Chemical Operation Manual.pdf

KMPCL 6 x 600 MW Subcritical Coal-fired Power Plant Project
KSK Mahanadi Power Company Limited
6 x 600 MW Thermal Power Project Nariyara, Chhattisgarh, India
SEPCO ELECTRIC POWER CONSTRUCTION CORP.
No. C-001 Chemical Operation Manual Total 129 pages
Chemical Operation Manual
Drafted by: Wei Zhitong
Reviewed by: Lin Xinli
Approved by: Li Mingda

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CONTENTS
PART 1 Operation Rules for Raw Water Pretreatment.............................................................................1
Chapter 1 System Overview....................................................................................................................1
Chapter 2 System Introduction................................................................................................................3
Chapter 3 System Running.................................................................................................................... 11
Chapter 4 Equipment Accident Anticipation & Measures.....................................................................14
PART 2 Make-up Water System ................................................................................................................15
Chapter 1 System Overview..................................................................................................................15
Chapter 2 Pretreatment System.............................................................................................................16
Chapter 3 Ultrafiltration & Reverse Osmosis System...........................................................................19
Chapter 4 Ion Exchanger Put-in & Regeneration..................................................................................30
Chapter 5 Accident Anticipation & Measures.......................................................................................37
PART 3 Condensate System .......................................................................................................................39
Chapter 2 Start-up and Shutdown Operation of Equipment..................................................................41
Chapter4SafetyTechnicalMeasuresforCondensateDemineralizingEquipmentOperation....................................46
Chapter 5 Regeneration of High-speed Mixed Bed...............................................................................47
PART 4 Water-steam Quality Supervision & Chemical Feed Operation...............................................56
Chapter 2 System Introduction..............................................................................................................56
Chapter 3 Water-steam Quality Supervision Standard ..........................................................................58
Chapter 4 Chemical Supervision for Cold and Hot Start-up of Unit.....................................................59
Chapter 5 Supervision in Normal Unit Operation.................................................................................63
Chapter 7 Steam-water Sampling Operation.........................................................................................69
Chapter 8 Operation of Chemical Feed System ....................................................................................72
PART 5 Chemical Test Methods.................................................................................................................76
Chapter 1 Usage and Maintenance of Instruments................................................................................76
Chapter 2 Assay Methods......................................................................................................................81
PART 6 Circulating Cooling Water System..............................................................................................95
Chapter 2 System Introduction..............................................................................................................95
Chapter 3 Equipment Put-in & Shutdown.............................................................................................97
PART 7 Sewage Operating System ............................................................................................................99
Chapter 1 Coal-bearing Wastewater Treatment System........................................................................99
Chapter 2 Oily Wastewater Treatment System ...................................................................................103
Chapter 3 Domestic Sewage Treatment System .................................................................................106
PART 8 Rules for Hydrogen Generation Station System....................................................................... 113
Chapter 1 System Overview................................................................................................................ 113
Chapter 2 Safety Precautions .............................................................................................................. 114
Chapter 3 Technical Requirements...................................................................................................... 116
Chapter 4 Start-up, Operation and Shutdown of Equipment............................................................... 117
Chapter 5 Supervision & Maintenance of Equipment in Normal Operation....................................... 119
Chapter 6 Chemical Supervision on the Gas Displacement of Generator...........................................120

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Chapter 7 Test of Gas Purity ...............................................................................................................121
Chapter 8 Accident Anticipation & Measures for Preventing Explosion of Hydrogen Generation
Station & Hydrogen System................................................................................................................125

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PART 1 Operation Rules for Raw Water Pretreatment
Chapter 1 System Overview
1. Raw water treatment
The main task of water pretreatment is to remove the suspended solids and colloid by means of coagulation,
clarification and filtration.
1.1 Coagulation treatment
Coagulation treatment for water is such a process in which a kind of material named coagulant agent is
added to water to urge little granules to gather into large granule flocculates that separate from water. There
are many kinds of coagulant agents. This plant adopts polyaluminium chloride (PAC) and uses
polyacrylamide (PAM) as coagulant acid in order to improve the coagulation treatment.
1.2 Clarification treatment
Clarification treatment means adding coagulant agents to the reaction tank, in which coagulant agents are
ionized and hydrolyzed and then produce a material (flocculate) with absorbability and bindability that can
further collide with, absorb, and bind the foreign matters in water to form larger flocculates (slime sludge)
so as to improve the effects of sediment treatment accordingly. This plant adopts mechanically accelerated
clarification tank.
1.3 Water source data
The water source for the whole plant in this project is the Mahanadi/riverine system, and the water supply
system is a circulating water system.
In this phase, it is to build up a 60X104
m3
raw water-storage reservoir and reserve the place for extending
another water-storage reservoir with the same volume in the next phase. Raw water pretreatment system is
supplied with water through the raw water booster pump nearby the water-storage reservoir. The raw water
pretreatment system has a treatment capacity of 9,000m3
/h and continuous water yield of 8,151m3
/h
(tentative).
1.4 A raw water pretreatment system device is installed in the power plant for the 6 600MW sub-critical
coal-fired units in this phase of project (including supporting sludge treatment system, excluding
chlorination system)
1.5 Raw water quality is described in the following table.
Sr. No. Test Samples Design Raw Water Analysis
1 Color (Pt Co Units) 20
2 Temperature ℃ 27
3 pH value 8.4
4 Odor Un-objectionable
5 Total suspended solids, mg/l 1500 (During Monsoon)
6 Turbidity NTU222…fff 1000 (During Monsoon)
7 Free chloride/residual oxidant Nil
8 Total dissolved solids, mg/l 400
9 E C (μs/cm) 600
10 Total hardness CaCO3, mg/l 185
11 High calcium hardness CaCO3, mg/l 115

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Sr. No. Test Samples Design Raw Water Analysis
12 Magnesium hardness CaCO3, mg/l 70
13 Natrium Na, mg/l 30
14 Potassium K, mg/l 5
15 High carbonate rock hardness CaCO3, mg/l 185
16. High non-carbonate rock hardness CaCO3, mg/l Nil
17 Phenolphthalein alkalinity CaCO3, mg/l Nil
18 Methyl orange alkalinity CaCO3, mg/l 185
19 Sulphate SO4, mg/l 35
20 Chloride Cl, mg/l 22
21 Nitrate NO3, mg/l 3
22 Sulphide as H2S, mg/l 0.01
23 Phosephates as PO4, mg/l 0.03
24 Activated silica SiO2, mg/l 14
25 Silicon dioxide, mg/l (Non-reactive) 8
26 BOD5, mg/l 7
27 COD, mg/l 35
28 T O C -
29 Phenol /Other arene <0.01
30 a Grease, mg/l <1
b Free floating, mg/l <1
c Emulsifying agent, mg/l <1
31 Carbon dioxide CO2, mg/l 0.9
32. Free ammonia, mg/l Nil
Heavy metal :
33 Iron Fe, mg/l <0.5
34 Manganese Mn, mg/l <0.01
35 Chromium Cr, mg/l <0.01
36 Copper Cu, mg/l <0.01
37 Nickel Ni, mg/l <0.01
38 Zinc Zn, mg/l <0.01
39 Aluminum Al, mg/l <0.01
40 Cadmium Cd, mg/l <0.01
41 Arsenic As, mg/l <0.01
42 Boron B, mg/l 0.05
43 Mercury Hg, mg/l <0.001
44 Lead Pb, mg/l <0.01
45 Dissolved oxygen, mg/l 6
46 Cyanide CN, mg/l <0.01
47 Fluorine F, mg/l 0.5
48 Barium Ba, mg/l Nil
49 Strontium Sr, mg/l <0.01
50 Kjeldahl Nitrogen, mg/l 1
51 Vanadium V, mg/l <0.01
52 Selenium Se, mg/l <0.01

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Chapter 2 System Introduction
2.1 Working principle of clarification tank
This project uses an efficient solid-contact clarification tank for the pretreatment of raw water, and the
coagulant sent is sent by chemical feeder to the feeding point before clarification tank to fully mix with the
raw water from water-storage reservoir through a static mixer and the mixture flows into the clarification
tank. The clean water treated in the efficient solid-contact clarification tank flows automatically into the
clean water pond, and the turbid water therefrom flows automatically into the sludge storage pond and is
lifted by the sludge lift pump up to the sludge thickening tank, after which the thickened supernatant is
boosted and sent back by the reflux pump to the efficient solid-contact clarification tank via the inlet for
recycling and retreatment, and the thickened turbid water flows automatically into the sludge balancing
tank and is lifted and sent by the sludge lift pump to the centrifugal sludge dehydrator for dewatering, the
sludge cakes after dewatering are transported by vehicle to the ash yard nearby the power plant, the drain
water of dehydrator flows automatically to the sludge thickening tank.
Major equipment include: solid-contact clarification tank agitator, sludge scraper, inclined tube filler,
sludge storage pool agitator, sludge lift pump, sludge thickening tank scraper, sludge lift pump of sludge
balancing tank, reflux pump, centrifugal sludge dehydrator, valves, control system, chemical feeding
equipment and static mixer, etc.
2.2 Technical parameters table of clarification tank:
No. Relevant parameters Unit Value Remarks
A Basic parameters
1. Type Sludge recycling
separation type
2. Quantity Set 4
3. Inner diameter m Φ14.3
4. Straight edge height m 7.0
5. Total height m 9.42
6. Effective volume m3
1060
7. Bottom slope 12%
8. Arrangement type
9. Normal flow m3
/h 380
10. Maximum flow m3
/h 430
11. Residence time in the first reaction
chamber
min 4.5
12. Residence time in the second
reaction chamber
min 21
13. Total residence time min 180
14. Flow rate in the first reaction
chamber
mm/s 180
15. Flow rate in the second reaction
chamber
mm/s 20
16. Up-flow velocity in separation zone mm/s <0.8mm/s
When 3 sets are
running
17. Lift flow m3
/h 1320
18. Sludge reflux ratio 4:1
B First reaction chamber
19. Material Carbon steel
20. Diameter m 2
21. Height m 5
22. Steel plate thickness mm 6

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C Second reaction chamber
24. Diameter m 6
25. Height m 5.87
26. Steel plate thickness mm 8
D Separation zone
27. Separation area in separation zone m2
132
28. Height of clean water area m 1.5
29. Separation zone volume m3
4
E Water collection sump
30. Form Ring form
32. Quantity (each) Set 12
33. Section size mm 400×
500
F Inclined tube
34. Tube material Ethylene-propylene
copolymer
35. Height Inclined length 1000mm
36. Area ≥130m2
/set
Meet the system
requirements
37. Form Φ50 hexagonal
beehive
G Agitator
38. Model HX-14.3-JJ
39. Quantity (each clarification tank) Set 1
40. Supporting motor power kW 7.5
41. Supporting motor IP IP55
42. Reducer model GFF77
43. Reduction ratio 72
44. Input shaft speed r/min 1450
45. Output shaft speed r/min 5-20
46. Agitator regulating range r/min 5-20
47. Agitator type Flat paddle type
48. Impeller diameter m 1200
49. Height 570
50. Agitator manufacturer Jiangsu Yihuan
Wuxi Power Station
Auxiliary Equipment
Plant
Jiangsu Zhaosheng
H Scraper
51. Model HX-14.3-JG
52. Type Center-driven scraper
53. Quantity (each clarification tank) 1
54. Supporting motor model Y801-4
55. Supporting motor power kw 0.37
56. Supporting motor IP IP55
57. Reduction ratio 5133
58. Output shaft speed r/min ~0.05
59. Scraper regulating range r/min ~0.05
60. Scraping arm diameter m 12.8
61. Scraper manufacturer Jiangsu Yihuan
Wuxi Power Station
Auxiliary Equipment
Plant
Jiangsu Zhaosheng
I Sludge thickening cone

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62. Type Mechanical agitation
63. Quantity (each clarification) 1
64. Volume 1.5
65. Mounted position Lower part
66. Agitator type Grid
67. Speed ~0.05
J Awning structure
68. Type Steel structure
69. Design load kg 800
70. Steel corrosion type Paint for corrosion
protection
71. Covering range 2000×
2500 Covering the
whole motor
72. Height 2500
73. Main material Carbon steel
74. Steel structure form of supporting
mechanical device
Section steel structure
75. Design load of steel structure kg 700
76. Steel corrosion type Paint for corrosion
protection
77. Height 2500mm
78. Main material Carbon steel
79. Corrosion type and material of steel
fittings in tank
Carbon steel for
corrosion protection
K Outlet water indicators
80. Turbidity ≤10NTU
81. Suspended solids ≤10
2.3 Chemical feed system
Flocculant feeder and coagulant aid feeder are used for full automatically preparation and feeding of solid
dry powder chemicals and used in the clarification tank and sludge thickening tank for feeding of
chemicals. Liquid chlorination system is in together with the circulating water liquid chlorination system.
2.3.1 Self-priming chemical lift pump
Pump model FSB series Shaft power 2.25 kW
Quantity 2 sets Allowable suction lift 3 m
Pump type
Vertical single-stage
single-suction
self-priming pump
Rated speed 2900 r/min
Delivery medium
Flocculant solution at
concentration of 10%
Efficiency at rated
operating conditions
≥60%
Design flow 20 m3
/h Shaft seal type
Dynamic centrifugal
seal
Design head 0.12 MPa Bearing type Imported SKF bearing
Nominal priming diameter 65 mm
Nominal outlet water
diameter
50 mm
Total weight of pump set 85 kg Motor IP IP55
Rated power 3 kW Insulation class
Insulation class of F,
temp. rise class of B
Power supply
AC 415V (3-phase
4-wire), 50Hz
Local electrical
control box IP
IP65

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2.3.2 Three tanks of flocculant (dissolving tank, aging tank and storage tank):
Type of chemical
Solution at concentration
of 10% (PAC)
Material
Concrete + corrosion
protection
Dimensions of single set
of tanks
Horizontal square 2.5m×
2.5m×
2.5m
Anti-corrosion
specifications of inner
wall
Epoxy glass fiber
reinforced fiber for
Volume of single set of
tanks
15 m3
Working pressure Atmospheric pressure
Quantity 2 sets
All the three tanks are configured with reducer, axial-propelled and trefoil curved-surface electric agitating
blades which and the shaft are made from SS304. There are two blades set in the dissolving tank, and the
storage tank is set with level meter inside that controls start/stop of the preparation device through liquid
level.
2.3.3 Flocculant (coagulant) metering pump:
Manufacturer
MILTON ROY or
PULSAFEEDER
Design head 0.6 MPa
Quantity and
operating
conditions
6 sets, including 5 sets that
one-to-one correspond to the
clarification tank, operating in
unit system; another 1 set is put
into the inlet of sludge
thickening tank.
Transmission ratio 9.5:1
Water pump type
Imported motor driven
mechanical double diaphragm
metering pump
Stroke speed 152SPM
Control mode
Inverter regulation (ABB
inverter)
Adjustment accuracy
of metering pump
±
1%
Design flow 650L/h Pump casing material SS316
Diaphragm
material
PTFE (Polytetrafluoroethylene) Pump head material SS316
Delivery medium
Medium temperature
Total weight of
pump set
85kg
Supporting motor
model
IEC90
Rated power 1.1 kW Power supply AC 415V, 50Hz
Motor IP IP55 Insulation class
2.3.4 Solution dissolving and solution preparation equipment requirements:
The concentration of coagulant acid and coagulant acid solution is designed to be 0.1%.
a) The pressure regulating valve is used to automatically regulate the water pressure, which stops the unit
automatically and makes alarm in the case of too low water pressure or water break.
The solenoid valve is equipped with a manual operator and a flow regulator that is used to automatically
regulate the amount of inlet water.
The solenoid valve is imported American ASCO products.
b) The feed assembly is composed of dry powder vacuum suction lifter, feed precipitator, storage hopper,
level meter, agitator, hopper vibrator, damp-proof heater, screw feeder, dispersed fogger etc.
The dry powder vacuum suction lifter sucks in and lifts the dry powder in vacuum up to the storage hopper.
The storage hopper has a volume of 130L that can meet the use level for one day.

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The level meter will make alarm when the storage hopper is full, and the lifter automatically stops running;
the level meter will also make alarm in case of low level.
The agitator equipped with structure paddle helps mixing and flowing of dry powder.
The hopper vibrator (or hopper scraper) can prevent dry powder cavitation and bypass from resulting in
accidents.
Since dry powders, if affected with damp, are prone to caking, the damp-proof heater is set for heating and
dehumidifying the dry powder regularly.
Inverter screw feeder can adjust the feed amount automatically, and thereby adjust the concentration of
solution which can be arbitrarily set in the range of 0.05% ~ 0.5%.
Dispersed fogger is used to prevent dry powder from moisture and caking in the screw.
The jet nozzle atomizes and spays inlet water, the dry powders flow out of the screw feeder and fall on the
atomized flow, so that the dry powders are sufficiently dispersed, diluted and dissolved to form a
homogeneous solution without clot. The jet nozzle is designed to non-blocking structure.
2.3.5 The coagulant aid preparation assembly is of 3-tank structure with concrete + corrosion protection,
the coagulant preparation is completed through the three tanks step-by-step, i.e. dissolving tank, aging tank
and storage tank.
3 tanks are connected through weir plates, which structure is designed to allow the water to flow according
as required so as to obtain solution of high-grade. Dissolving tank and aging tank have sufficient volume
so that the dissolving and aging time are at least over 1 hour to ensure sufficient reaction time. The volume
of the dissolving tank, aging tank and storage tank is 6m3
each.
Type of chemical
Coagulant aid solution at
concentration of 0.1%
Material
protection
Dimensions of single
set of tanks
Horizontal square
3m×
3m×
3m
Anti-corrosion
wall
Epoxy glass fiber
reinforced for
Volume of single set
of tanks
Tentative 18m3
Working pressure Atmospheric pressure
Quantity 2 sets
All the three tanks are configured with reducer, axial-propelled and trefoil curved-surface electric agitating
blades which and the shaft are made from SS304. There are two blades set in the dissolving tank, and the
other tanks can be set with one blade.
The storage tank is set with level meter inside that outputs 4-20mA signal and controls start/stop of the
preparation device through liquid level.
The tanks are also set with corresponding pipes, valves and instruments, etc.
2.3.6 Coagulant aid metering pump
Quantity and
operating conditions
5 sets, one-to-one
correspond to the
clarification tank, operating
in unit system
Control mode
Inverter regulation
(ABB inverter)
Water pump type
Double diaphragm metering
pump of drive machinery
Design flow 732L/h
Design head 0.6 MPa Transmission ratio 9.5:1
Stroke speed 152SPM
Adjustment accuracy
of metering pump
±
1%

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Pump casing material SS316 Diaphragm material
PTFE
(Polytetrafluoroethylene)
Pump head material SS316 Connection type Flange or bonding
Delivery medium 0.1% coagulant aid Medium temperature Normal temperature
Total weight of pump
set
85kg
Supporting motor
model
IEC90
Rated power 1.1 kW Power supply AC 415V, 50Hz
Motor IP IP55 Insulation class
Control cabinet IP IP65
2.3.7 Sludge dehydrant dissolving & solution preparation equipment:
Dehydrant, which is the polyacrylamide with purity ≥87%, relative molecular weight of 10 million ~15
million, powder, and granularity of 12 meshes above 90%.
Such equipment has the capability of continuously dissolving powdered dehydrant and continuous
automatic preparation of dehydrant solution at any concentration (0.05%~0.5%), and is designed with
0.1% dehydrant solution.
Type of chemicals
Dehydrant solution at
concentration 0.1%
(polyacrylamide)
Dimensions of single
set of tanks
Horizontal square,
6.0m×
6.0m×
4.0m
Quantity 2 sets
Volume of single set
of tanks
140m3
Material
protection
Anti-corrosion
wall
Epoxy glass fiber
reinforced for
Working pressure Normal pressure
2.3.8 Chemical feed metering pump
There 5 sets of chemical feed metering pump that is diaphragm type with single rated flow: 6730L/h, head:
0.5MPa.
Such pump is designed with 0.1% dehydrant solution.
Each chemical feed metering pump is equipped with Y type filter at the inlet, and with pulse damper,
safety valve, check valve, closing valve, pressure gauge or multifunctional valve (integrating pressure
release, anti-siphon, back pressure and start assistance), etc. that are supplied in company with the pump at
the outlet.
Chemical feed amount is adjusted automatically according to inlet water flow or (and) water quality
changes in centrifugal dehydrator.
The pump flow is selected by 130% of the feed amount.
Each chemical feed metering pump has a frequency control device with regulating range of 0~100%. With
the measuring accuracy at the maximum stroke point not less than 1%, such pump can also be adjusted
manually. Frequency control device accepts 4~20mA DC control signal and outputs 4~20mA DC position
feedback signal (self-provided power source).
Metering pumps use imported products of MILTONROY or PULSAFEEDER.

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2.3.9 Chemical feed program-control facilities and meters:
Main facilities provided include: 5 sets of streaming current meter, 5 sets of online turbidity meter, 6 sets
of electromagnetic flowmeter (DN150/PN1.0MPa).
2.3.10 Streaming current meter:
Model SC-3000B Mounted position
On the inlet pipe of
clarification tank (open)
Accuracy 1% Signal output 4~20mA
Power supply 220VAC, 50Hz, 46W IP IP56
Reading display
LCD screen display on site/in direct
serial connection with computer/
remote transmission via PLC
Online turbidity meter:
Model T53
Mounted
position
On the outlet pipe of
clarification tank (open)
Response time
Step response, with initial response of
1 minute and interval response of 15s
Accuracy
At 0~40NTU, ±
2% of
reading; at 40~100NTU,
±
5% of reading
Range 0.001~100NTU
Signal
averaging time
Users can select 6, 30,
60, 90s; and default is
30s
Signal output 4~20mA
Communication
mode
Hard-wired
Power supply 220V IP IP56
Reading display
LCD screen display on site/ in direct
serial connection with computer/remote
transmission via PLC
2.3.11 Static mixer:
Model JN-GH-600/ JN-GH-300
Mounted position On the inlet water pipe of clarification tank/thickening tank/dehydrator (open)
Quantity
There are 11 sets, 5 sets of which each corresponds to a clarification tank, 1 set is
mounted on the inlet pipe of sludge thickening tank, and the remaining 5 sets are
mounted on the inlet of centrifugal dehydrator.
Mixing time ≥3s
Design pressure 0.6MPa
Test pressure 0.75MPa
Material Steel-lined plastic (resistant to acid and alkali corrosion)
2.4 Centrifugal sludge dehydrator
Operating principle: the turbid water discharged from raw water pretreatment system is thickened in sludge
tank, then flows through sludge feed water pump (screw pump) into sludge dehydrator (horizontal spiral
centrifuge) for dehydration. The sludge tank is provided with liquid level meter, the sludge dehydrator
control system operates synchronously with the start and stop of sludge screw pump. After the dehydration
treatment of sludge dehydrator, the clarified water is discharged from the clarified liquor pipeline with
differential speed regulated according to the automatic feedback of load and sludge level changes. Shoving
power compensates automatically to ensure the constant dryness of dewatered sludge and more dry sludge

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cake could be offered. While the sludge cakes are discharged through the bleed hole of dehydrator and then
conveyed by flexible shaft-less sludge conveyor to the sludge warehouse for outward freight. The turbid
water separated out from dehydrator flows back to the sludge storage tank. Sludge to be treated is
continually input while clarified liquor and dewatered sludge are discharged and conveyed continually,
which is a fully automatic process. The whole device integrates chemical feed, charging, sludge conveying,
detection and control of the device’s running state and electrical control box, which makes it a full
automatic and intelligent complete set of operating unit. The control system receives the relevant signal of
chemical feed, charging and sludge feed water pump.
2.5 Sludge thickening tank
In this project, there are 4 radial-flow sludge thickening tanks, three of them are operating and one for
standby; the outer wall of tank is reinforced concrete and the internal unit is steel structure. Each tank has
an electric-agitating sludge scraper with horizontal turbine worm reducer and supported on a steel truss.
The scraper is set with bars in the form of thickening grid and bar rim line speed of 2m/min, the scraper
runs to scrap off sludge along the bottom of tank in whole course.
The sludge hopper at the bottom of thickening tank is also equipped with agitating paddle made of SS304
stainless steel.
There are sampling tubes set at different heights that are taken with anti-clogging measures. Sampling slots
are also set for cluster sampling.
Sludge content at the outlet of thickening tank: 4%-5%
Supporting sludge scraper model: JN-NGN-20
Speed reducer model of sludge scraper: BWED41-289-2.2
Rotate speed of sludge scraper arm: 2m/min
Diameter of sludge scraper arm: 19.5m
Number of sludge scraper arm: 2
2.6 Intermediate water pond:
In the project, there is one underground intermediate water pond, which is divided into to two cells, and
each cell has one reflux pump.
(1) Intermediate water pond:
Storage pond volume 5000m3
Total depth of pond 4.5m
Area 35.0m×
35.0m Effective depth of pond 4.0m
(2) Reflux pump :
Pump number 2 sets Efficiency 72%
Design flow 1020m3
/h Submergence 4.5 m
Design head 0.20MPa Blade type Closed
Rotation speed 1450 r/min Bearing lubrication type Rolling bearing
Outlet pipe diameter 350mm Motor model Y315S-4
Rated power 110kw

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Chapter 3 System Running
3.1 Conditions that shall be available before running of raw water pretreatment system
3.1.1 Insides of water storage pond, solids-contact clarification and intermediate water tank, clarified water
reservoir and sludge thickening tank shall be cleaned without foreign matters.
3.1.2 The capacity of power supply can meet the site requirements and steady and reliable. In-site and
indoor lighting and communication facilities have been put into operation and are steady and reliable in
service.
3.1.3The electrical appliances, thermal engineering, chemical instruments, operation boards and upper
machines in relation to the raw water pretreatment system shall have been installed, show correct
indication, operated sensitively and can be put into operation.
3.1.4 The specifications of filtering materials, agents, glass apparatuses and chemical instruments
necessary to the raw water pretreatment shall conform to the design and their quantities shall meet the
requirements of trial run.
3.1.5 All valves shall operate flexibly, tight and in good condition and have sign boards hung.
3.1.6 Chlorination system is sound and equipment is in standby state.
3.1.7 Chemical operators shall be familiar with the system and equipment and can operate them
independently after learning and training.
3.1.8 All apparatuses, instruments and various agents used for analysis shall have been configured
completely that can be used for various analyses and tests.
3.1.9 Breathing masks, gloves, protective spectacles and gas masks, etc. safety appliances shall be
provided completely.
3.2 Pretreatment chemical preparation
3.2.1 Open the blowdown valves of PAC dissolving tank, aging tank and storage tank, PAC dissolving tank
water filling valve to flush the three tanks.
3.2.2 After rinsing out, close the blowdown valves and fill water to 2/3 level, start PAC chemical feed
pump and adjust the feed pump stroke.
3.2.3 Open the blowdown valves of PAM dissolving tank, aging tank and storage tank, PAM dissolving
tank water filling valve to flush the three tanks.
3.2.4 After rinsing out, close the blowdown valves and fill water to 2/3 level, start PAM chemical feed
pump and adjust the feed pump stroke.
3.2.5 Pour 200 kg PAC into PAC dissolving tank, then fill with water to start 3-tank stirrer for stirring fully
dissolved.
Pour Polyacrylamide into the vacuum suction lifter of dry powder to be sucked and lifted to the hopper, the
level meter alarm is made when the hopper is full, and the lifter automatically stops running; at low level,
the level meter alarm is also made. Start the inverter screw feeder to automatically adjust the feeding
capacity thereby adjusting the concentration of solution, the concentration of preparation can be arbitrarily
set in the range of 0.05%~0.5%. Open the ejector nozzle inlet valve to eject the feedwater in atomized form,
and dry powder flows out from the screw feeder, and falls on the atomized flow, so that the dry powders
are sufficiently dispersed, diluted and dissolved to form a homogeneous, non-clot solution that flows into

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the dissolving tank, turn on the mixer to mix chemicals in dissolving tank fully dissolved.
Start feeding: first open the chemical feed valve, turn on the metering pump, and adjust to the set
conveying capacity, and then it can feed chemicals to the feed point.
Metered feeding: adjust the pump feed range to control coagulant (PAC) at 10 mg/L and coagulant aid
(PAM) at 0.1 mg/L.
Stop feeding: first stop the metering pump, and then close the chemical feed valve to stop the metered
feeding.
3.2.6 Pour dehydrant into the vacuum suction lifter of dry powder to be sucked and lifted to the hopper, the
level meter alarm is made when the hopper is full, and the lifter automatically stops running; at low level,
the level meter alarm is also made. Start the inverter screw feeder to automatically adjust the feeding
set in the range of 0.05% ~ 0.5%. Open the ejector nozzle inlet valve to eject the feedwater in atomized
form, and dry powder flows out from the screw feeder, and falls on the atomized flow, so that the dry
powders are sufficiently dispersed, diluted and dissolved to form a homogeneous, non-clot solution that
flows into the dissolving tank, turn on the mixer to mix chemicals in dissolving tank fully dissolved.
Metered feeding: adjust the pump feed range to control dehydrant at 0.1 mg/L
feeding.
3.3 Equipment put-in
3.3.1 Open the water inlet valve of solids-contact clarification tank, start the raw water pump and adjust the
flow to 50% of the normal flow, start the mixer when the water level in solids-contact clarification tank is
above the mixer blade, and adjust the mixer blade speed to 2-7 r/min.
3.3.2 Start PAC feed metering pump and adjust the PAC feed metering pump stroke, to make the feeding
amount of PAC into raw water optimal.
Start PAM feed metering pump and adjust the PAM feed metering pump stroke, to make the feeding
amount of PAM into raw water optimal, and start chlorination system to make the residual chlorine in
outlet water within the range of qualification.
3.3.3 Observe formation of alum floc in the solids-contact clarification tank, if the alum floc is few, it shall
increase the amount of coagulant and coagulant aid, low content of the sludge as commissioning may
influence the effect of coagulation, if so it can add a small amount of slime to increase the content of
sludge. Unqualified outlet water shall be discharged into a trench.
3.3.4 In the process of sludge formation, it shall be regularly sampled for determination of sludge settling
ratio in all parts of the tank, if the sludge settling ratio in the first reaction chamber and at the bottom of
tank begins to gradually increase, this indicates that the sludge is in formation (usually requires 2~3 hours).
3.3.5 When the sludge forms and outlet water turbidity meets the requirement within 2~2.5 hours, it shall
gradually increase the flow up to the rated output and recover normal feed amount of coagulant and

13
coagulant aid. In which, each increase of water flow shall not exceed 10% of the design water flow, and the
duration of which shall not be less than 1 hour.
3.3.6 When the sludge settling ratio in the second reaction chamber becomes more than 25% within 5
minutes, the solids-contact clarification tank shall be discharged with sludge.
3.3.7 Adjust the sludge settling ratio in the second reaction chamber to be 10%, 15%, 20%, 25%
respectively within 5 minutes and keep that for 4 hours by means of the bottom blowdown valve of
solids-contact clarification tank, observe the formation of alum floc in the solids-contact clarification tank
and the outlet water turbidity, ascertain the optimal control value of sludge settling ratio so as to make the
inlet water, outlet water, chemical feed amount and sludge discharge in dynamic equilibrium.
3.3.8 When the outlet water of solids-contact clarification tank becomes qualified, and the constant-level
water tank of solids-contact clarification tank is full of water, open the water outlet value to fill water to the
water pond.
3.4 Equipment outage
3.4.1 Shut down the chemical feed system and chlorination system.
3.4.2 Close solids-contact clarifier water inlet valve, clarified water pond inlet valve and shut down the raw
water pump.
3.4.3 If the outage of solids-contact clarification tank is a short term (less than 3 hours), it may take no
measures; if the outage is 3-24 hours, both water and sludge may not be discharged, but because sludge is
compacted, and sometimes even corruption may occur, so the sludge at bottom shall be discharged first as
recovery of running, and then increase he coagulant input and reduce the amount of water inlet, and then
gradually adjust to the normal state when outlet water quality becomes stabile. If the outage is long, plus a
high temperature, sludge is prone to corrupt and becomes smelly, so the sludge in tank shall be discharged
thoroughly after outage.
3.5 Operation of the sludge treatment system
3.5.1 Muddy water discharged from the clarification tank self-flows to the sludge storage tank, when the
sludge storage tank level is above l one meter, start the sludge storage tank mixer for stirring and mixing of
slurry, and then start the sludge lift pump to lift and transfer slurry to the sludge thickening tank.
3.5.2 Start the flocculant metering pump to flocculate slurry once again, start the scraper for scraping and
thickening of mud, with supernatant produced self-flows to the intermediate tank, when the water level is
above one meter, start reflux pump to boost and send back to the efficient solids-contact clarification tank
inlet for recycling and retreatment, with concentrated turbid water self-flows to the sludge balance tank.
3.5.3 When the level of balance tank is above one mete, start the sludge feed pump, start dehydrant feed
pump, boost and feed into the centrifugal sludge dewatering machine for dewatering, start the dewatering
machine with dehydrated sludge cake under centrifugal force transported to the ash yard nearby the power
plant and drainage of dewatering machine self-flows to the sludge thickening tank.

14
Chapter 4 Equipment Accident Anticipation & Measures
4.1 Equipment abnormality and treatment
No. Fault Causes Treatment
1
Water from
mechanical
accelerated
clarification
tank is turbid
1) At the initial stage of equipment’s operation,
the amount of sludge is less.
2) Mud discharge amount is insufficient.
3) Mud discharge amount is too much.
4) Chemical dosing amount is too much or too
less.
5) Flow rate is improper.
6) Fluctuation of water temperature is too big.
7) Air mixed in.
1) Adjust flow rate smaller to
accumulate sludge.
2) Increase sludge discharge amount.
3) Reduce sludge discharge amount.
4) Adjust chemical dosing amount.
5) Adjust flow rate.
6) Adjust water temperature.
7) Reduce entry of air.
4.2 Supervision in normal operation
4.2.1 Operating maintenance of rotating equipment
a) During operation of equipment, it shall perform round-check every one hour.
b) The operation sound of equipment shall be normal.
c) The bearing temperature of rotating equipment ≤80℃.
d) Check whether the lubricating oil level is normal without oil injection and oil leakage phenomena; the
oil quality is clean, if finding deteriorated oil quality, it shall change new oil in time.
e) Periodically switch equipment.
f) Packing has no leakage or over heat phenomena, the water level of water tank and pond shall not be
lower than the specified value.
g) Air supply system is in good operation state, and the pressure of compressed air is not less than 0.4MPa.
4.2.2 Supervision in the operation of clarification system
After the water clarification system is in operation, in order to find out the optimum operating condition, it
needs to perform adjusting test to determine the optimum operating parameters, and adjust operating
condition according to the operating parameters. Mainly including: the height of clean water layer, sludge
amount suspended in reaction chamber, sludge concentration chamber and tank bottom, etc. parts, in-water
flow rate, chemical dosing amount, water temperature, mud discharge time and the opening of mud
discharge valve, etc. parameters.

15
PART 2 Make-up Water System
1. General Rules
1.1 Process flow of make-up water system
The water source of whole plant in the project is river water. After treated by clarification equipment, river
water flows into circulating cooling water system to be evaporated and concentrated in cooling tower, and
then the discharge water is treated by clarification equipment and supplied to the boiler make-up water
treatment system.
Biocide, coagulant and coagulant-aid

Circulating drainage waterClarification tank Clean water tankClean water pumpDual-media filter
Filter water tankUltrafiltration feed water pump
Antiscalant, reductant, acid

Automatic cleaning filterUltrafiltration device  Ultrafiltration water tank Booster pumpSecurity
filterReverse osmosis deviceReverse osmosis water tankReverse osmosis make-up pumpCation
bedAnion bedMixed bedDemineralized water tankMain plant building

Circulating water system
1.2 Technical data sheet of water tank
Water tank
Name Filter water tank Ultrafiltration
water tank
Reverse osmosis
water tank
Demineralized
water tank
Type Vertical barrel
straight type
Vertical
cylindrical straight
type
Vertical
cylindrical straight
type
Vertical
cylindrical
straight type
Quantity 2 sets 2 sets 2 sets 4 sets
Effective volume (m3
) 500m3
500m3
500m3
1600m3
Diameter (mm) Φ9500 Φ9500 Φ9500 Φ14000
Straight height (mm) H=8200 H=8200 H=8200 H=11500
Total height (mm) ≈9500 ≈9500 ≈9500 ≈13000
1.3 Standards of water samples
Name of water sample Item Symbol Unit
Control
standard
Analysis
interval
Remarks
Dual-media filter
Inlet water
turbidity
NTU mg/L 10-20 24h
Outlet water
turbidity
NTU mg/L 2-5 24h
Ultrafiltration system Inlet water
turbidity
NTU mg/L ≤100 24h
PH range 2-13 24h
Max inlet
water pressure
bar 3.0 24h

16
Reverse osmosis water yield
Water temp. ℃ 4~45 24h
DD μS/cm ≤20 24h
Primary demineralized water system
Conductivity DD μS/cm ≤5 2h
Silica SiO2 μg/L ≤100 2h
Mixed bed outlet water
Conductivity DD μS/cm ≤0.2 2h
Demineralized water
Conductivity DD μS/cm ≤0.2 2h The lab
measures
copper and
iron ions
regularly.
Sodium Na+
μg/L ≤10 2h
pH 6-7.5 2h
Chapter 2 Pretreatment System
2.1 Technical parameters table: clarification tank
Relevant parameters Unit Value Remarks
Outlet water turbidity NTU ≤2
Type Sludge circulation separation type
Quantity Set 4
Inner diameter m Φ14.3
Straight side height m 7.0
Total height m 9.42
Effective volume m3
1060
Coagulant aid feeder (used for chemical feeding of clarification tank)
Coagulant aid
Name of chemical PAM
Feed amount mg/l 2~3
Concentration of preparation % 0.1
Technical parameters table of dehydrant feeder (used for centrifugal dehydrator)
Dehydrant dissolving equipment and solution preparation equipment 1
Type 3-tank
Quantity Set 1
Feed amount of dry powder (productive capacity) Kg/h 3
Concentration of preparation ％ 1%
Water supply capacity m3
/h 3
Chemical feed amount g/kg 4
Technical parameters table of sludge thickening tank:
Type Gravity concentration type
Quantity Set 1
Diameter m 7
Effective water depth m 4
Total height m 6.5
Effective volume m3
150
Technical parameters table of centrifugal dehydrator
Solid rate of sludge cake % 25~30
Amount of sludge cake t/d 4
Centrifugal dehydrator

17
Type Horizontal screw centrifugal dehydrator
Model LW300D
Quantity Set 2
Treatment capacity m3
/h 5
Absolute amount of dry sludge cake Kg/h 150
MaxAbsolute amount ofdrysludgecake Kg/h 300
Min inlet water pressure MPa 0.2
Max inlet water pressure MPa 0.6
2.2 Equipment operation
2.2.1 Pretreatment chemical preparation
1) Open the water filling and drainage valves of PAC dissolving tank and solution tank to flush the PAC
dissolving tank and solution tank.
2) After rinsing out, fill water to 2/3 level, start PAC chemical feed metering pump and adjust the PAC feed
metering pump stroke.
3) Open the water filling valves of PAM dissolving and mixing tank and PAM storage tank to flush the
PAM dissolving and mixing tank and PAM storage tank.
4) After rinsing out, fill water to 2/3 level, start PAM chemical feed metering ump and adjust the PAM feed
metering pump stroke.
5) Pour 200 kg polyaluminium chloride into PAC dissolving tank, then fill with water to start stirrer for
stirring fully dissolved, and then start the solution transfer pump to transfer solution to the solution tank for
standby. (Shared by chemical solution and ultrafiltration)
6) Pour Polyacrylamide into the vacuum suction lifter of dry powder to be sucked and lifted to the hopper,
the level meter alarm is made when the hopper is full, and the lifter automatically stops running; at low
level, the level meter alarm is also made. Start the inverter screw feeder to automatically adjust the feeding
set in the range of 0.05%~0.5%. Open the ejector nozzle inlet valve to eject the feedwater in atomized form,
and dry powder flows out from the screw feeder, and falls on the atomized flow, so that the dry powders
are sufficiently dispersed, diluted and dissolved to form a homogeneous, non-clot solution that flows into
the dissolving tank, turn on the mixer to mix chemicals in dissolving tank fully dissolved.
7) Open the water filling valve of sodium hypochlorite solution mixing tank to flush it.
After rinsing out, fill water to 2/3 level, start the chemical feed metering pump and adjust its stroke.
Pour sodium hypochlorite into the sodium hypochlorite dissolving tank, fill with water and start the stirrer
for stirring until fully dissolved. (Shared by chemical solution and ultrafiltration)
Metered feeding: adjust the pump feed range to control coagulant (PAC) at 10 mg/L and coagulant aid
(PAM) at 0.1 mg/L.
feeding.
Pour dehydrant into the vacuum suction lifter of dry powder to be sucked and lifted to the hopper, the level
meter alarm is made when the hopper is full, and the lifter automatically stops running; at low level, the

18
level meter alarm is also made. Start the inverter screw feeder to automatically adjust the feeding capacity
thereby adjusting the concentration of solution, the concentration of preparation can be arbitrarily set in the
range of 0.05% ~ 0.5%. Open the ejector nozzle inlet valve to eject the feedwater in atomized form, and
dry powder flows out from the screw feeder, and falls on the atomized flow, so that the dry powders are
sufficiently dispersed, diluted and dissolved to form a homogeneous, non-clot solution that flows into the
dissolving tank, turn on the mixer to mix chemicals in dissolving tank fully dissolved.
Metered feeding: adjust the pump feed range to control dehydrant at 0.1 mg/L
feeding.
2.2.2 Equipment put-in
1) Open the water inlet valve of solids-contact clarification tank, start the circulating water pump and
adjust the flow to 50% of the normal flow, start the mixer when the water level in solids-contact
clarification tank is above the mixer blade, and adjust the mixer blade speed to 2-7 r/min.
2) Start PAC feed metering pump and adjust the PAC feed metering pump stroke, to make the feeding
amount of PAC into raw water optimal.
Start PAM feed metering pump and adjust the PAM feed metering pump stroke, to make the feeding
amount of PAM into raw water optimal.
Start chlorination system to make the residual chlorine in outlet water within the range of qualification.
(Shared by ultrafiltration)
3) Observe formation of alum floc in the solids-contact clarification tank, if the alum floc is few, it shall
increase the amount of coagulant and coagulant aid, low content of and fragmental sludge as
commissioning may influence the effect of coagulation, if so it can add a small amount of slime to increase
the content of sludge. Unqualified outlet water shall be discharged into a trench.
4) In the process of sludge formation, it shall be regularly sampled for determination of sludge settling
ratio in all parts of the tank, if the sludge settling ratio in the first reaction chamber and at the bottom of
tank begins to gradually increase, this indicates that the sludge is in formation (usually requires 2~3 hours).
5) When the sludge forms and outlet water turbidity meets the requirement within 2~2.5 hours, it shall
gradually increase the flow up to the rated output and recover normal feed amount of coagulant and
coagulant aid. In which, each increase of water flow shall not exceed 10% of the design water flow, and the
duration of which shall not be less than 1 hour.
6) When the sludge settling ratio in the second reaction chamber becomes more than 25% within 5 minutes,
the solids-contact clarification tank shall be discharged with sludge.
7) Adjust the sludge settling ratio in the second reaction chamber to be 10%, 15%, 20%, 25% respectively
within 5 minutes and keep that for 4 hours by means of the bottom blowdown valve of solids-contact
clarification tank, observe the formation of alum floc in the solids-contact clarification tank and the outlet
water turbidity, ascertain the optimal control value of sludge settling ratio so as to make the inlet water,

19
outlet water, chemical feed amount and sludge discharge in dynamic equilibrium.
8) When the outlet water of solids-contact clarification tank becomes qualified, and the constant-level
water tank of solids-contact clarification tank is full of water, open the water outlet value to fill water to the
water pond.
2.2.3 Equipment outage
1) Shut down the chemical feed system and chlorination system.
2) Close solids-contact clarifier water inlet valve, clarified water pond inlet valve and shut down the raw
water pump.
3) If the outage of solids-contact clarification tank is a short term (less than 3 hours), it may take no
measures; if the outage is 3-24 hours, both water and sludge may not be discharged, but because sludge is
compacted, and sometimes even corruption may occur, so the sludge at bottom shall be discharged first as
recovery of running, and then increase he coagulant input and reduce the amount of water inlet, and then
gradually adjust to the normal state when outlet water quality becomes stabile. If the outage is long, plus a
high temperature, sludge is prone to corrupt and becomes smelly, so the sludge in tank shall be discharged
thoroughly after outage.
2.2.4 Operation of the sludge treatment system
1) Muddy water discharged from the clarification tank self-flows to the sludge thickening tank, when the
sludge thickening tank level is above l one meter, start the dehydrant feed pump and sludge transfer pump
to send the sludge to centrifugal dehydrator for dehydration.
2) Supernatant produced is discharged to a trench.
3) Dehydrated sludge cake is transported by vehicle to the ash yard nearby the power plant and drainage of
dehydrator is discharged to a trench.
Chapter 3 Ultrafiltration & Reverse Osmosis System
3. System introduction
3.1 Ultrafiltration system
Water yield
capacity
220 m3
/h (set) (25 ℃, after
operating for 3 years)
SDI ≤1 (after operating for 3 years)
Filter cycle
≥30 minutes (after
operating for 3 years)
Water
recovery
≥90%
Total duration of
back washing
≤2 minutes
Chemical
cleaning cycle
≥30 days
Temperature 15~40 ℃
3.2 Reverse osmosis system
Water yield
capacity
≥150m3
/h (set) (25 ℃,
after operating for 3 years)
Demineralizati
on rate
≥98% (after operating for 1 year);
≥95% (after operating for 3 years)
Recovery
≥75 % (after operating for
3 years)
3.3 Equipment structure
3.3.1 Ultrafiltration system:
This system consists of pump, ultrafiltration device, supporting instrumentation, piping, valves, proper
assembly frame, back washing equipment, washing equipment, chemical feed device and chemical

20
cleaning device, etc.
Relevant parameters Value Relevant parameters Value
1. Ultrafiltration feed water pump
Type
Horizontal centrifugal
pump
Quantity 4 sets
Flow 440m3
/h Head 0.25MPa
2. Automatic cleaning filter
Type CTF-M30-M8 Filter precision 100μm
Flow 440m3
/h Material Case
Carbon steel 37-2
lined with epoxy resin
coating
Quantity 3 sets
Filter element
(strainer)
SS316L
Back washing mode
Endogenous back
washing
Back washing flow 50m3
/h
Back washing pressure 0.20MPa
3. Ultrafiltration device
a) Quantity 6 sets Single set flow (13℃) 220m3
/h
b) Membrane element
Type Hollow-fiber membrane Model
TARGA10072
(V1072-35-PMC)
Quantity of membrane
elements
44 piece/set Membrane diameter 0.9 mm
Effective membrane area 80.9 m2
/piece
Filtration molecular
weight
100 thousand
Membrane material
Special modified
polysulfone
Operating pressure 0.20 MPa
Max inlet water pressure 0.31 MPa
Max inlet water
temperature
40℃
Membrane flux
recommended by
manufacturer
65 l/m2
·
h
Membrane flux
designed by
engineering company
65 l/m2
·
h
Recovery 95 % Attenuation rate 1 %/year
Control mode Fully automatic Operation mode Cross-flow filtration
Conventional back wash
cycle
30 min
Enhanced back
wash cycle
1 time/day
Conventional back wash
procedure
Upper back washing,
lower back washing, and
washing
Time of conventional
back wash process
3 min
Each washing time 0.50 min Washing flow 504 m3
/h
Each back washing time 1 min
Conventional back
washing flow
580 m3
/h
Enhanced back washing
flow
290 m3
/h
Chemical type and
concentration for
enhanced back
washing
200mg/l
Chemical cleaning cycle 3 months
Chemical cleaning
flow
340 m3
/h (cleaning
half for each time )
Chemical type and feed
concentration
200 mg/l (NaClO)
Service life Not less than 5 years
450 mg/l (HCl)
450 mg/l (NaOH)
c) Supporting ultrafiltration membrane case
Model Membrane components Quantity 44 piece/set

21
supporting
Case material PVC Operating pressure 0.5 MPa
Diameter 357 mm Length 2011 mm
d) Automatic SDI detector
Quantity 2 sets Model Three channels
Manufacturer RIZONSDI
4. Back washing equipment
a) Back washing pump
Model
Horizontal centrifugal
pump
Quantity
3 sets (2 in service, 1
for standby)
Flow 300 m3
/h Head 0.25 MPa
b) Frequency converter
Quantity 3 sets Power 45 kW
Manufacturer and origin
ABB/SIEMENS
products
c) Filter
Model Vertical Quantity 1 set
Flow 600 m3
Filter precision 100μm
5. Ultrafiltration acid feed device
a) Chemical feed amount
Preparation
concentration for
ultrafiltration back
washing
30 % Chemical feed amount 450 mg/l
Preparation
concentration for reverse
osmosis make-up water
30 % Chemical dosage 20 mg/l
b) Metering solution tank
Model Vertical barrel Quantity 1 set
Volume 3 m3
Diameter 1620 mm
Height 2040 mm
c) Chemical feed metering pump for ultrafiltration back washing
Model GB0600 Type Diaphragm pump
Quantity 2 sets Flow 500 l/h
Outlet pressure 0.50 MPa
d) Chemical feed metering pump for reverse osmosis make-up water
Model GM0120 Type Diaphragm pump
Quantity 2 sets Flow 100 l/h
e) Acid and alkali resistant chemical drum pump
Type Drum pump Model P90H−60S
Quantity 2 sets Flow 132 l/min
Head 11.5 m Pipe line length 1.1 m
Pipe line material PVDF
f) Acid mist absorber
Quantity 1 set Nominal diameter 350 mm

22
Specification and name
of filler
φ38 Polyhedral Hollow
Ball
Filler height 750 mm
Absorption material PVC
6 Ultrafiltration alkalify device
a) Chemical feed dosage
Preparation
concentration for
washing
30 % Chemical feed amount 450 mg/l
Type Vertical barrel Quantity 1 set
Volume 3 m3
Diameter 1620 mm
Height 2040 m
Carbon dioxide
absorber
1 set
c) Chemical feed metering pump for ultrafiltration back washing
Quantity 2 sets Single set flow 500 l/h
Outlet pressure 0.50 MPa Motor power 0.55 kW
d) Chemical feed metering pump for reverse osmosis water yield and alkalify
Outlet pressure 0.70 MPa Motor power 0.55 kW
7. Sodium hypochlorite feed device
a) Chemical feed amount
Preparation
concentration for
washing
10% Chemical dosage 200 mg/l
Type Horizontal barrel Quantity 2 sets
Single set volume 8 m3
Diameter 1600 mm
8. Ultrafiltration chemical cleaning device
a) Cleaning tank
Type Vertical Quantity 1 set
Volume 5 m3
Diameter 1740 mm
Height 2440 mm
Performance
parameter of electric
heater
60 kw
b) Cleaning pump
Single set flow 340 m3
/h Head 0.2 MPa
c) Security filter
/h Diameter DN550 mm
Filtration precision 100μm
Filter element
specification
910PBHAC
Filter element quantity
(each set)
6 (folded large flux
filter)
Material cylinder SS316

23
Filter component PP
9. Security filter
Type Vertical Quantity 6 sets
Single unit flow 200 m3
/h Diameter DN600mm
Design pressure 0.6 MPa Test pressure 0.9 MPa
Cylinder thickness 5 mm Filtration precision 5μm
(each set)
6
Material cylinder
SS316
Filter component PP
10. Variable-frequency high-pressure pump
a) High-pressure pump
Model PWT125-80-315S Type Horizontal cylinder
Quantity 6 sets Flow 200 m3
/h
Head 1.20 MPa Rotate speed 2900 r/min
b) Frequency converter
Quantity 6 sets Power 90 Kw
3.3.2 Reverse osmosis device
Reverse osmosis system consists of ultrafiltration water pump, security filter, high-pressure pump, reverse
osmosis device, supporting instrumentation, piping, valves, proper assembly frame, chemical feed device,
chemical cleaning device and flushing water pump, etc.
1) Quantity 6 sets Single set flow (15℃) 150 m3
/h·
set
2) Membrane element
Model TFC 8040 -FR- 400 Quantity 204 piece/set
Arrangement (level and
section) mode
21: 13
Demineralization rate
(within 3 years)
98 %
Demineralization rate (after
3 years)
95 % Membrane material Polyamide
Effective membrane area 37 m2
/piece
Maximum operating
temperature
40 ℃
Max operating pressure 2.1 MPa Max pressure drop 0.4 MPa
Max inlet water flow 12 m3
/h Min inlet water flow 4 m3
/h
Membrane flux
recommended by
manufacturer
21 l/m2
·
h Recovery 75 %
Attenuation rate 1 %/year Control mode Full automatic
Chemical cleaning cycle 1 month Chemical cleaning flow 210 m3
/h
Service life 3 years
3) Reverse osmosis scale inhibitor feed device
a) Electric stirring solution tank
Single set volume 2 m3
Diameter 1300 mm
Height 1820 mm
b) Chemical feed metering pump
Model GM0090 Mode Diaphragm pump

24
4) Reducing agent feed device
a) Electric stirring solution tank
Diameter 1300 mm
height 1820 mm
b) Chemical feed metering pump
4)Reverse osmosis chemical cleaning device
a) Cleaning tank
Volume 5 m3
Diameter 1740 mm
Height 2440 mm Wall thickness No less than 6 mm
Proper material and
anti-corrosion of equipment PE
Performance parameters of
electric heater
60 kw
b) Cleaning pump
/h Head 0.35 MPa
c) Security filter
Flow 210 m3
/h Diameter DN600mm
Design pressure 0.6 MPa Test pressure 0.9 MPa
Filtration precision 5μm Filter element specification 910PBBAB
(each set)
6 Filter component PP
6) Flushing water pump
/h Head 0.35 MPa
3.4 Conditions and requirements for equipment operation:
3.4.1 Chemicals:
Biocide, coagulant, acids, alkalis, reducing agents, scale inhibitors and cleaning agents used in
ultrafiltration and reverse osmosis system.
Chemical composition Purity Grade Comment
a) Biocide NaClO 10% Industrial pure
b) Coagulant FeCl ≥42%
c) Hydrochloric acid HCl ≥31% Iron content ≤0.01%
d) Sodium hydroxide NaOH ≥40% Industrial pure
e) Sodium bisulphite NaHSO3 >98%
f) Antiscalant Liquid dedicated inhibitors are non-phosphorous organic composite.
3.4.2 Raw water equipment operates properly, chemical feed system is normal and chemical solution in
each chemical box is adequate.

25
3.4.3 It is prohibited to starting the device in the following cases:
(1) Anyone item of high-pressure pump protection device is abnormal.
(2) Anyone item in high-pressure pump interlock test failed.
(3) The main instrument does not work and no other monitor mean.
(4) Raw water supply is abnormal.
(5) Air compressor system operates abnormally, and control air source works abnormally.
(6) Dilute lubrication station of high-pressure pump operates abnormally.
(7) Cooling water system of high-pressure system operates abnormally.
(8) The main control valve does not work.
(9) The main water pumps can not be put into operation normally.
(10) Emergency stop button is abnormal.
3.5 Put-in and operation of equipment
3.5.1 Start the dual-media filter.
(1) Open the outlet and inlet valves of clean water pump, dual-media filter inlet valve and air valve.
(2) Start the clean water pump, when the air valve of dual-media filter outputs water, open washing valve
and close air valve until the outlet water reaches the control standard.
(3) Open outlet valve and close washing valve when the outlet water is qualified, and supply water to
filtration tank.
3.5.2 Operation supervision
1) Outlet water of filter keeps clear in operation and is within control standard according to assay.
2) When the differential pressure between inlet valve and outlet valve of filter is >0.05MPa, back wash the
filter.
3.6 Back washing operation of dual-media filter
3.6.1 Start the back washing pump, open the back washing water inlet valve and drain valve of dual-media
filter to back wash the dual-media filter from bottom to top, in order to remove the dirt in filter media and
promote rational distribution of filter layer, after the outlet water becomes clarified, close the inlet valve
and drain valve of back washing and stop the back washing pump.
3.6.2 Washing the filter
Start the clean water pump, open water inlet valve and washing drain valve to wash the dual-media filter
from top to bottom. Check whether drainage is clarified or not, and filtrate normally if drainage is clarified
and meets the requirement of water outlet, or conduct air-water back washing.
3.6.3 Air scrubbing and back washing
Reduce the water level in dual-media filter to about 200mm above filter layer, open air inlet valve, exhaust
valve and back washing drain valve. Blow air from bottom, and close the air inlet valve after the air has
scrubbed filter layer for 3-5 minutes, then start back washing pump and slowly open the water inlet valve
of back washing. After the container is filled with water, close the exhaust valve and increase flow
gradually, which is better that no filter medium in outlet water, until drainage is clear.
3.6.4 Washing
Start clean water pump, open water inlet and drain valve, put into operation or standby when outlet water is
clear and achieve the requirements of outlet water turbidity<5mg/l by washing.

26
3.7 Ultrafiltration system put-in:
3.7.1 Ultrafiltration system startup conditions:
3.7.2 The filtration tank level is on low, ultrafiltration feed water pump fails to start and plays the role of
protection.
3.7.3 Ultrafiltration system start:
3.7.4 Open all inlet and outlet valves of ultrafiltration water intake pump.
3.7.5 Open all inlet and outlet valves of automatic cleaning filter.
3.7.6 Open hand-operated ultrafiltration valves: water inlet valve, water yield valve, reflux valve and back
washing air inlet valve.
3.7.7 Start ultrafiltration feed water pump and automatic cleaning filter; open ultrafiltration water inlet
pneumatic valves, reflux pneumatic valve, and water yield pneumatic regulating valve to start to produce
water and supply water to ultrafiltration water tank. The exhaust valve automatically closes after
discharging air in membrane modulus thoroughly.
3.7.8 Ultrafiltration equipment operations, conventional back washing, enhanced back washing and other
operation procedures are program controlled and automatically monitored.
3.8 Back flushing of ultrafiltration:
Back washing equipment consists of back washing pumps, back washing filters, back washing chemical
feed device, pipelines, valves, flow meters, pressure gauges, fans, etc.
3.8.1 There are three back washing pumps, two in service and one for standby. The flow of each pump can
reach 50% of back washing flow of a single ultrafiltration device.
3.8.2 Three back washing pumps can finish the back washing operation of 6 ultrafiltration devices within
30 minutes of ultrafiltration device back washing cycle, as follows:
When ultrafiltration device is in normal back washing, start two back washing pumps; when ultrafiltration
device is back washed with chemical feed, start one back washing pump. Ultrafiltration device operation is
divided into: shutdown, back washing, fast flushing, operating, chemical feed back washing and waiting
state. When one ultrafiltration device needs back washing, it is necessary to judge whether the other five
ultrafiltration devices are in the state of back washing, fast flushing or chemical feed back washing, etc. If
not, the ultrafiltration device gets into back washing state automatically and begins back washing steps; if
so, judge whether the differential pressure of this ultrafiltration device is above 0.1MPa or not, when the
differential pressure is above 0.1MPa, then enters waiting state until other ultrafiltration devices enter
shutdown or operating state, or keep operating state until other ultrafiltration devices enter shutdown or
operating state. Set 3 frequency converters for back washing pump to meet the different requirements of
conventional and enhanced back washing.
Back washing water is drawn from the ultrafiltration water tank.
Configure flow meter, local pressure gauge and pressure remote transmission device on back washing
header.
Configure one set, ≤100μ filter of pipeline type on back washing header.
3.9 Cleaning of ultrafiltration
Conduct chemical cleaning in the following cases:
3.9.1 Trans-membrane pressure (TMP) of filter membrane reaches the set value (typically 1.5bar).

27
3.9.2 Maintenance cleaning: conduct once maintenance cleaning after the system has operated for 7 days.
3.9.3 Restoration cleaning: conduct once restorative cleaning after the system has operated for 30 days.
3.9.4 Water yield declines and differential pressure increases significantly.
Maintenance cleaning: when the trans-membrane pressure reaches the set value (1.5m), or after the system
has operated for a period (typically 48~72 hours, it can depend on the actual situations) and in other
necessary cases, the membrane modulus needs maintenance and cleaning.
TMP is the control parameter resulted from calculation of actual data. The calculation formula is as
follows:
TMP= (inlet water pressure+ concentrated water pressure)/2- water yield pressure
Cleaning chemicals:
No. Name Specification Chemical preparation concentration
1 Citric acid Chemical pure
The concentration is 0.2wt%, add sodium
hydroxide until pH=2
2
Sodium hypochlorite
+EDTA+ sodium hydroxide
Chemical pure
Sodium hypochlorite concentration is 100-200ppm,
EDTA0.1-0.5%,add sodiumhydroxideuntil pH=11-11.5
3.9.5 Cleaning conditions:
(1) Cleaning fluid flow: 250m3
/h
(2) Cleaning fluid temperature: 30-45℃
(3) Cleaning pressure: 0.25Mpa
(4) Air inflow: 0.5-0.8m3
/min (half of the air inflow for back washing)
(5) Air intake pressure: 0.1Mpa
3.9.6 Cleaning procedures:
(1) Cleaning water tank is full of water yield, turn on the electric heater until the temperature increases to
about 30℃ (but not exceed 40℃).
(2) Chemical preparation: pour all necessary chemicals into cleaning water tank, then open recirculation
valve and start cleaning pump for chemical circulation, stop the pump until chemicals are fully dissolved.
(3) Water yield pause: close all automatic valves after membrane modulus to be cleaned quits operation.
(4) Drainage: open upper drain valve and lower drain valve of back washing to drain the water in
membrane modulus, and then close the lower drain valve.
(5) Cleaning solution inflow: open ultrafiltration cleaning water yield reflux valve, concentrated water
reflux valve and cleaning water inlet valve; close cleaning pump recirculation valve, open cleaning pump
outlet valve to start cleaning pump until membrane modulus are filled with chemical solution (circulating
30 minutes).
(6) Soak and air inlet: stop cleaning pump, close cleaning water inlet valve, keep the upper drain valve
open, and open air inlet valve. Blow in the compressed air and soak the membrane modulus for 30
minutes.
(7) Drainage: open lower drain valve of back washing to drain water in membrane modulus.
(8) Back washing: execute back flushing procedure and back wash for 2 minutes until PH of outlet water
reaches neutral.
(9) Washing: open water inlet valve, reflux valve and water yield drain valve, flush out the residual
cleaning solution.

28
(10) Water yield switching: switch the membrane modulus to ―Put-in‖ state, put water yield into operation.
3.9.7 Restorative cleaning:
1) Cleaning chemicals and cleaning conditions are the same with maintenance cleaning
2) Cleaning procedures:
(1) Operate as the (1) - (4) steps of maintenance cleaning procedures
(2) Circulation cleaning + air purge: start cleaning pump and open air inlet valve for 30 minutes.
(a) Soak: stop cleaning pump, close air inlet valve and soak for 60 minutes.
(b) Circulation cleaning + air purge: open air inlet valve and start cleaning pump, conduct cleaning
solution circulation again for 30 minutes.
(c) Drain out the cleaning solution: open lower drain valve and upper drain valve to drain out cleaning
solution in membrane modulus, and then close valves.
(d) Back washing: conduct back washing procedures for 2 minutes.
(e) Washing: is the same as maintenance cleaning operation.
(f) Water yield switching: switch the membrane modulus to ―operating‖ state and put water yield into
operation.
3.9.8 Precautions for cleaning:
(1) Membrane to be under chemical cleaning must quit operation.
(2) Time in cleaning procedures can be adjusted according to the actual situation.
(a) Regularly monitor the changes of PH value in cleaning process, adjust the chemical feed in time if
changes are significant.
(b) During alkaline cleaning, the residual chlorine in membrane modulus must be flushed out.
(c) Keep cleaning solution temperature at 30℃.
3.10 Reverse osmosis start
3.10.1 The liquid level of ultrafiltration tank is above 1 meter.
3.10.2 Open boost pump outlet valve and fill the security filter with water.
3.10.3 Open the reverse osmosis inlet valve, drain valve of unqualified water and make the reverse osmosis
full of water.
3.10.4 Start the HP pump, to exhaust reverse osmosis when frequency is converted to 10% to compact the
reverse osmosis membrane modulus.
3.10.5 Slowly adjust frequency conversion, start the antiscalant, reductant and acid feed pump, open the
qualified yield water valve if the yield water is qualified as tested, and close the unqualified water valve to
supply water to the reverse osmosis water tank.
3.11 Membrane modulus maintenance:
3.11.1 Short-term outage of system (1-3 days)
1) After the outage of high pressure pump, clean the membrane modulus with low pressure fresh water to
flush out the internal concentrated water.
2) Restore the system to standby state.
3.11.2 Medium-term outage of system (7-14 days)
(1) After the outage of high pressure pump, clean the system with low pressure fresh water.
(2) Conduct cleaning with low pressure fresh water every three days until start-up.

29
3.11.3 Long-term outage of system (over 2 weeks)
(1) After the outage of high pressure pump, clean the system with low pressure fresh water.
(2) Prepare 1% sodium bisulphite solution and input it into membrane modulus at low voltage.
(3) Close all valves for protection.
(4) Replace protection solution every 30 days.
3.11.4 Chemical cleaning
1) Principle of chemical cleaning:
(1) After the initial flow is stable, if the water yield flow decreases 5-15%, it is necessary to clean the
membrane modulus.
(2) It is necessary to clean the membrane modulus if its permeable salt rate increases 30-40%.
2) Cleaning solution
Pollutant Conventional chemical cleaning Enhanced chemical cleaning
Calcium carbonate
scale
2.0% citric acid, pH 4.0 (adjust pH with
aqueous ammonia)
HCl, pH 2.5
Calcium, barium and
strontium sulfate scale
2.0% STPP and 0.8%Na-EDTA, pH 10 HCl, pH 2.5
Metal oxides,
hydroxide
2.0wt% citric acid, pH 4.0 (adjust pH
with aqueous ammonia)
1.0% sodium bisulphite, pH 11.5 (Fe and
Mn use 0.2% oxalic acid, pH 2
Inorganic collid
pollution
2.0wt% citric acid, pH 4.0 (adjust pH
with aqueous ammonia)
HCl, pH2.5
Organic-inorganic
hybrid collid pollution
2.0% STPP and 0.8% Na-EDTA, pH 10 0.1%NaOH and 0.03%SDS, pH 11.5
Silicon No 0.1wt% NaOH, pH 11.5
Biological pollution 2.0% STPP and 0.8% Na-EDTA, pH 10
2.0% STPP and 0.25% Na-DDBS, pH 10
or 0.1% NaOH and 0.03% SDS, pH 11.5
Dissolved organic
pollutant
2.0% STPP and 0.8% Na-EDTA, pH 10
2.0% STPP and 0.25% Na-DDBS, pH 10
or 0.1% NaOH and 0.03% SDS, pH 11.5
3.11.5 Cleaning procedures:
1) Chemical preparation: prepare the cleaning solution listed in the table according to the membrane
pollutant.
2) Chemical solution circulation: open cleaning solution inlet valve of membrane modulus, and cleaning
reflux valve and concentrated water reflux valve of water yield; close other valves, start cleaning pump to
fill chemical solution at low flow into membrane modulus. The circulation lasts 30 minutes.
(1) Soak: stop cleaning pump and soak for 1 hour.
(2) Flushing: flush out chemical solution in membrane modulus.
(3) Put into operation.
3.11.6 Precautions for cleaning:
(1) It is better that the cleaning solution temperature maintains at 30℃.
(2) Cleaning circulation and soak time can be adjusted according to the actual situation.
(3) Regularly monitor the changes of PH value in cleaning process, adjust the chemical feed in time if
changes are significant.
(4) Chemical solution needs to be prepared with SWRO water yield or low hardness water.

30
Chapter 4 Ion Exchanger Put-in & Regeneration
4.1 System introduction
Parameters Value Parameters Value
4.1.1 Design parameters
Design water flow 3×
240 m3
/h Design pressure 0.6 MPa
Design temperature 50℃
4.1.2 Parameters of chemicals
1) Hydrochloric acid (HCl)
Total acidity (in HCl) ≥31 Iron (in Fe) ≤0.01
Ignition residue ≤0.15 Free chlorine (in Cl) ≤0.01
Arsenic (in Sn) ≤0.0001 Sulphate (in SO4) —
2) Sodium hydroxide (NaOH)
Sodium hydroxide (in NaOH) ≥40 Sodium carbonate (in Na2CO3) ≤0.6
Sodium chloride (in NaCl) ≤2.0 Ferric oxide (in Fe2O3) ≤0.01
4.1.3 Double-medium filter
Type Vertical barrel Quantity 14 sets
Diameter φ3000 Normal flow 95 m3
/h
Max flow 98 m3
/h Design pressure 0.6 MPa
Test pressure 0.75 MPa Design temperature 50℃
Medium layer height
(anthracite/quartz sand)
400/800 mm
4.1.4 Floating bed cation exchanger:
Parameters Value
Type
Quantity
Diameter
Normal flow
Max flow
Design pressure
Test pressure
Test temperature
Resin loading height
White ball loading height
Proper material
Regenerant medium
Floating type
3 sets
Φ2800
240 m3
/h
300 m3/h
0.60MPa
0.75Mpa
50℃
1200mm
300mm
Carbon steel lined with rubber
Dilute hydrochloric acid
4.1.5 Resin trap:
Equipment specification:
Parameters Value
Type
Quantity
Diameter
Normal flow
Max flow
Design pressure
Test pressure
Test temperature
Vertical barrel
6 sets
DN600
240 m3
/h
300 m3
/h
0.60 MPa
0.75 MPa
50℃

31
4.1.6 Floating bed anion exchanger:
Parameters Value
Type
Quantity
Diameter
Normal flow
Max flow
Design pressure
Test pressure
Test temperature
White ball loading height
Proper material
Regenerant medium
Floating type
3 sets
Φ2800
240m3
/h
300m3
/h
0.60 MPa
0.75 Mpa
50℃
2500mm
300mm
Carbon steel lined with rubber
Dilute sodium hydroxide
4.1.7 Mixed bed:
Parameters Value
Type
Quantity
Diameter
Normal flow
Max flow
Design pressure
Test pressure
Test temperature
Regeneration mode
Cation resin
anion resin
Regenerant medium
Internal regeneration
3 sets
Φ2500
240 m3
/h
300 m3
/h
0.60 MPa
0.75 MPa
50℃
Internal regeneration
500 mm
1000 mm
Dilute hydrochloric acid and Dilute
sodium hydroxide
4.1.8 Cation resin cleaning tank:
Parameters Value
Quantity
Diameter
Design pressure
Test pressure
Test temperature
Direct height of barrel
1 set
Φ2800
0.60MPa
0.75MPa
50℃
2400 mm
4.1.9 Anion resin cleaning tank:
Parameters Value
Quantity
Diameter
Design pressure
Test pressure
Test temperature
Direct height of barrel
1 set
Φ2800
0.60 MPa
0.75 MPa
50℃
5000 mm

32
4.1.10 Acid storage tank:
Parameters Value
Type
Quantity
Effective volume
Diameter
Straight edge length of barrel
Design pressure
Test pressure
Test temperature
Medium
Horizontal
2 sets
20 m3
Φ2500
3900 mm
Atmospheric pressure
Full water test
50℃
31%HCl
4.1.11 Alkali storage tank:
Equipment specification
Parameters Value
Type
Quantity
Effective volume
Diameter
Straight edge length of barrel
Design pressure
Test pressure
Test temperature
Medium
Horizontal
2 sets
20 m3
Φ2500
3900 mm
Full water test
50℃
40%NaOH
4.1.12 Acid metering tank:
Equipment specification
For cation bed For mixed bed
Quantity
Diameter
Barrel height
Design pressure
Test pressure
Test temperature
1 set
φ1250
1400
Full water test
Atmospheric temperature
1 set
φ1000
1400 mm
Full water test
4.1.13 Alkali metering tank:
For anion bed For mixed bed
Quantity
Diameter
Barrel height
Design pressure
Test pressure
Test temperature
1 set
Φ1250
1400 mm
Full water test
1 set
Φ1250
1400 mm
Full water test

33
4.1.14 Acid ejector:
For cation bed For mixed bed
Quantity
Outlet flow
Outlet pressure
Chemical concentration at outlet
Raw water pressure at inlet
Chemical concentration at inlet
Material
1 set
30.7 m3
/h
0.25MPa
3%HCl
0.45MPa
31% HCl
Fiberglass
reinforced plastics
1 set
24.5 m3
/h
0.25 MPa
5 %HCl
0.45 MPa
31 % HCl
Fiberglass
reinforced plastics
4.1.15 Alkali ejector:
For anion bed For mixed bed
Quantity
Outlet flow
Outlet pressure
Chemical concentration at outlet
Raw water pressure at inlet
Chemical concentration at inlet
1 set
30.7 m3
/h
0.25 MPa
3 %NaOH
0.45 MPa
40% NaOH
1 set
24.5 m3
/h
0.25 MPa
4 %NaOH
0.45 MPa
40 % NaOH
4.2 Operation and outage of ion water treatment system
4.2.1 Ion system startup
Inspection before startup
1) The reverse osmosis system shall be in the state of available water supply.
2) Check that the ammeter, pressure gauges, flow meters and all chemical measuring instruments are in
good standby state.
3) Chemicals, instruments and meters shall be prepared sufficiently and completely.
4) All the valves in system shall be flexible and reliable in standby, pneumatic valves shall be in a free state,
the filter and demineralization apparatus shall be in good standby state.
5) Pump and motor shall be in good standby state.
6) The gas supply system shall be in good operating condition, and the compressed air pressure shall not be
less than 0.4MPa.
7) The program-control system shall be in good standby state, and the inlet and outlet valves of
demineralized water tank are open.
4.2.2 Equipment startup
1) Start the pump according to the reverse osmosis water tank level.
2) Open cation bed water inlet valve and open the flushing drain valve to start the feed water pump, and at
the same time control the flow rate at not less than 80m/h to form a bed until the output water becomes
qualified, then open the cation bed water outlet valve and close the cation bed flushing drain valve.
3) Open the anion bed water inlet valve and open the flushing drain valve, at the same time control the
flow rate at not less than 80m/h to form a bed until the output water becomes qualified, then open the anion
bed water outlet valve and close the anion bed flushing drain valve.
4) Open the mixed bed water inlet valve and exhaust valve, and open the washing drain valve and close

34
exhaust valve after the exhaust valve outputs water. Wash until the output water’s content of SiO2 <20μg/L,
and conductivity<0.2μs/cm (25℃), then open the water outlet valve and demineralized water tank inlet
valve to supply water to the demineralized water tank;
5) Adjust the opening degree of clean water pump outlet valve according to the inlet flow rate of mixed
bed and cation bed;
6) Open sampling valve of chemical instrument of chemical equipment, and put chemical instrument into
operation after adjustment of flow rate;
7) It is required to perform water quality analysis for specified items within a quarter hour after water
making start, during operation and before outage;
8) Adjust the flow rate of the demineralization system in operation according to the supply of water and the
water tank level;
9) Perform water quality analysis, recording of meter reading and routine inspection at the specified
interval during operation.
4.2.3 Operation supervision
Filter
1) During operation, the filter output water shall be always clear and transparent, the inlet and outlet water
differential pressure shall be normal.
2) If the inlet and outlet water differential pressure of filter is >0.05MPa, the filter shall be back washed.
First-stage demineralization equipment
3) After the start of first-stage demineralization system, adjust the flow rate timely and keep the
intermediate water tank level stable at 1/2 ~ 2/3.
4) Check the equipment operation conditions regularly every hour to find out and deal with abnormality.
5) When either indicator of the output water quality of cation and anion beds exceeds standard, it is
required to stop for regeneration timely.
6) Adjust the operation of equipment reasonably to avoid simultaneous failure of two sets of equipment.
Mixed bed
7) Check whether there is resin in the resin trap, and deal with timely if any.
8) When either indicator of the output water quality exceeds standard, it is required to stop for regeneration
timely.
9) Check whether the resin in long-running mixed bed has been confused.
4.2.4 Outage of ion equipment
1) Open the washing drain valve of mixed bed, and close the water outlet valve of mixed bed.
2) Stop the clean water pump.
3) Close the water inlet and outlet valves and sampling valves of cation bed and anion bed.
Close the water inlet valve of mixed bed, and the washing drain valve.
4.3 Ion equipment regeneration
4.3.1 Resin cleaning
The cleaning principle of first-stage demineralization equipment:
External cleaning is made every 15 cycles of cation exchanger, and 10 cycles of anion exchanger.
4.3.2 Goal and steps of external cleaning:

35
After a certain operating cycle, the dirt trapped in the resin increases the differential pressure of inlet and
outlet water quality of the running bed, which makes resin prone to break and also affects water quality,
and increases regenerative acid and alkali consumption. So after some running cycle, it is required to
perform a thorough cleaning of the resin.
4.3.3 External cleaning of cation and anion beds
1) Resin conveying: after the cation (anion) resin fails and falls off bed, open the exchanger back washing
inlet valve, ion exchanger resin output valve, resin flush valve, cleaning tank resin inlet valve, inlet and
outlet valves of non-utility pump. Start the non-utility pump, slowly turn down the resin flush valve
according to the flow of resin observed via peep hole until the concentration of mixed resin and water
becomes appropriate. After resin is conveyed to the cleaning tank, stop the non-utility pump, close the
exchanger back washing water inlet valve, resin flush valve, resin output valve, and resin input valve of
cleaning tank.
2) Back washing: open back washing water inlet and outlet valves of cleaning tank, start the non-utility
pump, pay attention to regulating backwash flow and monitoring backwash drainage to the extent of not
flushing out resin. Back wash until water becomes clear. Stop the non-utility pump, and close the back
washing water inlet valve.
3) Compressed air scrubbing: Open the intermediate drain valve to drain water to the cleaning tank until
the water level is slightly lower than 1/2 of the peep hole, slowly open the compressed air inlet valve, with
air inlet pressure not greater than 0.1MPa under control, scrub 5min, then close the air inlet valve. Note
that it is prohibited to open the compressed air inlet valve to full once.
4) Back washing: After the resin settles, perform the same procedure as 2).
5) Convey the clean resin to the exchanger: open exchanger resin output valve, back washing water drain
valve, back washing water inlet valve, cleaning tank resin output valve, and washing water inlet valve. Start
the non-utility pump, slowly turn down the back washing water inlet valve according to the flow of resin
observed via peep hole until the concentration of mixed resin and water becomes appropriate. After resin is
all conveyed to the exchanger, let water flow through 3min to clean off resin in conveying pipe, then stop
the non-utility pump, close the water inlet and outlet valves of non-utility pump, exchanger resin output
valve, back washing water drain valve, cleaning tank resin output valve, back washing water inlet valve and
washing water inlet valve.
After external cleaning, double the amount of regenerant.
4.3.4 Cation and anion resin regeneration operation
1) Pre-injection:
Operation: open the exchanger acid (alkali) inlet valve, back washing water drain valve, acid ejector water
inlet valve, and start the regeneration pump to ejector water inlet valve to control the regeneration flow rate
at 5m/h.
2) Acid (alkali) inlet:
Operation: open the outlet sampling valve of (alkali) acid concentration meter to regulate the flow, power
on the acid (alkali) concentration meter, open the outlet valve of acid (alkali) metering tank to adjust the
opening degree of acid (alkali) measurement tank outlet valve and control acid alkali concentration at
3-4% (or by manually-measured specific gravity), acid inlet amount at 31% HCL 1601Kg, and alkali inlet
amount at 40% NaOH 1342Kg.

36
3) Displacement:
Operation: close the outlet valve of acid (alkali) metering tank to enter the displacement stage. When the
acid (alkali) concentration meter indicates zero, close the sampling valve of acid (alkali) concentration
meter (alkali), and power off the concentration meter power. After stopping acid inlet, keep the ejector run
at original regeneration flow rate for displacement until the acidity of the liquid discharge is less than 5
mmol/L (the conductivity of anion bed is less than 100us/cm), stop the non-utility, and close the water inlet
valve of acid (alkali) ejector and the acid (alkali) inlet valve of cation (anion) bed.
4.3.5 Regeneration operation of mixed bed
1) Back washing stratification:
a. Open mixed bed back washing drain valve, start self-service pump, and gradually open back washing
inlet valve to control back washing water flow at 5-40 t/h, and make the resin swell height reach the
endoscopic centerline, and no effective exchanger particles in the drainage.
b. When the drainage becomes clear and cation and anion resin are separated relatively thoroughly,
gradually close the back washing inlet valve and back washing drain valve to stop the self-service pump.
c. Open the air valve of mixed bed to let the resin subside naturally, check the stratification between anion
and cation, back washing stratification shall be performed once again.
d. If it is still not clear after the second back washing stratification, immerse the mixed bed into 30%
NaOH0.3M3 with alkali concentration of 4-5% for 30 minutes, and then perform back washing
stratification once again.
2) Water discharge:
a. After back washing stratification, open washing discharge valve and close it when the liquid level drops
to resin 100-200mm.
b. During water discharge, it shall open the intermediate drain valve to check whether drainage is smooth,
and whether there is exchanger particle in water.
3) Acid and alkali inlet:
a. Start the self-service pump
b. Open the alkali inlet valve of mixed bed, open alkali ejector outlet, open the water inlet valve of alkali
ejector, adjust alkali injection flow rate to 13 t/h, open the intermediate drain valve and close the air valve
when the liquid level rose up to the centerline of peep window.
c. Open the acid inlet valve of mixed bed, water inlet valve of acid ejector, and adjust the acid ejector flow
to 12 t/h.
d. Observe that the liquid level in bed is stable, intermediate water drainage is smooth, open the acid
metering box outlet and vacuum extraction valve to control into the concentration of inlet acid and alkali to
be about 2%.
e. Feed 30% sodium hydroxide 0.35m3
and 30% hydrochloric acid 0.35m3
for regeneration of mixed bed
4) Washing;
a. When feeding of the alkali and acid metered is completed, respectively close the acid metering box
outlet valve and vacuum extraction valve, and keep the ejecting water flow constant to wash the resin.
b. When the intermediate drainage conductivity is ≤ 20us, close the water inlet valves of acid ejector and
alkali ejector, close the intermediate drain valve, acid inlet valve and alkali inlet valve of mixed bed.

37
c. Open the air valve and washing drain valve of mixed bed, close the washing drain valve when the liquid
level drops to resin 100mm.
5) Resin mixed washing:
a. Start the compressed air system, open the back washing drain valve and compressed air valve of mixed
bed for mixing resin. (Generally mixed for 5 minutes)
b. When the resin is uniformly mixed, start the self-service pump, rapidly close the compressed air inlet
valve and back washing drain valve, open the inlet valve and washing drain valve of mixed bed to force the
resin to drop.
c. In the process of resin forced dropping, adjust the mixed bed water inlet flow rate to be greater than the
drain flow rate, and close the air valve when the air valve overflows water for washing.
d. Check the resin mix, and remix if it is poor.
e. Stop the compressed air system after resin is mixed uniformly.
f. Adjust the mixed bed washing flow.
g. When washing becomes qualified, close the water inlet valve and washing drain valve of mixed bed,
close the air valve after pressure release in bed, and stop the self-service pump.
Chapter 5 Accident Anticipation & Measures
1. Fault treatment
No. Fault symptom Causes Treatment
1
SDI of
ultrafiltration
yield water is too
high
1. Operation is improper.
2. Ultrafiltration membrane is
broken.
1. Test sample once again.
2. Repair the Ultrafiltration membrane.
2
Motor-operated
valve fails to
operate
1. Auto-control system has fault.
2. Defect in the valve
1. Contract the control instrumentation
division for treatment.
2. Contact the maintenance division for
treatment.
3
Water yield of
membrane drops.
Differential
pressure is
higher
1. Membrane is contaminated by
suspended solids or deposited
inorganic salt.
1. Clean the membrane timely (with water
or chemical), and also check the SDI of
inlet water and heavy metal ion in water.
4
Water yield of
membrane
increase, and
yield water
conductivity
rises.
1. The membrane is damaged.
2. Inlet water pressure is high.
1. Replace the membrane
2. Reduce the inlet water pressure
5
Desalinization
ratio of
membrane is
low.
1. Membrane is scaled or
contaminated.
2. Recovery rate is too high.
1. Clean the membrane.
2. Reduce the recovery rate, and adjust the
flow of thick and thin water.
6
R/O water yield
reduces.
1. Inlet water temperature is low;
2. Inlet water pressure is low;
3. There is contaminant or
membrane is scaled;
4. Salt content of inlet water is too
high;
5. Flow of thick water is too high.
1. Raise the inlet water temperature;
2. Increase the inlet water pressure and
increase the velocity of flow thereof;
3. Clean membrane parts or replace it;
4. Test the salt content of supply water.
5. Adjust the flow of thick and thin water.

38
7
Metering pump
fails to transfer
chemical
solution
1. Pump inlet valve is not opened.
2. Inlet pipe is blocked up.
3. Liquid level of metering tank is
low.
1. Open the inlet valve.
2. Unblock the inlet pipe.
3. Add chemical into the metering tank.
8
Pump fails to
raise water
1. Pump has air inside and water
is not full before startup.
2. Water inlet valve is not opened
or valve core dropped.
3. Pump runs reversely.
4. Water level of water tank is low.
5. Inlet water pipe leaks air.
1. Exhaust air.
2. Fully open the valve or contact
maintenance division.
3. Contact electrical division for
maintenance.
4. Raise the water level of water tank.
5. Contact maintenance division.
9
Pump vibrates
greatly or has
noise
1. Pump has air inside or outlet
opening is too small.
2. Foundation screw becomes
loose.
3. Motor is unbalanced with the
axis, and there is serious friction
between the bearing and rotating
part.
4. Rotating part becomes loose or
damaged.
5. Run with overload.
1. Exhaust air in pump.
5. Run with reduced load.
10
Bearing becomes
too hot or has
noise
1. Oil quality is poor or oil level is
too low.
2. There is no clearance in the oil
seal.
3. Bearing is worn.
4. Oil level is jammed.
5. Oil level is too high
1. Stop the pump to change and add oil.
2. HP pump fault and treatment
No. Fault symptom Causes Treatment
1 Pump stops
running
suddenly
1. Control system has fault.
2. There is no water incoming.
1. Contact the control instrumentation
division for treatment.
2. Check whether the pretreatment
system’s water yield is normal.
2 Pump fails to
stop running.
1. Control system has fault. 1. Press the emergency button for
shutdown, and contact the control
instrumentation division for treatment.
3 Pump fails to
operate
1. Control circuit is broken or
damaged.
2. Fuse blown.
3. Winding has short circuit.
4. Cable is damaged.
1. Check the control circuit.
2. Check and change fuse.
3. Check the winding voltage.
4. Check motor and its cable.
4 Pump operates
but fails to
reach the rated
output.
1. Outlet valve is closed partially.
2. Reverse osmosis membrane is
contaminated.
3. Pump is jammed by foreign
bodies inside.
4. Pump is damaged.
1. Check the valve.
2. Clean the reverse osmosis membrane.
3. Clean and check the pump
4. Check the pump

39
PART 3 Condensate System
1.1 System configuration
The system is made up of 6 high-speed mixed bed system (one for each unit), 2 external regeneration
systems (one for three units), 2 auxiliary systems (one for three units), 2 corresponding monitoring
instruments (one for three units) and resin etc.. Fine treatment plays an important role in stabilizing the
water quality of boiler feed water system when the complete unit starts, which can reduce the start-up time
of complete unit to make the unit begins normal operation as soon as possible so as to save a lot of start-up
costs.
1) For condensate recovery in unit start-up, the condensate demineralizing equipment shall be put into
operation to conduct 50% treatment with the condensate.
2) When the unit is in normal operation, condensate quality is good and feed water is qualified, the
condensate demineralizing equipment can be shut down for standby.
3) When the condenser is found leaking during operation, the condensate demineralizing equipment shall
be put into operation immediately, and 50% or 100% treatment shall be conducted with the condensate
according to the leakage condition of condenser.
4) When condensate hardness is≤2.0umol/L, condensate shall be 50% demineralized.
1.2 Design and operating conditions
1.2.1 Regenerant
1) Hydrochloric acid (HCl)
Parameters Value
Total acidity (in HCl)
Ferrum (in Fe)
Hydrochloride (in SO4)
Arsenic (in Sn)
≥31
 0.01
 0.007
 0.0001
2) Sodium hydroxide (NaOH)
Parameters Value
Sodium hydroxide (in NaOH)
Sodium carbonate (in NaCO3)
Sodium chloride (in NaCl)
Ferric oxide (in Fe2O3)
Sodium chlorate
Calcium oxide
Aluminum oxide
Silicon dioxide
Sulfate (in Na2SO4)
≥ 32
 0.06
 0.007
 0.0005
 0.002
 0.0005
 0.0006
 0.002
 0.002
1.2.2 Technical parameters of condensate fine treatment system:
1) Single unit condensing capacity
Rated flow of condensate pump in TMCR: 1490 t/h
Condensate pump flow in VWO+3% make-up water: 1743 t/h

40
2) Condensate pump head
Operating pressure: 3.6 MPa
Condensate pump shutoff head: 4.6 MPa
3) Condensate temperature
Normal operating temperature: ≯50℃
Maximum temperature: 55℃
1.2.3 Circulating cooling water quality
The salt content of make-up water is about 400mg/l and concentration ratio is 4, and the treatment
system adding sulfuric acid, stabilizer and biocide is adopted.
1.3 Process parameters of major equipment
Specifications of major equipment are as follows: (6 units)
No. Name of equipment Model and specifications Unit Qty
(I) High-speed mixed bed
1 High-speed mixed bed
Ф3000 P=4.0MPa HR=1000, ratio of
cation to anion resin =1:1
Set 18
2 Resin trap Ф600 P=4.0MPa Set 18
3 Recirculating pump
ZE200-3250 Q=500m3
/h P=0.32MPa
pump casing withstands pressure 4.0MPa
Set 6
(III) Resin regeneration unit (three mixed bed units share one resin regeneration unit)
1 Resin separation vessel Ф2400/Ф1600 Set 2
2 Cation resin regeneration vessel Ф1600 Set 2
3 Anion resin regeneration vessel Ф1600 Set 2
4 Waste water resin trap Ф1200 Set 2
5 Movable resin filling bucket V= 0.15m3
Set 2
(IV) Flushing water pump unit
1 Flushing water pump IH100-65-200 Q=100t/h H=50m Set 6
Shaft power/motor power N= 22KW
(V) Roots blower unit
1 Roots blower BK6008 Q=9.22Nm3
/min P=80KPa Set 4
(VI) Acid metering unit
1 Acid metering box Ф1300 V=2.5 m3 Set 2
2
Hydrochloric acid metering pump (with
safety valve)
7660H-S-E Q=2500L/h Set 4
(VII) Alkali metering unit
1 Alkali metering box Ф1300 V=2.5 m3 Set 2
2 Alkali metering pump (with safety valve) 7660H-S-E Q=2500L/h Set 4
(VIII) Electric heating water tank unit
1 Electric heating water tank Ф1800 V=10 m3
Set 2
(IX) Compressed air tank Ф1800 V=10m3
Set 4
(X) Storage system of acid and alkali
1 Acid storage tank DN2500 V=20m3
Set 4
2 Alkali storage tank DN2500 V=20m3
Set 4
3 Acid mist absorber Ф500 Set 2
4 Acid transfer pump CQB65-50-150F Set 4
5 Alkali transfer pump CQB65-50-150F Set 4
6 Safety shower Stainless steel Set 2

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