commissioning manual- water and waste water treatment

8/10/2019 Commissioning Manual- Water and Waste Water Treatment

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Uong Bi 300MW Extension Power Plant Goshu Kohsan Co., Ltd.M4/5/6 Water and Wastewater Treatment

Pre-Com and Commissioning Manual Page 1 of 71 09 Jan., 06 Rev. A

PRE-COMMISSIONING AND COMMISSIONING MANUAL

1. GENERAL

This manual covers the general requirements for the Pre-Commissioning and CommissioningWorks of Water and Wastewater Treatment Plants for Uong Bi 300MW Extension Power Plant,under the EPC contractor Vietnam Machinery Erection Corporation (LILAMA), which consists ofRaw Water Treatment System, Demineralization System, Wastewater Treatment Plant, andDomestic Wastewater Treatment Plant. These works shall commence after the completion ofinstallation work.


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2. PRE-COMMISSIONING

The purpose of pre-commissioning work is to check the actual condition of the plant and toperform necessary adjustments on the equipments in preparation for the commissioning work.

Mechanical Equipment Pre-Commissioning includes the following steps:1. Flushing and Cleaning2. Chemical Preparation3. Filter Media Loading4. Resin Loading5. Oil Interceptor Check6. Trial Run

Electrical & Instrument Equipment Pre-Commissioning includes the following steps:1. MCC Power Energize2. MCC Function Test3. Motor No-Load Test4. On-Off Valve Loop Test5. Instrument Loop Test6. System Function Test7. Input-Output Test8. Sequence Test


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2.1. MECHANICAL EQUIPMENT PRE-COMMISSIONING

1. FLUSHING and CLEANING Flush inside of pipe with water for few minutes until effluent is clear. Open valves slowly to flush all dirt, debris, excess sealant and scale. Clean inner surface of filters and exchanger vessels.

2. CHEMICAL PREPARATION

Pre-caution:1. Person who prepares harmful or dusty chemicals should wear suitable protective equipment.2. Training and advises shall be given to workers in order to understand the cause of harm that

would occur while working with chemicals. Method of prevention and measures to be used

in tending to the accident should be explained clearly to the workers.3. Provide water for cleaning within the place of preparation.4. Consider which chemical uses service water for dilution, and which one uses filtered water.

Preparation:1. Alum is prepared as per the following procedure;

1.1. Coagulation dissolving tank (10GBN10BB001) Fill the tank with filtered water until half of required level H Load 255.5 kg/day of alum (flake) into the tank via electrical hoist manually Further fill the tank with filtered water until required level H = 1,600 mm Start Agitator (10GBN10AM001) for 1 hour or until alum is dissolved

1.2. Coagulation Feed Tank (10GBN10BB002)

Open On-off valve (10GBN10AA301) manually from local SVB to transferdissolved alum at 10% concentration into feed tank by gravity.

1.3. Illustration

M

H

COAGULATION DISSOLVING

TANK (10GBN10BB001)

COAGULATION FEED TANK

(10GBN10BB002)

10GBN10AA301

COAGULA TION FEED PUMP

1A/B (10GBN11/12AP001)

CLARIFIER TANK A

(10UGE11BB001)

COAGULATION DISSOLVING TANK

AGITATOR (10GBN10AM001)

ALUM 10%


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Table 2: List of Filter Media:NO VESSEL TO BE

LOADED

KKS NO FILTER MEDIA QUANTITY

1 Auto Gravity Filter 10GBB11/12AT001 Gravel 5.04 m3Sand 7.56 m3

2 A/C Filter (Potable) 10GBB20AT001 Gravel 0.48 m3Activated Carbon 0.90 m3

3 A/C Filter (Demin) A/B 10GCB11/12AT001 Gravel 1.2 m3Activated Carbon 2.34 m3

4 A/C Filter (WWTP) 10GNB10AT001 Gravel 1.92 m3Activated Carbon 3.78 m3

4. RESIN LOADING

Precautions:1. It is important to cross check the resin volumes loaded into each vessel. Record the actual

resin level in delivery form after backwashing and settling.2. A careful measurement of the freeboard (in delivery form) should be made, reported, and

checked with the original design. If necessary, corrective action should be undertaken toeither load resin or download some.

3. Whenever possible, avoid the direct contact of the active resin with the nozzles.4. Resins to be loaded are listed in Table 3.

Procedure:1. Remove the top head of the vessel and top nozzle plate.2. Fill 1/3 of the vessel with water. Loading resin into water ensures that any air and dirt are

floated off the resin and come out to the surface of the water. This will allow the resin bed tosit evenly & homogeneously throughout the height of column.

3. Load the active resin as per the specified quantity.4. Load inert resin as per the specified quantity.5. Close the top head of the vessel.

Table 3: List of Resin:NO VESSEL TO BE

LOADEDVESSEL TAG NO RESIN QUANTITY

1 Cation Exchanger A/B 10GCF11/12AT001 Dowex Mono C-600 1,725 LitersDowex IF-62 150 Liters

2 Anion Exchanger A/B 10GCF21/22AT001 Dowex Mono A-500 2,225 LitersDowex IF-62 225 Liters

3 M/B Exchanger A/B 10GCF31/32AT001 Dowex Marathon C 375 Liters

Dowex Marathon A 475 Liters

5. OIL INTERCEPTOR CHECK

5.1. Make sure that all internal equipments are in place and no tools or other loose itemsare left in the interceptor.

5.2. With the automatic closure device in oil chamber feed, fill all interceptor compartmentswith clear water to the outlet level.

5.3. Check that the stainless steel automatic device follows the level of the water.


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6. TRIAL RUN

General:The following equipments shall undergo trial run to demonstrate that they can operate safelyand satisfactorily under the required operating conditions.

1. Clarifier tank A/B (RWTS)2. Gravity filter A/B

Manual backwash Auto backwash

3. Demin Train A A/C filter A (Demin) soaking Manual regeneration Auto regeneration

4. Demin Train B

A/C filter B (Demin) soaking Manual regeneration Auto regeneration

5. Clarifier tank (WWTP)6. Sludge receiver tank7. A/C filter (WWTP)

Soaking Manual backwash Auto backwash

Manual Backwash:It is very essential to perform manual backwash operation on each of Auto Gravity and Carbon

Filters before operating to auto-mode so that foreign particle present in the media duringdelivery are washed out from the vessel. In this operation, preliminary adjustments of manual &actuator-operated valves, instrument set points, flowrate, etc. should also be done.

Auto Backwash:When all necessary adjustments are completed, it is important to perform a trial run in automode for one cycle before performing the commissioning proper in order to counter-check theadjustments made. Final adjustments shall be done after one cycle, when necessary. Operationis the same as the commissioning operation (Refer to the section COMMISSIONING).

Activated Carbon Soaking:Activated carbon is filled with internal pores where air may exist. Before backwashing, bed must

be set in completely submerged condition to allow carbon pores to fill with water. Otherwise, thereduced density of carbon due to air in the pores may result in excessive backwash losses.

Manual Regeneration:It is very essential to first perform manual regeneration and backwashing before setting to auto-mode so that preliminary adjustments in the plant can be done; such as manual and actuator-operated valves adjustment, instruments set points, flowrate adjustment, chemical dosingadjustment, etc. This is also essential for the resin in order to wash away foreign particlespresent during delivery. This step shall prepare the correct ionic exchanging capacity of resin.Manual regeneration literally means regeneration of each step of every unit in manual operation.


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Automatic Regeneration:When all necessary adjustments and preparations are completed, it is important to perform a

trial run in auto mode for one cycle before performing the commissioning proper in order tocounter-check the adjustments made. Final adjustments shall be made after one cycle, whennecessary. Operation is the same as the commissioning operation (Refer to the sectionCOMMISSIONING).

Initial Resin Regeneration:Irrespective of the form delivered, the resin bed should receive at least a double amount ofregenerant compared to the design level. This means a double-injection-time only, whiledisplacement and rinse should be performed as per original design.

First Run:Expected high water quality will be achieved only after final rinsing, after Mixed Bed Exchanger

in the case of Demineralizer, but provided that endpoint is monitored correctly and the plant isnot overrun.

Procedure:A. Manual and Auto Backwash Operation

1. Set following pumps & blowers to manual mode operation in MCC and Local ControlPanel; Freshwater Supply Pump (10GAF10AP001) Backwash Water Pumps A/B (10GBK11/12AP001) Air Blowers A/B (10GBC11/12AN001) Filtered Water Transfer Pumps A/B (10GBK41/42AP001) Demin Feed Pumps A/B (10GCK11/12AP001)

Clarified Water Transfer Pumps A/B (10GNK31/32AP001) Backwash Pumps A/B (10GNK61/62AP001)

2. Set all actuator-operated valves used in Auto Gravity and Carbon filtering processinto manual mode operation in the Local Control Panel.

3. Perform manual preliminary washing in each filter in order to wash away foreignparticles present in the media during delivery until the effluent is clear.

4. Perform manual backwash operation in accordance with the Operation Chart andSequence of Auto Gravity and Carbon Filters, and P&ID.

5. Make necessary adjustments in order to meet the required water quality.6. Perform backwash operation again, this time in auto backwash operation.7. Make final adjustments as required.

B. Manual and Auto Regeneration Operation1. Set the following pumps and blowers into manual mode operation in the MCC and

Local Control Panel; Demin Feed Pumps A/B (10GCK11/12AP001) Booster Pumps A/B (10GCK21/22AP001) Regeneration Pumps A/B (10GCK31/32AP001) Degasifier Blowers A/B (10GCH11/12AN001) HCl Feed Pumps A/B (10GCN11/12AP001) NaOH Feed Pumps A/B (10GCN21/22AP001)

2. Set all actuator-operated valves used in Demineralizer into manual modeoperation in the Local Control Panel.


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3. Perform manual regeneration of Demineralizer in accordance with OperationChart and Sequence of Demineralization Train A & B by train and P&ID,sequentially as follows; A/C Filters A/B (10GCB11/12AT001) Cation Exchangers A/B (10GCF11/12AT001) Degasifier Tower & Sump A/B (GCH11/12AW001 & GCH11/12BB001) Anion Exchangers A/B (10GCF21/22AT001) Mixed Bed Exchangers A/B (10GCF31/32AT001)

4. Make necessary adjustments in order to meet the required water quality.5. Perform regeneration operation again, this time in auto mode regeneration.6. Make final adjustments, as necessary.


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FILTER BACKWASH WATERPIT (10UGH10BB001)

FRESHWATERPUMP HOUSE

STATION

AUTO-GRAVITY FILTER(10GBB11/12AT001)

10GBD11/12AA301

CLARIFIER TANK A(10UGE11BB001)

10GAC21AA001

10GAC21QP001

MCLARIFIER TANK A AGITATOR10GBD11AM001

NaOH FEED PUMP(10GBN41/42AP001)

POLYMER FEED PUMP(10GBN31AP001)

COAGULATIONFEED PUMP

(10GBN11/12AP001)pH

QT

TRIAL RUN PACKAGE M4:

Steps of Clarifier Tank A (UGE11BB001) Trial Run:

1.) Fill Water

Purpose: To supply raw water from Freshwater pond to Clarifier A (RWTS)

Operation:

Receive freshwater from Freshwater pump house station

Open Control valve (10GAC21AA001) manually from local SVB

Start Chemical feed pumps simultaneously with raw water flow in manual operation

o Coagulation feed pump 1A/B (10GBN11/12AP001)

o NaOH feed pump 2A/B (10GBN41/42AP001)

o Polymer feed pump 1A/B (10GBN31AP001)

Flow rate: 106.5 m3/hr

Duration: Until water level is 100mm below overflow line, then close control valve and stop

chemical feed pumps

Illustration:


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STATION


10GBD11/12AA301


10GAC21AA001

10GAC21QP001

MCLARIFIER TANK A AGITATOR(10GBD11AM001)




(10GBN11/12AP001)pH

QT

2.) Agitation

Purpose: To create disturbance inside Clarifier to enhance coagulation and flocculation

Operation:

Start Clarifier tank A agitator (10GBD11AM001) manually from LOP

Duration: ~2 hours or until floc is formed

(Note: Agitation continues until shutdown.)

Illustration:


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STATION


10GBD11/12AA301


10GAC21AA001

10GAC21QP00

M

CLARIFIER TANK AAGITATOR (10GBD11AM001)




(10GBN11/12AP001)pH

QT

3.) Start Operation

Purpose: To further receive freshwater from Freshwater pump house station

Operation:

Open Control valve (10GAC21AA001) manually from local SVB

Flow rate:

50% of 106.5 m3/hr until sludge blanket is 500 mm lower than overflow

100% of 106.5 m3/hr

Duration: Continues operation

Illustration:


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AUTO-GRAVITY FILTERA/B (10GBB11/12AT001)

CLARIFIER TANK A/B(10UGE11/12BB001)

10GBB11/12AA301

10GBB11/12AA302

FILTERED WATER PIT(10UGG10BB001)

BACKWASH WATERPUMP (GBK11/12AP001)

AIR BLOWER(10GBC11/12AN001)

10GBB11/12AA303

10GBB11/12AA306

10GBB11/12AA304

10GBB11/12AA305


Steps of Auto-Gravity Filter A/B (10GBB11/12AT001) Manual Preliminary Operation:

1.) Washing

Purpose: To wash away foreign particles from gravel in preparation for the filter operation

Operation:

Open On-off valve (10GBB11/12AA301) manually from local SVB


Other On-off valves are closed

Flow rate: 105 m3/hr

Duration: Until effluent is clear

Illustration:


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10GBB11/12AA301

10GBB11/12AA302




10GBB11/12AA303

10GBB11/12AA306

10GBB11/12AA304

10GBB11/12AA305


Steps of Auto-Gravity Filter A/B (10GBB11/12AT001) Manual Backwash Operation:

1.) Water Drain

Purpose: To reduce water level in vessel to prevent overflowing of media

Operation:



Flow rate: 0 m3/hr

Duration: 10 minutes

Illustration:


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10GBB11/12AA301

10GBB11/12AA302




10GBB11/12AA303

10GBB11/12AA306

10GBB11/12AA304

10GBB11/12AA305


2.) Air Backwash

Purpose: To polish the media to remove foreign particles that attached to the media

Operation:

Keep On-off valve (10GBB11/12AA304) open

Start Air blower A/B (10GBC11/12AN001) manually from LOP



Flow rate: 12.6 Nm3/min


Illustration:


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10GBB11/12AA301

10GBB11/12AA302




10GBB11/12AA303

10GBB11/12AA306

10GBB11/12AA304

10GBB11/12AA305


3.) Water Backwash

Purpose: To remove foreign particles detached from the media out of the vessel

Operation:

Keep On-off valve (10GBB11/12AA304) open

Close On-off valve (10GBB11/12AA3046) manually from local SVB

Stop Air blower A/B (10GBC11/12AN001) manually from LOP

Start B/W water pump A/B (10GBK11/12AP001) manually from LOP





Illustration:


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10GBB11/12AA301

10GBB11/12AA302




10GBB11/12AA303

10GBB11/12AA306

10GBB11/12AA304

10GBB11/12AA305


4.) Stop


Operation:


Stop B/W water pump A/B (10GBK11/12AP001) manually from LOP



Flow rate: 0 m3/hr


Illustration:


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10GBB11/12AA301

10GBB11/12AA302




10GBB11/12AA303

10GBB11/12AA306

10GBB11/12AA304

10GBB11/12AA305

FILTER BACKWASH WATER

PIT (10UGH10BB001)

5.) Washing


Operation:






Illustration:

Note: Repeat Manual Backwash Operation Until Effluent Is Clear.


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Steps of A/C Filter Potable (10GBB20AT001) Manual Backwash Operation:

1.) Soaking

Purpose: To saturate the carbon with water in order to optimize backwashing

Operation:

Open manhole MH manually

Start Filtered water transfer pump A/B (10GBK41/42AP001) manually from LOP

Open On-off valve (10GBB20AA301) manually from local SVB, then close valve

when water reaches top distributor level by looking through the manhole MH


Close manhole MH manually

Duration: 1 hour or until activated carbon is fully saturated

(Note: If some carbon still found floating on water surface, use any wooden paddle to

sweep or disturb floating carbon so that water may enter into the available pores)

Illustration:

AA301

FILTERED WATER

TRANSFER PUMP A/B

(10GBK41/42AP001)A/C FILTER

(10GBB20AT001)

POTABLE WATER

TANK

P

AA304

AA302

AA305

AA303

P

FI

(10GBK35CF501)

CP501

CP502

MH

FILTER B/W WATER

PIT

AA501


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2.) Washing

Purpose: To wash away foreign particles from gravel

Operation:

Keep Filtered water transfer pump A/B (10GBK41/42AP001) running

Keep On-off valve (10GBB20AA301) open

Open On-off valve (10GBB20AA305) manually from local SVB


Flow rate: 10 m3/hr


Illustration:

AA301

FILTERED WATER

TRANSFER PUMP A/B


(10GBB20AT001)

POTABLE WATER

TANK

P

AA304

AA302

AA305

AA303

P

FI

(10GBK35CF501)

CP501

CP502

MH

FILTER B/W WATER PIT

(10UGH10BB001)

AA501

Note: Open Air Vent valve (10GBB20AA501) once a day, anytime of the day, to releasesome air trapped in vessel


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3.) Backwashing

Purpose: To remove foreign particles of filter media

Operation:

Keep Filtered water transfer pump A/B (10GBK41/42AP001) running

Close On-off valve (10GBB20AA301, 10GBB20AA305) manually from local SVB

Open On-off valve (10GBB20AA303, 10GBB20AA304) manually from local SVB


Flow rate: 10 m3/hr


Illustration:

AA301

FILTERED WATER

TRANSFER PUMP A/B


(10GBB20AT001)

POTABLE WATER

TANK

P

AA304

AA302

AA305

AA303

P

FI

(10GBK35CF501)

CP501

CP502

MH


(10UGH10BB001)

AA501


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5.) Washing

Purpose: To remove foreign particles remaining in the bottom of filter bed

Operation:

Start Filtered water transfer pump A/B (10GBK41/42AP001) manually from LOP

Open On-off valve (10GBB20AA301, 10GBB20AA305) manually from local SVB


Flow rate: 10 m3/hr

Duration: 10 minutes or until effluent does not show activated carbon powder

Illustration:

AA301

FILTERED WATER

TRANSFER PUMP A/B

(10GBK41/42AP001) A/C FILTER

(10GBB20AT001)

POTABLE WATERTANK

P

AA304

AA302

AA305

AA303

P

FI

(10GBK35CF501)

CP501

CP502

MH


(10UGH10BB001)

AA501


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TRIAL RUN PACKAGE M5:

Steps of Demineralization Train A/B Manual Regeneration Operation

For A/C Filter A/B:

1.) Soaking


Operation:


Start Demin feed pump A/B (10GCK11/12AP001) manually from LOP

Open On-off valve (10GCB11/12AA301) manually from local SVB, then close valve




Duration: 1 hour or until carbon is fully saturated



Illustration:

AA301

DEMIN FEED PUMP A/B

10GCK11/12AP001

A/C FILTER A/B

(10GCB11/12AT001)

10UGV10BB001

CATION EXCH. A/B

(10GCF11/12AT001)

P

AA304

AA302

AA305

AA303

P

FI

(10GCK13CF501/502)

CP501

CP502

MH

AA501


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3.) Backwashing

Purpose: To remove foreign particles of filter media

Operation:

Keep Demin feed pump A/B (10GCK11/12AP001) running

Close On-off valve (10GCB11/12AA301) manually from local SVB


Open On-off valve (10GCB11/12AA303) manually from local SVB



Flow rate: 41 m3/hr


Illustration:

AA301

DEMIN FEED PUMP A/B

10GCK11/12AP001

A/C FILTER A/B

(10GCB11/12AT001)

10UGV10BB001

CATION EXCH. A/B

(10GCF11/12AT001)

P

AA304

AA302

AA305

AA303

P

FI

(10GCK13CF501/502)

CP501

CP502

MH

AA501


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4.) Stop

Purpose: To allow floating filter media to settle by gravity

Operation:

Stop Demin feed pump A/B (10GCK11/12AP001) manually from LOP




Flow rate: 0 m3/hr


Illustration:

AA301

DEMIN FEED PUMP A/B

(10GCK11/12AP001)

A/C FILTER A/B

(10GCB11/12AT001)

10UGV10BB001

CATION EXCH. A/B

(10GCF11/12AT001)

P

AA304

AA302

AA305

AA303

P

FI

(10GCK13CF501/502)

CP501

CP502

MH

AA501


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5.) Washing


Operation:

Start Demin feed pump A/B (10GCK11/12AP001) manually from LOP




Flow rate: 25 m3/hr

Duration: 10 minutes or until effluent does not show activated carbon powder

Illustration:

AA301

DEMIN FEED PUMP A/B

10GCK11/12AP001

A/C FILTER A/B

(10GCB11/12AT001)

10UGV10BB001

CATION EXCH. A/B

(10GCF11/12AT001)

P

AA304

AA302

AA305

AA303

P

FI

(10GCK13CF501/502)

CP501

CP502

MH

AA501


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6.) Service

Purpose: To produce filtered water

Operation:

Keep Demin feed pump A/B (10GCK11/12AP001) running

Keep On-off valve (10GCB11/12AA301) open




Flow rate: 41 m3/hr

Duration: 1,200 minutes

Illustration:

AA301

DEMIN FEED PUMP A/B

10GCK11/12AP001

A/C FILTER A/B

(10GCB11/12AT001)

10UGV10BB001

CATION EXCH. A/B

(10GCF11/12AT001)

P

AA304

AA302

AA305

AA303

P

FI

(10GCK13CF501/502)

CP501

CP502

MH

AA501


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For Cation Exchanger A/B:

1.) SAC Compaction

Purpose: To lift the bed without reclassification of cation resin layers and pushes out any

solids or fines that have accumulated on top of the bed.

Operation:

Start Regen pump A/B (10GCK31/32AP001) manually from LOP

Open On-off valve (10GCF11/12AA303) manually from local SVB



Flow rate: 29 m3/hr

Duration: 5 minutes

Illustration:

AA301

AA302

A/C FILTER A/B

(10GCB11/12AT001)

AA304

CATION

EXCH A/B(10GCF11/12

AT001)

PI

DEGASIFIER TOWER

A/B (10GCH11/12AW001)

PI

AA305

REGEN PUMP A/B

(10GCK31/32AP001)

HCl FEED PUMP

A/B

AA303

AA80110GCK62AA801

FT

(10GCK14/15CF001)

FI

10GCK63CF001

10GCN78AA801

FI

(10GCN78CF501)

10UGV10BB001

FI

(10GCK62CF502)


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2.) Regenerant HCl 30% Injection

Purpose: To regenerate exhausted cation resin

Operation:

Keep Regen pump A/B (10GCK31/32AP001) running

Close On-off valve (10GCF11/12AA303) manually from local SVB

Keep On-off valve (10GCF11/12AA304) open

Open On-off valves (10GCK62AA801, 10GCF11/12AA801) manually from local SVB

Start HCl feed pump A/B (10GCN11/12AP001) manually from LOP

Open On-off valve (10GCN78AA801) manually from local SVB


Flow rates: HCl 30% = 1.20 m3/hr, Regen water = 7.1 m3/hr


Illustration:

AA301

AA302

A/C FILTER A/B

(10GCB11/12AT001)

AA304

CATIONEXCH A/B

(10GCF11/12

AT001)

PI

DEGASIFIER TOWER

A/B (10GCH11/12AW001)

PI

AA305

REGEN PUMP A/B

(10GCK31/32AP001)

HCl FEED PUMP A/B

(10GCN11/12AP001)

AA303

AA80110GCK62AA801

FT

(10GCK14/15CF001)

FI

(10GCK63CF001)

10GCN78AA801

FI

(10GCN78CF501)

10UGV10BB001

FI

(10GCK62CF502)


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3.) Acid Displacement (Slow rinse)

Purpose: To push active regenerant from bottom to top of resin bed and start rinsing out

Operation:


Keep On-off valves (10GCF11/12AA304, 10GCK62AA801, ) open

Close On-off valve (10GCN78AA801) manually from local SVB

Stop HCl feed pump A/B (10GCN11/12AP001) manually from LOP



Flow rates: 7.1 m3/hr


Illustration:

AA301

AA302

A/C FILTER A/B

(10GCB11/12AT001)

AA304

CATION

EXCH A/B

(10GCF11/12

AT001)

PI

DEGASIFIER TOWER

A/B (10GCH11/12AW001)

PI

AA305

REGEN PUMP A/B

(10GCK31/32AP001)

HCl FEED PUMP A/B

(10GCN11/12AP001)

AA303

AA80110GCK62AA801

FT

(10GCK14/15CF001)

FI

(10GCK63CF001)

10GCN78AA801

FI

(10GCN78CF501)

10UGV10BB001

FI

(10GCK62CF502)


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4.) Resin Bed Settling

Purpose: To allow floating resin to settle by gravity

Operation:

Stop Regen pump A/B (10GCK31/32AP001) manually from LOP

Close On-off valves (10GCF11/12AA304, 10GCK62AA801, 10GCF11/12AA801)

manually from respective local SVBs


Flow rates: 0 m3/hr


Illustration:

AA301

AA302

A/C FILTER A/B

(10GCB11/12AT001)

AA304

CATION

EXCH A/B

(10GCF11/12

AT001)

PI

DEGASIFIER TOWER

A/B (10GCH11/12AW001)

PI

AA305

REGEN PUMP A/B

(10GCK31/32AP001)

HCl FEED PUMP A/B(10GCN11/12AP001)

AA303

AA80110GCK62AA801

FT

(10GCK14/15CF001)

FI

(10GCK63CF001)

10GCN78AA801

FI

(10GCN78CF501)

10UGV10BB001

FI

(10GCK62CF502)


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5.) Rinsing

Purpose: To finally rinse out remaining regenerant and to arrange resin layer

Operation:

Start Demin feed pump A/B (10GCK11/12AP001) manually from LOP to feed

filtered water through A/C filter A/B (10GCB11/12AT001)

Open On-off valves (10GCF11/12AA301, 10GCF11/12AA305) manually from

respective local SVBs


Flow rates: 41 m3/hr

Duration: 7 minutes

Illustration:

AA301

AA302

A/C FILTER A/B

10GCB11/12AT001

AA304

CATION

EXCH A/B

(10GCF11/12

AT001)

PI

DEGASIFIER TOWER

A/B (10GCH11/12AW001)

PI

AA305

REGEN PUMP A/B

(10GCK31/32AP001)

HCl FEED PUMP A/B

(10GCN11/12AP001)

AA303

AA80110GCK62AA801

FT

(10GCK14/15CF001)

FI

(10GCK63CF001)

10GCN78AA801

FI(10GCN78CF501)

10UGV10BB001

FI

(10GCK62CF502)


36/71



6.) Service

Purpose: To produce soft water

Operation:

Keep Demin feed pump A/B (10GCK11/12AP001) running to feed filtered water

through A/C filter A/B (10GCB11/12AT001)


Close On-off valve (10GCF11/12AA305) manually from respective local SVBs

Open On-off valve (10GCF11/12AA302) manually from respective local SVBs




Illustration:

AA301

AA302

A/C FILTER A/B

10GCB11/12AT001

AA304

CATION

EXCH A/B

(10GCF11/12

AT001)

PI

DEGASIFIER TOWER

A/B 10GCH11/12AW001

PI

AA305

REGEN PUMP A/B

(10GCK31/32AP001)

HCl FEED PUMP A/B

(10GCN11/12AP001)

AA303

AA80110GCK62AA801

FT

(10GCK14/15CF001)

FI

(10GCK63CF001)

10GCN78AA801

FI

(10GCN78CF501)

10UGV10BB001

FI

(10GCK62CF502)


37/71



For Degasifier A/B

Purpose: To remove CO2

Operation:

Keep A/C filter A/B (10GCB11/12AT001) and Cation Exchanger A/B

(10GCF11/12AT001) in service


Start Degasifier blower A/B (10GCH11/12AN001) manually from LOP



Illustration:

10GCF11/12AA302

DEGASIFIER BLOWER

A/B (10GCH11/12AN001)

DEGASIFIER SUMP A/B

(10GCH11/12BB001)

DEGASIFIER TOWER A/B

(10GCH11/12AW001)

CATION EXCH A/B

(10GCF11/12AT001)

ANION EXCH A/B

(10GCF21/22AT001)

BOOSTER PUMP A/B

(10GCK21/22AP001)

LT


38/71


39/71


40/71



3.) Acid Displacement (Slow rinse)

Purpose: To push active regenerant from bottom to top of resin bed and start rinsing out

Operation:




Keep On-off valves (10GCK62AA803, 10GCF21/22AA801) manually from local SVB


Stop NaOH feed pump A/B (10GCN21/22AP001) manually from LOP


Flow rates: 7.30 m3/hr


Illustration:

AA301

AA302

MIXED BED EXCH A/B

(10GCF31/32AT001)

AA304

ANIONEXCH A/B

(10GCF21/22

AT001)

PI

BOOSTER PUMP A/B

(10GCK21/22AP001)

PI

AA305

REGEN PUMP A/B

(10GCK31/32AP001)

NaOH FEED PUMP A/B

(10GCN21/22AP001)

AA303

AA80110GCK62AA803

FT

(10GCK37/38CF001)

FI

(10GCK63CF001)

10GCN91AA801

FI

(10GCN91CF501)

10UGV10BB001

FI

(10GCK62CF504)


41/71



4.) Resin Bed Settling

Purpose: To allow floating resin to settle by gravity

Operation:


Close On-off valves (10GCF21/22AA304, 10GCK62AA803, 10GCF21/22AA801)

manually from respective local SVBs


Flow rates: 0 m3/hr


Illustration:

AA301

AA302

MIXED BED EXCH A/B

(10GCF31/32AT001)

AA304

ANION

EXCH A/B

(10GCF21/22

AT001)

PI

BOOSTER PUMP A/B

(10GCK21/22AP001)

PI

AA305

REGEN PUMP A/B

(10GCK31/32AP001)

NaOH FEED PUMP A/B(10GCN21/22AP001)

AA303

AA80110GCK62AA803

FT

(10GCK37/38CF001)

FI

(10GCK63CF001)

10GCN91AA801

FI

(10GCN91CF501)

10UGV10BB001

FI

(10GCK62CF504)


42/71



5.) Rinsing

Purpose: To finally rinse out remaining regenerant and to arrange resin layer

Operation:

Start Booster pump A/B (10GCK21/22AP001) manually from LOP






Illustration:

AA301

AA302

MIXED BED EXCH A/B

(10GCF31/32AT001)

AA304

ANION

EXCH A/B

(10GCF21/22

AT001)

PI

BOOSTER PUMP A/B

(10GCK21/22AP001)

PI

AA305

REGEN PUMP A/B

(10GCK31/32AP001)

NaOH FEED PUMP A/B(10GCN21/22AP001)

AA303

AA80110GCK62AA803

FT

(10GCK37/38CF001)

FI

(10GCK63CF001)

10GCN91AA801

FI

(10GCN91CF501)

10UGV10BB001

FI

(10GCK62CF504)


43/71


44/71



For Mixed Bed Exchanger A/B:

1.) Backwashing

Purpose: To separate anion and cation resin layers

Operation:







Illustration:

ANION EXCH A/B

(10GCF21/22AT001)

AA806

DEMIN WATER

TANK A/B

(10GCL11/12BB01

PI

REGEN PUMP A/B

(10GCK31/32AP001)

NaOH FEED PUMP

1A/B

AA305

10UGV10BB001

AA804

AA302

AA306

AA803

AA801

AA805

AA802

MIXED BED

EXCH A/B

(10GCF31/32

AT001)

FI

(10GCK63CF001)

FI (10GCK62CF503)

10GCK62AA804

10GCN90AA801

FI (10GCN90CF501)

FI (10GCK62CF501)

10GCK62AA802

FI (10GCN77CF501)

10GCN77AA801

HCl FEED PUMP 1A/B

(10GCN11/12AP001)

AIR RECEIVER

(10QEF10BB001)

10GCF21/22AA302

PI


45/71



2.) Stop

Purpose: To allow floating resins to settle by gravity

Operation:


Close On-off valves (10GCF31/32AA805, 10GCF31/32AA806) manually from



Flow rate: 0 m3/hr


Illustration:

ANION EXCH A/B

(10GCF21/22AT001)

AA806

DEMIN WATER

TANK A/B

(10GCL11/12BB01)

PI

REGEN PUMP A/B

(10GCK31/32AP001)

NaOH FEED PUMP

1A/B

AA305

10UGV10BB001

AA804

AA302

AA306

AA803

AA801

AA805

AA802

MIXED BED

EXCH A/B

(10GCF31/32

AT001)

FI

(10GCK63CF001)

FI (10GCK62CF503)

10GCK62AA804

10GCN90AA801

FI (10GCN90CF501)

FI (10GCK62CF501)

10GCK62AA802

FI (10GCN77CF501)

10GCN77AA801

HCl FEED PUMP 1A/B

(10GCN11/12AP001)

AIR RECEIVER

(10QEF10BB001)

10GCF21/22AA302

PI


46/71



3.) Regenerant NaOH 50% Injection

Purpose: To regenerate exhausted anion resin

Operation:


Open On-off valves (10GCF31/32AA801, 10GCF31/32AA802, 10GCF31/32AA804,

10GCK62AA804, 10GCK62AA802) manually from respective local SVBs

Start NaOH feed pump A/B (10GCN21/22AP001) manually from LOP



Flow rate: NaOH 50% = 0.16 m3/hr, Downward = 2.10 m3/hr, Upward = 2.20 m3/hr


Illustration:

ANION EXCH A/B

(10GCF21/22AT001)

AA806

DEMIN WATER

TANK A/B

(10GCL11/12BB01)

PI

REGEN PUMP A/B

(10GCK31/32AP001)

NaOH FEED

PUMP 1A/B

(10GCN21/22AP001)

AA305

10UGV10BB001

AA804

AA302

AA306

AA803

AA801

AA805

AA802

MIXED BED

EXCH A/B

(10GCF31/32

AT001)

FI

(10GCK63CF001)

FI (10GCK62CF503)

10GCK62AA804

10GCN90AA801

FI (10GCN90CF501)

FI (10GCK62CF501)

10GCK62AA802

FI (10GCN77CF501)

10GCN77AA801

HCl FEED PUMP 1A/B

(10GCN11/12AP001)

AIR RECEIVER

(10QEF10BB001)

10GCF21/22AA302

PI


47/71



4.) Displacement of NaOH 50% (Slow rinse)

Purpose: To displace active NaOH 50% residual from the line before ends of spray nozzle

Operation:


Keep On-off valves (10GCF31/32AA801, 10GCF31/32AA802, 10GCF31/32AA804,

10GCK62AA804, 10GCK62AA802) open


Stop NaOH feed pump A/B (10GCN21/22AP001) manually from LOP




Illustration:

ANION EXCH A/B

(10GCF21/22AT001)

AA806

DEMIN WATER

TANK A/B

(10GCL11/12BB01)

PI

REGEN PUMP A/B

(10GCK31/32AP001)

NaOH FEED PUMP

1A/B

AA305

10UGV10BB001

AA804

AA302

AA306

AA803

AA801

AA805

AA802

MIXED BED

EXCH A/B

(10GCF31/32

AT001)

FI

(10GCK63CF001)

FI (10GCK62CF503)

10GCK62AA804

10GCN90AA801

FI (10GCN90CF501)

FI (10GCK62CF501)

10GCK62AA802

FI (10GCN77CF501)

10GCN77AA801

HCl FEED PUMP 1A/B

(10GCN11/12AP001)

AIR RECEIVER

(10QEF10BB001)

10GCF21/22AA302

PI


48/71



5.) Regenerant HCl 30%

Purpose: To regenerate exhausted cation resin

Operation:


Keep On-off valves (10GCF31/32AA801, 10GCF31/32AA802, 10GCF31/32AA804,

10GCK62AA804, 10GCK62AA802) open

Start HCl feed pump A/B (10GCN11/12AP001) manually from LOP



Flow rate: HCl 30% = 0.39 m3/hr, Upward = 2.20 m3/hr, Downward = 2.10 m3/hr


Illustration:

ANION EXCH A/B

(10GCF21/22AT001)

AA806

DEMIN WATER

TANK A/B

(10GCL11/12BB01)

PI

REGEN PUMP A/B

(10GCK31/32AP001)

NaOH FEED PUMP

1A/B

AA305

10UGV10BB001

AA804

AA302

AA306

AA803

AA801

AA805

AA802

MIXED BED

EXCH A/B

(10GCF31/32

AT001)

FI

(10GCK63CF001)

FI (10GCK62CF503)

10GCK62AA804

10GCN90AA801

FI (10GCN90CF501)

FI (10GCK62CF501)

10GCK62AA802

FI (10GCN77CF501)

10GCN77AA801

HCl FEED

PUMP 1A/B

(10GCN11/12AP001)

AIR RECEIVER

(10QEF10BB001)

10GCF21/22AA302

PI


49/71


50/71


51/71



8.) Resin Air Mixing

Purpose: To mix back cation and anion resins

Operation:




Flow rate: 47.1 Nm3/hr


Illustration:

ANION EXCH A/B

(10GCF21/22AT001)

AA806

DEMIN WATERTANK A/B

(10GCL11/12BB01)

PI

REGEN PUMP A/B

(10GCK31/32AP001)

NaOH FEED PUMP

1A/B

AA305

10UGV10BB001

AA804

AA302

AA306

AA803

AA801

AA805

AA802

MIXED BED

EXCH A/B

(10GCF31/32

AT001)

FI

(10GCK63CF001)

FI (10GCK62CF503)

10GCK62AA804

10GCN90AA801

FI (10GCN90CF501)

FI (10GCK62CF501)

10GCK62AA802

FI (10GCN77CF501)

10GCN77AA801

HCl FEED PUMP 1A/B

(10GCN11/12AP001)

AIR RECEIVER

(10QEF10BB001)

10GCF21/22AA302

PI


52/71



9.) Vessel Filling

Purpose: To fill the vessel with water until required level

Operation:

Start Booster pump A/B (10GCK21/22AP001) manually from LOP to feed demin

water through Anion Exchanger A/B (10GCF21/22AT001)





Duration: 2 minutes

Illustration:

ANION EXCH A/B

(10GCF21/22AT001)

AA806

DEMIN WATER

TANK A/B

(10GCL11/12BB01)

PI

REGEN PUMP A/B

(10GCK31/32AP001)

NaOH FEED PUMP

1A/B

AA305

10UGV10BB001

AA804

AA302

AA306

AA803

AA801

AA805

AA802

MIXED BED

EXCH A/B

(10GCF31/32

AT001)

FI

(10GCK63CF001)

FI (10GCK62CF503)

10GCK62AA804

10GCN90AA801

FI (10GCN90CF501)

FI (10GCK62CF501)

10GCK62AA802

FI (10GCN77CF501)

10GCN77AA801

HCl FEED PUMP 1A/B

(10GCN11/12AP001)

AIR RECEIVER

(10QEF10BB001)

10GCF21/22AA302

PI

AA801


53/71



10.) Rinsing

Purpose: To fill the vessel with water until required level

Operation:

Keep Booster pump A/B (10GCK21/22AP001) running to feed demin water through

Anion Exchanger A/B (10GCF21/22AT001)






Illustration:

ANION EXCH A/B

(10GCF21/22AT001)

AA806

DEMIN WATER

TANK A/B

(10GCL11/12BB01)

PI

REGEN PUMP A/B

(10GCK31/32AP001)

NaOH FEED PUMP

1A/B

AA305

10UGV10BB001

AA804

AA302

AA306

AA803

AA801

AA805

AA802

MIXED BED

EXCH A/B

(10GCF31/32

AT001)

FI

(10GCK63CF001)

FI (10GCK62CF503)

10GCK62AA804

10GCN90AA801

FI (10GCN90CF501)

FI (10GCK62CF501)

10GCK62AA802

FI (10GCN77CF501)

10GCN77AA801

HCl FEED PUMP 1A/B

(10GCN11/12AP001)

AIR RECEIVER

(10QEF10BB001)

10GCF21/22AA302

PI


54/71



11.) Service

Purpose: To further polish demin water

Operation:

Keep Booster pump A/B (10GCK21/22AP001) running to feed demin water through

Anion Exchanger A/B (10GCF21/22AT001)






Illustration:

ANION EXCH A/B

(10GCF21/22AT001)

AA806

DEMIN WATER

TANK A/B

(10GCL11/12BB01)

PI

REGEN PUMP A/B

(10GCK31/32AP001)

NaOH FEED PUMP

1A/B

AA305

10UGV10BB001

AA804

AA302

AA306

AA803

AA801

AA805

AA802

MIXED BED

EXCH A/B

(10GCF31/32

AT001)

FI

(10GCK63CF001)

FI (10GCK62CF503)

10GCK62AA804

10GCN90AA801

FI (10GCN90CF501)

FI (10GCK62CF501)

10GCK62AA802

FI (10GCN77CF501)

10GCN77AA801

HCl FEED PUMP 1A/B

(10GCN11/12AP001)

AIR RECEIVER

(10QEF10BB001)

10GCF21/22AA302

PI


55/71


56/71



2.) WWTP Clarifier Tank

Purpose: To separate sludge and clear water

Operation:

Keep Wastewater pump (10GNK21/22AP001) running

Keep Chemical feed pumps simultaneously running

o Coagulation feed pump 2A/B (10GNN11/12AP001) = 100 mg/L

o HCl feed pump 2A (10GNN30AP001) = 50 mg/L

o NaOH feed pump 3A (10GNN50AP001) = 100 mg/L

o Polymer feed pump 2A/B (10GNN21/22AP001) = 1 mg/L

Start WWTP Clarifier tank agitators (10GND10AM001) when wastewater level is

over the blades of agitator

Start Thinner sludge pump A/B (10GNK41/42AP001) manually from LOP to

transfer partially thickened sludge to Sludge receiver tank (10UGT10BB001)

Flow rate: 70 m3/hr

Duration: Continuous

Illustration:

M

WWTP CLARIFIER TANK

AGITATOR (10GND10AM001)

MIXING PIT

(10UGP20BB001)

CLARIFIED WASTEWATER

PIT (10UGR10BB001)

WWTP CLARIFIER TANK(10UGQ10BB001)

THINNER SLUDGE PUMP

A/B (10GNK41/42AP001)


57/71


58/71



Steps of A/C Filter WWTP (10GNB10AT001) Manual Backwash Operation:

1.) Soaking


Operation:


Start Clarified water transfer pump A/B (10GNK31/32AP001) manually from LOP

Open On-off valve (10GNB10AA301) manually from local SVB, then close valve




Duration: 1 hour or until activated carbon is fully saturated



Illustration:

AA301

CLARIFIED WATER

TRANSFER PUMP A/B

(10GNK31/32AP001)A/C FILTER WWTP

(10GNB10AT001)

NEUTRALIZATION PIT

(10UGU10BB001)

P

AA304

AA302

AA305

AA303

P

FI

(10GNK21CF501)

CP501

CP502

MH

WASTEWATER PIT

(10UGN10BB001)

BACKWASH PUMP A/B

(10GNK61/62AP001)

AA501


59/71



2.) Washing

Purpose: To wash away foreign particles from gravel

Operation:

Keep Clarified water transfer pump A/B (10GNK31/32AP001) running

Open On-off valve (10GNB10AA301) manually from local SVB



Flow rate: 70 m3/hr

Duration: 10 minutes or until effluent is clear

Illustration:

AA301

CLARIFIED WATER

TRANSFER PUMP A/B


(10GNB10AT001)

NEUTRALIZATION PIT

(10UGU10BB001)

P

AA304

AA302

AA305

AA303

P

FI

(10GNK21CF501)

CP501

CP502

MH

WASTEWATER PIT

(10UGN10BB001)

BACKWASH PUMP A/B

(10GNK61/62AP001)

AA501

Note: Open Air Vent valve (10GNB10AA501) once a day, anytime of the day, to releasesome air trapped in vessel


60/71


61/71



4.) Stop

Purpose: To allow floating filter media to settle by gravity

Operation:

Stop Backwash pump A/B (10GNK61/62AP001) manually from LOP

Close On-off valve (10GNB10AA303, 10GNB10AA304) manually from local SVB


Flow rate: 0 m3/hr


Illustration:

AA301

CLARIFIED WATER

TRANSFER PUMP A/B


(10GNB10AT001)

NEUTRALIZATION PIT(10UGU10BB001)

P

AA304

AA302

AA305

AA303

P

FI

(10GNK21CF501)

CP501

CP502

MH

WASTEWATER PIT

(10UGN10BB001)

BACKWASH PUMP A/B(10GNK61/62AP001)

AA501


62/71



5.) Washing


Operation:

Start Clarified water transfer pump A/B (10GNK31/32AP001) manually from LOP

Open On-off valve (10GNB10AA301, 10GNB10AA305) manually from local SVB


Flow rate: 40 m3/hr


Illustration:

AA301

CLARIFIED WATER

TRANSFER PUMP A/B


(10GNB10AT001)

NEUTRALIZATION PIT(10UGU10BB001)

P

AA304

AA302

AA305

AA303

P

FI

(10GNK21CF501)

CP501

CP502

MH

WASTEWATER PIT

(10UGN10BB001)

BACKWASH PUMP A/B(10GNK61/62AP001)

AA501


63/71



6.) Service

Purpose: To filtered wastewater

Operation:

Keep Clarified water transfer pump A/B (10GNK31/32AP001) running

Keep On-off valve (10GNB10AA301) open

Close On-off valve (10GNB10AA305) manually from local SVB



Flow rate: 70 m3/hr


Illustration:

AA301

CLARIFIED WATER

TRANSFER PUMP A/B


(10GNB10AT001)

NEUTRALIZATION PIT

(10UGU10BB001)

P

AA304

AA302

AA305

AA303

P

FI

(10GNK21CF501)

CP501

CP502

MH

WASTEWATER PIT

(10UGN10BB001)

BACKWASH PUMP A/B

(10GNK61/62AP001)

AA501


64/71



2.2. ELECTRICAL & INSTRUMENT EQUIPMENT PRE-COMMISSIONING

1. MCC POWER ENERGIZEProcedure:1. Prior to energizing the MCC, the operator should check selector switches of each MCC module for

equipments such as pumps, blowers, agitators, etc., if they are in OFF position. Release to Local signal fromMMI shall not be activated (Logic = 0). Below is a list of equipments with their respective local control panels:

NO KKS NO EQUIPMENT NAME LOP NO

1 10GBN11AP001 COAGULATION FEED PUMP 1A 10GBY10CX101

2 10GBN12AP001 COAGULATION FEED PUMP 1B 10GBY10CX101

3 10GNN11AP001 COAGULATION FEED PUMP 2A 10GBY10CX101

4 10GNN12AP001 COAGULATION FEED PUMP 2B 10GBY10CX101

5 10GBN10AM001 COAG DISSOLVING TANK AGITATOR 10GBY10CX101

6 10GBN21AP001 NaOCl FEED PUMP 1A 10GBY10CX1027 10GBN22AP001 NaOCl FEED PUMP 1B 10GBY10CX102

8 10GRN11AP001 NaOCl FEED PUMP 2A 10GBY10CX102

9 10GRN12AP001 NaOCl FEED PUMP 2B 10GBY10CX102

10 10GBN31AP001 POLYMER FEED PUMP 1A 10GBY10CX103

11 10GBN32AP001 POLYMER FEED PUMP 1B 10GBY10CX103

12 10GNN21AP001 POLYMER FEED PUMP 2A 10GBY10CX103

13 10GNN22AP001 POLYMER FEED PUMP 2B 10GBY10CX103

14 10GBD11AM001 CLARIFIER TANK A AGITATOR 10GBY10CX104

15 10GBD12AM001 CLARIFIER TANK B AGITATOR 10GBY10CX105

16 10GBK21AP001 UNDERFLOW SLUDGE PUMP A 10GBY10CX10617 10GBK22AP001 UNDERFLOW SLUDGE PUMP B 10GBY10CX106

18 10GBK31AP001 FILTERED WATER PUMP A 10GBY10CX106

19 10GBK32AP001 FILTERED WATER PUMP B 10GBY10CX106

20 10GBC11AN001 AIR BLOWER A 10GBY10CX106

21 10GBC12AN001 AIR BLOWER B 10GBY10CX106

22 10GBK11AP001 BACKWASH WATER PUMP A 10GBY10CX107

23 10GBK12AP001 BACKWASH WATER PUMP B 10GBY10CX107

24 10GBK41AP001 FILTERED WATER TRANSFER PUMP A 10GBY10CX107

25 10GBK42AP001 FILTERED WATER TRANSFER PUMP B 10GBY10CX107

26 10GKA11AP001 PORTABLE WATER PUMP A 10GBY10CX108

27 10GKA12AP001 PORTABLE WATER PUMP B 10GBY10CX108

28 10GCK21AP001 BOOSTER PUMP A 10GCY10CX101

29 10GCK22AP001 BOOSTER PUMP B 10GCY10CX101

30 10GCH11AN001 DEGASIFIER BLOWER A 10GCY10CX101

31 10GCH12AN001 DEGASIFIER BLOWER B 10GCY10CX101

32 10GCN11AP001 HCl FEED PUMP 1A 10GCY10CX102

33 10GCN12AP001 HCl FEED PUMP 1B 10GCY10CX102

34 10GNN30AP001 HCl FEED PUMP 2A 10GCY10CX102


65/71



NO KKS NO EQUIPMENT NAME LOP NO

35 10GNN40AP001 HCl FEED PUMP 2B 10GCY10CX102

36 10GCN21AP001 NaOH FEED PUMP 1A 10GCY10CX10337 10GCN22AP001 NaOH FEED PUMP 1B 10GCY10CX103

38 10GBN41AP001 NaOH FEED PUMP 2A 10GCY10CX103

39 10GBN42AP001 NaOH FEED PUMP 2B 10GCY10CX103

40 10GNN50AP001 NaOH FEED PUMP 3A 10GCY10CX103

41 10GNN60AP001 NaOH FEED PUMP 3B 10GCY10CX103

42 10GCK51AP001 NEUT WATER DISPOSAL PUMP A 10GCY10CX104

43 10GCK52AP001 NEUT WATER DISPOSAL PUMP B 10GCY10CX104

44 10GCK41AP001 DEMIN WATER TRANSFER PUMP A 10GCY10CX105

45 10GCK42AP001 DEMIN WATER TRANSFER PUMP B 10GCY10CX105

46 10GCK31AP001 REGENERATION PUMP A 10GCY10CX105

47 10GCK32AP001 REGENERATION PUMP B 10GCY10CX105

48 10GCK11AP001 DEMIN FEED PUMP A 10GCY10CX107

49 10GCK12AP001 DEMIN FEED PUMP B 10GCY10CX107

50 10GNK11AP001 OILY WASTEWATER PUMP A 10GNY10CX101

51 10GNK12AP001 OILY WASTEWATER PUMP B 10GNY10CX101

52 10GNC11AN001 MIXING BLOWER A 10GNY10CX102

53 10GNC12AN001 MIXING BLOWER B 10GNY10CX102

54 10GNK41AP001 THINNER SLUDGE PUMP A 10GNY10CX102

55 10GNK42AP001 THINNER SLUDGE PUMP B 10GNY10CX102

56 10GNK71AP001 THICKER SLUDGE PUMP A 10GNY10CX103

57 10GNK72AP001 THICKER SLUDGE PUMP B 10GNY10CX103

58 10GNK21AP001 WASTEWATER PUMP A 10GNY10CX103

59 10GNK22AP001 WASTEWATER PUMP B 10GNY10CX103

60 10GNK61AP001 BACKWASH PUMP A 10GNY10CX104

61 10GNK62AP001 BACKWASH PUMP B 10GNY10CX104

62 10GNK51AP001 TREATED WATER PUMP A 10GNY10CX104

63 10GNK52AP001 TREATED WATER PUMP B 10GNY10CX104

64 10GNK31AP001 CLARIFIED WATER TRANSFER PUMP A 10GNY10CX104

65 10GNK32AP001 CLARIFIED WATER TRANSFER PUMP B 10GNY10CX104

66 10GNS10AM001 SLUDGE RECIEVER TANK AGITATOR 10GNY10CX105

67 10GND10AM001 WWTP CLARIFIER TANK AGITATOR 10GNY10CX106

68 10GNE10AM001 pH ADJUSTMENT PIT AGITATOR 10GNY10CX107

69 10GNE20AM001 MIXING PIT AGITATOR 10GNY10CX107

70 10GNE30AM001 NEUTRALIZATION PIT AGITATOR 10GNY10CX107

71 10GRK11AP001 DWWTP SLUDGE PUMP A 10GNY10CX108

72 10GRK12AP001 DWWTP SLUDGE PUMP B 10GNY10CX108

73 10GRC11AN001 BLOWER A 10GNY10CX109

74 10GRC12AN001 BLOWER B 10GNY10CX109


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2. Energizing the MCC Refer to separate manual of MCC for energizing procedure Select the following motor starter modules to remote mode operation

RAW WATER TREATMENT SYSTEM

NO KKS NO EQUIPMENT NAME

1 10GBK31AP001/10GBK32AP001 FITERED WATER PUMP A/B

2 10GBK11AP001/10GBK12AP001 BACKWASH WATER PUMP A/B

3 10GKA11AP001/10GKA12AP001 PORTABLE WATER PUMP A/B

4 10GBK21AP001/10GBK22AP001 UNDERFLOW SLUDGE PUMP A/B

5 10GBC11AN001/10GBC12AN001 AIR BLOWER A/B

6 10GBK41AP001/10GBK42AP001 FILTERED WATER TRANSFER PUMP A/B

7 10GBD11AM001/10GBD12AM001 CLARIFIER TANK A/B AGITATOR8 10GBN10AM001 COAGULATION DISOVING TANK AGITATOR

9 10GBN11AP001/10GBN12AP001 COAGULATION FEED PUMP 1A/1B

10 10GBN21AP001/10GBN22AP001 NaOCl FEED PUMP 1A/1B

11 10GBN31AP001/10GBN32AP001 POLYMER FEED PUMP 1A/1B

12 10GBN41AP001/10GBN42AP001 NaOH FEED PUMP 2A/2B

DEMINERALIZATION SYSTEM


1 10GCK11AP001/10GCK12AP001 DEMIN FEED PUMP A/B2 10GCH11AN001/10GCH12AN001 DEGASIFIER BLOWER A/B

3 10GCK21AP001/10GCK22AP001 BOOSTER PUMP A/B

4 10GCK41AP001/10GCK42AP001 DEMINERALIZED WATER TRANSFER PUMP A/B

5 10GCK31AP001/10GCK32AP001 REGENERATION PUMP A/B

6 10GCN11AP001/10GCN12AP001 HCl FEED PUMP 1A/1B

7 10GCN21AP001/10GCN22AP001 NaOH FEED PUMPS 1A/1B

8 10GCK51AP001/10GCK52AP001 NEUTRALIZED WATER DISPOSAL PUMP A/B

WASTEWATER TREATMENT PLANT


1 10GNK11AP001/10GNK12AP001 OILY WASTEWATER PUMP A/B

2 10GNC11AN001/10GNC12AN001 MIXING BLOWER A/B

3 10GNK21AP001/10GNK22AP001 WASTEWATER PUMP A/B

4 10GNK31AP001/10GNK32AP001 CLARIFIED WATER TRANSFER PUMP A/B

5 10GNK61AP001/10GNK62AP001 BACKWASH PUMP A/B

6 10GNK51AP001/10GNK52AP001 TREATED WATER PUMP A/B

7 10GNK41AP001/10GNK42AP001 THINNER SLUDGE PUMPS A/B

8 10GNK71AP001/10GNK72AP001 THICKENER SLUDGE PUMPS A/B


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9 10GNN30AP001/10GNN40AP001 HCl FEED PUMP 2A/2B

10 10GNN50AP001/10GNN60AP001 NaOH FEED PUMP 3A/3B11 10GND10AM001 CLARIFIER TANK AGITATOR

12 10GNE10AM001 pH ADJUSTMENT PIT AGITATOR

13 10GNE20AM001 MIXING PIT AGITATOR

14 10GNE30AM001 NEUTRALIZATION PIT AGITATOR

15 10GNS10AM001 SLUDGE RECEIVER TANK AGITATOR

16 10GNN11AP001/10GNN12AP001 COAGULATION FEED PUMP 2A/2B

17 10GNN21AP001/10GNN22AP001 POLYMER FEED PUMP 2A/2B

18 10GRC11AN001/10GRC12AN001 BLOWER A/B

19 10GRK11AP001/10GRK12AP001 SLUDGE PUMP A/B

20 10GRN11AP001/10GRN12AP001 NaOCl FEED PUMP 2A/2B

3. Energize each equipment in the MCC as per following requirementsFor equipment with auto-mode/ manual-mode, select of each equipment via MMI Operation mode of each equipment shall be selected to the following;

RAW WATER SYSTEM

NO EQUIPMENT NAME AUTO MANUAL STAND-BY LOP NO.1 COAGULATION DISSOLVING TANK

AGITATORN/A 10GBN10AM001 - 10GBY10CX101

2 COAGULATION FEED PUMP1A/1B

10GBN11AP001 SELECTABLE 10GBN12AP001 10GBY10CX101

3 NaOCl FEED PUMP 1A/1B 10GBN21AP001 SELECTABLE 10GBN22AP001 10GBY10CX102

4 POLYMER FEED PUMP 1A 10GBN31AP001 SELECTABLE - 10GBY10CX103

5 POLYMER FEED PUMP 1B 10GBN32AP001 SELECTABLE - 10GBY10CX103

6 NaOH FEED PUMP 2A/2B 10GBN41AP001 SELECTABLE 10GBN42AP001 10GCY10CX103

7 CLARIFIER TANK AAGITATOR

10GBD11AM001 SELECTABLE - 10GBY10CX104

8 CLARIFIER TANK BAGITATOR

10GBD12AM001 SELECTABLE - 10GBY10CX105

9 FILTERED WATER PUMP A/B 10GBK31AP001 SELECTABLE 10GBK32AP001 10GBY10CX106

10 AIR BLOWER A/B 10GBC11AN001 SELECTABLE 10GBC12AN001 10GBY10CX106

11 UNDERFLOW SLUDGEPUMP A/B

10GBK21AP001 SELECTABLE 10GBK22AP001 10GBY10CX106

12 BACKWASH WATER PUMP A/B 10GBK11AP001 SELECTABLE 10GBK12AP001 10GBY10CX10713 FILTERED WATER TRANSFERPUMP A/B

N/A 10GBK41AP001 10GBK42AP001 10GBY10CX107

14 POTABLE WATER PUMP A/B N/A 10GKA11AP001 10GKA12AP001 10GBY10CX108


NO EQUIPMENT NAME AUTO MANUAL STAND-BY LOP NO.1 DEGASIFIER BLOWER A 10GCH11AN001 SELECTABLE - 10GCY10CX101

2 DEGASIFIER BLOWER B 10GCH12AN001 SELECTABLE 10GCH12AN001 10GCY10CX101

3 BOOSTER PUMP A 10GCK21AP001 SELECTABLE - 10GCY10CX101

4 BOOSTER PUMP B 10GCK22AP001 SELECTABLE - 10GCY10CX101


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NO EQUIPMENT NAME AUTO MANUAL STAND-BY LOP NO.5 HCl FEED PUMP 1A/1B 10GCN11AP001 SELECTABLE 10GCN12AP001 10GCY10CX102

6 NaOH FEED PUMP 1A/1B 10GCN21AP001 SELECTABLE 10GCN22AP001 10GCY10CX103

7 NEUTRALIZED WATER DISPOSALPUMP A/B

10GCK51AP001 SELECTABLE 10GCK52AP001 10GCY10CX104

8 DEMINERALIZED WATERTRANSFER PUMP A

N/A 10GCK41AP001 - 10GCY10CX105

9 DEMINERALIZED WATERTRANSFER PUMP B

N/A 10GCK42AP001 - 10GCY10CX105

10 REGENERATION PUMP A/B 10GCK31AP001 SELECTABLE 10GCK32AP001 10GCY10CX105

11 DEMIN FEED PUMP A/B 10GCK11AP001 SELECTABLE 10GCK12AP001 10GCY10CX107


NO EQUIPMENT NAME AUTO MANUAL STAND-BY LOP NO.

1 COAG FEED PUMP 2A/2B 10GNN11AP001 SELECTABLE 10GNN12AP001 10GBY10CX1012 POLYMER FEED PUMP 2A/2B 10GNN21AP001 SELECTABLE 10GNN22AP001 10GBY10CX103

3 NaOCl FEED PUMP 2A/2B N/A 10GRN11AP001 10GRN12AP001 10GBY10CX102

4 HCl FEED PUMP 2A 10GNN30AP001 SELECTABLE - 10GCY10CX102

5 HCl FEED PUMP 2B 10GNN40AP001 SELECTABLE - 10GCY10CX102

6 NaOH FEED PUMP 3A 10GNN50AP001 SELECTABLE - 10GCY10CX103

7 NaOH FEED PUMP 3B 10GNN60AP001 SELECTABLE - 10GCY10CX103

8 OILY WASTEWATER PUMP A/B 10GNK11AP001 SELECTABLE 10GNK12AP001 10GNY10CX101

9 MIXING BLOWER A/B 10GNC11AN001 SELECTABLE 10GNC12AN001 10GNY10CX102

10 THINNER SLUDGEPUMP A/B

N/A 10GNK41AP001 10GNK42AP001 10GNY10CX102

11 WASTEWATER

PUMP A/B

10GNK21AP001 SELECTABLE 10GNK22AP001 10GNY10CX103

12 THICKER SLUDGEPUMP A/B

N/A 10GNK71AP001 10GNK72AP001 10GNY10CX103

13 CLARIFIEDWATER TRANSFERPUMP A/B


14 BACKWASH PUMP A/B 10GNK61AP001 SELECTABLE 10GNK62AP001 10GNY10CX104

15 TREATED WATERPUMP A/B


16 SLUDGE RECEIVER TANKAGITATOR

10GNS10AM001 SELECTABLE - 10GNY10CX105

17 WWTP CLARIFIER TANKAGITATOR

10GND10AM001 SELECTABLE - 10GNY10CX106

18 pH ADJUSTMENT PIT

AGITATOR

10GNE10AM001 SELECTABLE - 10GNY10CX107

19 MIXING PIT AGITATOR 10GNE20AM001 SELECTABLE - 10GNY10CX107

20 NEUTRALIZATION PIT AGITATOR 10GNE30AM001 SELECTABLE - 10GNY10CX107

21 DWWTP SLUDGEPUMP A/B

10GRK11AP001 SELECTABLE 10GRK12AP001 10GNY10CX108

22 BLOWER A/B N/A 10GRC11AN001 10GRC12AN001 10GNY10CX109


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2. MCC FUNCTION TEST

Refer to Appendix __

3. MOTOR NO-LOAD TEST

ProcedureThe procedure of pre-commissioning works for the above check-items of Electrical andInstrument Equipment shall be based on GKC Standard Procedure. Electric motors ofequipments subject for Motor no-load test are listed in table below.

RAW WATER TREATMENT SYSTEM


1 10GAF10AP001 FRESHWATER SUPPLY PUMP

2 10GBK31AP001/10GBK32AP001 FITERED WATER PUMP A/B

3 10GBK11AP001/10GBK12AP001 BACKWASH WATER PUMP A/B

4 10GKA11AP001/10GKA12AP001 POTABLE WATER PUMP A/B

5 10GBK21AP001/10GBK22AP001 UNDERFLOW SLUDGE PUMP A/B

6 10GBC11AN001/10GBC12AN001 AIR BLOWER A/B

7 10GBK41AP001/10GBK42AP001 FILTERED WATER TRANSFER PUMP A/B

8 10GBD11AM001/10GBD12AM001 CLARIFIER TANK A/B AGITATOR

9 10GBN10AM001 COAGULATION DISOVING TANK AGITATOR



1 10GCK11AP001/10GCK12AP001 DEMIN FEED PUMP A/B

2 10GCH11AN001/10GCH12AN001 DEGASIFIER BLOWER A/B

3 10GCK21AP001/10GCK22AP001 BOOSTER PUMP A/B

4 10GCK41AP001/10GCK42AP001 DEMINERALIZED WATER TRANSFER PUMP A/B

5 10GCK31AP001/10GCK32AP001 REGENERATION PUMP A/B

6 10GCK51AP001/10GCK52AP001 NEUTRALIZED WATER DISPOSAL PUMP A/B



1 10GNK11AP001/10GNK12AP001 OILY WASTEWATER PUMP A/B

2 10GNC11AN001/10GNC12AN001 MIXING BLOWER A/B

3 10GNK21AP001/10GNK22AP001 WASTEWATER PUMP A/B

4 10GNK31AP001/10GNK32AP001 CLARIFIED WATER TRANSFER PUMP A/B

5 10GNK61AP001/10GNK62AP001 BACKWASH PUMP A/B

6 10GNK51AP001/10GNK52AP001 TREATED WATER PUMP A/B

7 10GNK41AP001/10GNK42AP001 THINNER SLUDGE PUMP A/B


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3. COMMISSIONING

GKC and Lilama Staffs shall together perform the Commissioning Work, or if necessary, withEVN Staff also. GKC Staff shall explain the operation of the Water Treatment Plant and trainLilama and EVN Staffs, as well.

3.1. PERFORMANCE TEST

General:Performance Test shall be done by running the plant for two cycles. Demineralized andCondensate water quality shall be checked with conductivity meters. Commissioning resultsshall be recorded in the Commissioning Result form. Period of commissioning shall be

referred to the Table below;

Table: Commissioning PeriodITEMS

SYSTEM Treating Capacity xCycle

Analysis(Raw/Treated)

Mechanical Electrical

Gravity Filter 105 m3/hr x 2 2 x 2 x 2 x

Carbon Filter (Potable) 90 m3/day x 2 2 x 2 x 2 x

Carbon Filter (Demin) 41 m3/hr x 2 2 x 2 x 2 x

Demineralizer Trains 41 m3/hr x 2 2 x 2 x 2 xCarbon Filter (WWTP) 70 m3/hr x 2 2 x 2 x 2 x

Procedure:1. Run the plant for 24 hours per day for 2 days.2. Take data of influent flowrates for Clarifier Tank, Gravity Filter, Carbon Filter, Cation

Exchanger, Anion Exchanger, and Mixed Bed Exchanger every hour.3. Take data of pressures for Gravity Filter, Carbon Filters, Cation Exchanger, Anion

Exchanger, and Mixed Bed Exchanger every hour.4. Take data of conductivity for Anion Exchanger and Mixed Bed Exchanger every hour.5. Take data of pH in Clarifier Tank every hour.6. Take sampling at sampling cocks of Gravity Filter, Carbon Filters, Anion Exchanger, and

Mixed Bed Exchanger every 4 hours for analysis. GKC and Lilama will take sampling atthe same time and perform internal analysis for comparison purposes.

7. Take note of the running time of first on-line Demineralizer train following switched-over ofthe standby train.

8. Take note of the duration of regeneration period in every regeneration cycle.

commissioning manual- water and waste water treatment

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