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1.1 Introduction
WATERTRAK
STANDARD
1.1 Introduction
Introduction
Congratulations on purchasing one of the best-engineered and manufactured water purification systems available.
Aquatech International is a privately held Pennsylvania Corporation located in suburban Pittsburgh. At this eight (8)
acre location, we own and operate a 30,000 square foot manufacturing facility with railroad accessibility. The
administrative and engineering personnel reside in a 10,000 square foot building that allows excellent inter-
departmental interface and proximity to the factory to ensure a high degree of quality control for compliance to
customer specification. We specialize in the manufacture and construction of Custom Engineered Water and Waste
Water Treatment Systems for Semiconductor Manufacturers, Generating Stations, Chemical, Pulp, Paper and Steel
Mills, Electronic, Fertilizer, Petroleum and Petrochemical Industries. These systems include the following equipment:
c. Filtration Systems including Gravity Filters, Vertical and Horizontal Pressure Filters with Sand, Activated Carbon
and Mixed Media.
g. Condensate Polishers.
l. Electro-Dialysis Systems.
m. Control Systems to Monitor, Control and Record from one Central Control Panel (Cubicle or Console Type) for
Local or Remote Operation, including Graphic/Mimic Displays.
Special features of our automatic control systems include the latest in programmable controllers and operator interface
systems which permit selective sequencing with variance in steps without rewiring of the control system. Aquatech
provides complete technical services on a project from the conceptual stage by assisting the customer with the
preparation of specifications, through engineering and manufacturer, to the installation and startup of Water, Waste
Page 1 of 2
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT #P-00101
Location: Punto Fijo / Puerto LaCruz
1.1 Introduction
Water and Hazardous Waste Treatment facilities. Aquatech prefers to supply the customer a "systems-approach" to
meet the desired water quality standards.
This includes design, manufacture, construction, startup and annual certification. This unique ability has been
developed over the last 17 years and Aquatech has the full-time in-house professionals to meet project needs. This
operation and maintenance manual should be kept near the workplace and plant engineering office. Periodically, it
needs to be updated to reflect modifications, additions, and deletions or other changes affecting the original design
concept. Prior to design changes, Aquatech strongly recommends the owner contact our Customer/Field Support
representative for review and comments or issues of spare parts, field service and documentation, please direct your
inquiry to:
WARRANTY DISCLAIMER
The system should be operated and maintained per the operating instructions provided by seller. The Purchaser is to
maintain documents such as operation records, log sheets, etc., and also records of periodic maintenance program
undertaken by Purchaser. Failure or refusal to fully disclose to Seller, the use and operating parameters, shall render
all warranties null and void. Seller strictly takes no liability for any damages caused for non compliance of these
provisions by the Purchaser.
Page 2 of 2
OPERATION & MAINTENANCE MANUAL
1.2 Safety
WATERTRAK
STANDARD
Safety First
The ultimate goal of safety is the complete prevention of personnel injury, loss of life, destruction of
property as a result of accidents, fires, explosions, or other hazardous situations. While this goal may
seem illusionary, adequate safety and fire prevention emphasizes the prevention of accidents and
failures. Unfortunately, the technical principles and practices in many fields are insufficiently
established for valid evaluation of all calculated risks, thus leaving to the individual owner-operator the
sole responsibility for adequate safety. Therefore, Aquatech International cannot accept any
responsibility for the Owners/ Operators in regards to safety and related issues. Aquatech
supports and promotes safety education for users of process equipment. Various agencies have
developed standards for safety and Aquatech advises its clients to broadly apply these codes and to
conform specifically to local regulation. Typical examples of safety codes are shown in table below:
Typical Standards Utilized
Codes Description
SBC Standard Building Code
NEC National Electric Code
AGA American Gas Association
ANSI American National Standards Institute
ASTM American Society of Testing Material
NFPA National Fire Protection Association
AHSRAE American Society of Heating, Refrigeration and Air Conditioning Engineers
SPC Standard Plumbing Code
SGC Standard Gas Code
SMC Standard Mechanical Code
ASME American Society of Mechanical Engineers
CFR Code of Federal Regulations
API American Petroleum Institute
Page 1 of 4
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
provided around all platforms and all uncovered sumps or pits. Ladders serving platforms more than
12 feet above grade should be provided with cages extending down 8 feet above grade or platform.
Handling facilities should be provided to lift all equipment which must be handled during maintenance
operations. Mobile equipment should be used for this purpose whenever possible and accessways
should be arranged to facilitate this. Items not accessible with mobile equipment should be serviced
by portable equipment. Davits should be provided for manway covers, exchanger bonnets, and relief
valves. Elevated equipment not accessible to mobile equipment which requires servicing and involves
weight in excess of 1000 pounds should be provided with permanent handling facilities. Trolley
beams or cranes should be provided for servicing large compressors or drivers. Suitable guards are
necessary for all rotating equipment, belt drives, and chain drives, and powered conveyors. Screening
devices, dryers, packaging, and similar equipment should also be provided on process equipment
undergoing servicing or maintenance while the alternate equipment is in use. Personnel entry into the
process equipment is permitted only when all flow is positively and completely shut off by double-
block valves with intervening vents or by blind flanges or double-disk valves with vents between
seats. Valve motor operators should be disconnected or interlocked and hand valve red tagged,
locked, or guarded by personnel. Operators and workers must be protected against contact with hot
piping, or vessels.
Storage and Handling
The safe storage and handling of hazardous material requires a thorough knowledge of chemical
properties for positive containment and avoidance of leakage. Storage tanks, piping, valving and
pump material must be selected for resistances to rapid corrosion or other deteriorate (caustic
embrittlement, etc.) which can lead to structural failure. Dikes or low walls are to be provided around
storage vessels. Dike capacity should be at least 110% of the vessel volume. Chlorine and similar
toxic gases are preferably stored in exterior locations to permit dissipation of minor leakage and with
sunshade roofs to minimize corrosion and pressure rise. Hazardous storage areas should be fenced
to assure against entry by no one other than assigned personnel. Hazardous materials are handled
more safely in closed systems. When drum shipments are unavoidable, personnel should be fully
protected by suitable clothing, gloves, and masks. Relief valve leakage must be avoided with lethal or
other extremely hazardous materials. Accordingly, rupture diaphragms are used as auxiliary positive
seals. Emergency showers and eyewash stations must be provided in all areas for storage, handling,
transfer, and processing materials harmful to human tissue. These facilities should be operable in all
types of weather and should be simple and reliable to ensure that an injured man (evenly temporarily
blinded) can operate them.
Page 2 of 4
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
Sodium Hydroxide
Sodium Hydroxide (NaOH) or caustic soda can cause severe burns on contact with skin or eyes
or when taken internally. Great care should be take when handling the anhydrous material or
when preparing or handling caustic soda solutions.
Page 3 of 4
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
A work permit and close supervision are recommended for anyone working on the electrical system.
Common Errors That Make A Lockout System Ineffective
1. System not enforced and properly supervised by management.
2. Failure to use the lock.
3. Locking out the incorrect disconnect.
4. Leaving the key in the lock.
5. Asking others to do the locking out.
6. Failure to use the tags.
7. Failure to check inside switch box to make sure disconnect is positive.
8. Pulling fuses and not locking out.
9. Not identifying all switches and disconnects to the equipment.
10. Assuming the equipment is inoperable.
11. Assuming the job is too small to merit locking out.
Conclusions
Effective plant safety and fire protection extend to every phase of engineering, operation, and
maintenance. As a minimum, the design of structures and equipment should reflect industry
standards in reducing all safety risks as far as possible and with full awareness and careful
assessment of special situations for which average industry practices may not be adequate. Proper
safety equipment and individual safety plans must be strictly adhered to not only for normal service
but also for emergency demands to avoid failures that would impair recovery from a plant mishap.
Aquatech International Corporation will assume no responsibility for any injury in connection to the
handling of chemicals and associated utilities and components/equipment. The owner/ operators
will not hold Aquatech International Corporation, its associates and employees responsible for any
injury or death that which may occur.
Page 4 of 4
OPERATION & MAINTENANCE MANUAL
WATERTRAK
STANDARD
Acids A large class of chemical substances whose water solutions have the ability to react with
cation resins to regenerate exhausted resins which permits the resin to be used over and over
again. Acids are also used to lower the pH of waste water to a desired range, (typically 7±1).
Acids utilized in Aquatech processes are hydrochloric (20° Be HCl) or sulfuric 66° Be H2SO4
technical grade. pH of acids is less than 7.0.
Air Scour - Air enters bottom head of pressure vessel and flow through the strainer plate
nozzles evenly distributed through the vessel’s media. Air agitates the media loosening any
compacted media by breaking any crust formed due to solids.
Anion An ion having a negative charge like sulfate (SO4-), carbonate (CO3-) hydroxide (OH-), and
chloride (Cl-), etc.
Alkalinity capacity of water to neutralize acids, a property imparted by the water's content of
carbonate, bicarbonate, hydroxide, and on occasion borate, silicate, and phosphate. It is
expressed in milligrams per liter of equivalent calcium carbonate (mg/l CaCO3).
Anti-Scalant – is a chemical agent added to the RO feed water to inhibit the precipitation or
crystallization of salt compounds.
Backwash - During the service cycle, the filter media bed collects some suspended impurities
from the water. Some of the media particle/beads breakup into fines and the bed becomes
somewhat compacted. Introducing water at calculated flow rates in the opposite direction to
the service flow lifts the bed that loosens and expands into the free board provided for the
purpose, forcing the suspended particles and the media fines out of the unit. At the same time,
the bed loses its compaction, reducing the chances of channeling that could cause water to
bypass some of the effective media bed. Compaction and fines also cause excessive pressure
drop. Water for the same quality as the influent is introduced from the bottom of the vessel and
is collected at the top and then is directed to the drain. Proper backwash rate is of great
importance since higher than the suggested rate may cause media loss and the lower rate
may not be sufficient to do the proper backwash. Any sudden shock in the backwash cycle
should be avoided, since this may cause media loss.
Bases The opposite of acids with pH > 7.0 and is used to regenerate anion resins and to
upwardly adjust the pH of waste water to the desired level. The Aquatech process uses sodium
hydroxide (50% NaOH) rayon grade.
Biocides chemical agents with the capacity to kill biological life forms. Bactericides,
insecticides, pesticides, etc. are examples
Brackish Water – is water in which the dissolved solids contents fall between that of drinking
water and sea water. Generally the TDS range is 1,000 to 10,000 ppm.
Cation An ion having a positive charges like calcium (Ca++), sodium (Na+), Magnesium (Mg++),
Iron (Fe+3), and Hydrogen (H+).
Capacity of a resin is the amount of ions exchanged per regeneration to a selected point, i.e. 20
Kilogram capacity per cubic foot at 8 pounds regenerant per cubic foot dosage. Means that 1
Page 1 of 7
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
cubic foot of the resin when regenerated with 8 pounds of regenerant would exchange ions
equivalent to 20 Kilograms of calcium carbonate providing a treated water of the selected quality
Chlorination – the addition of small amounts of free chlorine to water for the purpose of killing
harmful microorganisms
Chemical precipitation: (1) the process of utilizing chemicals to produce a separable solid
phases within a liquid medium; in analytical chemistry, precipitation is used to separate a solid
phase in an aqueous solution. (2) The process of softening water by the addition of lime and
soda ash as the precipitants
Conductivity The property of a substance (water) that describes it ability to transfer electricity.
It is the inverse of resistively.
Quality of Water Obtained From Various Sources
Quality (Electrical
Type of Water Resistance In Terms Of
Megaohms-cms.)
Theoretical maximum quality (calculated) 26
Water after 28 distillations in quartz 18.3 25° C
Water treated by strongly acidic-strongly based system 18
Water after three distillations in quartz 2
Water after three distillations in glass 1
Water in equilibrium with the carbon dioxide in the atmosphere 0.7
Water after a single distillation in glass 0.5
Approximate quality of U.S.P. distilled water * 0.1
* The US Pharmacopoeia specifies that USP distilled water must not contain more that 5 ppm
total dissolved solids.
Displacement (Slow) Rinse The process of displacement of regenerants and the eluted ions
from the resin is started at a slow pace, normally at the same rate as the dilution flow of the
regeneration injection. This not only displaces the regenerants through and out of the resin, but
also provides a few more minutes of contact time.
Exhaustion/ Regeneration An ion exchanger exchanges ions dissolved in the influent water
with the active ions in its resin, i.e., a zeolite softener unit exchanges calcium and magnesium with
sodium. This slowly reduces the concentration of available active ions. The resin is termed as
Page 2 of 7
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
exhausted when the active ion concentration reaches a low level and effluent has a pre-selected
high leakage of un-exchanged ions, known as end point leakage. Using sodium chloride, the
exhausted resin is regenerated, bringing back the level of active ion concentration.
Fast Rinse After the slow rinse the resin is rinsed further at a higher flow rate. Rinsing removes
excess regenerant from the resin, at the same time all the eluted ions are displaced from the resin
bed, bringing the resin back to active condition, ready to be put into service.
Fouling the process in which undesirable foreign matter accumulates in a bed of media, clogging
pores and coating surfaces.
Freeboard the vertical distance between a bed of media and the collector for backwash water.
This distance is the height available for bed expansion during back washing. Freeboard is usually
expressed as a percentage of bed depth.
Hardness a characteristic of water, imparted by salts of calcium, magnesium, and iron, such as
bicarbonates, carbonates, sulfates, chlorides, and nitrates that cause curdling of soap, deposition of
scale in boilers, damage in some industrial process, and sometimes objectionable taste. It may be
determined by a standard laboratory procedure or computed from the amounts of calcium and
magnesium as well as iron, aluminum, manganese, barium, strontium, and zinc; expressed as
equivalent parts per million of calcium carbonate.
Temporary hardness is due to calcium and magnesium alkaline salts, such as magnesium
bicarbonates and carbonates. Temporary hardness is also known as "carbonate hardness" or
"alkaline hardness". Mostly, temporary hardness is due to bicarbonates of calcium and magnesium.
Permanent hardness is due to neutral salts of calcium of magnesium that includes chlorides,
sulfates, nitrates, and fluorides of calcium and magnesium. Permanent hardness is also known as
"non-carbonate hardness" or "non-alkaline hardness".
Leakage an amount of un-exchanged ions which are present in the effluent. There is always
some leakage of ions in the effluent from an ion exchange. It varies throughout the service cycle
reaching a maximum at the end of the service cycle. Capacity of a resin is based upon this end
point leakage. The leakage may be as little as 1 PPB (1 parts per billion, i.e., 1 pound of
substance per billion pounds of water).
Langelier Scaling Index (LSI) LSI predicts tendency of water to form calcium carbonate or in
other words how likely it is for calcium carbonate to precipitate. In order to avoid calcium
carbonate scaling, CaCO3 should tend to dissolve in concentrate stream rather than
precipitate. At pH of saturation (pHs), water is in equilibrium with CaCO3. To control calcium
carbonate scaling by acid addition alone, LSI in reject (concentrate) stream must be negative.
Page 3 of 7
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
Because a high quality scale inhibitor is available for this particular application concentration
stream can have LSI up to 1.5. Anti-scalant addition will help to reduce or eliminate need for
acid consumption.
Oxidation in a broad sense oxidation is the increase in positive valence of any element in a
substance. On the basis of the electron theory, oxidation is a process in which an element
losses electrons. In a narrow sense, oxidation means the chemical addition of oxygen to a
substance.
Parts per million (ppm) the unit commonly used to represent the degree of pollutant
concentration where the concentrations are small. Larger concentrations are given in
percentages. 1ppm = 1mg/L. In BOD analysis, the results are expressed in ppm, whereas in
the suspended solids test, the values are expressed in percents. In air, ppm is usually a
volume/volume ratio; in water, ppm represents a weight/volume ratio.
(1)
pH = Log (---------)
(H+)
Pure water is the standard used in arriving at this value. Under ordinary conditions water
molecules disassociate into the ions H+ & OH-, with recombination at such a rate that with very
pure water at 22° C this is a concentration of oppositely charged ions of 1/10,000,000, or 10-7,
mole per liter. This is commonly expressed by saying that pure water has a pH of 7, which means
that its concentration of hydrogen ions are expressed by the exponent 7, without it's minus sign.
When acids or hydroxyl- containing bases are in water solution they ionize more or less
completely, furnishing varying concentrations of H+ & OH- ions, respectively, to the solution.
Strong acids and bases ionize much more completely than weak acids and bases; thus strong
acids give solutions of pH 1 to 3, while solutions of weak acids have a pH of about 6. Strong
bases give solutions of pH 12 or 13, while weak bases give solutions of pH about 8. As the pH
scale is logarithmic, the intervals are exponential, and thus represent far greater differences in
concentration than the values themselves seem to indicate.
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Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
Examples
Liquid pH Value
Pure water 7
Sea water 7.8 - 8.2
Blood 7.3 - 7.5
Milk 6.5 - 7
Soil (optimum for crops) 6-7
Cola Soft Drinks 2-3
Precipitate to cause a dissolved substance to form a solid particle which can be removed by
settling or filtering such as the removal of dissolved iron by oxidation, precipitation and filtration.
Precipitate is also used to refer to the solid formed as a result of precipitation.
Residual is the amount of a specific material remaining in the water following a treatment
process. May refer to the incomplete removal (such as leakage) or to material meant to remain in
treated water (such as residual chlorine).
Reverse Osmosis (RO) – is the reverse of the natural osmosis process. It is achieved by
external application of sufficient pressure to cause the solvent (water) to flow in the reverse
direction, i.e. from the more concentrated solution to the dilute solution.
RO Membrane – It is the active surface of the element through which the RO feed water is
processed into permeate and concentrate (reject) streams.
Page 5 of 7
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
RO Permeate – Within the RO vessel are a series of membranes. Pressurized water flows into
the RO vessel and the pressure forces water through the filtering layers of the membranes and
into the permeate chamber. Permeate comes out both end of the vessel from the center of the
membranes. Permeate connections from each array are headered together. 85% of the feed
water into the vessel becomes permeate water. Permeate will have the majority of suspended
solids, organic material such as bacteria, and dissolved mineral and salts removed.
RO Reject – The remaining water that does not flow into the permeate chamber is called reject
or concentrate. The concentrate has ions which are too large to flow through the membranes.
The concentrate from the first array flows feeds the
second array. As with the first array, the pressure forces some of the concentrate through the
membranes. The concentrate from the second array flows feeds the third array. As with the
second array, the pressure forces some of the concentrate through the membranes. The
concentrate flow leaving the third array is limited to 15% of the feed by adjusting the globe
valve on the RO bank’s reject line.
* The US Pharmacopoeia specifies that USP distilled water must not contain more that 5 ppm
total dissolved solids.
Acids A large class of chemical substances whose water solution have the ability to react with
cations resins to regenerate exhausted resins which permits the resin to be used over and over
again. Acids are also used to lower the pH to a desired range, typically (7+-1,) of waste water.
Acids utilized in Aquatech processes are hydro-chloric (20°Be HCl) or sulfuric 66°Be H2SO4
technical grade. pH of acids are less than 7.0.
Specific Gravity (Sp.Gr.) The ratio of the density of a substance to the density of a reference
substance; it is an abstract number that is unrelated to any units. For solids and liquids, specific
gravity is numerically equal to density, but for gases it is not, because of the difference between
the densities of the reference substances. Which are usually water (1 g/cc) for solids and liquids
Page 6 of 7
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
and air (0.00120 g/cc, or 1.29 g/l at 0 and 760 mm) for gases. The specific gravity of solids and
liquids is the ratio of their density to that of water at 4° C taken as 1.0 as 1 cc of water weighs 1
gram. Thus a solid or liquid with a density of 1.5 g/cc has a specific gravity of 1.5. Since weights of
liquids and gases vary with temperature, it is necessary to specify both temperatures involved,
except for rough or approximate values.
Suspended solids (1) solids that either floats on the surface of, or is in suspension in, water,
wastewater, or other liquids, and which are largely removable by laboratory filtering. (2) The
quantity of material removed from wastewater in a laboratory test, as prescribed in “Standard
Methods” and referred to as non-filterable residue.
Turbidity Foreign suspended particles in water imparting an unsightly appearance and will result
in deposits in water lines, process equipment, etc. It is measured by a nephelometer that which
senses the quantity of light transmitted through a water sample. The units are given as NTU.
Page 7 of 7
OPERATION & MAINTENANCE MANUAL
WATERTRAK
STANDARD
A. Inspections
1. Condition of equipment.
2. Verify Operation Sequences.
3. Ensure chemical consumption is correct.
4. Update Operations and Maintenance Manuals.
5. Audit operational records and preventative maintenance program.
6. A recent water analysis and resin sample or analysis should be sent to AIC at
Least 2 weeks prior to arrival at site.
B. Field Reports
C. Training
This intensive week long program will enable the management and personnel at your
operating facility to be assured the overall water plant will be operating properly.
Additionally, as Aquatech's innovative designs become available and water plant practices
improve, Aquatech will transfer this information to its customers via our technical service
group.
Note: For current field service rates please refer to Aquatech International's field
service terms and conditions.
Page 1 of 1
OPERATION & MAINTENANCE MANUAL
WATERTRAK
STANDARD
This system receives feed water and then pumps it into the Activated Carbon Filters through Three (3) Feed
Water pumps; each rated at 280 gpm max at 100psig (64m3/hr @ 6.8 barg). The water then enters two (2)
100% Activated Carbon Filters. Each filter is rated for a service flow rate of 157gpm (36m3/hr) and a
backwash flow rate of 280gpm (64m3/hr).
The water then enters two (2) 100% Strong Acid Cations each rated for Service flow of 157 gpm (36m3/hr).
These units remove Cationic ions from the water. Then the water enters through two (2) 100% Strong Base
Anions. Again, these are rated for 157gpm (36m3/hr) flow rate each. The Strong Base Anions remove
Anions from the water stream. The last equipment to process the water is two (2) 100% Mixed Bed units.
These units contain both Anion and Cation resin mixed together. This mixed resin polishes the water,
greatly reducing the conductivity level.
Two Regeneration Water Pumps are also supplied as auxiliary equipment. These pumps provide
regeneration water to the regeneration skids. Two different regeneration skids are supplied with the plant.
One Acid regeneration skid and one Caustic regeneration skid. They each provide the necessary amount of
dilute chemical to the demineralization vessels to regenerate the resins contained inside. The mixed bed
units also have a mixing air blower. This blower is used during regeneration to remix the resin after it has
been regenerated.
OPERATION & MAINTENANCE MANUAL
WATERTRAK
STANDARD
WATERTRAK
STANDARD
WATERTRAK
STANDARD
2.5 Consumables
WATERTRAK
STANDARD
Page 1 of 1
OPERATION & MAINTENANCE MANUAL
WATERTRAK
STANDARD
1 INTRODUCTION................................................................................................................................... 2
2 BASIS OF DESIGN ................................................................................................................................ 4
3 SYSTEM CONTROL PHILOSOPHY ................................................................................................. 5
3.1 DEMIN SYSTEM MAKE-UP ..................................................................................................................... 5
3.1.1 Water Treatment System Master Control ................................................................................5
3.1.1.1 WTS “Auto” Operation .................................................................................................................... 6
3.1.1.2 WTS “Semi-auto” Operation .......................................................................................................... 8
3.1.1.3 WTS Lead / Lag control .................................................................................................................. 9
3.1.1.4 Loss of Instrument Air or Control Power ...................................................................................... 9
3.1.2 Feed water Pumps ..................................................................................................................9
3.1.3 Activated Carbon Filters (UNIT# 1/2) ....................................................................................10
3.1.4 Strong Acid Cations (UNIT# 1/2) / Strong Base Anions (UNIT# 1/2) ....................................14
3.1.5 Mixed Bed units (UNITS# 1/2)...............................................................................................20
3.1.6 Dilution Water Pumps (A/B) ..................................................................................................27
3.1.7 Acid Regeneration Skid (XXX) ..............................................................................................27
3.1.8 Caustic Regeneration Skid (XXX) .........................................................................................28
4 COMMON CONTROL PHILOSOPHIES ........................................................................................ 29
4.1 Rotating Equipment Control ..................................................................................................................... 29
Page 1 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
1 INTRODUCTION
Aquatech is supplying the Demineralization System for the PONTO FIJO/ PUERTO LACRUZ Facility in
Venezuela.
The Demin System is designed to treat and produce 35.6 m3/hr maximum of demineralized water from the
demin system. The plant will utilize one source of water for treatment:
• City Water
This document is the Control Philosophy for the plant operation. The Water Treatment System is operated
via a Man Machine Interface Unit and the system logic resided in a Programmable Logic Controller
provided by Aquatech. Partial data for monitoring will be transferred to the central control room DCS.
The overall system is comprised of two sections, demineralizer system make-up units and demin system
accessory units.
From the raw water supply of min 7 ft NPSH, raw water is pumped by Feed water Pumps to the two (2) x
100% Activated Carbon filter units.
STRONG ACID CATIONS (UNIT # 1/2)/ STRONG BASE ANIONS (UNIT # 1/2):
The de-cationized strong acid cation effluent is piped directly to the strong base anion units. The strong
base anion unit effluent is fed directly to the inlet of the mixed beds.
The strong acid cation vessel consists of strong acid cation resins and most of the cations are exchanged
for hydrogen ion. Effluent water coming out of this vessel is called as decationized water. Decationized
water flows to the anion units.
Page 2 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
Strong acid cation units are to be regenerated after 25 hours of service when sodium leakage is expected
to start. On high flow throughput, the strong acid cation is requires regeneration to bring the resins back to
Hydrogen form. This is done by acid injection for cation resin.
Strong Base Anion units are to be regenerated after 25 hours of service when silica leakage is expected to
start. Conductivity is measured at the outlet of the anion vessel. On high flow throughput, the strong base
anion requires regeneration to bring the resins back to hydroxide form. This is done by sodium hydroxide
injection for strong base resin.
Conductivity is closely monitored at the outlet of the mixed beds. On high conductivity or high throughput,
the mixed bed is regenerated to bring the resins back to H and OH form. This is done by acid injection for
cation resin and caustic injection for anion resin. Prior to this the resins are separated by means of back
washing the resin. Cation resin being heavier will fall to the bottom and anion resin being lighter will remain
the top. After the chemical injection is done, the resins are re-mixed by application of air from plant air
provided for this purpose.
There are two (2) 100% Acid Regeneration Pumps each of 750 LPH capacity. Electronic stroke control on
the acid regeneration pump is interlocked with the dilute acid concentration requirement during the cation
regeneration (1.5% & 3.0%) and Mixed Bed (4.0%) regeneration. Acid pump stroke rate will automatically
adjust through the PLC to meet the set point.
Acid system is provided with block and bleed inlet, outlet and drain valves in the discharge of the acid
pumps for safety. Reference sequence of operation charts for strong acid cation units and mixed bed units
for these valve operations and pump requirements.
There are two (2) x 100% Caustic Regeneration Pumps each of 870 LPH capacity. Each of these pumps is
equipped with electronic stroke controller to pump required quantity of caustic to meet the dilute caustic
concentration requirement during the regenerations.
Caustic system is provided with block and bleed inlet, outlet and drain valves in the discharge of the caustic
pumps for safety. Reference sequence of operation charts for strong base anion units for mixed bed units
to see valve operations and pump requirements.
Page 3 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
2 BASIS OF DESIGN
Based on the above influent water, the Water treatment system is designed to produce Demineralized
water of the following quality:
Page 4 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
Control system for the demineralization systems allows for both automatic startup and shutdown and semi-
automatic startup and shutdown.
The Water Treatment System has a total of two (2) flow paths under which the system will operate in “Auto”
or “Semi-auto”. From the list of make-up equipment above Filter-1, Cation-1, Anion-1 and Mixed Bed-1
comprises Train-1. Filter-2, Cation-2, Anion-2 and Mixed Bed-2 comprise Train-2. Trains will be put into
service as one single entity. Cleaning and regenerations are operated as stand-alone units but
regeneration of Cation and Anion units are operated as single entity.
The service flow path from raw water supply to demin storage tank can flow through …
• Train-1 (ACF-1, SAC/SBA-1 and MB-1)
• Train-2 (ACF-2, SAC/SBA-2 and MB-2)
The following HMI operators are given to control how the “WTS” make-up water is made:
Page 5 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
• “Auto” Operation button is enabled when system is in “Semi-auto if all the units in at least one of the
Trains is not “Off-line”. If any units in both Trains are “Off-line” or if both Feed water Pumps are NOT in
“Auto” the operator will not be permitted to go into “Auto” operation.
• “Standby” Mode button: is common to both “Auto” operation and “Semi-auto” operation. In this mode all
the units and pumps are in STOP condition.
• “Semi-auto” Operation button is enabled in “Auto” operation and in “Standby” mode. If the operator
wishes to go from “Auto” mode to “Semi-auto” operation, the “Semi-Auto” mode must be selected. In
Semi-auto mode “Service” button for all individual units in “Standby” is enabled.
• “Service” button for individual units are enabled only in “Semi-auto” operation. When permissive are
satisfied the respective units of Trains units will sequence into “Service” upon selecting the respective
“Service” buttons. When in “Semi-auto” operation “Service” will be possible by selecting “Service”
buttons for all the units – i.e.) Train 1 or Train 2.
During “Service” mode when Train regeneration is required the Train will stay in “Service” till lag Train
comes to “Service” after “Pre-Service rinse”. Lead Train in time will go to “Standby”. If the lag Train is not in
“Standby” mode then the Lead train will go to “Standby” mode after a preset time.
The Units with “Regen Required” completes the regeneration sequence. WTS will then return to actual
“Service” mode by returning the regenerated Train to “Service”. If the Train regeneration is selected for
automatic initiation by PLC, the demineralization system can operate continuously.
When the Demin Storage Tank level rises above the high level set point, “Auto” operation will go into
“Standby” mode. WTS will wait for the tank level to fall to low set point.
With system in “Semi-auto” operation, the system will go to “Auto” operation upon operator pressing
“Auto” button if all of the following permissive are satisfied.
¾ At least one Feed water Pump in “Auto”
¾ All units in at least one Train in “Standby”
These permissive will be displayed on the HMI per the following color code:
Red text = NOT satisfied
Orange text = minimum conditions satisfied
Black text = Satisfied
Upon any of following condition PLC will take WTS from “Auto” mode to “Semi-Auto” Mode:
¾ Operator press “Semi-Auto” button
When in “Standby” mode under “Auto” system will go to “Service” based on Demin Water Storage Tank
level. Under “Semi-Auto” mode operation operator will have to initiate based on the requirements.
Page 6 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
The following events will happen when the Demin reaches high level or upon an Abnormal Trip
condition while under “Auto” operation:
1. Feed water Pump will stop.
2. All the units in train in “Service” will go into “Standby”.
Permissives for WTS to go into Service into “Service” mode from “Standby” mode:
¾ Demin Storage Tank Level alarm Low
¾ At least one Feed water Pumps in “Auto”
¾ All the Units in at least one Train in “Standby”.
If all the above permissive are met, then the following events will sequence when demin storage tank
falls to low level with System in “Auto” mode:
1. All the Units in Lead Train will have “Service Pending” displayed
2. Lead Feed water Pump will start
3. ACF in Lead Train will go into “Pre-service Rinse”
4. ACF in Lead Train completes “Pre-service Rinse” and goes into “Service”
5. SAC/SBA in Lead Train will go into “Pre-service Rinse”
6. SAC/SBA in Lead Train completes “Pre-service Rinse” and goes into “Service”
7. Corresponding MB will go into “Pre-service Rinse”.
8. MB unit completes “Pre-service Rinse” and goes into “Service”
Any of the following abnormal alarms will trip the WTS from “Service” mode into “Standby” mode:
♦ Any unit in train throughput alarm high and all the units in other Train not in “Standby”
♦ Anion unit in train effluent conductivity Alarm High and all the units in other Train not in “Standby”
♦ Any unit in train in “Service” reaches high throughput and all the units in other Train not in “Standby”
♦ MB in train in “Service” conductivity alarm high and all the units in other Train not in “Standby”
Permissives for the Lead unit from “Service” mode into “Standby” mode and Lag unit from “Standby”
mode into “Service” mode:
♦ Any unit of Lead Train throughput alarm high and all the units in Lag Train in “Standby”
♦ Any unit of train in “Service” reaches high throughput and all the units of other Train in “Standby”
♦ MB in “Service” reaches high throughput and all the units of other Lag Train in “Standby”
If all the above permissive are met, then the following events will sequence when demin storage tank
level is low with System in “Auto” mode and Lead unit in “Service” mode:
1. All the units in Lag Train will have “Service Pending” displayed
2. Lag Feed water Pump will start
3. ACF of Lag Train will go into “Pre-service Rinse”
4. ACF of Lag Train completes “Pre-service Rinse” and goes into “Service”
5. SAC/SBA of Lag Train will go into “Pre-service Rinse”
6. SAC/SBA of Lag Train completes “Pre-service Rinse” and goes into “Service”
Page 7 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
When the Demin Storage Tank level rises above the high level set point, “Semi-auto” operation will go into
“Standby” mode. If the operator presses “Standby” button at any time before the level reaches high set
point, the WTS units will go to “Standby” mode and system will wait for operator to press the appropriate
“Service” buttons. Operator will have to select Mixed Bed first for service followed by SAC/SBA unit and
last ACF unit
If any of following conditions is true PLC will take WTS from “Service” mode to “Standby” Mode:
♦ Feed water Pumps unavailable
♦ Demin Tank Level Alarm High
♦ Any unit in train throughput alarm high
♦ Anion unit in “Service” effluent conductivity Alarm High
♦ Any unit in train in “Service” reaches high throughput
♦ MB in train in “Service” conductivity alarm high
The following events will happen when operator presses “Standby” button or when the Demin reaches
high level or upon an Abnormal Trip condition while in “Service” mode:
1. Feed water Pump will stop
2. All the individual units in train in “Service” will go to “Standby”
Note: When pressing “Standby” mode button, all the individual units in Train(s) in “Service” will go into
“Standby”. To select an individual unit for “Off-line” status the operator must press that individual unit’s
“Off-line” button.
Page 8 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
On loss of control power Aquatech Control Panel for Demin Water system, power will be lost to the PLC
power supplies and therefore also the PLC input/output modules. The back planes of PLC racks of which
the PLC modules connect into would no longer supply power to the PLC. All air-to-open/air-to-close
(AO/AC) valves would close. All air-to-open/spring-to-close (AO/SC) valves would spring closed. All air to
close /spring to open (AC/SO) valves would spring open. All control valves with I-P (Current to Pressure)
positioners are controlled by 4 to 20 mA from PLC analog output modules. On loss of control power the
analog outputs to positioners will have 4 mA outputs and therefore the control valves will go to a closed
position.
Upon low of instrument air the WTS: All air-to-open/air-to-close (AO/AC) valves would close. All air-to-
open/spring-to-close (AO/SC) valves would spring closed. All air to close /spring to open (AC/SO) valves
would spring open. All control valves with I-P (Current to Pressure) positioners are controlled by 4 to 20
mA from PLC analog output modules. On loss of control power the analog outputs to positioners will have 4
mA outputs and therefore the control valves will go to a closed position. The operator should then do the
needful to restore instrument air pressure above 80 PSIG.
Permissive for Feed water Pump to start in either “Auto” or “Manual” at HMI:
¾ Emergency stop push-button (ES) not pressed in the Local Panel.
¾ Raw Water Tank Level Alarm Low () does not exist
Lead Feed water Pump will start in “Auto” upon any of the following conditions:
- Either Train in “Pre-service Rinse”
- Either Train in “Service”
- Either Train in “Service for Regen”
- Either Train in “ACF Fill” and not in ACF “Cleaning Shutdown”
- Either Train in “ACF Backwash” and not in ACF “Cleaning Shutdown”
Page 9 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
- Either Train in “ACF Fast Rinse” and not in ACF “Cleaning Shutdown”
- Either Train in “Cation Fast Rinse” and not in Train “Regen Shutdown”
- Either Train in “Anion Fast Rinse” and not in Train “Regen Shutdown”
If none of the above conditions are true, lead pump will no longer have an “Auto” start and will
therefore stop.
Running Feed water Pump will trip under any of the following conditions:
♦ Emergency stop push-button (ES) pressed in at the Local Panel.
♦ Raw Water Tank Level Alarm Low-Low ()
♦ Operator selects pump’s “Stop” button with pump in “Manual”
“Feed water Pump Unavailable Alarm” will occur when a pump is needed to “Auto” start and any of the
following conditions is true:
♦ Both the Feed water Pumps are “Failed”
♦ Both the Feed water Pumps are in “Manual”
♦ One Feed water Pump is “Failed “and the other is in “Manual”
Refer to Rotating Equipment Control Philosophy section for description of the HMI control buttons, status
indication and lead/ lag operation of the pumps.
There are two x 100 % activated carbon filters with a net service flow capacity of min 35.6 m3/h each is
provided to filter raw water.
Activated carbon filters are provided with the following push buttons in the operator interface unit.
¾ OFFLINE
¾ STANDBY
¾ SERVICE
¾ CLEANING REQUEST
OFFLINE
This is provided for maintenance purposes. If the Filter is placed in OFFLINE status, then this Filter will not
be considered for regular operation.
Page 10 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
Filter in OFFLINE status can be got out of this status by placing that Filter in Standby. This is accomplished
by pressing the STANDBY button in the Semi auto mode.
STANDBY
In this status, Filter is ready to go to any other status as required. The Filter is available for operation.
¾ In semi Auto mode, operator presses STANDBY button while the Filter is in Service or cleaning
pending.
¾ In Auto mode, system logic will decide this status based on the permissive and trip conditions.
¾ Once Filter completes its cleaning cycle, then it comes automatically to standby condition.
Activated Carbon Filter in Standby status can be placed in other status by pressing their respective
buttons. This can be done in Semi auto mode.
PRESERVICE RINSE
In this status, the filter is ready to go to service. This is an intermediate status condition. Prior to going to
Service, all the stagnant water in the Filter is rinsed out to waste. This operation ensures that good quality
water reaches the Down stream system.
Filter must go through its timed pre Service Rinse prior to going to Service. Filter in Pre service rinse can
be placed in standby by pressing the Standby button in the Semi auto mode.
SERVICE:
During this operating status, Filter in Service, produces filtered water, which is the product.
Page 11 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
During this operating status, Filter is in Service without Pre-Service Rinse, produces filtered water, which is
used in either SAC/SBA unit Regen steps or Mixed Bed unit Regen steps .
Filter in “Service for Regen” will come out of service and go to “Standby” once there is no requirement or
the Regen steps are complete.
CLEANING REQUIRED:
Following conditions will place Filter in cleaning required status:
In Semi Auto mode, if the Filter in Service requires cleaning, an alarm will be annunciated with reason and
the filter will remain in service. Operator should then place the standby train in to service. On confirmation
that the next Train is in service, the filter requiring cleaning can then be placed in to standby by pressing
the standby button and then placed in to cleaning pending by pressing the cleaning request button. This is
to ensure that continuous demin supply is available.
In Auto mode, on occurrence of cleaning required condition, the Lag train will go to Service after
completing required “Pre-Service Rinse”. Then the train who’s filter requiring cleaning will come out of
service and the filter will go to cleaning if all cleaning permissive are satisfied.
CLEANING PENDING:
Cleaning pending is an intermediate status that will provide opportunity for checking the permissives for
starting the Cleaning for a media Filter.
A cleaning pending filter, if was placed in cleaning pending without any requirement of cleaning, can be
placed in to Standby in Semi auto mode by pressing the Standby button.
CLEANING:
When the cleaning required condition has occurred, Filter needs to be taken out of Service and cleaned.
This is to remove all filtered suspended material and bring the Filter back to its normal condition.
Page 12 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
1. Backwash:
During this step, water at a higher flow rate is passed through the filter bed of Filter in a
direction opposite to the Service flow direction. This will remove all suspended particulate
and fines from the filter media and also will help in re classifying the filter media.
2. Settle:
Filter in this step is practically not doing any activity. This is to allow the filter to settle after
the turbulent backwash previously.
3. Final Rinse:
Once the Filter is settled, Influent water at Service flow rate is passed through the Filter to
rinse of any dirty water in the Filters and bring it back to its normal condition.
Please refer to the Sequence of Operation charts for the corresponding valve, pump sequences in each of
this step and the time period for each of these steps.
Cleaning Auto:
This button places the cleaning in Auto mode. In Auto mode the cleaning steps are automatically stepped
based on the preset time once the cleaning is started.
Cleaning Start:
This button is provided to Start the Cleaning of the filter if in Semi Auto mode. Operator after ensuring all
the Cleaning permissives are satisfied will press this button to start the cleaning. Once in cleaning, this
button is de activated
Cleaning Shutdown:
By pressing this button, operator can place a cleaning in Shut down. All the valves and pumps will be shut
off and the step time will remain frozen at the same time during which Shutdown condition occurred.
Page 13 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
Cleaning Resume:
This button is available for operation only if the Cleaning goes to shutdown. Operator can press this button
to continue the cleaning after the Shutdown condition occurrence. Cleaning will resume from where it
stopped during the occurrence of Shutdown condition.
CLEANING COMPLETE:
This status informs the operator that the cleaning has been successfully completed and that the filter is
ready for its next service cycle
3.1.4 Strong Acid Cations (UNIT# 1/2) / Strong Base Anions (UNIT# 1/2)
Two (2) 100% strong acid cations are provided for de-cationizing the raw water from others. The effluent
from the cation unit-1 is piped directly to anion unit-1 and effluent from the cation unit-2 is piped directly to
anion unit-2. The effluent from the anion unit-1 is piped directly to Mixed Bed unit-1 and effluent from the
anion unit-2 is piped directly to Mixed Bed unit-2.
Each of the SAC/SBA units will display one and only one of the following status on the HMI:
0. OFFLINE
1. STANDBY
2. SERVICE PENDING
3. PRE-SERVICE RINSE
4. SERVICE
5. REGEN REQUIRED
6. REGEN PENDING
7. REGEN
8. REGEN COMPLETE
9. SERVICE “HOLD”
Following HMI control buttons are provided for operator use for each of SAC/SBA units:
OFFLINE
STANDBY
SERVICE
RESET – resets either “Service Pending” or “Regen Pending” status
REGEN REQUEST
SAC/SBA “Off-line”:
This is provided for maintenance purposes. If a SAC/SBA unit is placed in “Off-line” status, then this
SAC/SBA unit will not be considered for regular operation.
Page 14 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
Note: All permissive listed in Section 3.1.1 for WTS to go from “Standby” mode into “Service” mode
under “Auto” operation be satisfied for a SAC/SBA unit to go from “Standby” to “Service Pending” in
“Auto” Operation.
Conditions that will cause a lead SAC/SBA unit to go to “Service Pending” from “Standby”:
• In WTS “Semi-auto” mode, when operator selects Lead Train’s “Service” HMI button
• In “Semi-auto” mode corresponding lead MB unit is in “Service Pending”.
• In WTS “Auto” operation when Demineralized Water Storage Tank (1DW-TK-0210) level fall below
low set point.
Conditions that will cause a lag SAC/SBA unit to go to “Service Pending” from “Standby”:
• In WTS “Semi-auto” mode, when operator selects the Lag Train’s “Service” button
• In “Semi-auto” mode corresponding lag MB unit is in “Service Pending”.
• In WTS “Auto” operation Lead Train in “Service” mode, when Demineralized Water Storage Tank
(XXX) level fall below low set point and any individual unit in lead train throughput High.
SAC/SBA unit “Pre-service Rinse”: This is an intermediate status condition between “Service Pending” and
“Service”. In SAC/SBA unit “Pre-service Rinse” all the stagnant water in the SAC/SBA unit is rinsed out to
the neutralization tank. This ensures that good quality water reaches the down stream mixed bed units.
Permissive for lead SAC/SBA unit to go to “Pre-service Rinse” from “Service Pending” in WTS “Semi-
auto” :
¾ Corresponding downstream MB in “Service Pending”
¾ Corresponding upstream ACF in “Service”.
Permissives for lag SAC/SBA unit to go to “Pre-service Rinse” from “Service Pending” in WTS “Semi-
auto”:
¾ Corresponding downstream MB in “Service Pending”
¾ Corresponding ACF in “Service”.
Permissives for lead SAC/SBA unit to go to “Pre-service Rinse” from “Service Pending” in WTS “Auto”
mode:
¾ At least one Feed water Pump in “Auto”
¾ Raw Water Storage Tank above the low level set point
¾ All the units in the Lead train in “Standby”.
Page 15 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
Permissives for lag SAC/SBA unit to go to “Pre-service Rinse” from “Service Pending” in WTS “Auto”
mode:
¾ At least one Feed water Pump in “Auto”
¾ Raw Water Storage Tank above the low level set point
¾ Lag ACF in “Service”
¾ Lag Mixed bed in “Service Pending”.
Permissive for lead SAC/SBA unit to go to “Service” from “Pre-service Rinse” in WTS “Semi-auto”
mode:
¾ Corresponding downstream MB in “Service Pending”
¾ Anion bed’s effluent conductivity is below the high set point for 45 continuous seconds.
Permissives for lag SAC/SBA unit to go to “Service” from “Pre-service Rinse” in WTS “Semi-auto”
mode:
¾ Corresponding downstream MB in “Service Pending”
¾ Anion bed’s effluent conductivity is below the high set point for 45 continuous seconds.
Permissive for lead SAC/SBA unit to go to “Service” from “Pre-service Rinse” in WTS “Auto” mode:
¾ Corresponding MB is in “Service Pending”
¾ Anion bed’s effluent conductivity is below the high set point for 45 continuous seconds.
Permissive for lag SAC/SBA unit to go to “Service” from “Pre-service Rinse” in WTS “Auto” mode:
¾ Lead Train in “Service” and unit needs Regeneration or Cleaning.
¾ Lag Anion bed’s effluent conductivity is below the high set point for 45 continuous seconds.
If the WTS is in “Semi-auto” mode, operator can put lead SAC/SBA unit into “Standby” by selecting the
“Standby” mode button. This will also place all units in this unit into “Standby”.
In WTS “Auto” mode and the lead SAC/SBA unit in “Service” has reached high throughput, the lag Train
will go into “Pre-service Rinse”. When the lag Train completes “Pre-service Rinse” and is in “Service”, all
the units in the lead train will go to “Standby” mode. SAC/SBA unit with high throughput will go to “Regen
Required.” All valves will be closed for a Train in “Regen Required”.
SAC/SBA unit in “Service for Regen” will come out of service and go to “Standby” once there is no
requirement or the Regen steps are complete.
Page 16 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
When a SAC/SBA unit reaches high throughput and goes to “Regen Required” and Corresponding Train
will not be allowed to go into “Service”. “Regen required” will be displayed until operator place unit into
“Regen”.
In WTS “Semi-auto” mode, a SAC/SBA unit in “Service” will go into “Regen Required” and an alarm occurs.
To acknowledge the operator should select the “Service” button for the lag Demin Train. When lag Train
completes “Pre-service Rinse” and is in “Service” operator can put the Lead Train in “Standby“ and press
“Regen Request” button for the SAC/SBA unit with “Regen Required”.
In WTS “Auto” mode and the lead Train in “Service” and SAC/SBA unit has reached high throughput, the
other Train will become lead and will automatically go through “Service” sequence. When the “new” lead
Train completes “Pre-service Rinse” and is in “Service”, the Lag Train goes to “Standby” and the SAC/SBA
unit with high throughput will go to “Regen Required”. If “SAC/SAB Regen Initiation” is in “Auto”, SAC/SBA
unit with high throughput alarm will go directly into “Regen” if all permissive are met. If “SAC/SBA Regen
Initiation” is in “Semi-Auto”, SAC/SBA with high throughput alarm will stay in “Regen required” till operator
initiates the “Regen”. If all the permissives are met and operator Press “Regen Start” button the unit will go
to “Regen”.
If these conditions are satisfied, operator can put a SAC/SBA unit into “Regen Pending” by selecting that
unit’s “Regen Request” button. Note that “Regen Required” being displayed is not necessary for a regen to
be requested. Operator can decide to regenerate a SAC/SBA unit before reaching high throughput.
SAC/SBA “Regen”:
When SAC/SBA “Regen Required” condition has occurred, That Train needs to be taken out of Service
and SAC/SBA unit regenerated. This is to bring the SAC/SBA unit to the required form - Hydrogen (H+) for
cation resin in the Cation unit and Hydroxide (OH-) for the strong anion resin in the Anion unit
Only if all the above conditions are met, a SAC/SBA can go in to regeneration, otherwise system will alarm
that Regen conditions are not met and missing criteria will be displayed on the HMI.
Page 17 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
Following steps are involved in regenerating a SAC/SBA unit: Reference document P-00101-PD-PCE-
sequenceofoperations-C for details on the valves that are open and pumps that are running for each
particular step.
Page 18 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
Following regeneration HMI control buttons are provided common to both SAC/SBA units:
• SAC/SBA Regen (Initiation) Auto
• SAC/SBA Regen (Initiation) Semi-auto
• SAC/SBA Regen Start
• SAC/SBA Regen Normal
• SAC/SBA n Regen Prolong
• SAC/SBA Regen Step Advance
• SAC/SBA Regen Hold
• SAC/SBA Regen Resume
• SAC/SBA Regen Shutdown
• SAC/SBA Regen Revert
Page 19 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
the same time during which HOLD occurred. If within this 15 minutes, the condition causing HOLD is
not resolved, then the Regen will be SHUTDOWN. All the valves and pumps will be shut off.
SAC/SBA Regen Hold can occur automatically based on the following conditions;
♦ Acid dilution water Flow Alarm Low (1DW-FAL-0701)
♦ Acid dilution water Flow Alarm High (1DW-FAH-0701)
♦ Dilute acid Concentration Alarm Low (1DW-AAL-0701)
♦ Dilute acid Concentration Alarm High (1DW-AAH-0701)
♦ Caustic dilution water Flow Alarms Low (1DW-FAL-0801)
♦ Caustic dilution water Flow Alarm High (1DW-FAH-0801)
♦ Dilute caustic Concentration Alarm High (1DW-AAH-0801)
♦ Dilute caustic Concentration Alarm Low (1DW-AAL-0801)
SAC/SBA Regen “Shutdown” will occur automatically under any of the following conditions:
♦ Neutralization Tank level alarm high-high
♦ Demin Storage Tank level alarm low-low during “Acid Injection” or “Acid Displacement” or
“Caustic Injection” or “Caustic Displacement”.
♦ Acid Level Low Low alarm during “Acid Injection” step.
♦ Acid dosing pumps not available or “Fail” during “Acid Injection” Step.
♦ Caustic Level Low Low alarm during “Caustic Injection” step.
♦ Caustic dosing pumps not available or “Fail” during “Caustic Injection” Step.
♦ Feed water Pumps unavailable in “Rinse” steps.
♦ Corresponding ACF not in “Service for Regen” in “Rinse” steps.
Each of the Mixed Beds will display one and only one of the following status on the HMI:
Page 20 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
0. OFF-LINE
1. STANDBY
2. SERVICE PENDING
3. PRE-SERVICE RINSE
4. SERVICE
5. REGEN REQUIRED
6. REGEN PENDING
7. REGEN
8. REGEN COMPLETE
Following HMI control buttons are provided for operate use each of the Mixed Beds:
OFFLINE
STANDBY
SERVICE
RESET – resets either “Service Pending” or “Regen Pending” status
REGEN REQUEST
A MB can be returned to “Standby” from “Off-line” by selecting the “Standby” button at any time. There is
no permissive within the PLC to prevent operator from going from “Off-line” to “Standby”.
A MB “Standby” status can be placed in other status by pressing the respective buttons. In AUTO mode,
the system logic decides the status.
Page 21 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
Note: All permissive listed in section 3.1.1 for WTS to go from “Standby” to “Service” mode under “Auto”
operation. All permissive listed in section 3.1.2.2 for WTS to go from “Standby” mode to “Service”
mode must be satisfied for a MB to go from “Standby” to “Service Pending”. In addition to these
permissive the following permissive must also be met.
Conditions for lead MB to go to “Service Pending” from “Standby” when permissives are met:
• In Demin “Semi-auto” operation, operator presses “SERVICE” mode button
• In Demin “Auto” operation, when in “Service” mode the lead MB will go to “Service Pending” when
the Demineralized Water Storage Tank level falls below the high set point.
Conditions for lag MB to go to “Service Pending” from “Standby” when permissives are met:
• In Demin “Semi-auto” operation, operator presses “SERVICE” mode button
• In Demin “Auto” operation, when Lead Train is in “Service” mode and any lead train unit has High
throughput alarm The lag MB will go to “Service Pending” if the Demineralized Water Storage Tank
level falls below the high set point. Provided all the units in Lag unit are in “Standby”.
Permissive for lead MB to go to “Pre-service Rinse” from “Service Pending” in WTS “Semi-auto” mode:
¾ All the upstream units are in “Service”
Permissives for lag MB to go to “Pre-service Rinse” from “Service Pending” in WTS “Semi-auto” mode:
¾ All the upstream units are in “Service”
Permissive for lead MB to go to “Pre-service Rinse” from “Service Pending” in WTS “Auto” mode:
¾ Lead Train in Service
¾ All the upstream units in the Train are in “Service”
Permissives for lag MB to go to “Pre-service Rinse” from “Service Pending” in WTS “Auto” mode:
¾ Lead Train in “Service” mode and any unit in lead train have High Throughput Alarm.
¾ All the upstream units in Lag Train in “Service”
If the WTS is in “Semi-auto”, operator can press “Standby” button at any time and place the MB in
“Standby” from “Pre-service Rinse”.
If the WTS is in “Auto” or “Semi-auto”, if the Demineralized Water Storage Tank level is greater than high
level set point, then the stream(s) in Service will go to “Standby”, which includes the Mixed Bed.
Page 22 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
In WTS “Semi-auto” mode, operator can press “Standby” button at any time and place the Mixed Bed into
“Standby” from “Service”.
In WTS “Auto” mode and the Demineralized Water Storage Tank level reaches High level, then the
stream(s) in “Service” will go to “Standby”, which includes the Mixed Bed. If the Mixed Bed in service has
reached its Throughput or if High Conductivity occurs, then the other Train if in Standby will come on line
and the Train in Service will go to Standby with a MB Regen Required alarm.
Following conditions will place lead Mixed Bed in “Regen Required” from “Service”:
¾ Lead MB Flow Total Alarm High (1DW-FQAH-0501/5022)
¾ Lead MB effluent Conductivity Alarm High (1DW-AAH-0501/501)
In WTS “Semi-auto” operation, a Mixed Bed in Service will go to Standby under the above conditions with
an alarm of the condition. This will also bring the entire stream to standby. Operator needs to place the
other stream in Service as required.
In WTS “Auto” mode, on occurrence of “Regen Required”, Train in “Service” will go to “Standby” and before
this happens will place the other Train if in Standby to Service.
REGEN PENDING:
“Regen Pending” is an intermediate status between “Standby” or “Regen Required” and “Regen” that will
provide opportunity for checking the permissive for starting the regeneration of the Mixed Beds.
Permissive for operator placing a MB in “Regen Pending” from “Standby” or “Regen Required”:
¾ Other MB should NOT be in “Regen Pending”.
¾ Neither SAC/SBA units should be in “Regen” or “Regen Pending”.
¾ At least one Air Blower should be in Auto.
¾ No other MB can be in “Regen”
¾ At least one Acid Regen Pump in ”Auto”
¾ Sulfuric Acid Storage Tank Level Alarm Low-Low does not exist
¾ At least one Caustic Regen Pump in ”Auto”
¾ Caustic Bulk Storage Tank Level Alarm Low-Low does not exist
¾ Neutralization Tank level not high
¾ Demineralized Water Storage Tank Storage Tank level not low
If these conditions are satisfied, operator can put MB into “Regen Pending” by selecting that MB’s “Regen
Request” button. Note that “Regen Required” being displayed is not necessary for a regen to be requested.
Operator can decide to regenerate a MB before it reaches high throughput.
This can be accomplished in the “Standby” mode.
REGEN:
Page 23 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
When the Regen required condition has occurred, the Mixed bed needs to be taken out of Service and
regenerated. This is to bring the Mixed resins back to the required form i.e., H for cation resin and OH for
anion resin.
Only if all the above conditions are met, a MB can go in to regeneration, otherwise the message “MB
Regen Permissive missing” will be displayed on the HMI. Below this message the permissive(s) that are
not satisfied will also be displayed.
Following steps are involved in regenerating the Mixed Bed. See Aquatech document P-00101-PD-PCE-
sequenceofoperations-C for sequence step presets, flow rates, automatic valve positions, and pump
requirements.
Page 24 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
Following Regeneration HMI control buttons are provided common to both Mixed Beds:
• MB Regen (Initiation) Semi-Auto
• MB Regen (Initiation) Auto
• MB Regen Normal
• MB Regen Prolong
• MB Regen Start
• MB Regen Hold
• MB Regen Shutdown
• MB Regen Step Advance
• MB Regen Resume
MB Regen Start:
This button is provided to Start the Regen of a Mixed Bed. Operator after ensuring all the Regen
Permissive are satisfied will press this button to start the Regen. Once in Regen, this button is de-
activated
MB Regen Normal:
This button places the Regen in Normal mode. In Normal mode the Regen steps are automatically
stepped based on the preset time once the Regen is started.
Page 25 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
MB Regen Prolong:
This button prolongs the current regen sequence step. Regen will remain in this step unit the operator
presses the “Normal” button to allow the sequence to time out to the next step.
MB Regen Shutdown:
By pressing this button, operator can place a Regen in Shut Down. All the valves and pumps will be
shut off and the step time will remain frozen at the same time during which shut down condition
occurred.
MB Regen Shutdown will occur automatically under any of the following conditions
♦ Backwash flow alarm high
♦ Neutralization Tank Level Alarm High-High
♦ Demin Storage Tank level alarm low-low during injection or displacement steps of regen.
♦ MB Regen Hold Timer done
♦ No upstream Trains in “Service” during “Rinse”.
MB Regen Hold:
By pressing this button, operator can place a Regen in HOLD. This button will be active during the
chemical injection steps only. During HOLD condition, all chemical valves (acid and caustic) and
chemical injection pumps (acid and caustic) will be shut off but the dilution water valve and pumps
will continue to be open/ running for a period of 15 minutes after the occurrence of the HOLD
condition. Step time will remain frozen at the same time during which HOLD occurred. If within this
15 minutes, the condition causing HOLD is not solved, then the Regen will be SHUTDOWN. All the
valves and pumps will be shut off.
MB Regen Hold will occur automatically upon any of the following alarms:
♦ Backwash Flow Alarm Low will hold the time accumulated but backwashing will continue.
♦ Dilute acid concentration Analyzing Alarm High (1DW-AAH-0701)
♦ Dilute acid concentration Analyzing Alarm Low (1DW-AAL-0701)
♦ Acid dilution water Flow Alarm High (1DW-FAH-0701)
♦ Acid dilution water Flow Alarm Low (1DW-FAL-0701)
♦ Dilute caustic concentration Analyzing Alarm High (1DW-AAH-0801)
♦ Dilute caustic concentration Analyzing Alarm Low (1DW-AAH-0801)
♦ Caustic dilution water Flow Alarm Low. (1DW-FAL-0801)
♦ Caustic dilution water Flow Alarm High (1DW-FAL-0801)
♦ Acid Regeneration Pumps unavailable
♦ Caustic Regeneration Pumps unavailable
Page 26 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
Permissive for a Dilution Water Pump to start in “Auto” position at the HMI:
¾ Emergency stop pushbutton (ES) not pressed in the Local Panel.
¾ Demin Water Storage Tank Level above low level set point
Lead Dilution Water Pump will start in “Auto” under any of the following conditions:
- SAC unit in “Compaction” or “Acid Inject” or “Acid Displacement” and not in “Regen Shutdown”
- SBA unit in “Compaction” or “Caustic Inject” or “Caustic Displacement” and not in “Regen
Shutdown”
- MB unit in “Acid/ Caustic Inject” or “Displacement” and not in “Regen Shutdown”
Running Dilution Water Pump will trip of stop under any of the following conditions;
♦ Demin Water Storage Tank Level Alarm Low-Low (XXX)
♦ Emergency stop button pressed in the Local Panel.
“Dilution Water Pump Unavailable” alarm will occur for any of the following conditions:
♦ If both the pumps are in “Manual” and neither pump is running
♦ If both the pumps are “Failed”
♦ If emergency stop push-button pressed in the Local Panel.
Please refer to Rotating Equipment Control Philosophy section for description of the HMI control buttons,
status indication and lead/ lag operation of the pumps.
Page 27 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
Permissive for a Acid Regeneration Pump to start in “Auto” or “Manual” from the PLC:
¾ Emergency stop push-button (ES) not pressed in the Local Panel.
¾ Sulfuric Acid Storage Tank (TK-XXX) Level Low-Low (LSLL-0701) signal does not exist
¾ Other Acid Regeneration pump is not running. (Interlock for both pumps being started from PLC at
the same time).
Any of the following conditions for will call for the lead Acid Regeneration Pump to “Auto” start:
¾ Demin Train regeneration in an “Acid Injection” step and not in “Regen Hold” and the dilution water
flow is above the low flow set point for dilution water flow through FIT-0701.
¾ Mixed bed polisher regeneration in an “Acid Injection” step and not in “Regen Hold” and the dilution
water flow is above the low flow set point for dilution water flow through FIT-0701.
When none of the above conditions are true the pump will no longer have an “Auto” start and the
pump will stop.
Acid system is provided with Block and Bleed inlet, outlet and drain valves in the discharge of the Acid
pumps for safety. Please refer to sequence of operation charts for SAC/SBA units and Mixed Bed for these
valve operations.
Permissive for a Caustic Regeneration Pump to start in “Auto” or “Manual” from the PLC:
¾ Emergency stop push-button (ES-A/B) not pressed in the Local Panel.
¾ Caustic Bulk Storage Tank (TK-XXX) Level Low-Low (LSLL-0801) signal does not exist
¾ Other Caustic Regeneration pump is not running. (Interlock for both pumps being started from PLC
at the same time).
Any of the following conditions for will call for the lead Caustic Regeneration Pump to “Auto” start:
¾ Demin Train regeneration sequence in an “Caustic Injection” step and not in “Regen Hold” and the
dilution water flow is above the low flow set point for dilution water flow through FIT-801.
Page 28 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
¾ MB unit regeneration sequence in an “Caustic Injection” step and not in “Regen Hold” and the
dilution water flow is above the low flow set point for dilution water flow through FIT-801.
When none of the above conditions are true the pump will no longer have an “Auto” start and the
pump will stop.
Caustic system is provided with Block and Bleed inlet, outlet and drain valves in the discharge of the
Caustic pumps for safety. Please refer to sequence of operation chart for SAC/SBA units and MB units
for these valve operations.
Redundant (100%) pumps/Blowers that have lead/lag operation are listed below
• Feed water Pumps
• Dilution Water Pumps
• Acid Regeneration Pump
• Caustic Regeneration Pumps
• Mixed Bed Air Blowers.
AUTO
If a pump is in “Auto” position, then the pump will “auto” start based on process requirement. Wherever,
two (2) x 100% pumps are available, pump which ran last time will not run the next time. Hence, both the
Page 29 of 30
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH PROJECT # P-00101
Location: Punto Fijo / Puerto LaCruz
3.1 Operating Philosophy
pumps will be alternatively take it’s turn to start and run. This will insure wear on the pumps is distributed
evenly.
Upon control panel (PLC) power up pump-A will be the “lead” pump and the pump-B will be the “lag” pump.
This is assigned by the PLC as default.
MANUAL
In “Manual” operator has to ensure that the down stream equipment is lined up prior to running the Pump.
Only condition that will prevent the pump from starting are the level or pressure interlocks that will also be
true in “Auto” position. After selecting “Manual” for a pump, “Start” button and “Stop” button are active and
operator can either start or stop the pump.
♦ During this condition, the pump start signal is stopped and the pump stops running. “Pump Failed”
alarm occurs to caution the operator.
♦ Pump also drops out of the “Auto” position and into “Manual”.
♦ Pump will remain in “Failed” condition until the operator presses the pump’s stop button. This will act as
a reset to clear the pump failure from the HMI.. Pump can then be placed back into “Auto”.
♦ When Lead Pump fails automatically the “Lag” pump becomes the “Lead” and will start.
♦ When both the pumps are in “Failed” condition or when both pumps are in “Manual” or when one pump
is “Failed” and other pump is in “Manual”, then “Pumps Unavailable” alarm will alert the operator.
Operator is to either clear one of the pumps’ failures or select one of the pumps for “Auto”.
Following status are shown on the HMI next to each pump for operator:
• Auto
• Manual
• Running - any running pump will be RED in color
• Stopped - any stopped pump will be GREEN in color
• Failed - any failed pump will be YELLOW in color
Page 30 of 30
OPERATION & MAINTENANCE MANUAL
WATERTRAK
STANDARD
AV-205/210
AV-203/208
AV-201/206
AV-204/209
01/02/03
M3 or Cubic Cubic
STEP STEP DESCRIPTION min.
SCFM Meter Meter
NOTES:
1.) All times and flow rates are estimated and adjustable during start-up.
2.) Caution: Care must be taken in adjustment of the backwash step to prevent loss of media.
3.) O = Valve Open; ON = Motor Running; M = Modulating Valve Operating
1 of 3
Fayette Energy Facility SAC-SBA regen Aquatech International Corporation
Duke Fluor Daniel
Aquatech Job# P-00026
er Valve AV-707)
ste Water outlet)
ductivity sample
d Outlet AV-802)
d Drain AV-703)
d Drain AV-803)
e Caustic Inlet)
O (Waste Water
d Inlet AV-701)
d Inlet AV-801)
ed Out AV-702)
ervice Outlet)
Service Inlet)
Service Inlet)
ater Pump
DilutionWater Pump
ed pump
Recirculation Valve
er Pump
d Pump
1/306
5/410
2/407
4/409
5/310
4/309
3/308
1/406
3/408
noid
601
Cubic
M3/Hr
7)
5)
Anion SEVO (Se
Acid Feed
BBI (Block Bleed
Caustic Fee
DWI (Dilution wate
Anion DCI (Dilute
AV-405
AV-402
AV-404
DWI(Dilution Wate
AV-305
AV-304
AV-303
AV-401
AV-403
Cation SEVI (S
Feed wate
Anion outlet cond
807
705
Anion WWO (Was
Dilution Wa
AV-6
Anion SEVI (S
Outlet)
1 CATION STANDY/ANION COMPACTION 3 0.0 50.0 M ON 150.00
2 CATION COMPACTION/ANION PREINJECT 3 36.5 12.5 M M ON 147.00
3 CATION ACID 1.5% INJECT / ANION CAUSTIC 4% INJECT 16 17.0 12.5 M ON M ON ON M 472.00
4 CATION ACID 3.0%INJECT/ANION CAUSTIC 4% INJECT 16 17.0 12.5 M ON M ON ON M 472.00
6 CATION ACID 4.5% INJECT/ANION DISPLACEMENT 9 17.0 12.5 M M ON ON M 265.50
7 CATION ACID DISPLACEMENT/ANION CAUSTIC DISPLACEMENT 15 17.0 12.5 M M ON M 442.50
8 CATION SETTLE/ANION CAUSTIC DISPLACEMENT 24 0.0 12.5 M ON M 300.00
9 CATION RINSE/ANION CAUSTIC DISPLACEMENT 9 35.6 12.5 M ON M ON 432.90
10 CATION RINSE/ANION SETTLE 10 35.6 0.0 ON 356.00
11 CATION SERVICE/ANION RINSE 19 35.6
35 6 35.6
35 6 ON 1352.80
1352 80
12 STANDBY 0.00
PRESERVICE RINSE 35.6 ON
SERVICE 35.6 ON
p recirculation valve AV
DCI (Dilute Causttic Inlet AV - 505/518)
BWO (Backwash Outlet AV - 501/514)
h Inlet AV - 510/526)
Pump P - A or B
--601
STEP STEP DESCRIPTION ((min.)) M3
DAO (Dilute Ac
DWI (Dilution W
DAI (Dilute Acid
Acid Feed P
BWI (Backwash
Dilution Wa
1 BACKWASH 20 5.45 0.00 yes ON 109.00
2 SETTLE 10 0.00 0.00
3 CATION BLOCK / ANION BLOCK 5 2.30 2.30 M M ON 23.00
4 4.0% ACID INJECT / 5.0% CAUSTIC INJECT 32 2.30 2.30 M ON M ON ON 147.20
5 ACID DISPLACEMENT /CAUSTIC DISPLACEMENT 36 2.30 2.30 M M ON 165.60
6 DRAIN DOWN 10 0.00 14.00 140.00
7 AIR MIX 20 94.00 0.00
8 AIR MIX / DRAIN DOWN 5 94.00 14.00
9 REFILL 15 0.00 15.00 YES ON
10 FAST RINSE 35.6 0.00 15.00 YES ON 534.00
11 STAND-BY
Notes:
WATERTRAK
STANDARD
A B C D E F G H
ALARM DESCRIPTION Instrument Tag No. LOCATION of Instrument P & ID REFERENCE SETPOINT Eng. Units Time
1 DRAWING Delay
Feed water Pump failed 1DW-P-1/2/3 Feed water Pump skid P-00101-DW-AE- 001P1-C N/A N/A 5 sec.
2
3 Feed Water Pumps unavailable 1DW-P-1/2/3 Feed water Pump skid P-00101-DW-AE- 001P1-C N/A N/A 5 sec.
4 ACF Unit# 1 service flow HIGH 1DW-FIT-0201 Activated Carbon Filter inlet P-00101-DW-AE- 001P2-C 37 m3/hr 30 sec.
5 ACF Unit# 2 service flow HIGH 1DW-FIT-0202 Activated Carbon Filter inlet P-00101-DW-AE- 001P2-C 37 m3/hr 30 sec.
6 ACF Unit# 1/2 Flow Total (between Cleanings) HIGH 1DW-FQI-0201/ 0202 Activated Carbon Filter inlet P-00101-DW-AE- 001P2-C 890 m3 0
7 SBA unit A/B Conductivity HIGH 1DW-AIT-00401/0402 Strong Base Anion P-00101-DW-AE- 001P4-C 5.0 micro 10 sec.
8 SAC/SBA unit# 1/2 "Pre-service Rinse" over-time PLC Strong Base Anion P-00101-DW-AE- 001P4-C 10 minutes NA
9 Mixed Bed Conductivity HIGH 1DW-AIT-0501/502 Mixed Bed P-00101-DW-AE- 001P5-C 0.10 uS/cm 10 sec.
10 Mixed Bed Backwash flow HIGH 1DW-FIT-0501/0502 Mixed Bed P-00101-DW-AE- 001P5-C 5.8 m3/hr 30 sec.
11 Mixed Bed Backwash flow LOW 1DW-FIT-0501/0502 Mixed Bed P-00101-DW-AE- 001P5-C 5.2 m3/hr 30 sec.
12 Mixed Bed service flow HIGH 1DW-FIT-0501/0502 Mixed Bed P-00101-DW-AE- 001P5-C 37 m3/hr 30 sec.
13 Mixed Bed service flow LOW 1DW-FIT-0501/0502 Mixed Bed P-00101-DW-AE- 001P5-C 34 m3/hr 30 sec.
14 Mixed Bed "Pre-service Rinse" over-time PLC Mixed Bed P-00101-DW-AE- 001P5-C 10 minutes NA
15 Acid Dilution water flow to MB HIGH 1DW-FIT-0701 Acid Regeneration skid P-00101-DW-AE- 001P7-C 2.5 m3/hr 30 sec.
16 Acid dilution water flow to MB LOW 1DW-FIT-0701 Acid Regeneration skid P-00101-DW-AE- 001P7-C 2.1 m3/hr 30 sec.
17 Compaction water flow to SAC LOW 1DW-FIT-0701 Acid Regeneration skid P-00101-DW-AE- 001P7-C 35 m3/hr 30 sec.
18 Acid dilution water flow to SAC HIGH 1DW-FIT-0701 Acid Regeneration skid P-00101-DW-AE- 001P7-C 18 m3/hr 30 sec.
19 Acid dilution water flow to SAC LOW 1DW-FIT-0701 Acid Regeneration skid P-00101-DW-AE- 001P7-C 16 m3/hr 30 sec.
20 Dilution Water Pumps unavailable 1DW-P-1/2 Dilution Water Pump skid P-00101-DW-AE- 001P6-C N/A N/A 5
21 Dilution Water Pump A/B failed 1DW-P-1/2 Dilution Water Pump skid P-00101-DW-AE- 001P6-C N/A N/A 5
22 Acid Regeneration Pumps unavailable 1DW-P-1/2 Acid Regeneration skid P-00101-DW-AE- 001P7-C NA NA 5 sec.
23 Acid Regeneration Pump A/B failed 1DW-P-1/2 Acid Regeneration skid P-00101-DW-AE- 001P7-C NA NA 5 sec.
24 Dilute Acid Concentration to SAC (step 1) HIGH 1DW-AIT-0701 Acid Regeneration skid P-00101-DW-AE- 001P7-C 2.0 % weight 30 sec.
25 Dilute Acid Concentration to SAC (step 1) LOW 1DW-AIT-0701 Acid Regeneration skid P-00101-DW-AE- 001P7-C 1.0 % weight 30 sec.
26 Dilute Acid Concentration to SAC (step 2) HIGH 1DW-AIT-0701 Acid Regeneration skid P-00101-DW-AE- 001P7-C 3.5 % weight 30 sec.
27 Dilute Acid Concentration to SAC (step 2) LOW 1DW-AIT-0701 Acid Regeneration skid P-00101-DW-AE- 001P7-C 2.5 % weight 30 sec.
28 Dilute Acid Concentration to SAC (step 3) HIGH 1DW-AIT-0701 Acid Regeneration skid P-00101-DW-AE- 001P7-C 5.0 % weight 30 sec.
29 Dilute Acid Concentration to SAC (step 3) LOW 1DW-AIT-0701 Acid Regeneration skid P-00101-DW-AE- 001P7-C 4.0 % weight 30 sec.
30 Dilute Acid Concentration to MB Bed HIGH 1DW-AIT-0701 Acid Regeneration skid P-00101-DW-AE- 001P7-C 4.5 % weight 30 sec.
31 Dilute Acid Concentration to MB LOW 1DW-AIT-0701 Acid Regeneration skid P-00101-DW-AE- 001P7-C 3.5 % weight 30 sec.
32 Caustic Dilution Water Flow to SBA HIGH 1DW-FIT-0801 Caustic Regeneration skid P-00101-DW-AE- 001P8-C 13 m3/hr 30 sec.
33 Caustic Dilution Water Flow to SBA LOW 1DW-FIT-0801 Caustic Regeneration skid P-00101-DW-AE- 001P8-C 12 m3/hr 30 sec.
34 Compaction Water Flow to SBA LOW 1DW-FIT-0801 Caustic Regeneration skid P-00101-DW-AE- 001P8-C 49 m3/hr 30 sec.
35 Caustic Dilution Water Flow to Mixed Bed HIGH 1DW-FIT-0801 Caustic Regeneration skid P-00101-DW-AE- 001P8-C 37.0 m3/hr 30 sec.
36 Caustic Dilution Water Flow to Mixed Bed LOW 1DW-FIT-0801 Caustic Regeneration skid P-00101-DW-AE- 001P8-C 34.0 m3/hr 30 sec.
37 Caustic Regeneration Pumps unavailable 1DW-P-1/2 Caustic Regeneration skid P-00101-DW-AE- 001P8-C NA NA 5 sec.
38 Caustic Regeneration Pump 1/2 failed 1DW-P-1/2 Caustic Regeneration skid P-00101-DW-AE- 001P8-C NA NA 5 sec.
39 Dilute Caustic Concentration to SBA HIGH 1DW-AIT-0801 Acid Regeneration skid P-00101-DW-AE- 001P8-C 4.5 % weight 30 sec.
40 Dilute Caustic Concentration to SBA LOW 1DW-AIT-0801 Acid Regeneration skid P-00101-DW-AE- 001P8-C 3.5 % weight 30 sec.
41 Dilute Caustic Concentration to MB HIGH 1DW-AIT-0801 Acid Regeneration skid P-00101-DW-AE- 001P8-C 5.5 % weight 30 sec.
42 Dilute Caustic Concentration to MB LOW 1DW-AIT-0801 Acid Regeneration skid P-00101-DW-AE- 001P8-C 4.5 % weight 30 sec.
43 Sulfuric Acid StorageTank level HIGH-HIGH 1CI-LIT-701 Sulfuric Acid Storage Tank P-00101-DW-AE- 001P7-C 95 % FULL 60 sec.
44 Sulfuric Acid StorageTank level HIGH 1CI-LIT-701 Sulfuric Acid Storage Tank P-00101-DW-AE- 001P7-C 90 % FULL 60 sec.
45 Sulfuric Acid StorageTank level LOW 1CI-LIT-701 Sulfuric Acid Storage Tank P-00101-DW-AE- 001P7-C 40 % FULL 60 sec.
46 Sulfuric Acid StorageTank level LOW-LOW 1CI-LIT-701 Sulfuric Acid Storage Tank P-00101-DW-AE- 001P7-C 10 % FULL 60 sec.
Demineralized Storage Tank Level T.B.D. Demineralized Water P-00101-DW-AE- 001P1-C T.B.D. inches 10 sec.
47 HIGH HIGH Storage Tank
Demineralized Water Storage Tank Level T.B.D. Demineralized Water P-00101-DW-AE- 001P1-C T.B.D. inches 10 sec.
48 HIGH Storage Tank
Demineralized Water Storage Tank Level LOW T.B.D. Demineralized Water P-00101-DW-AE- 001P1-C T.B.D. inches 10 sec.
49 Storage Tank
Demineralized Water Storage Tank Level LOW LOW T.B.D. Demineralized Water P-00101-DW-AE- 001P1-C T.B.D. inches 10 sec.
50 Storage Tank
Demineralized Water Storage Tank Level LOW LOW T.B.D. Demineralized Water P-00101-DW-AE- 001P1-C T.B.D. inches 10 sec.
51 LOW Storage Tank
52 Bulk Caustic Storage Tank level LOW 1OW-LIT-0801 Bulk Caustic Storage Tank P-00101-DW-AE- 001P8-C 40 % FULL 10 sec.
53 Bulk Caustic Storage Tank level HIGH-HIGH 1OW-LIT-0802 Bulk Caustic Storage Tank P-00101-DW-AE- 001P8-C 95 % FULL 10 sec.
54 Bulk Caustic Storage Tank level HIGH 1OW-LIT-0803 Bulk Caustic Storage Tank P-00101-DW-AE- 001P8-C 90 % FULL 10 sec.
55 Bulk Caustic Storage Tank level LOW-LOW 1OW-LIT-0804 Bulk Caustic Storage Tank P-00101-DW-AE- 001P8-C 10 % FULL 10 sec.
Raw Water Storage Tank Level T.B.D. Raw Water Storage Tank P-00101-DW-AE- 001P1-C T.B.D. inches 10 sec.
56 HIGH
Raw Water Storage Tank Level LOW T.B.D. Demineralized Water P-00101-DW-AE- 001P1-C T.B.D. inches 10 sec.
57 Storage Tank
Raw Water Storage Tank Level LOW LOW T.B.D. Demineralized Water P-00101-DW-AE- 001P1-C T.B.D. inches 10 sec.
58 Storage Tank
WATERTRAK
STANDARD
INDEX
1. INTRODUCTION 2
3. RESIN MAINTENANCE 5
Page 1 of 8
Project: PERI Aquatech International Corp.
Customer: Global Management Partners, LLC AIC Project No.: P-00101
Location: Punta Fijo / Puerto LaCruz Page 2
1. INTRODUCTION
This section describes some of the common problems that can occur during operation of a water
treatment system and the steps an operator can take in finding their causes. Because the greatest
troubleshooting tool that an operator can have is his knowledge of the system, it is recommended
that he reads and be familiar with the rest of this manual prior to read this section.
The most helpful tool in troubleshooting problems is the operator's knowledge of normal operating
conditions for the system. Then, if the system develops a problem, the
operator may notice a change in operating conditions that could help him identify the
cause of the problem.
To troubleshoot flow blockage, examine valve positions, and investigate all the equipment
in that area until the source of the blockage is found.
To troubleshoot electrical problems, first identify the "control flow pattern", which is the
path that the signal takes from an input device to the controller, through the controller, then from
the controller to the output device. Second, investigate all the components of this "control flow
pattern" until the cause of the problem is discovered. Start with the easiest and most probable
components, such as the input and output modules.
The following pages describe solutions to typical problems with specific equipment used
in this project.
Page 2 of 8
Project: PERI Aquatech International Corp.
Customer: Global Management Partners, LLC AIC Project No.: P-00101
Location: Punta Fijo / Puerto LaCruz Page 3
Backwash rate too high (Note Check flow rates and water temperature.
Loss of that proper backwash rate varies)
Resin Surge during backwash Do not exceed flows specified by resin manufacturers
Breakdown of resin with water temperature rates. Consult Aquatech in case
(a) Chemical attack by oxidizing of resin loss.
agents (chlorine)
(b) excessively high pressure or Analyze resin to confirm suspected chemical attack if
Page 3 of 8
Project: PERI Aquatech International Corp.
Customer: Global Management Partners, LLC AIC Project No.: P-00101
Location: Punta Fijo / Puerto LaCruz Page 4
Short Check for use of specified wash rate and avoid surges
Circuiting - excessive turbidity in inlet of air.
(Channeling) water
- excessive `fines' in the bed Remove turbidity or chlorine from inlet water if
- chemical attack on ion applicable. Use correct wash rates in accordance with
exchanger water temperature.
- abusively high flow or
operating pressures Give unit an extended backwash (approximately 30
- inadequate backwash minutes) to clean bed. Use highest flow rate possible
- Damaged under-drain or without washing resin out of the unit.
inlet distributor
- Upset supporting bed
- air in backwash water
- surges during backwash
- careless placement of the
supporting bed
- excessive wash rate
Valve Defective valves. Repair or replace if necessary.
Leakage
Normal The aging is relatively slow. It may be more economical to provide a refill of new ion
Aging of Anion exchange is more exchange material.
Exchange susceptible to aging than cation
Resin exchangers.
Dirty or Resin or media agglomeration Perform an extended backwash with a proper flow rate or
Packed (clumps) not properly broken up the bed may need chemically cleaned to break up the
Bed during backwash or insufficient clumps.
backwash flow rate or duration.
Restricted Obstruction in instrument, piping Inspect and clean as required. All valves (except control
Flow or multi-port valve. Isolating valves) should be fully open.
valves throttled.
Page 4 of 8
Project: PERI Aquatech International Corp.
Customer: Global Management Partners, LLC AIC Project No.: P-00101
Location: Punta Fijo / Puerto LaCruz Page 5
3. RESIN MAINTENANCE
Ion exchange process depends upon transfer of ions from an aqueous solution to insoluble ion exchange resin,
and subsequent elution, or removal, of these ions from regenerant solution. Ion exchange process depends upon
transfer of ions from an aqueous solution to insoluble ion exchange resin, and subsequent elution, or removal, of
these ions from regenerant solution. This transfer, or exchange, takes place not only on surface of resin particle,
but within interior of resin. The routes to interior exchange sites within resin lead through pores in resin particles. If
deposits clog these pores, or if inert matter coats resin surface, capacity of ion exchange resin will be reduced
and quality of water from ion exchange unit will be impaired. In addition, certain contaminants in water may react
adversely with ion exchange resin, breaking down chemical structure of resin, and changing its characteristics so
that it is no longer an efficient ion exchanger.
Problem with Resin Remedy
Organic Fouling
This is perhaps most common type of The problem is evidenced by;
contamination effecting ion exchange resins. 1) decrease in capacity
Organic substances are present in most water 2) increased rinse water requirements
supplies, usually due to natural decomposition 3) reduction in pH value of anion effluent
products of wood, leaves, and other organic 4) increased conductivity of anion effluent.
substances, but sometimes due to industrial and
municipal wastes. They cover a wide range of Organics should be removed by pretreatment, as they
materials such as organic acids, tannings, have a gradual cumulative degradation effect on anion
phenolic materials and color bodies, resins. Good pretreatment consists of coagulation,
representing high molecular weight substances, chlorination, filtration and activated carbon filters. In
frequently acidic in nature. They are generally some instances where organics are low and turbidity is
absorbed by anion resin, hence their greatest not present chlorination plus activated carbon filters, or
effect is on anion resin, and usually strong base even activated carbon alone, may suffice. To treat anion
anion resin. These large organic molecules resins, which have become organically fouled, treatment
containing ionic groups are taken up by anion with hot brine and caustic is frequently beneficial, and in
exchange resin, and cause blockage of ion some cases, almost restores resin to original
exchange sites where small pore sizes prevent performance, in other cases, only partially restores resin.
them from diffusing out of exchange resin during However, if source of contamination is not removed by
regeneration process. adequate pretreatment, each successive fouling and
brine treatment will be increasingly less effective. The
resin should be given a triple regeneration following this
brine treatment to convert it to required form.
Page 5 of 8
Project: PERI Aquatech International Corp.
Customer: Global Management Partners, LLC AIC Project No.: P-00101
Location: Punta Fijo / Puerto LaCruz Page 6
Page 6 of 8
Project: PERI Aquatech International Corp.
Customer: Global Management Partners, LLC AIC Project No.: P-00101
Location: Punta Fijo / Puerto LaCruz Page 7
Note: Prior to acid washing, make sure tank and internals are resistant to attack by acid.
Where existing equipment proves unsuitable for treatment purposes, i.e., ejector ratio is too wide or
continuous dilution system cannot be regulated to give required acid concentration, it will be necessary to
pump or eject acid into void above resin bed using an improvised system. This, in principle, consists of
pumping/injecting acid from its bulk container(s) through flexible rubber or plastic hose into open top of
unit (having first drained water above bed down to within 8" - 12" (20 - 30 cms) of bed surface.
Regulating flow to drain from unit using acid rinse outlet valve to match flow at which dilute acid enters.
This method will invariably apply in case of a sodium cycle softener where most or all of unlined plant
materials are unsuitable for use or contact with mineral acid. To prevent corrosion of metal surfaces
during acid treatment of resin bed in such softeners, it is necessary to use a corrosion inhibitors with
dilute acid. There are a number of such inhibitors commercially available and there should be no problem
in obtaining an adequate quantity from a bulk chemical supplier. Because many of these corrosion
inhibitors are phosphate based, it is advisable to regenerate softener with brine at a level of about 20%
NaCl (12.45 lbs. NaCl/cu ft) resin before carrying out cleaning treatment with inhibited acid solution to
avoid precipitating calcium phosphate in resin bed.
Under No Circumstances should Formaldehyde be used to inhibit corrosive action of HCl. Although
used for many years for this purpose, it is now known that one of compounds which can be formed
by this reaction is Volatile Carcinogen and two chemicals should not be used for this reason.
The same considerations apply when acid washing resin in an anion unit, as possible lack of acid
corrosion resistance of some of anion regenerant handling equipment may sometimes make it necessary
to improvise an acid dilution and dispensing system. It is not advisable to bring corrosion inhibitors into
contact with anion resins as they may contain components that will adversely affect subsequent
performance of resin. When acid washing strong base anion resin it is advisable to take following
precautions to avoid:
1. Silica precipitation
2. Damage to resin.
Before carrying out acid wash, regenerate and rinse anion unit in usual way; this will remove bulk of any
silica on resin, preventing its precipitation during subsequent acid treatment. To prevent any damage to
resin arising from dehydration and volume change which occurs when OH form resin is brought into
contact with 10% HCl bed should first be treated with 3-4 bed volts. of 1-2% acid to convert resin to Cl
form, before allowing acid to reach resin at recommended 10%. Any acid treatment required for a bed of
Page 7 of 8
Project: PERI Aquatech International Corp.
Customer: Global Management Partners, LLC AIC Project No.: P-00101
Location: Punta Fijo / Puerto LaCruz Page 8
weak base anion resin should be carried out at finish of a service run, when resin is exhausted. There is
no risk of silica precipitation with this type of resin, and as it is not in a regenerated condition, it is
possible to use 10% HCl straight away with little risk of damage to beads. Although it is a relatively easy
matter to improve acid dispensing system required for treatment, choice of equipment and their treatment
process should be concern of trained in selection of acid handling equipment, due to obvious Hazards
associated with corrosive liquids. At conclusion of acid cleansing treatment (cation or anion) spent acid
should be rinsed out with 4 bed Volumes of feedwater, at usual rinse rate for unit in question.
Bed is then regenerated and rinsed before being returned to service, minimum regeneration level required
being:
Extra salt/caustic should be included with first prepared quantity of alkaline brine to allow for this and at
finish of treatment, before tank is again used for preparation of caustic regenerant, dead volume of
alkaline brine must be drained or pumped/siphoned out. Where a continuous dilution system is employed
for caustic injection, this is unlikely to lend itself to preparation and injection of alkaline brine at required
concentration, so it will be necessary to improvise a separate solution into unit; using technique
described previously under acid washing. At conclusion of alkaline brine treatment bed should be rinse
with 2 bed Volumes of feed water at usual rinse rate. bed is then regenerated using twice design quantity
of caustic regenerant at usual 4 - 5% concentration and rinse at design rinse flow rate for design time
before being returned to service.
Page 8 of 8
OPERATION & MAINTENANCE MANUAL
WATERTRAK
STANDARD
Laboratory Procedures
LABORATORY PROCEDURES
Determination of Alkalinity
Procedure
Alkalinity to Phenolphthalein
Place 100 ml of sample in a porcelain basin or a conical flask over a white surface. Add two or three drops of
phenolphthalein indicator. If the sample turns pink, triturate with standard acid until the pink color is just
discharged. If no color is produced, the alkalinity to phenolphthalein is zero.
Total Alkalinity
Use the sample to which phenolphthalein has been added. Add a few drops of methyl orange indicator. If the
sample turns yellow, continue the titration with standard acid until the first perceptible color change towards
orange takes place. If the sample is orange without the addition of acid, total alkalinity is zero. Any difficulty
experienced in detecting the endpoint may be reduced by placing a second 100 ml sample with the same
amount of indicator in a similar container alongside that in which the titration is being carried out.
Calculation
In either case:
Alkalinity for 100 ml sample as mg CaCO3 per liter.
= Volume N/10 acid (ml) x 50 or Volume N/50 acid (ml) x 10
Note that the total alkalinity is given by the total titration (see "Procedure") and not by the acid
required in the titration under "Total Alkalinity".
Determination Of Acidity and Free Mineral Acidity (FMA) of Waters
Procedure For Indicator Method
A. Phenolphthalein Acidity (Total)
The titration should be made in a glass cylinder, using a plunger-type stirring rod, to avoid loss of CO2 and to
improve the visibility of the endpoint.
Pipet 50.0 or 100.0 ml of the settled sample into the cylinder placed on a white surface.
Add 4 drops of phenolphthalein indicator. Use a glass rod of large diameter as a plunger to mix the solution
during titration. The plunger should not be withdrawn completely from the solution while making; this
avoids introduction of air bubbles.
Titrate with 0.02 N NaOH to the first appearance of permanent pink color.
B. Methyl Orange Acidity (FMA)
Add 2 drops of methyl orange to another portion of the sample used for the total acidity and continue
titration with 0.02 N NaOH until the color changes from pink to yellow.
Page 1 of 6
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH JOB # P-00101
Location: Punto Fijo / Puerto La Cruz
Laboratory Procedures
Laboratory Procedures
Note: It must be recognized that this determination may not yield a true value for the actual free
acidity; titration to a methyl orange endpoint has been arbitrarily chosen to represent a
satisfactory measure of free acidity. Alternative indicators having color changes in the same pH
range as methyl orange may be substituted. Both total and free mineral acidity are calculated in
the same way.
ml. titrant x N of titrant x 50 x 103
mg/l acidity as CaCO3 = ml. sample
mg/1 acid = ml. titrant x n of titrant x 103 ml sample.
Determination of Chloride in Water
Use a 100 ml. sample of a suitable diluted aliquot. If the sample is highly colored, add 3 ml. Al(OH)3
suspension, mix, allow to settle, filter, wash, and combine filtrate and washing. If sulfide, sulfite or thiosulfate
is present, make the water alkaline to phenolphthalein with sodium hydroxide solution. Add 1 ml H2O2 and
stir. Neutralize with sulfuric acid.
Titrate samples in the pH range 6-9 directly. Adjust samples not in this range with sulfuric acid or sodium
hydroxide solution. Add 1.0 ml K2CrO4 indicator solution. Titrate with standard silver nitrate to a pinkish
yellow endpoint.
Establish the reagent blank value by the titration method outlined above. A blank of 0.2 to 0.3 ml. is usual for
the method.
Calculation:
mg/l Cl = (A-B) x N x 35.450
ml sample
where: A = ml. titration for sample
B = ml. titration for blank
N = normality of AgNO3
mg/l NaCl = mg/l CL x 1.65
mg/l as CaCO3 = mg/l CL x 1.4
Determination of Sulfate in Water
Using the corrected absorption, read the sulfate concentration in mg/l directly from the standard curve.
(Apply the appropriate dilution factor, if any.) To convert to mg/l as CaCO3 multiply the SO4 concentration
by 1.04.
SO4 mg/l (as CaCO3) = (mg/l SO4 from curve) x (dilution factor) x (1.04)
Page 2 of 6
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH JOB # P-00101
Location: Punto Fijo / Puerto La Cruz
Laboratory Procedures
Laboratory Procedures
Determination of Total Hardness
Procedure
Place a suitable volume of sample, filtered if necessary, in a porcelain basin, beaker, or conical flask
placed on a white surface. For a total hardness below 100 mg/l use 100 ml and for a total hardness greater
that 100 mg/l use 50 ml. Add 1 ml buffer solution for each 50 ml of sample, mix well, and add 1 ml
sodium sulfide inhibitor solution if necessary. Mix and add one or two drops of indicator solution. In the
presence of calcium or magnesium ions the solution will be wine-red in color. Titrate immediately with
the standard EDTA solution with continuous stirring. As the endpoint is approached some blue coloration
will be observed but a reddish tinge will still be visible. Add the last few drops of EDTA solution at
intervals of three to five seconds until the last reddish tinge disappears. Do not allow the time taken for
the titration to exceed five minutes after adding the buffer solution and do not use more than 5 ml EDTA
solution. If these conditions require less that 50 ml of sample, dilute the aliquot to 50 ml with water
before titration, otherwise some precipitation of calcium carbonate may occur leading to low results and a
drifting endpoint.
Calculation
Total hardness - Volume M/100 EDTA(ml) x 1000 mg/l as CaCO3 Volume of sample (ml)
Turbitmetric Determination of Sulfate
Procedure
A. Preparation of Standard Curve
Prepare 0.0 mg/l,5.0 mg/l,10.0 mg/l,15.0 mg/l,20.0 mg/l,25.0 mg/l,30.0 mg/l,35.0 mg/l and 40.0 mg/l
standard solutions. By pipetting 0.0 ml, 5.0 ml, 10.0 ml, 15.0 ml, 20.0 ml, 25.0 ml, 25.0 ml, 30.0 ml, 35.0 ml
and 40.0 ml of standard sulfate solution into six 100 ml volumetric flasks. Dilute to 100 ml with deionized
water.
Transfer each standard solution to separate 250 ml erlenmeyer flasks. Do not rinse flask.
Process standards exactly as samples.
Plot the absorbance values obtained against the corresponding sulfate concentration..
Page 3 of 6
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH JOB # P-00101
Location: Punto Fijo / Puerto La Cruz
Laboratory Procedures
Laboratory Procedures
B. Sample Treatment
Samples containing a large amount of suspended matter should be filtered through Whitman No. 2 filter
paper prior to analysis.
Prepare a blank by measuring 100 ml of distilled water into a 250 ml erlenmeyer flask.
Check the reliability of the standard curve by running one or two known standards with each series of
unknowns.
Measure 100 ml sample into a 250 ml erlenmeyer flask.
Set spectrophotometer to 420 nm wavelength and 2 nm slit width. Allow at least 10 minute warm up.
Add exactly 5.00 ml of conditioning reagent to blank, standard and samples.
Zero the spectrophotometer with blank.
Add a magnetic stir bar to blank and adjust stirring speed to 400 rpm.
Add one level spoonful (.2 ml - .3 ml) of barium chloride crystals.
After stirring for exactly one minute, fill both of the 50 mm absorption cells with the blank solution and
adjust spectrophotometer to zero absorption.
Measure the turbidity of standard and sample.
Note: In order to correct for sample color and turbidity, measure and record the absorption (ao) of the sample
before the barium chloride is added.
Add a one inch magnetic stir bar to the flask and adjust stirring speed to 400 rpm.
Add one level spoonful of barium chloride crystals.
After stirring for exactly one minute, fill the 50 mm absorption cell and note the absorbency at 30 second
intervals for 4 minutes.
Record the maximum absorption reading (al) obtained in that 4 minute period.
8. Calculation: Determine the corrected absorption be subtracting the absorption reading before adding
barium chloride (ao) from the absorption reading after the addition of barium chloride (al).
Corrected absorption = al – ao
Page 4 of 6
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH JOB # P-00101
Location: Punto Fijo / Puerto La Cruz
Laboratory Procedures
Test Procedure
Take the temperature of the feed water. The temperature should not be more than +/- 1° C (1.8° F)
between the start and end of the test
Bleed any entrained air tin the filter holder. Depending on the model of the filter holder, either open the
bleed valve, or loosen the filter holder while cracking the ball valve. Then close the bleed valve or filter
holder.
Place a 500 ml graduated cylinder under the filter to measure the amount of water that passes through the
filter.
Open the ball valve fully and measure the time required collect 100 ml and 500 ml from the time the ball
valve is opened. Record these times leaving the ball valve open and letting the flow continue.
After 5 minutes, repeat the time measurement required to collect 100 ml and 500 ml samples. Repeat
again after 10 and 15 minutes of elapsed time.
If the time required to collect 100 ml sample is greater than 60 seconds, pluggage will be about 90%, and
it is not necessary to continue the test.
Measure the water temperature again to ensure that it did not vary by more than 1°C from the initial
temperature.
After completing the test and disconnecting the apparatus the filter paper may be saved in a plastic bag for
future reference.
Page 5 of 6
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH JOB # P-00101
Location: Punto Fijo / Puerto La Cruz
Laboratory Procedures
SDI Calculations
The silt density index into the RO header is determined by the equation
Tt = Total test time in minutes (usually 15 minutes, but may be less if 75% pluggage occurs in less
than 15 minutes
Notes:
* Time to collect 500 ml should be approximately 5 times greater then the time to collect 100 ml. If
500 ml collection time is much greater than 5X, SDI should be calculated using 500 ml collection times.
** For accurate SDI measurement P30 should not exceed 75%. If P30 exceeds this value, re-run test
and obtain Tf at a shorter time, (T).
Example:
If T0 equals 20 seconds and Tf equals 60 seconds after 15 minutes total time, then
Page 6 of 6
OPERATION & MAINTENANCE MANUAL
WATERTRAK
STANDARD
FOR
Global Management Services
Page 1 of 5
Date 6/6/2008 Issue 3
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH JOB# P-00101
Location: Punto Fijo / Puerto La Cruz
This procedure is to be used as a guideline for the storage of Aquatech equipment at the job site,
prior to start up. At times the equipment is stored for many months before start up actually occurs and it
is necessary to perform certain preventive measures to protect the equipment. This procedure is to be
used as applicable, for long term lay up of equipment previously in operation or as a guideline for
equipment operating outdoors in extreme conditions such as near freezing temperature, heavy rainfall
and humidity, temperature above 49o C. This equipment is designed for indoor operation and therefore
shall generally be stored indoors.
Outdoor storage is possible provided the equipment is protected from the weather, direct sunlight
and temperature extremes. The equipment shall also be placed on solid supports, pallets or dunnage, in
well-drained areas and covered for weather and dirt protection. The equipment shall be stored in a
common area in view of the rust preventative inspection program.
VESSELS
be stored upright and level to drain properly with drains open. During temperatures below –29o C, a
blow to the exterior of the vessel would cause cracking of the lining on the interior. The interior
temperature of the vessel should not be allowed to exceed the temperature specified in the lining
manufacturer's recommendations. The lining used is Devoe Devchem 253. Devchem 253 has a
maximum temperature rating of 149 degree C. The vessels should be covered and kept out of direct
sunlight. The manways shall be kept open. The vessel external surfaces are coated with Devoe
Cathacoat 302 Inorganic-Zinc Silicate Primer and then insulated to meet the project specifications. Care
must be taken to not damage the insulation or allow the insulation to get wet. The vessel nozzles, legs
and insulated surfaces shall be inspected monthly for rust formation and any rust touched up with equal
coating.
BRINEMAKER STORAGE
The Brinemaker needs to be kept on the shipping pallet to prevent the tank from tipping over
where high winds may be present. If the Brinemaker must be stored outdoors, it should be covered with
tarpaulins or protective covering. Moving or handling the tank should be done very carefully to avoid
sharp blows or dropping as the FRP tank can be damaged with a sudden blow. Any snow build up
should be removed to avoid any possible deformation or cracking of the FRP tank. If any salt is
dispensed into the tank during storage, DO NOT add any water or any other liquid solution in the tank.
The water may freeze and crack the FRP tank.
VALVES
Valves should also be examined monthly for rust formation. The valves should be keep in a cool
dry area since moisture will affect the diaphragm material and also cause damage to the parts that
require lubrication. If the valves are to be stored for a year or more, the seals and diaphragms should be
inspected prior to installation to determine if replacement is necessary. The Valves should be positioned
to be slightly open. The faces of each valve are covered with plastic to prevent damage to the seat face,
disc edge, or butterfly valve interior. Valves should be stored indoors with face protectors intact. When
valves are stored for a long time, open and close the valves every 3 months. Store valves so that no
heavy loads are applied to the bodies.
Page 3 of 5
Date 6/6/2008 Issue 3
Project: PERI AQUATECH INTERNATIONAL CORPORATION
Client: Global Management Partners, LLC AQUATECH JOB# P-00101
Location: Punto Fijo / Puerto La Cruz
BUTTERFLY VALVES
The disc should be positioned at 10 degrees open. The faces of each valve are covered with
plastic to prevent damage to the seat face, disc edge, or butterfly valve interior. Valves should be stored
indoors with face protectors intact. Temperature should preferably be -20 degrees C to 39 degrees C.
When valves are stored for a long time, open and close the valves every 3 months. Store valves so that
no heavy loads are applied to the bodies.
ROTATING EQUIPMENT
In general, the rotating equipment should be covered and stored away from the weather. All
machine parts that are exposed should be checked occasionally so that rust does not occur. The motors
should be kept moisture free. Refer to the pump manufacturer’s storage recommendations located within
Volume II of the Operation and Maintenance manual.
LADDERS / PLATFORMS
Ladders and Platforms should be observed weekly for rust formation. They should be inspected
to assure that no scratches or other damage is present. Ladders and Platforms have a hot dipped
galvanized coating and shall be kept out of direct sunlight.
BOXES/CARTONS
All boxes, cartons, etc. must be stored indoors or in a shelter area to avoid damaging the
equipment or the packaging.
LOOSE MATERIALS
All stainless steel (SS) material must be stored away from ferrous material like carbon steel (CS)
to avoid rusting of the stainless steel (SS).
Page 5 of 5
Date 6/6/2008 Issue 3
OPERATION & MAINTENANCE MANUAL
WATERTRAK
STANDARD
Page 1
Project: PERI Aquatech International Corp.
Customer: Global Management Partners, LLC AIC Project No.: P-00101
Location: Punto Fijo / Puerto La Cruz Page 2
2. Short the wires on field device side and check the continuity. (Instrument should show
continuity).
3. Open the wires on field device side and check continuity (Instrument should not show
continuity).
5. If results of step 2 and 3 are satisfactory, then the wires at field device end and the Local Box
end can be connected as per drawing.
Page 2
Project: PERI Aquatech International Corp.
Customer: Global Management Partners, LLC AIC Project No.: P-00101
Location: Punto Fijo / Puerto La Cruz Page 3
Cables dressing & glanding completed at local box and control panel end.
Cables inside control panel / local box stripped and neatly bunched and routed prior to entry
into wire duct.
Cables properly tagged as per cable schedule at both the control panel and local box end.
2. For Loop checking a multicore cable from Local Box to control panel any one core of the cable
should be identified on basis of color (in case of multi-colored cables) or on basis of core number
in case of numbered cables. This core can be used as a reference core.
3. To confirm the continuity of the reference core, short the reference core to earth at the Local Box
end and check the continuity at the control panel end with respect to earth. (Instrument should
show continuity)
4. Open the short between ref core & earth strip and check the continuity at Control Panel end.
(Instrument should show no continuity).
5. Repeat steps 3 and 4 two to three times and if results are OK, then the reference core can be
used to check the continuity of other cores.
6. Short reference core to other unidentified core of cable at local box end and check the continuity
between the core and reference core at control panel end. (Instrument should show continuity).
7. Open the short and check the continuity (Instrument should show no continuity).
8. Repeat steps 6 and 7 two to three times and if the results are satisfactory the wires can be
connected as drawing
9. Steps 6 to 8 can be repeated to check the continuity of other cores of the cable.
Page 3
Project: PERI Aquatech International Corp.
Customer: Global Management Partners, LLC AIC Project No.: P-00101
Location: Punto Fijo / Puerto La Cruz Page 4
2. Check for air leakage on solenoid valve / manifold and air lines to valves. If leakage is
present, tighten the connections and or use Teflon tape to arrest leakage.
3. Check that all valves are in the required state within no electrical supply present. If the
state of valve (without solenoid energizing) is not as per requirement change port of
solenoid and check valve position.
4. Energize the solenoid by giving required electrical voltage (either by giving supply at
terminals or by forcing on the respective output of solenoid through PLC).
7. Check if the limit switch is pressed and check the indication of valve on the HMI.
8. De-energize the solenoid of the valve and check valve position. Valve should travel back
to original position.
9. Check if the limit switch is pressed and also check indication on HMI.
Page 4
Project: PERI Aquatech International Corp.
Customer: Global Management Partners, LLC AIC Project No.: P-00101
Location: Punto Fijo / Puerto La Cruz Page 5
3. Check for leakage of process fluid from connection. If any, arrest the same.
4. Check the reading locally. Match the reading with the actual required reading.
5. In case of transmitters, check the output analog current (dc mA) and compare with actual required
value.
6. Check the reading in HMI. (If HMI indication provided) and compare with local reading and actual
required reading.
Page 5
Project: PERI Aquatech International Corp.
Customer: Global Management Partners, LLC AIC Project No.: P-00101
Location: Punto Fijo / Puerto La Cruz Page 6
Step 1: Manual
Step 2: Semi Auto
Step 3: Auto
For example: when a pump is running and it is to trip at low level in the tank from where the pump gets its
service fluid. The low set point is adjusted in such a way that the alarm will be generated and the pump will
trip.
In order to check the other interlocks such as the system going to standby due to the occurrence of
conditions like high throughput etc., manipulate the set point to create the interlock condition when the
system is running to check the interlock.
Page 6
OPERATION & MAINTENANCE MANUAL
WATERTRAK
STANDARD
WATERTRAK
STANDARD