10 0 2 MB
THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
OPERATION, MAINTENANCE & TROUBLESHOOTING MANUAL CLIENT
:
IFFCO PHULPUR
PROJECT
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ACTIVATED CARBON FILTER FOR AMMONIA & POWER PLANT
PLANT
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CONDENSATE POLISHING UNIT
CAPACITY
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150M3/HR
REFERENCE
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OC NO 200134
Thermax Limited, (C&W Service & Solutions Group) Thermax House, Mumbai Pune Road, Shivaji Nagar, Pune - 411005 Tel. : 020-25511010, Fax. : 020-25511236. WATER TREATMENT PLANT
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Improving Your Business Is Our Business On Thermax Group: Thermax’s vision is to be a globally respected high performance company offering sustainable solutions in energy and environment. The Thermax Group provides business to business solutions in the areas of heating, cooling, captive power, water treatment, air pollution control, waste management & resource recovery, and chemicals to a wide range of industry in Indian and international markets. In the energy business, Thermax executes projects in the areas of process heat, captive power and waste heat recovery. It also offers a range of heating equipment; energy efficient chillers and customized products such as waste heat and exhaust gas boilers. Thermax’s integrated expertise in energy has made GE to choose it as the ‘vendor on first call’ for its global Combined Heating Power and Cooling (CHPC) projects... Thermax offers industry its expertise over a hundred fuels including oil, gas and a wide variety of solid fuels including biomass. The Group’s Joint Venture, Thermax Babcock & Wilcox (TBW) has emerged as a leading and reliable project management companies with installations the world over; in the US, Saudi Arabia, Thailand, Egypt, Philippines and several other countries. Leveraging its leadership position in electricity saving vapor absorption technology, it offers process industries and commercial establishments like hotels, shopping malls and offices vapor absorption chillers a boon in power‐starved areas. These Eco‐friendly, energy efficient equipment have found prestigious customers such as BBC, Mercedes Benz, Audi, Bosch, Panasonic, Henry Ford Museum. In the environment area Thermax offers waste management expertise for solid, liquid and air pollution. Thermax provides solutions from pre‐treatment to waste water treatment and chemical conditioning of water for boiler and cooling water systems. Water recycling is a thrust area for Thermax. Hi‐grade resins from Thermax have found niche customers in US and Japanese markets. Thermax has an extensive international marketing network. Headquartered in Pune (Western India), Thermax's eleven international offices are located in South East Asia, Middle East, Africa, Russia, UK and the US. Thermax’s 4 overseas subsidiaries play a significant role in generating business in the International market: Thermax (Rus) Ltd., Thermax (Europe) Ltd., OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Thermax Inc., USA and ME Engineering, UK. Around 20 per cent of the group’s turnover come from exports – to the US and European markets, Japan, East Africa, the Middle East, South East Asian and CIS countries. The Thermax group’s manufacturing facilities. Spread over 14 plants, measuring a covered area of over 65,000 sq. Mts., are ISO 9000 and ISO 14001 accredited. Thermax manufactures to international standards like ASME, BS, DIN, and GOST. The facilities have been inspected by Lloyds, Bureau Veritas, SGS, and TUV. Thermax’s business is inspired by the conviction that ‘Improving your business is our business.’ Water & Waste Solutions MAKING INDUSTRY GREEN AND COMPETITIVE Cost competitive and Environment friendly technology innovated and developed through continuous research to keep industry green and competitive. Excellence in Technology and stringent quality control measures are the hallmarks in all projects undertaken by Thermax Water & Waste Solutions Division. Thermax Water & Waste solutions division takes on Retrofitting and Revamping orders to extend life of all aging plants. Our comprehensive service program is the first of its kind in India. It is a program that evaluates and then enhances the economical performance of all water & waste treatment plants. Thermax Water & Waste Solution Division’s wide spectrum of products and technology covers Pretreatment Process Water Treatment Ion Exchange Resins Reverse Osmosis and Electro dialysis Condensate Polishing Thermal Desalination Waste Water Treatment Sewage Treatment Recycling of water Range of Cooling Water Chemicals Range of Polyelectrolyte Incinerators. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
TABLE OF CONTENTS 1 : Water Treatment Fundamentals ………………………….…... ……………………… 6 1.1 : Water treatment general write up & Basic water chemistry ………………….6 1.2 : Importance of Water Analysis …….………………………………….……………...7 2 : Plant Configuration and Details …………………………………………………………...13 2.1 : System Details ………………………………………………….……………..………...13 3 : Control Philosophy …………………………………………………………………………15 3.1 : System Description ……..…..…………………………………………………………..15 3.2 : Process ……………………………………..…………………………………………...16 4 : Operation & Maintenance of "ACF Filter" ………………..………………………...17 4.1 : System operation for ACF ……………………………..……..………………………17 4.2 : Process flow diagram …………………………………………………………………...35
4.3 : Operation Conditions checks for ACF…………………..…………………………36 4.4 : Troubleshooting Guide (ACF) …………………..…………………………………..37 4.5 : Maintenance (ACF) ………………………………..…………………………………38 5 : Laboratory Details …………..……………………………………………………………39 5.1 : Laboratory Analysis ……..…………………………………………………………….39 5.2 : Daily Log- Sheet …………………………………………………………....................72 6: P & I Drawings .…..….………………………….…………………………………………...73 7: Valves Operating procedure………………………………………………………………...75 8 : Whom to Contact ……….………..……………………………….……….………………..76 (for support In case of problem)
Note: For operation and maintenance of individual equipments like pumps, blowers, motors, instruments etc please refer to the instruction manual of the respective equipments.
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 I N T R O D U C T I O N The Operation & Maintenance Manual gives a brief introduction to the total system supplied and gives instructions and guidelines for smooth, long lasting and trouble free operation of the plant. The O&M manual is prepared to make the operator familiar with the system/plant supplied (ACF unit) and its operation and maintenance of the Plant. The chapter Chemical Control describes the various laboratory tests and their procedures, to be carried out in the laboratory to understand quality of feed water to the plant and quality of product water. The regular analysis also helps in analyzing individual units' performance and total plant performance vis‐à‐vis output water produced and chemicals consumed. The maintenance of various equipment in general and resin units in particular are detailed in this O&M manual along with details of trouble shooting, safety precautions, etc. It is also to be noted that this O&M manual covers all areas relevant to the system supplied in general and certain problematic areas, in particular, with respect to operation and maintenance, based on our experience, as far as possible. In case of problems, which are not covered, and peculiar, the same can be referred to us or the various manufacturers as and when they arise. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
1. WATER TREATMENT FUNDAMENTALS 1.1 WATER TREATMENT GENERAL WRITE – UP & BASIC WATER CHEMISTRY: INTRODUCTION: The natural water contains solid, liquid and gaseous impurities and therefore, this water cannot be used for the generation of steam in the boilers. The impurities present in the water should be removed before it’s use in steam generation The necessity for reducing the corrosive nature & quantity of dissolved and suspended solids in feed water has become increasingly important with the advent of high pressure, critical & supercritical boilers. IMPURITIES IN WATER: ‐ The impurities present in the feed water are classified as given below •
Undissolved and suspended solid materials.
•
Dissolved salts and minerals.
•
Dissolved gases.
•
Other materials (as Oil, Acid) either in mixed or Unmixed forms.
•
Undissolved and suspended solid materials.
a) Turbidity and Sediment Turbidity in the water is suspended insoluble matter including coarse particles (mud, sediment, sand etc.) That settles rapidly on standing. Amounts ranges from almost zero in most ground waters and 60,000 ppm in muddy and turbulent river water. The Turbidity of feed water should not exceed 5 ppm. These materials can be removed by settling, coagulation and filtration. Their presence is undesirable because heating or evaporation produces hard stony scale deposits on the heating surface & clog fluid system. Both are objectionable as they cause damage to the Boiler system standard amount of measurement of hardness is taken as being the amount of Calcium Carbonate (CaCO3) in the water and is referred to in part per million (ppm) or grains per gallon (grains/gallon * 17.1 = ppm). b) Sodium and Potassium Salts These are extremely soluble in water and do not deposit unless highly concentrated. Their presence is troublesome as they are alkaline in nature and accelerate the corrosion. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 c) Chlorides Majority of the chloride causes increased corrosive action of water. d) Iron Most common soluble iron in water is ferrous bicarbonate. The water containing ferrous bicarbonate deposits becomes yellowish and reddish sediment of ferric hydroxide if exposed to air. Majority of ground surface water contains less than 5 ppm but even 0.3 ppm can create trouble in the feed water system by soft scale formation and accelerating the corrosion. e) Manganese It also occurs in similar form as iron & it is also equally troublesome. f) Silica Most natural water contains silica ranging from 1 to 100 ppm. Its presence is highly objectionable as it forms very hard scale in Boilers and forms insoluble deposits on turbine blades. In modern high pressure Boilers its presence is reduced as low as 10‐50 ppb. g) Microbiological Growth Various growths occur in surface water (lake & river). The microorganisms include diatons, moulds, bacterial slimes, algae, manganese & sulphate reducing bacteria and many others. These can cause coating on Heat Exchanger and clog the flow passages and reduce the heat transfer rates. h) Colour Surface waters from swampy areas become highly coloured due to decaying vegetation. Colour of feed water is objectionable as it causes foaming in Boilers and may interfere with treatment processes. It is generally removed by chlorination or adsorption by activated carbon. Dissolved Salts and Minerals Calcium and Magnesium Salts The Calcium and Magnesium salts present in the water in the form of carbonates, bicarbonates, and sulphates and chlorides. The presence of these salts is recognized by the hardness of the water (hardness of water is tested by soap Test). The hardness of water is classified as temporary and permanent hardness. The temporary hardness is caused by the bicarbonates of calcium and magnesium and can be removed by boiling. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 The boiling converts the soluble bicarbonates into less soluble carbonates, which can be removed by simple blow down method. The permanent hardness of the water is caused by the presence of chlorides, sulphates and nitrates of calcium and magnesium and they can not be removed just by boiling because they form a hard scale on heating surfaces. Dissolved Gases Oxygen It presents in surface water in dissolved form with variable percentage depending upon the water temperature and other solid contents in water. Its presence is highly objectionable, as it is corrosive to iron, zinc, brass and other metals. It causes corrosion and pitting of water lines, boiler exchangers. Its effect is further accelerated at high temperatures. b) Carbon Dioxide The river water contains 50 ppm and well water contains 2 to 50 ppm of CO2. It also causes the corrosion of stream, water and condenses lines. It also helps to accelerate the corrosive action of oxygen. The other gases are H2S, CH4, N2 and many others but their percentages are negligible, therefore, their effects are not discussed here. 4. Other Materials Free Mineral Acid Usually present as sulphuric or hydrochloric acid and causes corrosion. The presence is reduced by neutralization with alkalis. b) Oil Generally, the lubricating oil is carried with steam into the condenser and through the feed system to the Boiler. It causes sludge, scale and foaming in Boilers. It is generally removed by strainers and baffle separators. The effects of all the impurities present in the water are the scale formation on the different parts of the Boiler System and corrosion. The scale formations reduces the heat transfer rates and clog the flow passage and endanger the life of the equipment’s by increasing the temperature above safe limit. The corrosion phenomenon reduces the life of the Plant rapidly. Therefore, it is absolutely necessary to reduce the impurities below a safe limit for the proper working of the power plant.
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
1.2 Importance of Water Analysis Water analysis The process of determining how much of various substances (impurities) are present in given sample of water is known as Water Analysis. Need for Water Analysis Water analysis is essential for the following reasons: a) Raw water source selection. b) Analysis of raw water determines the type of treatment and unit size. c) Treated water analysis indicates the efficiencies of various units of water treatment. d) Designing of most economical water treatment plant. To design a water treatment plant knowing the impurities present in the water to be treated is needed. Complete analysis helps in determining the degree of pretreatment required in Ion Exchange and other process like reverse osmosis etc. Minor constituent like silica is very important since it may have influence on the regeneration technique used and can affect the capacities that can be obtained. Analysis of Iron and chlorine is important for reverse osmosis design. Definition used in water analysis pH: It is common practice to express hydrogen ion concentration in terms of pH. By definition the pH is the negative logarithm of hydrogen ion concentration to the base of l0. pH = ‐ log10 (H+) = log (1/H+) Ionic product of water Kw has a value of 1 x 10 ‐ 14 and in neutral water H + concentration is equal to OH ‐ concentration. Kw = H + x OH‐ = 1 x 10‐ 14 ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ (1) For neutral water = (H+) = (OH‐) = 1x10 ‐ 7 The equilibrium represented by equation (1) occurs universally in aqueous solution regardless of the equilibrium or the solutes present. Hence equation (1) should always be satisfied. Thus the terms pH expresses the acidity or basicity of water. Neutral water has a pH of 7. pH lower than 7 indicates acidity and greater than 7 is alkaline. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Alkalinity: As mentioned earlier alkalinity in water is due to presence of HCO‐3. CO‐3 and OHions. In raw water alkalinity is mostly due to HCO‐3, but in some cases CO‐3 ions also may be present. It is important to note that out of the three ions only two ions can exist in any system. That is HCO‐ 3, CO‐3 or OH‐ can exist alone or in combination with one more ion. Any water analysis reporting the presence of all three ions should be discarded. Alkalinity of water is determined by titration with phenolpthalein and methyl orange indicator. The result of titration with methyl orange indicator is called Total Alkalinity or MAlkalinity. M. Alk. = Total Alk = HCO‐3 + CO‐3 + OH‐. The result of titration with phenolpthalein indicator is called P‐Alkalinity. P. Alk = OH + 1/2 CO3. Hardness Calcium and Magnesium salts impart hardness to water. Hard water is defined as a water which does not lather or foam with soap easily. The salt of calcium and magnesium which causes hardness is divided in two parts. 1. Temporary hardness or carbonate hardness. 2. Permanent hardness or non‐carbonate hardness. The sum of temporary and permanent hardness is called Total Hardness. Total Hardness = Carbonate hardness + Non Carbonate hardness Carbonate Hardness It is mainly due to presence of bicarbonates of Calcium and Magnesium. Alkalinity in raw water is normally due to bicarbonate ions. Therefore, carbonate hardness (Alkalinity) plus Non Carbonate hardness is equal to total hardness. 1) Carbonate hardness = Alkalinity, when alkalinity is less than total hardness. 2) Carbonate hardness = Total hardness, when alkalinity is greater or equal to total hardness. Conductivity: The conductivity of water is dependent on the ionic content of water, specifically on the ability of ionic impurities in the water to conduct electricity. Ionic impurities have the ability to conduct electric current and thus there is direct linear relationship between ionic impurities and conductivity which help in determining the ionic impurities in water. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Conductivity is also related to TDS empirically = Conductivity x 0.65 = TDS. Total Dissolved Solids This represents all the soluble inorganic solids in water expressed in ppm. Total Solids Total solid is defined as SUM of soluble and insoluble solids. Electrolytes This is total ionizable dissolved solids in water. Total electrolyte is numerically equal to total cation or total anions (not sum of both). Total electrolyte does not include CO2 and silica. Total Cations Sum of calcium, magnesium, sodium and potassium all measured in the same unit. Total Anions Sum of alkalinity (HCO‐3 + CO‐3 + OH‐) + Cl + SO4 + NO3 all measured in the same unit. Total Cation = Total Anion = Total Electrolyte Equivalent Mineral Acidity (EMA) The equivalent mineral acidity, EMA is equal to the sum of equivalent concentration of sulphates, chloride and nitrate. It is also called sometimes as Total Mineral Acidity. Free Mineral Acidity (FMA) Free mineral acidity is equal to (EMA ‐ Sodium leakage). EMA ‐ Sodium leakage = FMA EMA ‐ FMA = Sodium leakage. Method of reporting water analysis There are various ways of reporting water analysis, but in general four methods which are commonly used are, 1. As ppm ion or mg/litre. 2. EPM or M.Eq./litre (Mill equivalent per litre) 3. ppm as CaCo3. 4. Grains per gallon as CaCo3. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 Water analysis Report Water analysis can be reported in many ways but most laboratories give in the format as given below. WATER TREATMENT PLANT Format for Reporting water Analysis Physical pH ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Colour ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Hazen Unit Taste and Odour ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ Turbidity ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ NTU Conductivity ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐ μmhos or milli mhos Chemical Suspended Solids ‐ in ppm Calcium ‐ as ppm CaCO3.* Magnesium ‐ as ppm CaCO3.* Hardness ‐ as ppm CaCO3.* M.Alkalinity ‐ as ppm CaCO3.* P.Alkalinity ‐ as ppm CaCO3.* Chloride ‐ as ppm or mg./litre. Sulphate ‐ as ppm or mg./litre. Nitrate ‐ as ppm or mg./litre. Silica ‐ as ppm or mg./litre. Iron ‐ as ppm or mg./litre. TDS ‐ as ppm CO2 ‐ as ppm * Sometimes calcium and Magnesium can be reported as in ppm as Ca or Mg. OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134
2. PLANT CONFIGURATION AND DETAILS 2.1 SYSTEM DETAILS ‐ PLANT DATA DESIGN DATA S.No
Description
Design Value
1
Unit Name
Activated Carbon Filter
2
No of Stream
01
3
Design Flow rate
150 M3/Hr
4
Specification
4 M Dia & 2.6 HOS
4
Design pressure
12.5 Kg/cm2
6
Design temperature
80C
OPERATING DATA S.No
Description
Design Value
1
Unit Name
Activated Carbon Filter
2
No of Stream
01
3
Flow rate
150 M3/Hr
4
Operating Time
20 Hrs
5
Operating pressure
9 – 11 Kg/cm2
6
Operating temperature
60C
7
Operation Mode
Manual
8
Backwash Time
30 min
9
Feed Water
Condensate outlet water
10
Differential pressure in vessel
0.6 Kg/cm2
11
Differential pressure in Basket filter
1.5 Kg/cm2
12
Blower for ACF
600m3/Hr at 0.4 Kg/cm2
OPERATION & MAINTENANCE MANUAL FOR ACTIVATED CARBON UNIT – CONDENSATE POLISHING UNIT
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THERMAX LTD | C & W SERVICE & SOLUTIONS GROUP OC No: 200134 ANALYSIS DATA S.No
Description
Inlet parameters
Outlet parameters
1
Ph
9.0 – 9.5
9.0 – 9.5
2
Conductivity
30 µS/Cm
30 µS/Cm
3
Oil & Grease