohms, and k = Cell constant FOR INSTRUMENT READING CONDUCTANCE : Electrical conductance, in dionic units (or micromhos per centimetre) = ck Where c = conductance in micromhos, and k = cell constant CORRELATION OF ELECTRICAL CONDUCTANCE TO TOTAL DISSOLVED SOLIDS For water containing a given mixture of mineral salts, the electrical conductance is closely proportional to the dissolved solids. When the samples are known to be free from wide fluctuation in mineral content, the electrical conductance offers a quick means of computing the total dissolved solids. Electrical conductance Dissolved Solids TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 5. TOTAL DISSOLVED SOLIDS (TDS) A well mixed filtered sample is evaporated in a weighed dish and dried to constant weight in an oven at 103 to 105 Deg. C. The increase in weight over that of the empty dish represents the total residue. APPARATUS 1. Silica or porcelain dish of 100 ml capacity 2. Desicator 3. Oven PROCEDURE Ignite the clean evaporating dish at 550 + 50 Deg. C for 1 hour. Cool, desiccate and weigh. Transfer the measured sample to the pre weighed dish and evaporate to dryness on a steam bath. Choose a sample volume that will yield a minimum residue of 25 mg to 250 mg. If necessary, add successive portions of sample to the same dish. Dry the evaporated sample for at least 1 hour at 103 to 105 Deg.C. Cool the dish in a desiccators and weigh. Repeat the cycle of drying, cooling and weighing until a constant weight is obtained. Calculations Wt of residue x 1000 Total dissolved solid, mg/L = ml. of sample taken OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 6. SUSPENDED MATTERS Suspended matter is the material retained on filter after filtration of a well mixed sample of water. The residue is dried at 103 to 105 Deg. C. APPARATUS 1. Gooch crucible 2. Silica or porcelain evaporating dish of 100 ml capacity 3. Desiccators 4. Oven adjustable to constant temp of 103 ‐ 105 Deg. C. 5. Water batch PROCEDURE Prepare a gooch crucible with asbestos (20 to 30 ml of 0.5% suspension of gooch asbestos added and washed under suction), dry and ignite at 500 Deg. C for at least 30 minutes, cool and weigh. Filter a suitable volume of the well mixed sample through the crucible. Wash with distilled water, dry at 105 Deg. C for one hour. Weigh. Calculations W x 106 Suspended matters in mg/L = V Where, w = wt. in g of the suspended matter V = vol. in ml. of the sample taken for filtration NOTE If Gooch Crucible is not available, standard "Whatman" filter paper may be used. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 7. HARDNESS Hardness in water is due to the presence of bicarbonates, chlorides and sulphates of calcium and magnesium. Temporary hardness is due to the presence of bicarbonates and permanent hardness due to the presence of chlorides and sulphates. Sometimes, hardness may include iron, aluminum, zinc, manganese, etc. METHOD A ‐ OMPLEXAMETRIC METHOD (EDTA METHOD) EDTA forms a chelated soluble complex when added to a solution of certain metal ions. If a small amount of EBT is added to an aqueous solution containing calcium and magnesium ions at pH of 10.0 + 0.1, the solution will become red wine. If EDTA is then added as a titrant, the calcium and magnesium will be complexes. After sufficient EDTA has been added to complex all the calcium and magnesium, the solution will turn blue from red wine. REAGENTS 1. Ammonia buffer of pH 10. 2. M solution of disodium salt of ethylenediamine tetra acetic acid. 3. Eriochrome black T indicator solution. PROCEDURE Take 50 ml of sample in an Erlenmeyer flask; add 4 to 6 drops of Eriochrome black T indicator solution. Add 1 ml of buffer solution and mix. Titrate immediately with EDTA solution till the colour changes from red to blue. Calculations: Total hardness as CaCO3 mg/lit = Vol. of 0.01 M EDTA solution x 1000 ml of sample ATER TREATMENT PLANT NOTE For checking hardness in soft water use 500 ml of the sample into 750 ml evaporating dish and add 3 ml of buffer solution followed by 10‐12 drops of indicator solution. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 METHOD B SOAP SOLUTION METHOD FOR HARDNESS TESTING This is a quick method for checking hardness of treated water or an accurate determination of the hardness of treated water, EDTA method for hardness should be used. REAGENTS 1. “B” soap solution 2. 40 ml shaking bottle PROCDURE Take water sample up to 40 ml mark in shaking bottle. Add 10 drops of the "B" soap solution. Shake vigorously. If lather is obtained which will last for 1 to 2 minutes, the water is soft. If no lather is obtained, or if the lather does not last, the water is hard. NOTE 1. Rinse the shaking bottle clean with soft water thoroughly. 2. The soap solution bottle should be kept tightly stoppered. It will otherwise evaporate and give false reading. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 CALCIUM HARDNESS The water sample is titrated against EDTA solution using Murexide indicator (ammonium purpurate) in highly alkaline medium. REAGENTS 1. Approximately 1 N sodium hydroxide solution 2. 0.01 M standard EDTA solution 3. Murexide indicator PROCEDURE: Prepare a colour comparison blank in a white porcelain basin by stirring 2.0 ml of 1 N. NaOH, 0.2 g solid indicator mixture (or 4 to 6 drops of indicator solution) into 50 ml of distilled water and sufficient EDTA titrant (0.05 to 0.1 ml) to produce an unchanging purple colour. Pipette into a similar basin 50 ml. of sample, neutralize the alkalinity with 0.02 N. HCl, boil for 2 to 3 minutes to expel the CO2 and cool to room temperature. Add 2.0 ml 1 N NaOH, or a volume sufficient to produce a pH of 12 to 13 and mix. Add 0.2 g of powdered indicator. Stirring constantly titrate with standard EDTA solution to the colour of comparison blank. Check the end point by adding 1 or 2 drops of titrant in excess to be sure that no further deepening of the purple colour takes place. Calculations Calcium, as CaCO3, mg/L = (A ‐) x C x 1000 ml of Sample Where A = ml of EDTA required for titration of sample B = ml of EDTA required for blank C = mg of CaCO3 equivalent to 1.0 ml of EDTA NOTE: The only serious interference with the EDTA titrant of calcium is that of orthophosphate ion. If the calcium hardness exceeds about 60 ppm CaCO3, and the concentration of orthophosphate is 10 ppm, or more, calcium phosphate is precipitated when the pH is raised to 12, giving low results. Phosphate, if present, can be removed by ion exchange. WATER TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 8. SILICA The silica content of natural water will vary to a considerable extent depending on the locality. The presence of silica is particularly objectionable in water used for boiler feed purpose as it may lead to the formation of hard dense scale. In addition, a very serious problem encountered in high pressure operations is the deposition of siliceous materials on turbine blades & super heaters. The gravimetric method is the standard applicable above 20 mg / lit SiO2 content. This method should be followed for standardization of standard silicate solution used in colorimetric methods. The heteropoly blue colorimetric method is adaptable for the range of 0 to 2 mg / lit SiO2 & yellow molyb silicate method in the range of 0 to 20 mg / lit. Reagent blank should always be used in all the three methods. METHOD A ‐ GRAVIMETRIC METHOD PROCEDURE Take a sample to contain at least 10 mg of SiO2 . If necessary clarify by filtration. Acidify with 2 or 3 ml of conc. HCl & evaporate to dryness in a platinum dish on a water bath. At regular intervals add 2 or more portions of 2 to 3 ml of conc. HCl as an additional quantity of sample is added to the dish. Bake the evaporated residue in an oven ad 110 Deg. C for about an hour. Add 5 ml. of conc. HCl warm & add 50 ml distilled water. Loosen the clinging residue from the sides & the bottom of the dish & filter collecting the filtrate. Wash the dish & residue with hot 1 : 50 HCl & finally with distilled water until the washings are free from chloride. Return the filtrate & washings to the platinum dish & again evaporate to dryness. Repeat as previously, collecting the residue in another filter paper. Dry the two filter papers with residue, burn, ignite at 1000‐1200 Deg.C in a platinum crucible & weigh. Moisten the residue with a few drops of distilled water; add 2 drops of H2SO4 & 10 ml. 48% HF. Cautiously evaporate to dryness on a steam bath in a fume cupboard. Again ignite at 1000‐1200 Deg.C Cool & weigh. Carry out a blank. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Calculations ( A ‐ B ) ‐ ( C ‐ D ) x 1000 SiO2 , as SiO2 mg / lit = ml of sample Where A = Weight of crucible & sample residue in mg. after first ignition B = Weight of crucible & sample residue in mg. after HF treatment & second ignition. C = Weight of crucible & blank residue in mg. after first ignition D = Weight of crucible & blank residue in mg. after HF treatment & second ignition. METHOD B ‐ REACTIVE SILICA COLOMETRIC ESTIMATION OF SILICA Ammonium molybdate at approximately pH 1.2 reacts with silica & any phosphate present to produce hteropoly acids. Oxalic acid is added to destroy the molybdophosphoric acid but not the molybdosilicic acid. Even if phosphate is known to be absent, the addition of oxalic acid is highly desirable & is a mandatory step. The intensity of the yellow colour is proportional to the concentration of molybdate‐ reactive silica. The yellow molybdosilicic acid is reduced by means of 1 Amino ‐ 2‐ naphthol ‐ 4 ‐ sulphonic acid to heteropoly‐ blue. The blue colour is more intense than the yellow colour & provides increased sensitivity. In at least one of its forms , silica does not react with molybdate even though it is capable of passing through filter paper & is not noticeable turbid. The presence of such a molybdate unreactive silica is undesirable in raw water .It will not be removed in the water treatment plant & will find its way to highly pressure stream system, where it will be converted to “molybdate‐reactive " silica. Such increase in silica content will give rise to scale problem. PLANT Chromate & large amounts of Fe, PO4, sulphide, tannin, colour & turbidity are potential interferences. Oxalic acid treatment suppresses PO4 & reduces tannin interference. Inorganic sulphide can be removed by boiling an acidified sample. The addition of 1 ml. of 1% EDTA solution after molybdate reagent overcomes high Fe & Ca concentrations. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 COLORIMETRIC ESTIMATION OF SILICA ‐ 0‐ 20 PPM SiO2 REAGENTS 1. Ammonium molybdate solution 2. 2 N sulphuric acid 3. 10 % oxalic acid 4. Lovibond comparator with standard silica disc. PROCEDURE 1. Fill one of the Nessler tubes to the 50 ml. mark with sample & place in the left hand compartment of Lovibond comparator. 2. Fill the other Nessler tube with 50 ml. of sample at 25 ‐ 30 Deg.C Add 2 ml. of acidified ammonium molybdate solution. Mix thoroughly, adds 4 ml. of oxalic acid & again mix thoroughly. Place in the right hand compartment & allow to stand for 10 minutes. 3. Stand the comparator facing a uniform source of light; compare the colour of the sample in the disc. Rotate the disc until the colours are matched. Calculations SiO2 in mg / lit as SiO2 = Disc reading x 20 NOTES 1. Should the colour in the test solution be deeper than the deepest standard , a fresh test should be carried out using a smaller quantity of sample & diluting to 50 ml. with distilled water before adding the REAGENTS. TREATMENT PLANT 2. Silica free water : 3. Distilled water from an all ‐ metal "Still " or water which has been passed successively through a mixed bed deionization unit & strongly basic anion exchanger such as Tulsion A27MP unit regenerated with a regeneration level of 320 gm per liter NaOH has been found to be suitable. Prepare & store in a polyethylene bottle a large batch of water containing not more than 0.005 ppm SiO2, determine the silica content of water by treating it as a sample. This water is used to prepare reagents & standards, & to dilute samples when necessary. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 COLOMETRIC ESTIMATION OF SILICA 0‐2 PPM SiO2 REAGENTS 1. Acidified ammonium molybdate solution. 2. 10 % oxalic acid. 3. Amino ‐ naphthol reducing agent. 4. Lovibond comparator with standard silica disc or spectrophotometer suitable for measurement at 815 micro siemens wave length. PROCEDURE 1. Fill one of Nessler tubes to the 50 ml. Mark with sample, & place in the left hand compartment of Lovibond comparator. 2. Fill the other Nessler tube with 50 ml. of sample, at 25 ‐30 Deg.C. Add 2 ml. of acidified ammonium molybdate solution. Mix thoroughly, stand for 5 minutes. Add 4 ml of oxalic acid & mix well. Then 2 ml. of reducing agent, mix well compared with that of a blank comprising the same water without reagents, using Lovibond comparator or read the absorbance using a spectrophotometer (wave length 815 micro siemens). Compute the silica content from the standard graph prepared from the standard silica solution. TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 METHOD C : DETERMINATION OF TOTAL SILICA (MOLYBDATE REACTIVE & UNREACTIVE SILICA) The molybdate unreactive silica is converted to the reactive form or state by digesting the sample with sodium bicarbonate. REAGENTS 1. Sodium bicarbonate. 2. 1 N sulphuric acid. 3. Other reagents as per previous method. PROCEDURE Take 100 ml. of sample or lesser quantity ( 20 ‐ 100 micrograms SiO2 ) but made up to 100 ml. distilled water in a platinum dish. Add 200 mg. of silica free sodium bicarbonate & digest on a stream bath for one hour. Cool & add slowly, with stirring, 2.5 ml. sulphuric acid ( 1 N ) . Do not interrupt the analysis but proceed at once with the remaining steps. Transfer quantitatively into a plastic container. For development of colour & CALCULATIONS refer the previous procedure. TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 9. CHLORIDE METHOD A ‐ SILVER NITRATE METHOD Chloride is determined by titration with std. silver nitrate solution in the presence of potassium chromate indicator at neutral Ph. Silver chloride is precipitated and at the end point red silver chromate is formed. REAGENTS 1. N Std. silver nitrate solution 2. Potassium chromate indicator 3. Phenolthalein Indicator solution 4. N Nitric Acid solution 5. Calcium carbonate PROCEDURE Take 50 ml. or 100 ml of sample in an Erlenmeyer flask. Add five drops of phenolthalein. If the sample turns pink, Neutralize with 0.02 N Nitric acid. If Acidic (as in the case of decationised water) add a small amount of A.R. calcium carbonates. Add 1 ml of potassium chromate indicator and titrate with std. silver nitrate solution with constant. Stirring until there is perceptible reddish colour. Subtract 0.2 ml. from titration fig. to allow for the excess of reagents required to form silver chromate. Calculation Chloride as CaC03 mg/lit = ml of AgN03 * 1000 ml of sample taken NOTE 1. If sample is highly coloured, add Al(OH)3 suspension, mix then let it settle , filter and combine filtrate and washing 2. If sulphide, sulphite and thiosulfate are present, add 1ml H2O2 and stir for 1 Min. 3. Bromide, iodide and cyanide register as Eqvt. Chloride concentration. WATER TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 METHOD B Chloride ion can be titrated with mercuric nitrate because of the formation of soluble, slightly dissociated mercuric chloride. In the Ph range 2.3 to 2.8 diphenylcarbozone indicates the end point of this titration by formation of purple complex with excess of mercuric ions. To keep the solution in Ph range +/‐ 0.1 Ph unit nickel nitrate with HNO3 is added. REAGENTS 1. 0.02 N Mercuric nitrate Std. solution 2. Diphenyl‐carbozone indicator solution 3. 4 M nickel nitrate solution PROCEDURE Take 50 ml. of sample, add 1 ml. of diphenylcarbozone indicator solution. Add 1 ml. of nickel nitrate solution. Titrate against Std. mercuric nitrate solution to colour change of green to violet. Carry out blank titration with DM Water. Calculation: Chloride as CaCO3 mg/lit = (A ‐ B ) * 1000 ml. of sample Where A = ml of titrant required for sample B = ml of titrant required for blank. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 METHOD C ‐ CHLOROMETRIC METHOD FOR CHLORIDE (MERCURY THIOCYNATE METHOD) This method depends upon the displacement of thiocynate ion from mercuric thiocynate by chloride ion. In the presence of ferric ion, a highly coloured ferric thiocynate complex is formed and the intensity of its colour is proportional to the original chloride ion concentration. WATER TREATMENT PLANT REAGENTS 1. Mercuric thiocynate solution 2. Ferric ammonium sulphate solution 3. Std. sodium chloride solution ‐0.1 mgCl / ml. PROCEDURE Take 10‐20 ml of water sample containing about 40 micrograms of chloride in a 25 ml. std. flask. Add 2.0 ml of ferric ammonium sulphate solution, followed by 2.0 ml of mercuric thiocynate solution. Make up to the volume. Measure the optical density at 460 micro siemens from the calibration curve for the Std., compute the value for the sample. Calculation Chloride, as CL mg /lit = Microgram of chloride from graph ml. of sample TREATMENT PLANT LANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 10. OILS AND GREASE OUTLINE OF THE METHOD The oils & grease are extracted by an organic solvent. The solvent is distilled off & the weight of the extracted matter is determined. Some extractable, especially unsaturated fats & fatty acids Oxidize rapidly hence, special precautions regarding temperature & solvent vapour displacement are necessary to minimise this effect. SAMPLING The most satisfactory method of sampling two ‐ phase liquids is to use a sampling tube that is capable of withdrawing a complete section of the water as it flows in a rectangular culvert or trough, in most instances, however, water will have to be sampled from the outfall of the pipe or from a stream & in these circumstances some of the water should first be collected in a large cylindrical vessel having a capacity of 10 to 15 litres. A sectional sampling tube should be used to withdraw the test sample from this. A sampling tube suitable for sampling water, that don’t contain highly viscous matter (for example, tar) consist of a heavy ‐ gauge brass tube, 1m. long, with an outside diameter of 40 mm. Over one end of the tube is fitted to the brass bucket made from a piece of tube 50 mm. long & sealed at one end. The bucket has an internal diameter of 1.5 mm. greater than the outside diameter of the main tube. To the opposite sides of the bucket, are braced two brass rods, 6mm. in diameter, which pass through guides braced to sides of the main tube. The rods are so arranged that the top of the bucket can be withdrawn to a distance of not less than 10 cm. from the bottom of the main tube, & they guide the bucket into a position covering the end of the tube when it is pushed back again. A suitable spring catch is provided on one of the guide rods so that the bucket is automatically locked into the top position when it is raised to its highest point. The open end of the sampling tube is fitted with a rubber bung. To take a sectional sample, the spring catch is released & the bucket is drawn as far away as possible from the end of main tube. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 The rubber bung is withdrawn from the other end. The tube is lowered vertically through the liquid to the sampled until the bottom of the bucket rest on the bottom of the culvert ANT or of the vessel that has been filled with the water. The main tube is then pushed down, guided by the brass rods, to the limits of his travel, whereupon the spring catch locks the bucket in the raised position covering the end of the tube. The rubber bung is tightly inserted in the open end & the tube is withdrawn. The outside of the sampler is wiped free of adhering liquid the bucket & the lower part of the tube are inserted In to a wide mouthed bottle of suitable capacity, & the rubber bung is removed. The sample section of the liquid will flow into the bottle leaving a small quantity of liquid in the bucket. The tube is then tilted, so that this liquid is added to the main bulk of the sample. The operation is repeated until sufficient quantity has been collected. At least 24 ‐ 25 mm. of air space should be left between the top level of the liquid & the stopper of the bottle. STORAGE OF SAMPLE Since many oils & hydrocarbons are utilised by bacteria, storage is obviously detrimental. However, if it becomes necessary to store the sample before analysis is taken up, the samples should be acidified with dilute sulphuric acid (1 : 1), 5 ml / lit., of the sample, to inhibit bacterial activity. APPARATUS SEPARATING FUNNELS Of 1.5 to 2 litres capacity. The stopper or stop cock should not be lubricated with matter soluble in petroleum ether. REAGENTS 1. Dilute Hydrochloric acid ‐ 1 : 1 2. Light Petroleum (Petroleum ether) ‐ boiling range 40 to 60C. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 PROCEDURE Place the sample, usually 1 litre, in a separating funnel of sufficient size to allow the addition of acid & solvent, & still have space for proper agitation. Acidify the sample with dilute hydrochloric acid, 5 ml /lit, of the sample. Rinse the sample bottle carefully with 15 ml. of petroleum ether & add the ether washings to the separating funnel. Add an additional 25 ml. of ether to the sample bottle, rotate the ether in the sample bottle & add the ether to the separating funnel. Shake vigorously for 2 minutes. Allow the ether layer to separate. Withdraw the aqueous portion of the sample into a clean container, & transfer the solvent layer into a clean, tarred distilling flask capable of holding at least 3 volumes of solvents (See Note). If a clear ether layer cannot be obtained, filter the solvent layer into tarred distilling flask through a funnel containing an ether moistened filter paper. The filter paper should be washed with petroleum either after folding to avoid inclusion of skin oils. Use a small funnel and filter paper as practical. NOTE While transferring the solvent layer from the separating funnel, a small quantity of it remains at the stem of the separating funnel, it is advisable to wash it with a few milliliters of solvent and to add the washings to the solvent layer. Return the aqueous portion of the sample to the separating funnel, rinsing the container with 15 ml. of ether. Add the ether washings and additional 25 ml. of ether to the separating funnel and agitate for about 2 Min. allow the solvent layer to separate and discard the aqueous phase. Add the ether washings to the tarred distilled flask . After all the ether from the 2 extractions and the final rinsing are included wash down the funnel and filter paper twice with fresh 5 ml. increments of the petroleum ether. Distil of all but approx. 10 ml. of the ether extract on a water batch or an electric heating mantle, observing necessary safety precautions and keeping the heat source at about 70 Deg c. Disconnect the condenser and boil of the remaining the solvent from the tarred flask at the same temp. Dry on a water bath or stream bath. When dry, lay the flask on its side to facilitate the removal of solvent vapour. Introduce Aprrox. 3 volumes of dry illuminating gas or Nitrogen into flask to displace solvent vapour. Cool in desiccator for 30 Min. and weigh. TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Calculation Oils and grease, mg/lit =
1000 W V
Where, W = weight in Mg. of the residue in the flask V = volume in ml. of the sample taken for the test. Express the result to the nearest Mg OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 11. RESIDUAL CHLORINE (ORTHOTOLYDINE ‐ ARSENI METHOD) Chlorine rapidly oxidises ortholydine (3,3‐dimethybenzdine) to the corresp. hologuinone which is intensely yellow. This provides a sensitive test for available chlorine. The test is subject to interference by production of false colour for chlorine when nitrite, iron or manganese is present in the water. The false colour produced with orthotoludine by interfering substance present in the presence of sodium arsenite but the colour due to residual chlorine does not. The test permits the measurement of the relative amounts of free available chlorine, combined available chlorine, and colour due to interfering substances. The temperature of the sample should never be above 20deg C. REAGENTS 1. Phosphate buffer solution ‐0.5% 2. Potassium dichromate solution 3. P‐Tolydine reagent 4. 5 % sodium arsenite solution PROCEDURE 1. VISUAL STANDARDS Pipette into 100 ml. Nessler cylinder 1,2,3 etc. ml of dilute chromate‐ dichromate solution an dilute to 100 ml with phosphate . Protect the solutions from dust, evaporation and direct sunlight. These Stds. correspond to residual chlorine Eqvt. Of 0.01, 0.02 ,0.03.... mg/lit Resp. 2. FREE AVAILABLE CHLORINE In a nessler tube take 0.5 ml of Toludine reagent and 9.5 ml of sample. Mix quickly and thoroughly and add 0.5 ml of NaAS02 followed by mixing. Compare the colour with Std. (Call this reading as A). 3. TOTAL AVAILABLE RESIDUAL CHLORINE In a nessler tube take 0.5 ml of 0‐Toludine reagent and 9.5 ml of sample, mix and compare the colour with standards colour in similar tube after 5 Min. (Call this reading as B). OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 4. BLANK Prepare a blank 9.5 ml sample and 0.5 ml NaAS02 solution and compare the colour with std. colour immediately and after 5 Min. (Call this reading as C1 and C2). Calculation Free available residual chlorine = Reading A ‐ Blank C1 Combined available residual chlorine = Reading B ‐ Blank A Total available residual chlorine = Reading B ‐ Blank C2 WATER TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 12. REAGENTS 1. STANDARD 1 N HCL SOLUTION Dilute 83 ml. of conc. HCL (about 11 N solution, specific gravity 1.174‐1.189 ) to 1lit. With distilled or deionised water . Standardise with standard sodium carbonate solution. 2. STANDARD 0.1 N HCL SOLUTION Dilute 8.3 ml. of conc. Hcl or 100 ml. of 1 N solution to 1000 with distilled water. Standardize with standard sodium carbonate solution. 3. STANDARD 0.02 N Hcl SOLUTION. Dilute 200 ml. of 0.1 N standard acid to 1000 ml. with distilled water. Standardize with standard sodium carbonate solution 4. STANDARD 1 N H2SO4 SOLUTION Dilute 28 ml. of conc. H2SO4 (about 36 N solution, specific gravity 1.834‐1.836 ) to 1lit. With distilled or deionised water. Standardise with standard sodium carbonate solution. 5. STANDARD 0.1 N H2SO4 SOLUTION Dilute 2.8 ml. conc. H2SO4 to 1 lit. with distilled or deionised water. Standardize with standard sodium carbonate solution. 6. STANDARD 0.02 N H2SO4 SOLUTION Dilute 200 ml. of 0.01 N H2SO4 to 1 lit. with distilled or deionised water. Standardize with standard sodium carbonate solution. 7. 1.0 N HNO3 SOLUTION Dilute 64 ml. of conc. HNO3 (about 15 N solution, specific gravity 1.409‐1.418 ) to 1lit. with distilled or de ionized water. Standardize with standard sodium carbonate solution. 8. STANDARD I.0 N NAOH SOLUTION Dissolve 40.0 gm. of NAOH to 1.0 lit. with carbon dioxide free distilled or deionised water . Standardize with standard acid solution. 9. STANDARD 0.1 N NAOH SOLUTION Dissolve 4.0 gms of NAOH to 1.0 lit. with carbon dioxide free distilled or deionised water. Standardise with standard acid solution. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 10. STANDARD SODIUM CARBONATE SOLUTION (Approx. 0.05 N ) Dry 3 to 5 g primary standard Na2CO3 at 250 deg C for 4 hours & cool in a desicator . Weigh 2.5 +/‐ 0.2 gms (to the nearest mg. ) Dilute to 1litre with deionised or distilled water. 11. STANDARD 0.02 N SILVER NITRATE SOLUTION. Dissolve 3.3927 gms. AgNO3 in distilled water & dilute to 1 lit. Standardise against 0.02 N NaCl standard solution. 12. STANDARD 0.02 N SODIUM CHLORIDE SOLUTION Dry 2‐3 g of primary standard NaCl at 140 deg C for 4 hours & cool it in a desicator. Weigh 1.689 gms (to the nearest mg. ) Dilute to 1litre with deionised or distilled water. 13. STANDARD 0.02 N MERCURIC NITRATE SOLUTION Dissolve 3.246 gm. mercuric nitrate in 100 ml of 5% HNO3 solution and make up to 1 lit. with D.M. water. Standardise with standard sodium carbonate solution. 14. STANDARD MERCURIC THIOCYANATE SOLUTION Weigh 1 gm Hg(SCN)2 & add 100 ml methanol & mix to obtain a saturated solution. Stored a amber bottle in a cool place. 15. FERRIC AMMONIUM SULPHATE Dissolve 12 g of Fe (NH4)2(SO4) 212H2O in 100 ml of 9 N HNO3 (580 ml. of conc. HNO3 in 1 lit. of water). Filter if necessary & store in a amber bottle. 16. 0.1 MG/LIT. STANDARD CHLORIDE SOLUTION Dissolve 1. 1648 g NaCl in 1 lit. of distilled or deionised water. 17. AMMONIA BUFFER OH pH 10 Dissolve 16.9 g of ammonium chloride in 143 ml. conc. ammonium hydroxide (NH4OH). Add 1.25 g of magnesium salt of EDTA. (If the magnesium salt of EDTA is unavailable dissolve 1.179 g disodium salt of EDTA & 780 mg. MgSO4.7H2O or 644mg. MgCl2.6H2O in 50 ml. distilled water.) & dilute to 250 ml. with distilled water. 18. STANDARD 0.01 M SOLUTION OF EDTA Dissolve 3.723 g of disodium salt of EDTA in 1 lit. of distilled or deionised water. Standardise with standard calcium solution. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 19. STANDARD CALCIUM SOLUTION Weigh 1 gm anhydrous calcium carbonate into a beaker, add a little at a time, dilute Hydrochloric acid until CaCO3 has dissolved. Wash down the beaker with carbon dioxide free water & makeup to 1 lit. 1 ml. of the solution contains 1mg of sulphates (as SO4) 20. STANDARD BARIUM CHLORIDE SOLUTION Dissolve 2.443 g of barium chloride (BaCl2, 2H2O) in distilled water & dilute to 1 lit. 1 ml. of this solution is equivalent to 0.36 mg. of sulphate (as SO4). 21. STANDARD POTASSIUM IODATE ‐IODATE SOLUTION Weigh accurately 0.713 g of potassium iodate & dissolve in about 150 ml. of distilled water. Add 7 g of potassium iodate & 0.5 g of sodium bicarbonate ,when dissolved, dilute the solution to exactly 1 liy. 22. STANDARD IRON SOLUTION Dissolve 1.404 g of ferrous ammonium sulphate Fe(NH4)2(SO4)2, 6H2O in 50 ml. distilled water & 20 ml. conc. H2SO4. Add 0.1 N KMNO4 dropwise to impart a faint but persistent pink colour & dilute to 1 lit. with distilled eater. Dilute 50 ml. of the above stock solution to 1 lit. with distilled water to form a standard solution containing 0.01 mg. fe/ml. 23. 1,10 PHENANTHROLINE MONOHYDRATE SOLUTION Dissolve 0.1 g in 100 ml. distilled water containing 2 drops conc. Hcl . (Not more than 0.1 mg. Fe can be determined). 24. AMMONIUM ACETATE BUFFER SOLUTION Dissolve 250 g of ammonium acetate in 150 ml. distilled water, add 700 ml. glacial acetic acid & dilute to 1 lit. 25. AMMONIUM MOLYBDATE SOLUTION FOR SILICA ESTIMATION 75 g of ammonium molybdate is dissolved in 500 ml. of distilled water. To 322 ml. of 10 N sulphuric acid the molybdate solution is added gradually with constant stirring. The solution is made upto 1 lit. 26. 10% OXALIC ACID Dissolve 10 gms. oxalic acid in 100 ml. of distilled water. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 27. AMINO NAPHTHOL REDUCING AGENT Dissolve 0.5 g of 1 amino‐2‐naphthol‐4sulphonic acid & 1gm. of sodium sulphite (Na2SO3) in 50 ml. distilled water, with gentle warming if necessary, add this to solution of 30 g sodium metabisulphite (NaHSO3)in 150 ml. distilled water. Filter into plastic bottle. Dicard the solution when it becomes dark. prolong reagent life by sorting in a refrigerator. 28. STOCK SILICA SOLUTION Dissolve 4.73 g of sodium metasilicate nonhydrate (Na2SiO3, 9H2O) in recently boiled & cooled water & dilute to approx. 900 ml. Analyse 100.0ml. portions by gravimetric method, adjust the remainder of the solution to contain 1.000 mg./1SiO2. Store in a tightly stoppered plastic bottle. 29. STANDARD SILICA SOLUTION Dilute 10 ml. stock solution to 1 lit. with recently boiled & cooled water this solution contains 10 mg/lit. SiO2 or 1 ml. =10 SiO2. Store in tightly stoppered plastic bottle. 30. AMMONIUM MOLYBDATE SOLUTION FOR PHOSPHATE ESTIMATION Dissolve 25 gms. of ammonium molybdate in 175 ml. of distilled water. In another container add, cautiously to 400 ml. of distilled water, 310 ml. of conc. H2SO4. Cool it & add the molybdate solution to this distilled acid & dilute the whole to 1 lit. 31. STANNOUS CHLORIDE SOLUTION Dissolve 2.5 gms. of fresh supply of stannous chloride (SnCl2,2H2O) in 10 ml. of conc. Hcl & dilute to 100 ml. with distilled or deionised water. Filter if it is turbid. Store the solution in a cool place in a aspirator bottle having class stopcock. A 5 mm. thick layer of pure mineral oil shall be floated over the surface of the solution to minimise oxidation. Always drain out a little of solution out of the stopcock before use. 32. STANDARD PHOSPHATE SOLUTION Dissolve 0.716 g of dry potassium dihydrogen phosphate (KH2PO4) in 1 lit. of distilled water. Dilute 100 ml. of solution to 1lit. 1ml. of this solution =0.05 mg of phosphate (as PO4 ). 33. STANDARD 0.1 N POTASSIUM PERMANGANATE SOLUTION Dissolve 3.1608 g of potassium permanganate (dried at 105 deg C ) in distilled water made upto 1 lit. This solution must be stored in the dark. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 34. STANDARD 0.1 N OXALIC ACID SOLUTION Dissolve 4.5018 g of oxalic acid in distilled water, make upto 1lit. 35. PHOSPHATE BUFFER SOLUTION O.5 M (FOR FREE CHLORINE) Dissolve 22.68 g Na2HPO4 & 46.19 g KH2PO4 (both dried overnight at 105 deg C) & dilute to 1 lit. with distilled water. Let this solution age for No. of days & filter if any precipitate appears. 36. PHOSPHATE BUFFER SOLUTION 0.1 M Dilute 200 ml. of 0.5 M filtered phosphate buffer solution to 1 lit. 37. STOCK CHROMATE‐ DICHROMATE SOLUTION Dissolve 1.55 g K2Cr2O7 & 4.65 g K2CrO4 in 0.1 M phosphate buffer solution. 38. DILUTE CHROMATE DICHROMATE SOLUTION Dilute 100 ml. stock solution to 1 lit. with 0.1 M phosphate buffer solution. On dilution of 1ml. of this solution to 100 ml. with 0.1 M phosphate buffer solution gives a very close visual match with the yellow colour produced by 0.01 mg/lit. residual chlorine. 39. O‐TOLUDINE REAGENT Dissolve 1.35 g of O‐toludine dihydrogen chloride in 500 ml. distilled water & add with constant stirring to a solution of 150 ml. conc. Hcl in 350 ml. distilled water. 40. SODIUM ARSENITE SOLUTION Dissolve 5 g of sodium meta arsenite in 1lit. distilled water. 41. PHENOLPHTHALEIN INDICATOR SOLUTION Dissolve 0.1 g of phenolphthalein in 60 ml. of rectified spirit and dilute with distilled water to 100 ml. 42. METHYL ORANGE INDICATOR SOLUTION Dissolve 50 mg. methyl orange powder in distilled water & dilute to 100 ml. 43. SCREENED METHYL ORANGE INDICATOR SOLUTION Dissolve 0.2 g crystalline methyl orange in a mixture of 25 ml. of methylated spirit & 25 ml. of deionised water. Dissolve 0.28 g xylene cyanol FF in a mixture of 25 ml. of methylated spirit & 25 ml. deionised water. Mix the two solutions together. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 44. 5% POTASSIUM DICHROMATE INDICATOR SOLUTION Dissolve 50 g K2CrO4 in little distilled water. Add Silver Nitrate solution until a definite red precipitate is formed. Let it stand for 12 hr. filter & dilute to 1 lit with distilled water. 45. SODIUM THIOSULPHATE 0.1 N SOLUTION Dissolve 25 gm Na2S2O3,5H2O & dilute to 1 lit. with distilled water. 46. DIPHENYL CARBAZONE INDICATOR SOLUTION Dissolve 0.4 g of di phenyl carbazone in 100 ml. of 95% is propanol 47. 4 M NICKEL NITRATE SOLUTION. Dissolve 1163 gms. of nickel nitrate (Ni(NO3)2,6H2O)in 1 lit. of D.M. water. 48. ERIOCHROME BLACK T INDICATOR SOLUTION a) Mix 0.5 g of sodium salts of Eriochrome Black T ( 1‐ hydroxy‐2‐naphthylazo)‐5‐ nitro‐2‐ naphthol‐4‐sulphonic acid) with 4.5 gms hydroxylamine hydrochloride. Dissolve this mixture in 100 ml. of 95% ethyl or isopropyl alcohol. b) Mix together 0.5 g dye & 100 g NaCl to prepare a dry powder mixture. 49. MUREXIDE INDICATOR SOLUTION a) Dissolve 150 g of Murexide (ammonium purpurate ) in 100 g of absolute ethylene glycol. Water solution of the dye is not stable for longer than a day. b) Mix 200 mg. of murexide with 100 gms. of solid NaCl & grinding the mixture to 40 to 50 mesh. c) Titrate immediately after adding the indicator because it is unstable under alkaline conditions. 50. STARCH INDICATOR SOLUTION Dissolve 5 gms of starch & 0.01 gms of mercuric iodide with 30 ml. of cold distilled water & slowly pour it with constant stirring into 1 lit. of boiling distilled water. Boil for 3 min & allow it to cool then decant off the supernatant clear liquid. 51. HYDROXYLAMINE HYDROCHLORIDE SOLUTION FOR Fe Dissolve 10 gms. NH2OH & HCl in 100 ml. distilled water.
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
5.2 DAILY LOG SHEET S.NO 1 2 3 4 5
INLET
PARAMETERS Pressure Temperature DPT across vessel DPT across basket filter Flow Rate
OUTLET
S.NO
PARAMETERS
1
pH
2
Conductivity
3
Turbidity
4
Oil & Grease
5
Silica
6
Chlorides
INLET
OUTLET
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
6. P&ID FOR ACF P&ID FOR POWER PLANT: OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 P&ID FOR AMMONIA PLANT:
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
REFILL
1
2
RINSE
2
5
AIR BLOWER
ACFB 1
CONDENSATE WATER OUTLET VALVE
VM
CONDENSATE WATER INLET VALVE
NC
VM
NC
DRIVE DRIVE DESCRPTION TAG
VM26 BLOWER DISCHARGE
NC
STEAM INLET
AIR RELEASE
VM12
NC
VM30
RINSE OUTLET
VM6
NC
LEGEND
NC
VM4 BACKWASH OUTLET
NC
A
AIR INLET
BACKWASH INLET
VM3
NC
SERVICE MODE
VM5
SERVICE OUTLET
VM2
STEP NO
1
REF DOC: 1) P AND I DIAGRAM FOR SOFTENER PLANT PACKAGE DRG.NO. WTBAA00054 REV 03.
NC
SERVICE INLET
VM1
STEP DESCRIPTION
ACF
STEP TIME IN MINS VALVE VALVE POSITION TAG VALVE DESCRPTION
S.NO
7.OPERATION PROCEDURE FOR ACTIVATED CARBON (ACF)
SERVICE
3
1200
2
BACKWASH MODE
B
DRAIN DOWN AIR SCORING STEAM BACKWASH SETTLE BED REFILL FINAL RINSE OFF
1 2 3 4 5 6 7 8
2 5 10 10 2 2 10
R
3
AIR RELEASE
C
2
M/S.THERMAX LTD, THERMAX HOUSE, NO.4. MUMBAI‐PUNE ROAD, SHIVAJINAGAR, PUNE. 411005.
ISSUED FOR INFORMATION
SHEET NO.1
NC ‐ VALVE POSITION NORMALLY CLOSE - VALVE OPEN CONDITION
R ‐ MOTOR TO RUN IN PARTICULAR STEP
CLIENT: IFFCO, PHULPUR UNIT, ALLAHABAD, UTTARPRADESH. PROJECT: ACTIVATED CARBON FILTER UNIT FOR AMMONIA & POWER PLANT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
8. TO WHOM CONTACT Service Manager – Regional Office SOUTHERN REGION THERMAX LIMITED, 312, ANNA SALAI, TEYNAMPET, CHENNAI-600018 TEL : 044 - 24353831 (4LINES); FAX : 044 - 24353841; Email : [email protected] NORTHERN REGION THERMAX LIMITED, 9, COMMUNITY CENTRE, BASANT LOK, NEAR PRIYA CINEMA, NEW DELHI – 110 057 TEL:011-26145319 FAX:011-26145311; Email: [email protected] EASTERN REGION THERMAX LIMITED, AZIMGANG HOUSE, 5TH FLOOR, 7, CAMAC STREET, KOLKATA;TEL:033-22826711/12/13; FAX:033-22826796; Email: [email protected] WESTERN REGION THERMAX LIMITED, WWS, SAI CHAMBERS, 15 MUMBAIPUNE ROAD, WAKADEWADI, PUNE – 411 003. TEL:020- 25541010 FAX:020- 25542235 Email: [email protected] Corporate Regional Manager SOUTHERN REGION THERMAX LIMITED, 312, ANNA SALAI, TEYNAMPET, CHENNAI-600 018 TEL:044-24353831(4LINES) FAX:044- 24353841 Email:[email protected] NORTHERN REGION THERMAX LIMITED, 9, COMMUNITY CENTRE, BASANT LOK, NEAR PRIYA CINEMA, NEW DELHI – 110 057 TEL:011-26145319 FAX:011-26145311 Email:[email protected] EASTERN REGION THERMAX LIMITED, AZIMGANG HOUSE, 5TH FLOOR, 7, CAMAC STREET, KOLKATA. TEL:033-22826711/12/13 FAX:033-22826796 Email:[email protected] WESTERN REGION THERMAX LIMITED, DHANRAJ MAHAL, 2ND FLOOR, CHATRAPATI SHIVAJI MARG, NEAR REGAL CINEMA, GATEWAY OF INDIA, COLABA, MUMBAI- 400 039 TEL:022- 22045391 FAX:022-22040859 Email:[email protected] Service Manager Head Office THERMAX LIMITED, WWS, SAI CHAMBERS, 15 MUMBAIPUNE ROAD, WAKADEWADI, PUNE – 411 003. TEL:020- 25541010 FAX:020- 25542235 Mobile : 98230 82588 Email:[email protected] Divisional Head THERMAX LIMITED, WWS, SAI CHAMBERS, 15 MUMBAIPUNE ROAD, WAKADEWADI, PUNE – 411 003. TEL:020-25541010 FAX:020- 25542235 For more information visit www.thermaxindia.com. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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OPERATION, MAINTENANCE & TROUBLESHOOTING MANUAL CLIENT
:
IFFCO PHULPUR
PROJECT
:
ACTIVATED CARBON FILTER FOR AMMONIA & POWER PLANT
PLANT
:
CONDENSATE POLISHING UNIT
CAPACITY
:
150M3/HR
REFERENCE
:
OC NO 200134
Thermax Limited, (C&W Service & Solutions Group) Thermax House, Mumbai Pune Road, Shivaji Nagar, Pune - 411005 Tel. : 020-25511010, Fax. : 020-25511236. WATER TREATMENT PLANT
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Improving Your Business Is Our Business On Thermax Group: Thermax’s vision is to be a globally respected high performance company offering sustainable solutions in energy and environment. The Thermax Group provides business to business solutions in the areas of heating, cooling, captive power, water treatment, air pollution control, waste management & resource recovery, and chemicals to a wide range of industry in Indian and international markets. In the energy business, Thermax executes projects in the areas of process heat, captive power and waste heat recovery. It also offers a range of heating equipment; energy efficient chillers and customized products such as waste heat and exhaust gas boilers. Thermax’s integrated expertise in energy has made GE to choose it as the ‘vendor on first call’ for its global Combined Heating Power and Cooling (CHPC) projects... Thermax offers industry its expertise over a hundred fuels including oil, gas and a wide variety of solid fuels including biomass. The Group’s Joint Venture, Thermax Babcock & Wilcox (TBW) has emerged as a leading and reliable project management companies with installations the world over; in the US, Saudi Arabia, Thailand, Egypt, Philippines and several other countries. Leveraging its leadership position in electricity saving vapor absorption technology, it offers process industries and commercial establishments like hotels, shopping malls and offices vapor absorption chillers a boon in power‐starved areas. These Eco‐friendly, energy efficient equipment have found prestigious customers such as BBC, Mercedes Benz, Audi, Bosch, Panasonic, Henry Ford Museum. In the environment area Thermax offers waste management expertise for solid, liquid and air pollution. Thermax provides solutions from pre‐treatment to waste water treatment and chemical conditioning of water for boiler and cooling water systems. Water recycling is a thrust area for Thermax. Hi‐grade resins from Thermax have found niche customers in US and Japanese markets. Thermax has an extensive international marketing network. Headquartered in Pune (Western India), Thermax's eleven international offices are located in South East Asia, Middle East, Africa, Russia, UK and the US. Thermax’s 4 overseas subsidiaries play a significant role in generating business in the International market: Thermax (Rus) Ltd., Thermax (Europe) Ltd., OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Thermax Inc., USA and ME Engineering, UK. Around 20 per cent of the group’s turnover come from exports – to the US and European markets, Japan, East Africa, the Middle East, South East Asian and CIS countries. The Thermax group’s manufacturing facilities. Spread over 14 plants, measuring a covered area of over 65,000 sq. Mts., are ISO 9000 and ISO 14001 accredited. Thermax manufactures to international standards like ASME, BS, DIN, and GOST. The facilities have been inspected by Lloyds, Bureau Veritas, SGS, and TUV. Thermax’s business is inspired by the conviction that ‘Improving your business is our business.’ Water & Waste Solutions MAKING INDUSTRY GREEN AND COMPETITIVE Cost competitive and Environment friendly technology innovated and developed through continuous research to keep industry green and competitive. Excellence in Technology and stringent quality control measures are the hallmarks in all projects undertaken by Thermax Water & Waste Solutions Division. Thermax Water & Waste solutions division takes on Retrofitting and Revamping orders to extend life of all aging plants. Our comprehensive service program is the first of its kind in India. It is a program that evaluates and then enhances the economical performance of all water & waste treatment plants. Thermax Water & Waste Solution Division’s wide spectrum of products and technology covers Pretreatment Process Water Treatment Ion Exchange Resins Reverse Osmosis and Electro dialysis Condensate Polishing Thermal Desalination Waste Water Treatment Sewage Treatment Recycling of water Range of Cooling Water Chemicals Range of Polyelectrolyte Incinerators. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
TABLE OF CONTENTS 1 : Water Treatment Fundamentals ………………………….…... ……………………… 6 1.1 : Water treatment general write up & Basic water chemistry ………………….6 1.2 : Importance of Water Analysis …….………………………………….……………...7 2 : Plant Configuration and Details …………………………………………………………...13 2.1 : System Details ………………………………………………….……………..………...13 3 : Control Philosophy …………………………………………………………………………15 3.1 : System Description ……..…..…………………………………………………………..15 3.2 : Process ……………………………………..…………………………………………...16 4 : Operation & Maintenance of "ACF Filter" ………………..………………………...17 4.1 : System operation for ACF ……………………………..……..………………………17 4.2 : Process flow diagram …………………………………………………………………...35
4.3 : Operation Conditions checks for ACF…………………..…………………………36 4.4 : Troubleshooting Guide (ACF) …………………..…………………………………..37 4.5 : Maintenance (ACF) ………………………………..…………………………………38 5 : Laboratory Details …………..……………………………………………………………39 5.1 : Laboratory Analysis ……..…………………………………………………………….39 5.2 : Daily Log- Sheet …………………………………………………………....................72 6: P & I Drawings .…..….………………………….…………………………………………...73 7: Valves Operating procedure………………………………………………………………...75 8 : Whom to Contact ……….………..……………………………….……….………………..76 (for support In case of problem)
Note: For operation and maintenance of individual equipments like pumps, blowers, motors, instruments etc please refer to the instruction manual of the respective equipments.
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 I N T R O D U C T I O N The Operation & Maintenance Manual gives a brief introduction to the total system supplied and gives instructions and guidelines for smooth, long lasting and trouble free operation of the plant. The O&M manual is prepared to make the operator familiar with the system/plant supplied (ACF unit) and its operation and maintenance of the Plant. The chapter Chemical Control describes the various laboratory tests and their procedures, to be carried out in the laboratory to understand quality of feed water to the plant and quality of product water. The regular analysis also helps in analyzing individual units' performance and total plant performance vis‐à‐vis output water produced and chemicals consumed. The maintenance of various equipment in general and resin units in particular are detailed in this O&M manual along with details of trouble shooting, safety precautions, etc. It is also to be noted that this O&M manual covers all areas relevant to the system supplied in general and certain problematic areas, in particular, with respect to operation and maintenance, based on our experience, as far as possible. In case of problems, which are not covered, and peculiar, the same can be referred to us or the various manufacturers as and when they arise. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
1. WATER TREATMENT FUNDAMENTALS 1.1 WATER TREATMENT GENERAL WRITE – UP & BASIC WATER CHEMISTRY: INTRODUCTION: The natural water contains solid, liquid and gaseous impurities and therefore, this water cannot be used for the generation of steam in the boilers. The impurities present in the water should be removed before it’s use in steam generation The necessity for reducing the corrosive nature & quantity of dissolved and suspended solids in feed water has become increasingly important with the advent of high pressure, critical & supercritical boilers. IMPURITIES IN WATER: ‐ The impurities present in the feed water are classified as given below •
Undissolved and suspended solid materials.
•
Dissolved salts and minerals.
•
Dissolved gases.
•
Other materials (as Oil, Acid) either in mixed or Unmixed forms.
•
Undissolved and suspended solid materials.
a) Turbidity and Sediment Turbidity in the water is suspended insoluble matter including coarse particles (mud, sediment, sand etc.) That settles rapidly on standing. Amounts ranges from almost zero in most ground waters and 60,000 ppm in muddy and turbulent river water. The Turbidity of feed water should not exceed 5 ppm. These materials can be removed by settling, coagulation and filtration. Their presence is undesirable because heating or evaporation produces hard stony scale deposits on the heating surface & clog fluid system. Both are objectionable as they cause damage to the Boiler system standard amount of measurement of hardness is taken as being the amount of Calcium Carbonate (CaCO3) in the water and is referred to in part per million (ppm) or grains per gallon (grains/gallon * 17.1 = ppm). b) Sodium and Potassium Salts These are extremely soluble in water and do not deposit unless highly concentrated. Their presence is troublesome as they are alkaline in nature and accelerate the corrosion. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 c) Chlorides Majority of the chloride causes increased corrosive action of water. d) Iron Most common soluble iron in water is ferrous bicarbonate. The water containing ferrous bicarbonate deposits becomes yellowish and reddish sediment of ferric hydroxide if exposed to air. Majority of ground surface water contains less than 5 ppm but even 0.3 ppm can create trouble in the feed water system by soft scale formation and accelerating the corrosion. e) Manganese It also occurs in similar form as iron & it is also equally troublesome. f) Silica Most natural water contains silica ranging from 1 to 100 ppm. Its presence is highly objectionable as it forms very hard scale in Boilers and forms insoluble deposits on turbine blades. In modern high pressure Boilers its presence is reduced as low as 10‐50 ppb. g) Microbiological Growth Various growths occur in surface water (lake & river). The microorganisms include diatons, moulds, bacterial slimes, algae, manganese & sulphate reducing bacteria and many others. These can cause coating on Heat Exchanger and clog the flow passages and reduce the heat transfer rates. h) Colour Surface waters from swampy areas become highly coloured due to decaying vegetation. Colour of feed water is objectionable as it causes foaming in Boilers and may interfere with treatment processes. It is generally removed by chlorination or adsorption by activated carbon. Dissolved Salts and Minerals Calcium and Magnesium Salts The Calcium and Magnesium salts present in the water in the form of carbonates, bicarbonates, and sulphates and chlorides. The presence of these salts is recognized by the hardness of the water (hardness of water is tested by soap Test). The hardness of water is classified as temporary and permanent hardness. The temporary hardness is caused by the bicarbonates of calcium and magnesium and can be removed by boiling. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 The boiling converts the soluble bicarbonates into less soluble carbonates, which can be removed by simple blow down method. The permanent hardness of the water is caused by the presence of chlorides, sulphates and nitrates of calcium and magnesium and they can not be removed just by boiling because they form a hard scale on heating surfaces. Dissolved Gases Oxygen It presents in surface water in dissolved form with variable percentage depending upon the water temperature and other solid contents in water. Its presence is highly objectionable, as it is corrosive to iron, zinc, brass and other metals. It causes corrosion and pitting of water lines, boiler exchangers. Its effect is further accelerated at high temperatures. b) Carbon Dioxide The river water contains 50 ppm and well water contains 2 to 50 ppm of CO2. It also causes the corrosion of stream, water and condenses lines. It also helps to accelerate the corrosive action of oxygen. The other gases are H2S, CH4, N2 and many others but their percentages are negligible, therefore, their effects are not discussed here. 4. Other Materials Free Mineral Acid Usually present as sulphuric or hydrochloric acid and causes corrosion. The presence is reduced by neutralization with alkalis. b) Oil Generally, the lubricating oil is carried with steam into the condenser and through the feed system to the Boiler. It causes sludge, scale and foaming in Boilers. It is generally removed by strainers and baffle separators. The effects of all the impurities present in the water are the scale formation on the different parts of the Boiler System and corrosion. The scale formations reduces the heat transfer rates and clog the flow passage and endanger the life of the equipment’s by increasing the temperature above safe limit. The corrosion phenomenon reduces the life of the Plant rapidly. Therefore, it is absolutely necessary to reduce the impurities below a safe limit for the proper working of the power plant.
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
1.2 Importance of Water Analysis Water analysis The process of determining how much of various substances (impurities) are present in given sample of water is known as Water Analysis. Need for Water Analysis Water analysis is essential for the following reasons: a) Raw water source selection. b) Analysis of raw water determines the type of treatment and unit size. c) Treated water analysis indicates the efficiencies of various units of water treatment. d) Designing of most economical water treatment plant. To design a water treatment plant knowing the impurities present in the water to be treated is needed. Complete analysis helps in determining the degree of pretreatment required in Ion Exchange and other process like reverse osmosis etc. Minor constituent like silica is very important since it may have influence on the regeneration technique used and can affect the capacities that can be obtained. Analysis of Iron and chlorine is important for reverse osmosis design. Definition used in water analysis pH: It is common practice to express hydrogen ion concentration in terms of pH. By definition the pH is the negative logarithm of hydrogen ion concentration to the base of l0. pH = ‐ log10 (H+) = log (1/H+) Ionic product of water Kw has a value of 1 x 10 ‐ 14 and in neutral water H + concentration is equal to OH ‐ concentration. Kw = H + x OH‐ = 1 x 10‐ 14 ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ (1) For neutral water = (H+) = (OH‐) = 1x10 ‐ 7 The equilibrium represented by equation (1) occurs universally in aqueous solution regardless of the equilibrium or the solutes present. Hence equation (1) should always be satisfied. Thus the terms pH expresses the acidity or basicity of water. Neutral water has a pH of 7. pH lower than 7 indicates acidity and greater than 7 is alkaline. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Alkalinity: As mentioned earlier alkalinity in water is due to presence of HCO‐3. CO‐3 and OHions. In raw water alkalinity is mostly due to HCO‐3, but in some cases CO‐3 ions also may be present. It is important to note that out of the three ions only two ions can exist in any system. That is HCO‐ 3, CO‐3 or OH‐ can exist alone or in combination with one more ion. Any water analysis reporting the presence of all three ions should be discarded. Alkalinity of water is determined by titration with phenolpthalein and methyl orange indicator. The result of titration with methyl orange indicator is called Total Alkalinity or MAlkalinity. M. Alk. = Total Alk = HCO‐3 + CO‐3 + OH‐. The result of titration with phenolpthalein indicator is called P‐Alkalinity. P. Alk = OH + 1/2 CO3. Hardness Calcium and Magnesium salts impart hardness to water. Hard water is defined as a water which does not lather or foam with soap easily. The salt of calcium and magnesium which causes hardness is divided in two parts. 1. Temporary hardness or carbonate hardness. 2. Permanent hardness or non‐carbonate hardness. The sum of temporary and permanent hardness is called Total Hardness. Total Hardness = Carbonate hardness + Non Carbonate hardness Carbonate Hardness It is mainly due to presence of bicarbonates of Calcium and Magnesium. Alkalinity in raw water is normally due to bicarbonate ions. Therefore, carbonate hardness (Alkalinity) plus Non Carbonate hardness is equal to total hardness. 1) Carbonate hardness = Alkalinity, when alkalinity is less than total hardness. 2) Carbonate hardness = Total hardness, when alkalinity is greater or equal to total hardness. Conductivity: The conductivity of water is dependent on the ionic content of water, specifically on the ability of ionic impurities in the water to conduct electricity. Ionic impurities have the ability to conduct electric current and thus there is direct linear relationship between ionic impurities and conductivity which help in determining the ionic impurities in water. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Conductivity is also related to TDS empirically = Conductivity x 0.65 = TDS. Total Dissolved Solids This represents all the soluble inorganic solids in water expressed in ppm. Total Solids Total solid is defined as SUM of soluble and insoluble solids. Electrolytes This is total ionizable dissolved solids in water. Total electrolyte is numerically equal to total cation or total anions (not sum of both). Total electrolyte does not include CO2 and silica. Total Cations Sum of calcium, magnesium, sodium and potassium all measured in the same unit. Total Anions Sum of alkalinity (HCO‐3 + CO‐3 + OH‐) + Cl + SO4 + NO3 all measured in the same unit. Total Cation = Total Anion = Total Electrolyte Equivalent Mineral Acidity (EMA) The equivalent mineral acidity, EMA is equal to the sum of equivalent concentration of sulphates, chloride and nitrate. It is also called sometimes as Total Mineral Acidity. Free Mineral Acidity (FMA) Free mineral acidity is equal to (EMA ‐ Sodium leakage). EMA ‐ Sodium leakage = FMA EMA ‐ FMA = Sodium leakage. Method of reporting water analysis There are various ways of reporting water analysis, but in general four methods which are commonly used are, 1. As ppm ion or mg/litre. 2. EPM or M.Eq./litre (Mill equivalent per litre) 3. ppm as CaCo3. 4. Grains per gallon as CaCo3. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Water analysis Report Water analysis can be reported in many ways but most laboratories give in the format as given below. WATER TREATMENT PLANT Format for Reporting water Analysis Physical pH ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Colour ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Hazen Unit Taste and Odour ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Turbidity ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ NTU Conductivity ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ μmhos or milli mhos Chemical Suspended Solids ‐ in ppm Calcium ‐ as ppm CaCO3.* Magnesium ‐ as ppm CaCO3.* Hardness ‐ as ppm CaCO3.* M.Alkalinity ‐ as ppm CaCO3.* P.Alkalinity ‐ as ppm CaCO3.* Chloride ‐ as ppm or mg./litre. Sulphate ‐ as ppm or mg./litre. Nitrate ‐ as ppm or mg./litre. Silica ‐ as ppm or mg./litre. Iron ‐ as ppm or mg./litre. TDS ‐ as ppm CO2 ‐ as ppm * Sometimes calcium and Magnesium can be reported as in ppm as Ca or Mg. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
2. PLANT CONFIGURATION AND DETAILS 2.1 SYSTEM DETAILS ‐ PLANT DATA DESIGN DATA S.No
Description
Design Value
1
Unit Name
Activated Carbon Filter
2
No of Stream
01
3
Design Flow rate
150 M3/Hr
4
Specification
4 M Dia & 2.6 HOS
4
Design pressure
12.5 Kg/cm2
6
Design temperature
80C
OPERATING DATA S.No
Description
Design Value
1
Unit Name
Activated Carbon Filter
2
No of Stream
01
3
Flow rate
150 M3/Hr
4
Operating Time
20 Hrs
5
Operating pressure
9 – 11 Kg/cm2
6
Operating temperature
60C
7
Operation Mode
Manual
8
Backwash Time
30 min
9
Feed Water
Condensate outlet water
10
Differential pressure in vessel
0.6 Kg/cm2
11
Differential pressure in Basket filter
1.5 Kg/cm2
12
Blower for ACF
600m3/Hr at 0.4 Kg/cm2
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 ANALYSIS DATA S.No
Description
Inlet parameters
Outlet parameters
1
Ph
9.0 – 9.5
9.0 – 9.5
2
Conductivity
30 µS/Cm
30 µS/Cm
3
Oil & Grease
<1.0 ppm
NIL
4
Turbidity
<1.0 NTU
<1.0 NTU
5
Silica
<0.02 ppm
<0.02 ppm
EQUIPMENT DATA S.No TAG NO
Description
QTY
SPECIFICATION
MOC
1
ACF
ACF VESSEL
1 NOS
4 M Dia & 2.6 HOS
MSEP
2
BS ½
BASKET STRAINER
2 NOS
FOR 150 M3/HR CAP
SS
3
ACFB 1
ACF AIR BLOWER
1 NO
600m3/Hr at 0.4 Kg/cm2
CI
DPT 351,
DIFFERENTIAL PRESSURE
DPT 352
TRANSMITTER
2 NOS
ACROSS VESSEL & BS
‐‐
5
FT 401
FLOW TRANSMITTER
1 NO
DP TYPE IN INLET
‐‐
6
FI
FLOW INDICATOR
1 NO
ROTAMETER IN INLET
‐‐
PRESSURE GAUGE
3 NOS
BOURDEN TYPE
‐‐
4
PG 101, 7
PG 102, PG 103
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
3. CONTROL PHILOSPHY 3.1 SYSTEM DESCRPTION: ACTIVATED CARBON FILTER BASICS Activated Carbon works by attracting and holding certain chemicals as water passes through it. Because AC is a highly porous material, it has an extremely high surface area for contaminant adsorption. The contaminant is more likely to diffuse into a pore and become adsorbed. The two principal mechanisms by which activated carbon removes contaminants from water are adsorption and catalytic reduction. Organics are removed by adsorption and residual disinfectants are removed by catalytic reduction. Activated carbon is proven technology for the removal of naturally occurring organics and residual disinfectants. Activated carbon filters are using granular activated carbon as media. Activated carbon filtration is most effective in removing organic contaminants from water. Organic substances are composed of two basic elements, carbon and hydrogen. Because organic chemicals are often responsible for taste, odor, and color problems. AC filtration can generally be used to improve aesthetically objectionable water. AC filtration will also remove chlorine. AC filtration is recognized by the Water Quality Association as an acceptable method to maintain certain drinking water contaminants within the limits of the EPA National Drinking Water Standards. Overall this study showed that activated carbon filters are extremely effective as primary filters and have the added benefit of organics reduction resulting in cost savings with reduced chlorine demand and safer water with reduced THM formation and cleaner distribution systems. Activated carbon beds are filters and need to be backwashed periodically. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
3.2 PROCESS (ACF) The ACF filter has a Activated Carbon Media, one of the most widely used media for adsorption of impurities. The Activated carbon is employed for_ • Dechlorination • Removal of Organics • Removal of Odour The residual chlorine in the water, where chlorination is used for Organics removal, as adsorbed by Activated Carbon Filter. Chlorination of water is widely used in Drinking Water Plants, Pretreatment of DM plant and Ro plants and effluent treatment plants. The VERSA ACF removes almost all of the residual chlorine in the water. The VERSA ACF also helps in removal of Organic matter from the water. It is used in treatment plants for Drinking water as polisher unit at the outlet of the plant and removes objectionable odours. The Activated carbon media has finite capacity of absorption and shall exhaust on prolonged usage depending upon the inlet impurity load. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
4. OPERATION AND MAINTENANCE OF ACF FILTER 4.1 SYSTEM OPERATION FOR ACTIVATED CARBON FILTER (ACF) The ACF unit for manual operation shall be divided into the following operations: 1. SERVICE cycle of ACF unit 2. BACKWASH operation of ACF unit 3. AIR RELEASE operation of ACF unit SERVICE CYCLE OF ACF UNIT: •
Ensure that the ACF filter is backwashed and is ready for service.
•
Ensure feed water is available in rated quantity/quality and pressure.
•
In the service mode Service Inlet Valve VM‐1 and the service outlet valve VM‐2 remain open.
The service cycle of ACF is 20 hours or differential pressure across the filter 0.6kg/cm2. SERVICE STEPS 1. RINSE 2. REFILL 3. SERVICE 1. RINSE: In this step Service inlet valve VM‐1 and Rinse outlet valve VM‐6 remains open. The step is carried out with the condensate outlet water for 5 minutes at the flow rate is 150 m3/Hr. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 2. REFILL: In this step the service inlet valve VM‐1 and air release valve VM‐12 remain open. All the other valves are in closed condition. Refill is carried out at the service flow rate till full bore of air comes from the air release line. The time set for refill is 2 minutes. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 3. SERVICE: The unit is taken into service. It remains in service for a cycle of 1200 min. After this it is taken into regeneration mode. Service inlet valve VM‐1 and Service outlet valve VM‐2 remain open. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 BACKWASHING OF ACF After completion of design service run hours (20 hours) or depending up on the differential pressure across the filter i.e Difference between inlet and outlet pressure gauge readings of 0.6 kg/cm2, the vessel is taken in backwash mode. BACKWASHH IMPORTANCE: The waste wash water drains should be kept free of clogging or sediment. The requisite up‐flow velocity of backwash water should be maintained at the design rate for proper cleaning of the media. Backwashing of filters should not be based on arbitrarily fixed time scheduled but the frequency should be in accordance with the filtrate quality and head loss measurement. Duration of cleaning should be dependent upon the turbidity of the wasted water. For better performance, carry out extended backwash for 30‐45 minutes once in a week or till backwash effluent is clear.
BACKWASH STEPS Backwash steps are as follows, 1. DRAIN 2. AIR SCOURING 3. STEAM 4. BACKWASH 5. SETTLE BED 6. RINSE STEP OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 BACKWASH STEPS 1. DRAIN: The backwash mode is initiated with the drain step. In this step Backwash Outlet Valve (VM‐ 4) and drain outlet valve or rinse outlet valve (VM‐6) remains open. All the other valves remain closed. The drain step is for a period of 5 minutes. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 2. AIR SCOURING: Air scouring step starts and is done through ACF Blower (ACFB‐1). Backwash outlet valve (VM4), Air Inlet valve (VM‐5) and Air release valve (VM‐12) remain open in this step. The step is carried for 5 minutes. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 3. STEAM: Steam scouring step starts and is done through steam inlet line. Backwash outlet valve (VM4), Steam Inlet valve (VM‐30) and Air release valve (VM‐12) remain open in this step. The step is carried for 10 minutes. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 4. BACKWASH: In this step the Backwash Inlet Valve (VM‐3) and Backwash Outlet Valve (VM‐4) remain open. The backwash is done through the Condensate outlet valve. The backwash is carried out at a flow rate of 150 m3/hr for 10 minutes. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 5. SETTLE BED: In this step the bed is allowed to settle for a period of 2 min. All the valves remain closed in this step. 6. RINSE STEP: The rinse step of ACF in backwash mode is carried out with the condensate outlet water. In this step VM‐1 of ACF remains open & rinse water is drained out through the rinse outlet valve VM‐ 6 of ACF. The rinse step is carried out for 5 minutes at the flow rate of 150m3/hr. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 AIR RELEASE OPERATION: Air release operation is an independent operation carried out to release the entrapped air from within the vessel. This single operation; when opened the Air release valve VM 12 in 2 min and the air release valve also gets closed manually after 2 mins. BASKET STRAINER IMPORTANCE: The Filtered/Treated Water is first passed to Basket Filter. This unit is provided for removal of fine suspended particles. This is a SS vessel housing with the SS screen Filter elements which prevents micron size particles up to 100 µ. If the differential pressure on the inlet to Basket Strainer sensed by DPT 352 is high value alarm is 1.5 Kg/cm2. ACF feed water valve close/trips in this case. ACF OUTLET FILTERED/TREATED WATER After Filtered/Treated water of ACF outlet water is sent directly to make up water day tank of the power plant for BFW make up in boiler through deaerator. After Filtered/Treated water of ACF outlet water is sent directly to make up water day tank of the ammonia plant for BFW make up in waste heat boiler through deaerator. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
4.2 PROCESS FLOW DIAGRAM SCHEMATIC DIAGRAM FOR ACTIVATED CARBON FILTER UNIT SURFACE CONDENSER CONDENSATE WATER INLET BASKET FILTER 1
ACF
TREATED WATER OUTLET BASKET FILTER 2
TO DEAERATOR
PROCESS STEPS: Process condensate water from surface condenser outlet to deaerator. SURFACE CONDENSER – ACF – BASKET FILTER – DEAERATOR. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
4.3 OPERATING CONDITION CHECKS FOR ACF YNIT PRE‐REQUISITE CONDITION ‐ OPERATION (MANUAL) ‐ ACF UNIT •
Check the all manually operated valves open or close condition such as VM‐1, VM‐2, VM‐3, VM‐4, VM‐5, VM‐12, VM‐30 & VM‐26.
•
Ensure all Pressure Gauge isolation valve (VM‐41) are open for all the Units & of Rotary equipment’s.
•
Ensure all Flow Indicators’ / Flow transmitter DP transmitter isolation valves (VM‐46) are open for all the Units.
•
While in service Condensate outlet header valve and ACF outlet header valve is open.
•
Inlet water pressure should not exceed 12 kg/cm2. Do not exceed the Max Operating Flow rate of 150 m3/hr, as this may deteriorate the quality of outlet water.
•
Inlet water temperature should not be more than 80 Deg.C
•
Check the differential pressure across the vessel & across the basket filter before start up the unit.
Now ACF unit is ready to take in to operation. MAINTENANCE CHECKS: •
Analyze inlet / outlet water in periodically i.e., hourly, shift basis, daily, weekly basis.
•
Ensure Air blower are sufficiently lubricated and continued oil levelers are filled up.
•
Inspect the vessel, piping externally once in year for damage to the painting.
•
Inspect the filter media every year, and replaced if required.
•
Give extended backwash to the filter once in a week for more than 45 min or till clear water.
•
Give air scouring to the filter media once in six months or if the filter is found heavily chocked, as described in maintenance section.
•
Use genuine spares (THERMAX SPARES).
•
Repaint as necessary.
•
Inspect vessel internally once in a year for any damaged in internals system or not. And repair the internals if found damaged.
•
If found consistently more than the design limit, consult THERMAX representatives.
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
4.4 TROUBLESHOOTING GUIDE (ACF) S.No
DEFECT
CAUSE
REMEDY
1
Condensate water
a. Filter not backwashed
a. Backwash filter regularly
quality not up to
b. Inlet Suspended Solids load b. Check inlet water quality.
the standard
increased
You may have to increase backwash
c. Excessive Flow Rate
frequency. Also Consult Thermax.
d. Channeling Collection/distribution
c. Please do not cross unit max service
e. Disturbed media layers.
flow rate. d. Check and ensure sufficient pressure. e.
Check
and
ensure
proper
segregated media layers 2
Backwash Frequency
a. Inlet Suspended Solids load a. Check inlet water quality. You may
Required is high
increased
have to increase backwash frequency. Also Consult Thermax.
3
Unit Rinse takes long time a. Flow rate too low
a. Adjust the flow rate to the normal
b. Improper Backwash
b. Give proper backwash as given in OPERATION section till clear water is observed.
4
Pressure Drop across bed a. No or Insufficient backwash is increasing day by day
b. Inlet Suspended Solids load b. Check inlet water quality.
increased
You may have to increase backwash frequency. Also Consult Thermax.
5
a. Backwash filter regularly.
Media comes out
a. Improper media charging at
a. Remove and recharge media
from bottom outlet
the time of erection
properly
b. Too much excessive backwash b. Always maintain backwash flow. flow rate/Pressure
Too much backwash flow rate/
c. The gap in collection box and dish Pressure can disturb media layers. is more than 5 mm. ( This should c. Remove the entire media, adjust have
been
checked
installation)
before the gap to 5 mm, segregate the media by type and recharge the media.
TREATMENT PLANT
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
4.5 MAINTENANCE (ACF) The routine maintenance of the filters should include the following _ VALVES At periodic intervals (say one month) open out the valves and check seating, gate, etc. Attend to gland packing. Replace if necessary, do routine lubrication of spindle. EXTENDED BACKWASH Once in a week extend the backwash operation to at least 45 minutes to keep the bed clean. AIR SCOURING AND CLEANING OF THE FILTER MEDIA Once in six months, open the manhole and examine the condition of the media. Throw away any lumps formed on the top of the bed. On units where no regular air scouring facilities are provided, air scouring should be done as follows – a. If compressed air supply is available, take a temporary tapping (say 1” hose). Attach the hose to a M.S. pipe about 1 M long with water level inside vessel about 3“above the level of the bed, insert the pipe into the bed till it is about halfway through. The media will be seen getting violently agitated. Move the pipe all over the bed. Carry out the air scour for a period of about 10 minutes. b. Drain the water till the surface of the bed and scrape off any fine dust. c. Close the manhole. TREATMENT PLANT DO’S AND DON’T’S • Never exceed the filter service flow • Analyses Inlet water for Turbidity regularly • Always check Inlet water for Oil & Grease content. Don’t allow exceed the limit. • Inlet Water Temp should not exceed 80 Deg.C • Do annual Media Check up and replacement as required. • Backwash the filter regularly as per Manual • Never allow corrosive liquids to pass through the Filter. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
5. LABORATORY DETAILS 5.1 LABORATORY ANALYSIS CONTENTS 1. pH 2. TURBIDITY 3. COLOUR 4. ELECTRICAL CONDUCTANCE 5. TOTAL DISSOLVED SOLIDS 6. SUSPENDED MATTERS 7. HARDNESS 8. SILICA 9. CHLORIDE 10. OILS AND GREASE 11. RESIDUAL CHLORINE 12. REAGENTS OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 1. pH: It is common practice to express hydrogen ion concentration in terms of pH. By definition the pH is the negative logarithm of hydrogen ion concentration to the base of l0. pH = ‐ log10 (H+) = log (1/H+) Ionic product of water Kw has a value of 1 x 10 ‐ 14 and in neutral water H + concentration is equal to OH ‐ concentration. Kw = H + x OH‐ = 1 x 10‐ 14 ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ (1) For neutral water = (H+) = (OH‐) = 1x10 ‐ 7 WATER TREATMENT PLANT The equilibrium represented by equation (1) occurs universally in aqueous solution regardless of the equilibrium or the solutes present. Hence equation (1) should always be satisfied. Thus the terms pH expresses the acidity or basicity of water. Neutral water has a pH of 7. pH lower than 7 indicates acidity and greater than 7 is alkaline. METHOD A – pH Indicator:
A pH indicator is a halochromic chemical compound that is added in small amounts to solution so that the pH(acidity or basicity) of the solution can be determined visually. Hence a pH indicator is a chemical detector forhydronium ions (H3O+) or hydrogen ions (H+) in the Arrhenius model. Normally, the indicator causes the colour of the solution to change depending on the pH. These commercial indicators (e.g., universal indicator and Hydrion papers ) are used when only rough knowledge of pH is necessary. METHOD B‐ PH CELL ( pH Meter): A pH meter is an electronic device used for measuring the pH (acidity or alkalinity) of a liquid (though special probes are sometimes used to measure the pH of semi‐solid substances). A typical pH meter consists of a special measuring probe (a glass electrode) connected to an electronic meter that measures and displays the pH reading. This is containing a pair of electrodes. The sample to be tested is poured into this cell. There are many forms of cell. There are several satisfactory commercial models. Operators, less they have adequate facilities, would be well advised to purchase a readymade instrument. P
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 2. TURBIDITY OUTLINE OF THE METHOD The sample is matched against standard suspensions of fullers earth in water. TERMINOLOGY For the purpose of this test, the following definition shall apply. Scale Unit ‐ Turbidity imparted by 1 mg of fullers earth when suspended in 1000 ml of distilled water. PREPARATION OF TURBIDITY STANDARDS Mix slowly with constant stirring 5.000 g of fullers earth previously dried and shifted through 75 micron IS Sieve with distilled water and dilute it to 1000 ml. Agitate intermittently for one hour and then allow to stand for 24 hours. Withdraw the supernatant liquid without disturbing the sediment. Vaporate about 50 ml of the removed liquid, dry the residue at 105 + 2 Deg. C and weigh the residue to determine the amount of clay in suspension. Prepare turbidity standards with this standardized stock suspension with distilled water. A drop of saturated mercuric chloride solution may be added as preservative. The standards are stable for three months. PROCEDURE Pour the sample after thorough shaking into a clear glass bottle of suitable capacity, say 1 lit. Compare it with the turbidity standards contained in similar bottles, holding them against a suitable background and using a source of light which illuminates them equally and is placed so that no rays reach the eye directly. The sample and the standards shall be shaken simultaneously immediately before comparison. If the sample has turbidity over 100 units, dilute it with distilled water before testing and multiply the result with an appropriate factor. NOTE Comparison of turbidity may also be done with the help of suitable instruments. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 3. COLOUR OUTLINE OF THE METHOD The colour of the sample is matched against a series of standards containing potassium chloroplatinate and cobalt chloride. TERMINOLOGY For the purpose of this test, the following definitions shall apply: True Colour
Colour due to substances in solution, after removal of suspended matter.
Apparent Colour
Colour due to substances which are in solution as well as in suspension. Colour obtained in a mixture containing either on milligram of Patinum or
Hazen Unit
2.49 mg of potassium chloroplatinate along with 2 mg of cobalt chloride (CoCl2.6H2O) in 1 litre of the solution.
APPARATUS Nessler Tubes ‐ Flat‐bottom tube of thin colourless glass. Two types of tubes are required. The longer tubes shall be 45 cm tall and 2.5 cm in internal diameter. The shorter tubes shall be 30 cm tall and 1.7 cm in internal diameter. Tubes of any one type shall be identical in shape, and the depth measured internally from the graduation mark to the bottom shall not vary by more than 2 mm in the tubes used. REAGENTS Platinum or Potassium Chloroplatinate Aqua Regia ‐ prepared by mixing one part by volume of concentrated nitric acid (conforming to IS: 264‐1950) with three parts by volume of concentrated hydrochloric acid (conforming to IS: 265‐ 1962). Cobalt Chloride‐Crystalline, with the molecular composition CoCl2.6H2). TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 PROCEDURE PREPARATION OF COLOUR STANDARDS Dissolve 0.500 g of metallic platinum in aqua regia and remove nitric acid by repeated evaporation to dryness on water bath after addition of excess of concentrated hydrochloric acid (conforming to IS:265‐1962). Dissolve the residue with 1.0 g of cobalt chloride in 100 ml of concentrated hydrochloric acid to obtain a bright solution, if necessary by warming. Dilute the solution to 1000 ml with distilled water. This stock solution has a colour of 500 Hazen units. A more convenient way of preparing the same solution is by dissolving 1.245 g of potassium chloroplatinate and 1.0 g of cobalt chloride in distilled water and diluting to 1 litre. Prepare a set of colour standards having colour 5, 10, 15, 20, 25, 30, 35, 40, 50, 60 and 70 Hazen units by diluting the stock solution with water. Protect these colour standards from evaporation and contamination when not in use. The colour standards shall be freshly prepared for each determination. But in routine practice, they may be used repeatedly, provided they are protected against evaporation and contamination when not in use. PROCEDURE FOR CLEAR SAMPLES For samples having turbidity under 5 mg/l, match the colour of the sample against the standard colours in the longer Nessler Tubes. Fill the tubes to mark and compare the colour by looking vertically downwards against a pure white surface. If the colour is found to exceed 70 units, dilute the sample with distilled water before comparison and multiply the result by appropriate factor. As matching is very difficult when the colour of the sample is below 5 Hazen units, report the colour as less than 5 Hazen units in such cases. When the colour of the sample exceeds 30 Hazen units, the comparison may, if desired, be made in the shorter Nessler tubes. TREATMENT PLANT PROCEDURE FOR TURBID SAMPLES If the sample has turbidity over 5 mg/l it becomes impossible to measure the true colour accurately by the method prescribed in PROCEDURE for clear samples and if an attempt is made, the value found shall be reported as "apparent colour". In the presence of turbidity, the true colour shall be determined after centrifuging. The sample shall be centrifuged until the supernatant liquid is clear. The centrifuged clear sample shall be compared by the method prescribed in PROCEDURE for clear samples. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 NOTE For estimating true colour, filter paper shall not be used since that leads to erroneous results. REPORT The results of colour determination shall be excess in whole numbers and shall be recorded as follows: Hazen Units Less than 5 Reports as "Less than 5 Hazen Units" 5 to 50 Reports to the nearest 1 Hazen Unit 51 to 100 Reports to the nearest 5 Hazen Unit 101 to 250 Reports to the nearest 10 Hazen Unit 251 to 500 Reports to the nearest 20 Hazen Unit NOTE The colour determination shall be made as early as possible after the collection of samples as certain biological change occurring in storage may affect the colour. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 4. ELECTRICAL CONDUCTANCE GENERAL The unit of conductance is the mho or reciprocal ohm. Specific conductivity is the conductance at a specified temperature across a column of a liquid 1 cm2 in area and 1 cm long, and is expressed mhos per centimeter. This is an inconveniently large unit for water testing and it is usual to use the micromho per centimeter known as the "dionic unit", which is one‐millionth part of a mho per centimeter. APPARATUS Several kinds of apparatus are available. They generally consist of two parts. CONDUCTIVITY CELL This is containing a pair of electrodes. The sample to be tested is poured into this cell. There are many forms of cell. One of the most convenient types is provided with a funnel for filling, a drain for emptying, and an overflow for maintaining constant level. Electrodes for use with samples having very low dissolved solids (such as condensates) should not be coated with platinum black. Platinum black which has been heated to redness until it is grey is suitable. Bright platinum or gold or heavily gold plated electrodes may be used. Some instruments are designed to work with particular form of conductivity cell, and are then calibrated directly in conductivity units. Other instruments, primarily introduced for more general application, are calibrated on conductance units and their readings require multiplication by a factor known as the "cell‐ constant" which shall be determined by experiment. Measuring Instrument ‐ For measuring the electrical conductance (or the resistance which is the inverse of conductance) between the electrodes of the cell. There are several satisfactory commercial models. Operators, less they have adequate facilities, would be well advised to purchase a readymade instrument. TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 PROCEDURE Determine the cell constant if necessary, either directly with a standard potassium chloride solution (say 0.002 N) or by comparison with a cell the constant of which is known accurately. (In the latter case, the concentration and nature of the electrolytes in the liquid which is used for the comparison should be the same and should be similar respectively to those of the liquids with which the cell is likely to be used in practice). Use some of the samples to wash out the conductivity cell thoroughly. Fill the conductivity cell with the sample. Calculations FOR INSTRUMENT READING RESISTANCE : 1 x 106
Electrical conductance, in dionic units (or micromhos per centimetre) = rk Where r = Resistance in ohms, and k = Cell constant FOR INSTRUMENT READING CONDUCTANCE : Electrical conductance, in dionic units (or micromhos per centimetre) = ck Where c = conductance in micromhos, and k = cell constant CORRELATION OF ELECTRICAL CONDUCTANCE TO TOTAL DISSOLVED SOLIDS For water containing a given mixture of mineral salts, the electrical conductance is closely proportional to the dissolved solids. When the samples are known to be free from wide fluctuation in mineral content, the electrical conductance offers a quick means of computing the total dissolved solids. Electrical conductance Dissolved Solids TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 5. TOTAL DISSOLVED SOLIDS (TDS) A well mixed filtered sample is evaporated in a weighed dish and dried to constant weight in an oven at 103 to 105 Deg. C. The increase in weight over that of the empty dish represents the total residue. APPARATUS 1. Silica or porcelain dish of 100 ml capacity 2. Desicator 3. Oven PROCEDURE Ignite the clean evaporating dish at 550 + 50 Deg. C for 1 hour. Cool, desiccate and weigh. Transfer the measured sample to the pre weighed dish and evaporate to dryness on a steam bath. Choose a sample volume that will yield a minimum residue of 25 mg to 250 mg. If necessary, add successive portions of sample to the same dish. Dry the evaporated sample for at least 1 hour at 103 to 105 Deg.C. Cool the dish in a desiccators and weigh. Repeat the cycle of drying, cooling and weighing until a constant weight is obtained. Calculations Wt of residue x 1000 Total dissolved solid, mg/L = ml. of sample taken OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 6. SUSPENDED MATTERS Suspended matter is the material retained on filter after filtration of a well mixed sample of water. The residue is dried at 103 to 105 Deg. C. APPARATUS 1. Gooch crucible 2. Silica or porcelain evaporating dish of 100 ml capacity 3. Desiccators 4. Oven adjustable to constant temp of 103 ‐ 105 Deg. C. 5. Water batch PROCEDURE Prepare a gooch crucible with asbestos (20 to 30 ml of 0.5% suspension of gooch asbestos added and washed under suction), dry and ignite at 500 Deg. C for at least 30 minutes, cool and weigh. Filter a suitable volume of the well mixed sample through the crucible. Wash with distilled water, dry at 105 Deg. C for one hour. Weigh. Calculations W x 106 Suspended matters in mg/L = V Where, w = wt. in g of the suspended matter V = vol. in ml. of the sample taken for filtration NOTE If Gooch Crucible is not available, standard "Whatman" filter paper may be used. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 7. HARDNESS Hardness in water is due to the presence of bicarbonates, chlorides and sulphates of calcium and magnesium. Temporary hardness is due to the presence of bicarbonates and permanent hardness due to the presence of chlorides and sulphates. Sometimes, hardness may include iron, aluminum, zinc, manganese, etc. METHOD A ‐ OMPLEXAMETRIC METHOD (EDTA METHOD) EDTA forms a chelated soluble complex when added to a solution of certain metal ions. If a small amount of EBT is added to an aqueous solution containing calcium and magnesium ions at pH of 10.0 + 0.1, the solution will become red wine. If EDTA is then added as a titrant, the calcium and magnesium will be complexes. After sufficient EDTA has been added to complex all the calcium and magnesium, the solution will turn blue from red wine. REAGENTS 1. Ammonia buffer of pH 10. 2. M solution of disodium salt of ethylenediamine tetra acetic acid. 3. Eriochrome black T indicator solution. PROCEDURE Take 50 ml of sample in an Erlenmeyer flask; add 4 to 6 drops of Eriochrome black T indicator solution. Add 1 ml of buffer solution and mix. Titrate immediately with EDTA solution till the colour changes from red to blue. Calculations: Total hardness as CaCO3 mg/lit = Vol. of 0.01 M EDTA solution x 1000 ml of sample ATER TREATMENT PLANT NOTE For checking hardness in soft water use 500 ml of the sample into 750 ml evaporating dish and add 3 ml of buffer solution followed by 10‐12 drops of indicator solution. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 METHOD B SOAP SOLUTION METHOD FOR HARDNESS TESTING This is a quick method for checking hardness of treated water or an accurate determination of the hardness of treated water, EDTA method for hardness should be used. REAGENTS 1. “B” soap solution 2. 40 ml shaking bottle PROCDURE Take water sample up to 40 ml mark in shaking bottle. Add 10 drops of the "B" soap solution. Shake vigorously. If lather is obtained which will last for 1 to 2 minutes, the water is soft. If no lather is obtained, or if the lather does not last, the water is hard. NOTE 1. Rinse the shaking bottle clean with soft water thoroughly. 2. The soap solution bottle should be kept tightly stoppered. It will otherwise evaporate and give false reading. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 CALCIUM HARDNESS The water sample is titrated against EDTA solution using Murexide indicator (ammonium purpurate) in highly alkaline medium. REAGENTS 1. Approximately 1 N sodium hydroxide solution 2. 0.01 M standard EDTA solution 3. Murexide indicator PROCEDURE: Prepare a colour comparison blank in a white porcelain basin by stirring 2.0 ml of 1 N. NaOH, 0.2 g solid indicator mixture (or 4 to 6 drops of indicator solution) into 50 ml of distilled water and sufficient EDTA titrant (0.05 to 0.1 ml) to produce an unchanging purple colour. Pipette into a similar basin 50 ml. of sample, neutralize the alkalinity with 0.02 N. HCl, boil for 2 to 3 minutes to expel the CO2 and cool to room temperature. Add 2.0 ml 1 N NaOH, or a volume sufficient to produce a pH of 12 to 13 and mix. Add 0.2 g of powdered indicator. Stirring constantly titrate with standard EDTA solution to the colour of comparison blank. Check the end point by adding 1 or 2 drops of titrant in excess to be sure that no further deepening of the purple colour takes place. Calculations Calcium, as CaCO3, mg/L = (A ‐) x C x 1000 ml of Sample Where A = ml of EDTA required for titration of sample B = ml of EDTA required for blank C = mg of CaCO3 equivalent to 1.0 ml of EDTA NOTE: The only serious interference with the EDTA titrant of calcium is that of orthophosphate ion. If the calcium hardness exceeds about 60 ppm CaCO3, and the concentration of orthophosphate is 10 ppm, or more, calcium phosphate is precipitated when the pH is raised to 12, giving low results. Phosphate, if present, can be removed by ion exchange. WATER TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 8. SILICA The silica content of natural water will vary to a considerable extent depending on the locality. The presence of silica is particularly objectionable in water used for boiler feed purpose as it may lead to the formation of hard dense scale. In addition, a very serious problem encountered in high pressure operations is the deposition of siliceous materials on turbine blades & super heaters. The gravimetric method is the standard applicable above 20 mg / lit SiO2 content. This method should be followed for standardization of standard silicate solution used in colorimetric methods. The heteropoly blue colorimetric method is adaptable for the range of 0 to 2 mg / lit SiO2 & yellow molyb silicate method in the range of 0 to 20 mg / lit. Reagent blank should always be used in all the three methods. METHOD A ‐ GRAVIMETRIC METHOD PROCEDURE Take a sample to contain at least 10 mg of SiO2 . If necessary clarify by filtration. Acidify with 2 or 3 ml of conc. HCl & evaporate to dryness in a platinum dish on a water bath. At regular intervals add 2 or more portions of 2 to 3 ml of conc. HCl as an additional quantity of sample is added to the dish. Bake the evaporated residue in an oven ad 110 Deg. C for about an hour. Add 5 ml. of conc. HCl warm & add 50 ml distilled water. Loosen the clinging residue from the sides & the bottom of the dish & filter collecting the filtrate. Wash the dish & residue with hot 1 : 50 HCl & finally with distilled water until the washings are free from chloride. Return the filtrate & washings to the platinum dish & again evaporate to dryness. Repeat as previously, collecting the residue in another filter paper. Dry the two filter papers with residue, burn, ignite at 1000‐1200 Deg.C in a platinum crucible & weigh. Moisten the residue with a few drops of distilled water; add 2 drops of H2SO4 & 10 ml. 48% HF. Cautiously evaporate to dryness on a steam bath in a fume cupboard. Again ignite at 1000‐1200 Deg.C Cool & weigh. Carry out a blank. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Calculations ( A ‐ B ) ‐ ( C ‐ D ) x 1000 SiO2 , as SiO2 mg / lit = ml of sample Where A = Weight of crucible & sample residue in mg. after first ignition B = Weight of crucible & sample residue in mg. after HF treatment & second ignition. C = Weight of crucible & blank residue in mg. after first ignition D = Weight of crucible & blank residue in mg. after HF treatment & second ignition. METHOD B ‐ REACTIVE SILICA COLOMETRIC ESTIMATION OF SILICA Ammonium molybdate at approximately pH 1.2 reacts with silica & any phosphate present to produce hteropoly acids. Oxalic acid is added to destroy the molybdophosphoric acid but not the molybdosilicic acid. Even if phosphate is known to be absent, the addition of oxalic acid is highly desirable & is a mandatory step. The intensity of the yellow colour is proportional to the concentration of molybdate‐ reactive silica. The yellow molybdosilicic acid is reduced by means of 1 Amino ‐ 2‐ naphthol ‐ 4 ‐ sulphonic acid to heteropoly‐ blue. The blue colour is more intense than the yellow colour & provides increased sensitivity. In at least one of its forms , silica does not react with molybdate even though it is capable of passing through filter paper & is not noticeable turbid. The presence of such a molybdate unreactive silica is undesirable in raw water .It will not be removed in the water treatment plant & will find its way to highly pressure stream system, where it will be converted to “molybdate‐reactive " silica. Such increase in silica content will give rise to scale problem. PLANT Chromate & large amounts of Fe, PO4, sulphide, tannin, colour & turbidity are potential interferences. Oxalic acid treatment suppresses PO4 & reduces tannin interference. Inorganic sulphide can be removed by boiling an acidified sample. The addition of 1 ml. of 1% EDTA solution after molybdate reagent overcomes high Fe & Ca concentrations. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 COLORIMETRIC ESTIMATION OF SILICA ‐ 0‐ 20 PPM SiO2 REAGENTS 1. Ammonium molybdate solution 2. 2 N sulphuric acid 3. 10 % oxalic acid 4. Lovibond comparator with standard silica disc. PROCEDURE 1. Fill one of the Nessler tubes to the 50 ml. mark with sample & place in the left hand compartment of Lovibond comparator. 2. Fill the other Nessler tube with 50 ml. of sample at 25 ‐ 30 Deg.C Add 2 ml. of acidified ammonium molybdate solution. Mix thoroughly, adds 4 ml. of oxalic acid & again mix thoroughly. Place in the right hand compartment & allow to stand for 10 minutes. 3. Stand the comparator facing a uniform source of light; compare the colour of the sample in the disc. Rotate the disc until the colours are matched. Calculations SiO2 in mg / lit as SiO2 = Disc reading x 20 NOTES 1. Should the colour in the test solution be deeper than the deepest standard , a fresh test should be carried out using a smaller quantity of sample & diluting to 50 ml. with distilled water before adding the REAGENTS. TREATMENT PLANT 2. Silica free water : 3. Distilled water from an all ‐ metal "Still " or water which has been passed successively through a mixed bed deionization unit & strongly basic anion exchanger such as Tulsion A27MP unit regenerated with a regeneration level of 320 gm per liter NaOH has been found to be suitable. Prepare & store in a polyethylene bottle a large batch of water containing not more than 0.005 ppm SiO2, determine the silica content of water by treating it as a sample. This water is used to prepare reagents & standards, & to dilute samples when necessary. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 COLOMETRIC ESTIMATION OF SILICA 0‐2 PPM SiO2 REAGENTS 1. Acidified ammonium molybdate solution. 2. 10 % oxalic acid. 3. Amino ‐ naphthol reducing agent. 4. Lovibond comparator with standard silica disc or spectrophotometer suitable for measurement at 815 micro siemens wave length. PROCEDURE 1. Fill one of Nessler tubes to the 50 ml. Mark with sample, & place in the left hand compartment of Lovibond comparator. 2. Fill the other Nessler tube with 50 ml. of sample, at 25 ‐30 Deg.C. Add 2 ml. of acidified ammonium molybdate solution. Mix thoroughly, stand for 5 minutes. Add 4 ml of oxalic acid & mix well. Then 2 ml. of reducing agent, mix well compared with that of a blank comprising the same water without reagents, using Lovibond comparator or read the absorbance using a spectrophotometer (wave length 815 micro siemens). Compute the silica content from the standard graph prepared from the standard silica solution. TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 METHOD C : DETERMINATION OF TOTAL SILICA (MOLYBDATE REACTIVE & UNREACTIVE SILICA) The molybdate unreactive silica is converted to the reactive form or state by digesting the sample with sodium bicarbonate. REAGENTS 1. Sodium bicarbonate. 2. 1 N sulphuric acid. 3. Other reagents as per previous method. PROCEDURE Take 100 ml. of sample or lesser quantity ( 20 ‐ 100 micrograms SiO2 ) but made up to 100 ml. distilled water in a platinum dish. Add 200 mg. of silica free sodium bicarbonate & digest on a stream bath for one hour. Cool & add slowly, with stirring, 2.5 ml. sulphuric acid ( 1 N ) . Do not interrupt the analysis but proceed at once with the remaining steps. Transfer quantitatively into a plastic container. For development of colour & CALCULATIONS refer the previous procedure. TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 9. CHLORIDE METHOD A ‐ SILVER NITRATE METHOD Chloride is determined by titration with std. silver nitrate solution in the presence of potassium chromate indicator at neutral Ph. Silver chloride is precipitated and at the end point red silver chromate is formed. REAGENTS 1. N Std. silver nitrate solution 2. Potassium chromate indicator 3. Phenolthalein Indicator solution 4. N Nitric Acid solution 5. Calcium carbonate PROCEDURE Take 50 ml. or 100 ml of sample in an Erlenmeyer flask. Add five drops of phenolthalein. If the sample turns pink, Neutralize with 0.02 N Nitric acid. If Acidic (as in the case of decationised water) add a small amount of A.R. calcium carbonates. Add 1 ml of potassium chromate indicator and titrate with std. silver nitrate solution with constant. Stirring until there is perceptible reddish colour. Subtract 0.2 ml. from titration fig. to allow for the excess of reagents required to form silver chromate. Calculation Chloride as CaC03 mg/lit = ml of AgN03 * 1000 ml of sample taken NOTE 1. If sample is highly coloured, add Al(OH)3 suspension, mix then let it settle , filter and combine filtrate and washing 2. If sulphide, sulphite and thiosulfate are present, add 1ml H2O2 and stir for 1 Min. 3. Bromide, iodide and cyanide register as Eqvt. Chloride concentration. WATER TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 METHOD B Chloride ion can be titrated with mercuric nitrate because of the formation of soluble, slightly dissociated mercuric chloride. In the Ph range 2.3 to 2.8 diphenylcarbozone indicates the end point of this titration by formation of purple complex with excess of mercuric ions. To keep the solution in Ph range +/‐ 0.1 Ph unit nickel nitrate with HNO3 is added. REAGENTS 1. 0.02 N Mercuric nitrate Std. solution 2. Diphenyl‐carbozone indicator solution 3. 4 M nickel nitrate solution PROCEDURE Take 50 ml. of sample, add 1 ml. of diphenylcarbozone indicator solution. Add 1 ml. of nickel nitrate solution. Titrate against Std. mercuric nitrate solution to colour change of green to violet. Carry out blank titration with DM Water. Calculation: Chloride as CaCO3 mg/lit = (A ‐ B ) * 1000 ml. of sample Where A = ml of titrant required for sample B = ml of titrant required for blank. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 METHOD C ‐ CHLOROMETRIC METHOD FOR CHLORIDE (MERCURY THIOCYNATE METHOD) This method depends upon the displacement of thiocynate ion from mercuric thiocynate by chloride ion. In the presence of ferric ion, a highly coloured ferric thiocynate complex is formed and the intensity of its colour is proportional to the original chloride ion concentration. WATER TREATMENT PLANT REAGENTS 1. Mercuric thiocynate solution 2. Ferric ammonium sulphate solution 3. Std. sodium chloride solution ‐0.1 mgCl / ml. PROCEDURE Take 10‐20 ml of water sample containing about 40 micrograms of chloride in a 25 ml. std. flask. Add 2.0 ml of ferric ammonium sulphate solution, followed by 2.0 ml of mercuric thiocynate solution. Make up to the volume. Measure the optical density at 460 micro siemens from the calibration curve for the Std., compute the value for the sample. Calculation Chloride, as CL mg /lit = Microgram of chloride from graph ml. of sample TREATMENT PLANT LANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 10. OILS AND GREASE OUTLINE OF THE METHOD The oils & grease are extracted by an organic solvent. The solvent is distilled off & the weight of the extracted matter is determined. Some extractable, especially unsaturated fats & fatty acids Oxidize rapidly hence, special precautions regarding temperature & solvent vapour displacement are necessary to minimise this effect. SAMPLING The most satisfactory method of sampling two ‐ phase liquids is to use a sampling tube that is capable of withdrawing a complete section of the water as it flows in a rectangular culvert or trough, in most instances, however, water will have to be sampled from the outfall of the pipe or from a stream & in these circumstances some of the water should first be collected in a large cylindrical vessel having a capacity of 10 to 15 litres. A sectional sampling tube should be used to withdraw the test sample from this. A sampling tube suitable for sampling water, that don’t contain highly viscous matter (for example, tar) consist of a heavy ‐ gauge brass tube, 1m. long, with an outside diameter of 40 mm. Over one end of the tube is fitted to the brass bucket made from a piece of tube 50 mm. long & sealed at one end. The bucket has an internal diameter of 1.5 mm. greater than the outside diameter of the main tube. To the opposite sides of the bucket, are braced two brass rods, 6mm. in diameter, which pass through guides braced to sides of the main tube. The rods are so arranged that the top of the bucket can be withdrawn to a distance of not less than 10 cm. from the bottom of the main tube, & they guide the bucket into a position covering the end of the tube when it is pushed back again. A suitable spring catch is provided on one of the guide rods so that the bucket is automatically locked into the top position when it is raised to its highest point. The open end of the sampling tube is fitted with a rubber bung. To take a sectional sample, the spring catch is released & the bucket is drawn as far away as possible from the end of main tube. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 The rubber bung is withdrawn from the other end. The tube is lowered vertically through the liquid to the sampled until the bottom of the bucket rest on the bottom of the culvert ANT or of the vessel that has been filled with the water. The main tube is then pushed down, guided by the brass rods, to the limits of his travel, whereupon the spring catch locks the bucket in the raised position covering the end of the tube. The rubber bung is tightly inserted in the open end & the tube is withdrawn. The outside of the sampler is wiped free of adhering liquid the bucket & the lower part of the tube are inserted In to a wide mouthed bottle of suitable capacity, & the rubber bung is removed. The sample section of the liquid will flow into the bottle leaving a small quantity of liquid in the bucket. The tube is then tilted, so that this liquid is added to the main bulk of the sample. The operation is repeated until sufficient quantity has been collected. At least 24 ‐ 25 mm. of air space should be left between the top level of the liquid & the stopper of the bottle. STORAGE OF SAMPLE Since many oils & hydrocarbons are utilised by bacteria, storage is obviously detrimental. However, if it becomes necessary to store the sample before analysis is taken up, the samples should be acidified with dilute sulphuric acid (1 : 1), 5 ml / lit., of the sample, to inhibit bacterial activity. APPARATUS SEPARATING FUNNELS Of 1.5 to 2 litres capacity. The stopper or stop cock should not be lubricated with matter soluble in petroleum ether. REAGENTS 1. Dilute Hydrochloric acid ‐ 1 : 1 2. Light Petroleum (Petroleum ether) ‐ boiling range 40 to 60C. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 PROCEDURE Place the sample, usually 1 litre, in a separating funnel of sufficient size to allow the addition of acid & solvent, & still have space for proper agitation. Acidify the sample with dilute hydrochloric acid, 5 ml /lit, of the sample. Rinse the sample bottle carefully with 15 ml. of petroleum ether & add the ether washings to the separating funnel. Add an additional 25 ml. of ether to the sample bottle, rotate the ether in the sample bottle & add the ether to the separating funnel. Shake vigorously for 2 minutes. Allow the ether layer to separate. Withdraw the aqueous portion of the sample into a clean container, & transfer the solvent layer into a clean, tarred distilling flask capable of holding at least 3 volumes of solvents (See Note). If a clear ether layer cannot be obtained, filter the solvent layer into tarred distilling flask through a funnel containing an ether moistened filter paper. The filter paper should be washed with petroleum either after folding to avoid inclusion of skin oils. Use a small funnel and filter paper as practical. NOTE While transferring the solvent layer from the separating funnel, a small quantity of it remains at the stem of the separating funnel, it is advisable to wash it with a few milliliters of solvent and to add the washings to the solvent layer. Return the aqueous portion of the sample to the separating funnel, rinsing the container with 15 ml. of ether. Add the ether washings and additional 25 ml. of ether to the separating funnel and agitate for about 2 Min. allow the solvent layer to separate and discard the aqueous phase. Add the ether washings to the tarred distilled flask . After all the ether from the 2 extractions and the final rinsing are included wash down the funnel and filter paper twice with fresh 5 ml. increments of the petroleum ether. Distil of all but approx. 10 ml. of the ether extract on a water batch or an electric heating mantle, observing necessary safety precautions and keeping the heat source at about 70 Deg c. Disconnect the condenser and boil of the remaining the solvent from the tarred flask at the same temp. Dry on a water bath or stream bath. When dry, lay the flask on its side to facilitate the removal of solvent vapour. Introduce Aprrox. 3 volumes of dry illuminating gas or Nitrogen into flask to displace solvent vapour. Cool in desiccator for 30 Min. and weigh. TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Calculation Oils and grease, mg/lit =
1000 W V
Where, W = weight in Mg. of the residue in the flask V = volume in ml. of the sample taken for the test. Express the result to the nearest Mg OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 11. RESIDUAL CHLORINE (ORTHOTOLYDINE ‐ ARSENI METHOD) Chlorine rapidly oxidises ortholydine (3,3‐dimethybenzdine) to the corresp. hologuinone which is intensely yellow. This provides a sensitive test for available chlorine. The test is subject to interference by production of false colour for chlorine when nitrite, iron or manganese is present in the water. The false colour produced with orthotoludine by interfering substance present in the presence of sodium arsenite but the colour due to residual chlorine does not. The test permits the measurement of the relative amounts of free available chlorine, combined available chlorine, and colour due to interfering substances. The temperature of the sample should never be above 20deg C. REAGENTS 1. Phosphate buffer solution ‐0.5% 2. Potassium dichromate solution 3. P‐Tolydine reagent 4. 5 % sodium arsenite solution PROCEDURE 1. VISUAL STANDARDS Pipette into 100 ml. Nessler cylinder 1,2,3 etc. ml of dilute chromate‐ dichromate solution an dilute to 100 ml with phosphate . Protect the solutions from dust, evaporation and direct sunlight. These Stds. correspond to residual chlorine Eqvt. Of 0.01, 0.02 ,0.03.... mg/lit Resp. 2. FREE AVAILABLE CHLORINE In a nessler tube take 0.5 ml of Toludine reagent and 9.5 ml of sample. Mix quickly and thoroughly and add 0.5 ml of NaAS02 followed by mixing. Compare the colour with Std. (Call this reading as A). 3. TOTAL AVAILABLE RESIDUAL CHLORINE In a nessler tube take 0.5 ml of 0‐Toludine reagent and 9.5 ml of sample, mix and compare the colour with standards colour in similar tube after 5 Min. (Call this reading as B). OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 4. BLANK Prepare a blank 9.5 ml sample and 0.5 ml NaAS02 solution and compare the colour with std. colour immediately and after 5 Min. (Call this reading as C1 and C2). Calculation Free available residual chlorine = Reading A ‐ Blank C1 Combined available residual chlorine = Reading B ‐ Blank A Total available residual chlorine = Reading B ‐ Blank C2 WATER TREATMENT PLANT OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 12. REAGENTS 1. STANDARD 1 N HCL SOLUTION Dilute 83 ml. of conc. HCL (about 11 N solution, specific gravity 1.174‐1.189 ) to 1lit. With distilled or deionised water . Standardise with standard sodium carbonate solution. 2. STANDARD 0.1 N HCL SOLUTION Dilute 8.3 ml. of conc. Hcl or 100 ml. of 1 N solution to 1000 with distilled water. Standardize with standard sodium carbonate solution. 3. STANDARD 0.02 N Hcl SOLUTION. Dilute 200 ml. of 0.1 N standard acid to 1000 ml. with distilled water. Standardize with standard sodium carbonate solution 4. STANDARD 1 N H2SO4 SOLUTION Dilute 28 ml. of conc. H2SO4 (about 36 N solution, specific gravity 1.834‐1.836 ) to 1lit. With distilled or deionised water. Standardise with standard sodium carbonate solution. 5. STANDARD 0.1 N H2SO4 SOLUTION Dilute 2.8 ml. conc. H2SO4 to 1 lit. with distilled or deionised water. Standardize with standard sodium carbonate solution. 6. STANDARD 0.02 N H2SO4 SOLUTION Dilute 200 ml. of 0.01 N H2SO4 to 1 lit. with distilled or deionised water. Standardize with standard sodium carbonate solution. 7. 1.0 N HNO3 SOLUTION Dilute 64 ml. of conc. HNO3 (about 15 N solution, specific gravity 1.409‐1.418 ) to 1lit. with distilled or de ionized water. Standardize with standard sodium carbonate solution. 8. STANDARD I.0 N NAOH SOLUTION Dissolve 40.0 gm. of NAOH to 1.0 lit. with carbon dioxide free distilled or deionised water . Standardize with standard acid solution. 9. STANDARD 0.1 N NAOH SOLUTION Dissolve 4.0 gms of NAOH to 1.0 lit. with carbon dioxide free distilled or deionised water. Standardise with standard acid solution. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 10. STANDARD SODIUM CARBONATE SOLUTION (Approx. 0.05 N ) Dry 3 to 5 g primary standard Na2CO3 at 250 deg C for 4 hours & cool in a desicator . Weigh 2.5 +/‐ 0.2 gms (to the nearest mg. ) Dilute to 1litre with deionised or distilled water. 11. STANDARD 0.02 N SILVER NITRATE SOLUTION. Dissolve 3.3927 gms. AgNO3 in distilled water & dilute to 1 lit. Standardise against 0.02 N NaCl standard solution. 12. STANDARD 0.02 N SODIUM CHLORIDE SOLUTION Dry 2‐3 g of primary standard NaCl at 140 deg C for 4 hours & cool it in a desicator. Weigh 1.689 gms (to the nearest mg. ) Dilute to 1litre with deionised or distilled water. 13. STANDARD 0.02 N MERCURIC NITRATE SOLUTION Dissolve 3.246 gm. mercuric nitrate in 100 ml of 5% HNO3 solution and make up to 1 lit. with D.M. water. Standardise with standard sodium carbonate solution. 14. STANDARD MERCURIC THIOCYANATE SOLUTION Weigh 1 gm Hg(SCN)2 & add 100 ml methanol & mix to obtain a saturated solution. Stored a amber bottle in a cool place. 15. FERRIC AMMONIUM SULPHATE Dissolve 12 g of Fe (NH4)2(SO4) 212H2O in 100 ml of 9 N HNO3 (580 ml. of conc. HNO3 in 1 lit. of water). Filter if necessary & store in a amber bottle. 16. 0.1 MG/LIT. STANDARD CHLORIDE SOLUTION Dissolve 1. 1648 g NaCl in 1 lit. of distilled or deionised water. 17. AMMONIA BUFFER OH pH 10 Dissolve 16.9 g of ammonium chloride in 143 ml. conc. ammonium hydroxide (NH4OH). Add 1.25 g of magnesium salt of EDTA. (If the magnesium salt of EDTA is unavailable dissolve 1.179 g disodium salt of EDTA & 780 mg. MgSO4.7H2O or 644mg. MgCl2.6H2O in 50 ml. distilled water.) & dilute to 250 ml. with distilled water. 18. STANDARD 0.01 M SOLUTION OF EDTA Dissolve 3.723 g of disodium salt of EDTA in 1 lit. of distilled or deionised water. Standardise with standard calcium solution. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 19. STANDARD CALCIUM SOLUTION Weigh 1 gm anhydrous calcium carbonate into a beaker, add a little at a time, dilute Hydrochloric acid until CaCO3 has dissolved. Wash down the beaker with carbon dioxide free water & makeup to 1 lit. 1 ml. of the solution contains 1mg of sulphates (as SO4) 20. STANDARD BARIUM CHLORIDE SOLUTION Dissolve 2.443 g of barium chloride (BaCl2, 2H2O) in distilled water & dilute to 1 lit. 1 ml. of this solution is equivalent to 0.36 mg. of sulphate (as SO4). 21. STANDARD POTASSIUM IODATE ‐IODATE SOLUTION Weigh accurately 0.713 g of potassium iodate & dissolve in about 150 ml. of distilled water. Add 7 g of potassium iodate & 0.5 g of sodium bicarbonate ,when dissolved, dilute the solution to exactly 1 liy. 22. STANDARD IRON SOLUTION Dissolve 1.404 g of ferrous ammonium sulphate Fe(NH4)2(SO4)2, 6H2O in 50 ml. distilled water & 20 ml. conc. H2SO4. Add 0.1 N KMNO4 dropwise to impart a faint but persistent pink colour & dilute to 1 lit. with distilled eater. Dilute 50 ml. of the above stock solution to 1 lit. with distilled water to form a standard solution containing 0.01 mg. fe/ml. 23. 1,10 PHENANTHROLINE MONOHYDRATE SOLUTION Dissolve 0.1 g in 100 ml. distilled water containing 2 drops conc. Hcl . (Not more than 0.1 mg. Fe can be determined). 24. AMMONIUM ACETATE BUFFER SOLUTION Dissolve 250 g of ammonium acetate in 150 ml. distilled water, add 700 ml. glacial acetic acid & dilute to 1 lit. 25. AMMONIUM MOLYBDATE SOLUTION FOR SILICA ESTIMATION 75 g of ammonium molybdate is dissolved in 500 ml. of distilled water. To 322 ml. of 10 N sulphuric acid the molybdate solution is added gradually with constant stirring. The solution is made upto 1 lit. 26. 10% OXALIC ACID Dissolve 10 gms. oxalic acid in 100 ml. of distilled water. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 27. AMINO NAPHTHOL REDUCING AGENT Dissolve 0.5 g of 1 amino‐2‐naphthol‐4sulphonic acid & 1gm. of sodium sulphite (Na2SO3) in 50 ml. distilled water, with gentle warming if necessary, add this to solution of 30 g sodium metabisulphite (NaHSO3)in 150 ml. distilled water. Filter into plastic bottle. Dicard the solution when it becomes dark. prolong reagent life by sorting in a refrigerator. 28. STOCK SILICA SOLUTION Dissolve 4.73 g of sodium metasilicate nonhydrate (Na2SiO3, 9H2O) in recently boiled & cooled water & dilute to approx. 900 ml. Analyse 100.0ml. portions by gravimetric method, adjust the remainder of the solution to contain 1.000 mg./1SiO2. Store in a tightly stoppered plastic bottle. 29. STANDARD SILICA SOLUTION Dilute 10 ml. stock solution to 1 lit. with recently boiled & cooled water this solution contains 10 mg/lit. SiO2 or 1 ml. =10 SiO2. Store in tightly stoppered plastic bottle. 30. AMMONIUM MOLYBDATE SOLUTION FOR PHOSPHATE ESTIMATION Dissolve 25 gms. of ammonium molybdate in 175 ml. of distilled water. In another container add, cautiously to 400 ml. of distilled water, 310 ml. of conc. H2SO4. Cool it & add the molybdate solution to this distilled acid & dilute the whole to 1 lit. 31. STANNOUS CHLORIDE SOLUTION Dissolve 2.5 gms. of fresh supply of stannous chloride (SnCl2,2H2O) in 10 ml. of conc. Hcl & dilute to 100 ml. with distilled or deionised water. Filter if it is turbid. Store the solution in a cool place in a aspirator bottle having class stopcock. A 5 mm. thick layer of pure mineral oil shall be floated over the surface of the solution to minimise oxidation. Always drain out a little of solution out of the stopcock before use. 32. STANDARD PHOSPHATE SOLUTION Dissolve 0.716 g of dry potassium dihydrogen phosphate (KH2PO4) in 1 lit. of distilled water. Dilute 100 ml. of solution to 1lit. 1ml. of this solution =0.05 mg of phosphate (as PO4 ). 33. STANDARD 0.1 N POTASSIUM PERMANGANATE SOLUTION Dissolve 3.1608 g of potassium permanganate (dried at 105 deg C ) in distilled water made upto 1 lit. This solution must be stored in the dark. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 34. STANDARD 0.1 N OXALIC ACID SOLUTION Dissolve 4.5018 g of oxalic acid in distilled water, make upto 1lit. 35. PHOSPHATE BUFFER SOLUTION O.5 M (FOR FREE CHLORINE) Dissolve 22.68 g Na2HPO4 & 46.19 g KH2PO4 (both dried overnight at 105 deg C) & dilute to 1 lit. with distilled water. Let this solution age for No. of days & filter if any precipitate appears. 36. PHOSPHATE BUFFER SOLUTION 0.1 M Dilute 200 ml. of 0.5 M filtered phosphate buffer solution to 1 lit. 37. STOCK CHROMATE‐ DICHROMATE SOLUTION Dissolve 1.55 g K2Cr2O7 & 4.65 g K2CrO4 in 0.1 M phosphate buffer solution. 38. DILUTE CHROMATE DICHROMATE SOLUTION Dilute 100 ml. stock solution to 1 lit. with 0.1 M phosphate buffer solution. On dilution of 1ml. of this solution to 100 ml. with 0.1 M phosphate buffer solution gives a very close visual match with the yellow colour produced by 0.01 mg/lit. residual chlorine. 39. O‐TOLUDINE REAGENT Dissolve 1.35 g of O‐toludine dihydrogen chloride in 500 ml. distilled water & add with constant stirring to a solution of 150 ml. conc. Hcl in 350 ml. distilled water. 40. SODIUM ARSENITE SOLUTION Dissolve 5 g of sodium meta arsenite in 1lit. distilled water. 41. PHENOLPHTHALEIN INDICATOR SOLUTION Dissolve 0.1 g of phenolphthalein in 60 ml. of rectified spirit and dilute with distilled water to 100 ml. 42. METHYL ORANGE INDICATOR SOLUTION Dissolve 50 mg. methyl orange powder in distilled water & dilute to 100 ml. 43. SCREENED METHYL ORANGE INDICATOR SOLUTION Dissolve 0.2 g crystalline methyl orange in a mixture of 25 ml. of methylated spirit & 25 ml. of deionised water. Dissolve 0.28 g xylene cyanol FF in a mixture of 25 ml. of methylated spirit & 25 ml. deionised water. Mix the two solutions together. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 44. 5% POTASSIUM DICHROMATE INDICATOR SOLUTION Dissolve 50 g K2CrO4 in little distilled water. Add Silver Nitrate solution until a definite red precipitate is formed. Let it stand for 12 hr. filter & dilute to 1 lit with distilled water. 45. SODIUM THIOSULPHATE 0.1 N SOLUTION Dissolve 25 gm Na2S2O3,5H2O & dilute to 1 lit. with distilled water. 46. DIPHENYL CARBAZONE INDICATOR SOLUTION Dissolve 0.4 g of di phenyl carbazone in 100 ml. of 95% is propanol 47. 4 M NICKEL NITRATE SOLUTION. Dissolve 1163 gms. of nickel nitrate (Ni(NO3)2,6H2O)in 1 lit. of D.M. water. 48. ERIOCHROME BLACK T INDICATOR SOLUTION a) Mix 0.5 g of sodium salts of Eriochrome Black T ( 1‐ hydroxy‐2‐naphthylazo)‐5‐ nitro‐2‐ naphthol‐4‐sulphonic acid) with 4.5 gms hydroxylamine hydrochloride. Dissolve this mixture in 100 ml. of 95% ethyl or isopropyl alcohol. b) Mix together 0.5 g dye & 100 g NaCl to prepare a dry powder mixture. 49. MUREXIDE INDICATOR SOLUTION a) Dissolve 150 g of Murexide (ammonium purpurate ) in 100 g of absolute ethylene glycol. Water solution of the dye is not stable for longer than a day. b) Mix 200 mg. of murexide with 100 gms. of solid NaCl & grinding the mixture to 40 to 50 mesh. c) Titrate immediately after adding the indicator because it is unstable under alkaline conditions. 50. STARCH INDICATOR SOLUTION Dissolve 5 gms of starch & 0.01 gms of mercuric iodide with 30 ml. of cold distilled water & slowly pour it with constant stirring into 1 lit. of boiling distilled water. Boil for 3 min & allow it to cool then decant off the supernatant clear liquid. 51. HYDROXYLAMINE HYDROCHLORIDE SOLUTION FOR Fe Dissolve 10 gms. NH2OH & HCl in 100 ml. distilled water.
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
5.2 DAILY LOG SHEET S.NO 1 2 3 4 5
INLET
PARAMETERS Pressure Temperature DPT across vessel DPT across basket filter Flow Rate
OUTLET
S.NO
PARAMETERS
1
pH
2
Conductivity
3
Turbidity
4
Oil & Grease
5
Silica
6
Chlorides
INLET
OUTLET
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
6. P&ID FOR ACF P&ID FOR POWER PLANT: OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
73
THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 P&ID FOR AMMONIA PLANT:
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
74
THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
REFILL
1
2
RINSE
2
5
AIR BLOWER
ACFB 1
CONDENSATE WATER OUTLET VALVE
VM
CONDENSATE WATER INLET VALVE
NC
VM
NC
DRIVE DRIVE DESCRPTION TAG
VM26 BLOWER DISCHARGE
NC
STEAM INLET
AIR RELEASE
VM12
NC
VM30
RINSE OUTLET
VM6
NC
LEGEND
NC
VM4 BACKWASH OUTLET
NC
A
AIR INLET
BACKWASH INLET
VM3
NC
SERVICE MODE
VM5
SERVICE OUTLET
VM2
STEP NO
1
REF DOC: 1) P AND I DIAGRAM FOR SOFTENER PLANT PACKAGE DRG.NO. WTBAA00054 REV 03.
NC
SERVICE INLET
VM1
STEP DESCRIPTION
ACF
STEP TIME IN MINS VALVE VALVE POSITION TAG VALVE DESCRPTION
S.NO
7.OPERATION PROCEDURE FOR ACTIVATED CARBON (ACF)
SERVICE
3
1200
2
BACKWASH MODE
B
DRAIN DOWN AIR SCORING STEAM BACKWASH SETTLE BED REFILL FINAL RINSE OFF
1 2 3 4 5 6 7 8
2 5 10 10 2 2 10
R
3
AIR RELEASE
C
2
M/S.THERMAX LTD, THERMAX HOUSE, NO.4. MUMBAI‐PUNE ROAD, SHIVAJINAGAR, PUNE. 411005.
ISSUED FOR INFORMATION
SHEET NO.1
NC ‐ VALVE POSITION NORMALLY CLOSE - VALVE OPEN CONDITION
R ‐ MOTOR TO RUN IN PARTICULAR STEP
CLIENT: IFFCO, PHULPUR UNIT, ALLAHABAD, UTTARPRADESH. PROJECT: ACTIVATED CARBON FILTER UNIT FOR AMMONIA & POWER PLANT
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
8. TO WHOM CONTACT Service Manager – Regional Office SOUTHERN REGION THERMAX LIMITED, 312, ANNA SALAI, TEYNAMPET, CHENNAI-600018 TEL : 044 - 24353831 (4LINES); FAX : 044 - 24353841; Email : [email protected] NORTHERN REGION THERMAX LIMITED, 9, COMMUNITY CENTRE, BASANT LOK, NEAR PRIYA CINEMA, NEW DELHI – 110 057 TEL:011-26145319 FAX:011-26145311; Email: [email protected] EASTERN REGION THERMAX LIMITED, AZIMGANG HOUSE, 5TH FLOOR, 7, CAMAC STREET, KOLKATA;TEL:033-22826711/12/13; FAX:033-22826796; Email: [email protected] WESTERN REGION THERMAX LIMITED, WWS, SAI CHAMBERS, 15 MUMBAIPUNE ROAD, WAKADEWADI, PUNE – 411 003. TEL:020- 25541010 FAX:020- 25542235 Email: [email protected] Corporate Regional Manager SOUTHERN REGION THERMAX LIMITED, 312, ANNA SALAI, TEYNAMPET, CHENNAI-600 018 TEL:044-24353831(4LINES) FAX:044- 24353841 Email:[email protected] NORTHERN REGION THERMAX LIMITED, 9, COMMUNITY CENTRE, BASANT LOK, NEAR PRIYA CINEMA, NEW DELHI – 110 057 TEL:011-26145319 FAX:011-26145311 Email:[email protected] EASTERN REGION THERMAX LIMITED, AZIMGANG HOUSE, 5TH FLOOR, 7, CAMAC STREET, KOLKATA. TEL:033-22826711/12/13 FAX:033-22826796 Email:[email protected] WESTERN REGION THERMAX LIMITED, DHANRAJ MAHAL, 2ND FLOOR, CHATRAPATI SHIVAJI MARG, NEAR REGAL CINEMA, GATEWAY OF INDIA, COLABA, MUMBAI- 400 039 TEL:022- 22045391 FAX:022-22040859 Email:[email protected] Service Manager Head Office THERMAX LIMITED, WWS, SAI CHAMBERS, 15 MUMBAIPUNE ROAD, WAKADEWADI, PUNE – 411 003. TEL:020- 25541010 FAX:020- 25542235 Mobile : 98230 82588 Email:[email protected] Divisional Head THERMAX LIMITED, WWS, SAI CHAMBERS, 15 MUMBAIPUNE ROAD, WAKADEWADI, PUNE – 411 003. TEL:020-25541010 FAX:020- 25542235 For more information visit www.thermaxindia.com. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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